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2001 INFINITI G20 P11 Series Service Manual PDF DOWNLOAD
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2001 INFINITI G20 P11 Series Service Manual PDF DOWNLOAD
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2001 INFINITI G20 P11 Series Service Manual PDF DOWNLOAD
Language : English
Pages : 2174
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
2001 INFINITI G20 P11 Series Service Manual PDF DOWNLOAD
fwd........................................................................................................................ 1 QUICK REFERENCE INDEX.................................................................................................. 1 FOREWORD............................................................................................................... 2 GI - General Information............................................................................................... 0 MA - Maintenance....................................................................................................... 0 EM - Engine Mechanical................................................................................................. 0 LC - Engine Lubrication & Cooling Systems.............................................................................. 0 EC - Engine Control System............................................................................................. 0 FE - Accelerator Control, Fuel & Exhaust Systems....................................................................... 0 CL - Clutch............................................................................................................ 0 MT - Manual Transaxle.................................................................................................. 0 AT - Automatic Transaxle............................................................................................... 0 AX - Front & Rear Axle................................................................................................. 0 SU - Front & Rear Suspension........................................................................................... 0 BR - Brake System...................................................................................................... 0 ST - Steering System................................................................................................... 0 RS - Restraint System.................................................................................................. 0 BT - Body & Trim....................................................................................................... 0 HA - Heater & Air Conditioner.......................................................................................... 0 SC - Starting & Charging System........................................................................................ 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 Inch to Metric Conversion Table........................................................................................ 4 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 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................ 11 Precautions for On Board Diagnostic (OBD) System of A/T and Engine................................................. 11 Precautions........................................................................................................ 11 Service Notice or Precautions...................................................................................... 13 Wiring Diagrams and Trouble Diagnosis.............................................................................. 14 PREPARATION............................................................................................................ 15 Special Service Tools.............................................................................................. 15 Commercial Service Tools........................................................................................... 17 OVERALL SYSTEM......................................................................................................... 19 A/T Electrical Parts Location...................................................................................... 19 Circuit Diagram.................................................................................................... 20 Cross-sectional View - RE4F03B..................................................................................... 21 Cross-sectional View - RE4F03W..................................................................................... 22 Hydraulic Control Circuit.......................................................................................... 23 Shift Mechanism.................................................................................................... 24 Control System..................................................................................................... 33 Control Mechanism.................................................................................................. 34 Control Valve...................................................................................................... 39 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION................................................................................. 41 Introduction....................................................................................................... 41 OBD-II Function for A/T System..................................................................................... 41 One or Two Trip Detection Logic of OBD-II.......................................................................... 41 OBD-II Diagnostic Trouble Code (DTC)............................................................................... 41 Malfunction Indicator Lamp (MIL)................................................................................... 45 CONSULT-II......................................................................................................... 45 TROUBLE DIAGNOSIS - INTRODUCTION....................................................................................... 61 Introduction....................................................................................................... 61 Work Flow.......................................................................................................... 65 TROUBLE DIAGNOSIS - BASIC INSPECTION................................................................................... 67 A/T Fluid Check.................................................................................................... 67 Stall Test......................................................................................................... 67 Line Pressure Test................................................................................................. 71 Road Test.......................................................................................................... 72 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION................................................................................ 91 Symptom Chart...................................................................................................... 91 TCM Terminals and Reference Value.................................................................................. 104 TROUBLE DIAGNOSIS FOR POWER SUPPLY..................................................................................... 109 Wiring Diagram - AT - MAIN......................................................................................... 109 Diagnostic Procedure............................................................................................... 110 DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH........................................................................... 112 Description........................................................................................................ 112 Wiring Diagram - AT - PNP/SW....................................................................................... 114 Diagnostic Procedure............................................................................................... 115 Component Inspection............................................................................................... 117 DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT......................................................................... 118 Description........................................................................................................ 118 Wiring Diagram - AT - FTS.......................................................................................... 120 Diagnostic Procedure............................................................................................... 121 Component Inspection............................................................................................... 123 DTC P0720 VEHICLE SPEED SENSOR.A/T (REVOLUTION SENSOR)................................................................. 124 Description........................................................................................................ 124 Wiring Diagram - AT - VSSA/T....................................................................................... 126 Diagnostic Procedure............................................................................................... 127 DTC P0725 ENGINE SPEED SIGNAL.......................................................................................... 129 Description........................................................................................................ 129 Wiring Diagram - AT - ENGSS........................................................................................ 130 Diagnostic Procedure............................................................................................... 131 DTC P0731 A/T 1ST GEAR FUNCTION........................................................................................ 133 Description........................................................................................................ 133 Wiring Diagram - AT - 1ST.......................................................................................... 136 Diagnostic Procedure............................................................................................... 137 Component Inspection............................................................................................... 138 DTC P0732 A/T 2ND GEAR FUNCTION........................................................................................ 140 Description........................................................................................................ 140 Wiring Diagram - AT - 2ND.......................................................................................... 143 Diagnostic Procedure............................................................................................... 144 Component Inspection............................................................................................... 145 DTC P0733 A/T 3RD GEAR FUNCTION........................................................................................ 146 Description........................................................................................................ 146 Wiring Diagram - AT - 3RD.......................................................................................... 149 Diagnostic Procedure............................................................................................... 150 Component Inspection............................................................................................... 151 DTC P0734 A/T 4TH GEAR FUNCTION........................................................................................ 152 Description........................................................................................................ 152 Wiring Diagram - AT - 4TH.......................................................................................... 156 Diagnostic Procedure............................................................................................... 157 Component Inspection............................................................................................... 161 DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE....................................................................... 162 Description........................................................................................................ 162 Wiring Diagram - AT - TCV.......................................................................................... 164 Diagnostic Procedure............................................................................................... 165 Component Inspection............................................................................................... 167 DTC P0744 A/T TCC S/V FUNCTION (LOCK-UP)............................................................................... 168 Description........................................................................................................ 168 Wiring Diagram - AT - TCCSIG....................................................................................... 171 Diagnostic Procedure............................................................................................... 172 Component Inspection............................................................................................... 178 DTC P0745 LINE PRESSURE SOLENOID VALVE................................................................................. 179 Description........................................................................................................ 179 Wiring Diagram - AT - LPSV......................................................................................... 181 Diagnostic Procedure............................................................................................... 182 Component Inspection............................................................................................... 185 DTC P0750 SHIFT SOLENOID VALVE A....................................................................................... 186 Description........................................................................................................ 186 Wiring Diagram - AT - SSV/A........................................................................................ 188 Diagnostic Procedure............................................................................................... 189 Component Inspection............................................................................................... 191 DTC P0755 SHIFT SOLENOID VALVE B....................................................................................... 192 Description........................................................................................................ 192 Wiring Diagram - AT - SSV/B........................................................................................ 194 Diagnostic Procedure............................................................................................... 195 Component Inspection............................................................................................... 197 DTC P1705 THROTTLE POSITION SENSOR..................................................................................... 198 Description........................................................................................................ 198 Wiring Diagram - AT - TPS.......................................................................................... 201 Diagnostic Procedure............................................................................................... 202 Component Inspection............................................................................................... 206 DTC P1760 OVERRUN CLUTCH SOLENOID VALVE................................................................................ 207 Description........................................................................................................ 207 Wiring Diagram - AT - OVRCSV....................................................................................... 209 Diagnostic Procedure............................................................................................... 210 Component Inspection............................................................................................... 212 DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE)........................................... 213 Description........................................................................................................ 213 Wiring Diagram - AT - BA/FTS....................................................................................... 215 Diagnostic Procedure............................................................................................... 216 Component Inspection............................................................................................... 219 DTC VHCL SPEED SEN.MTR VEHICLE SPEED SENSOR.MTR........................................................................ 220 Description........................................................................................................ 220 Wiring Diagram - AT - VSSMTR....................................................................................... 222 Diagnostic Procedure............................................................................................... 223 DTC CONTROL UNIT (RAM), CONTROL UNIT (ROM)............................................................................. 224 Description........................................................................................................ 224 Diagnostic Procedure............................................................................................... 224 DTC CONTROL UNIT (EEP ROM)............................................................................................. 226 Description........................................................................................................ 226 Diagnostic Procedure............................................................................................... 227 TROUBLE DIAGNOSES FOR SYMPTOMS......................................................................................... 228 Wiring Diagram - AT - NONDTC....................................................................................... 228 1. O/D OFF Indicator Lamp Does Not Come On......................................................................... 230 2. Engine Cannot Be Started In "P" and "N" Position................................................................ 233 3. In "P" Position, Vehicle Moves Forward Or Backward When Pushed.................................................. 234 4. In "N" Position, Vehicle Moves.................................................................................. 235 5. Large Shock. "N" -> "R" Position................................................................................ 237 6. Vehicle Does Not Creep Backward In "R" Position................................................................. 239 7. Vehicle Does Not Creep Forward In "D", "2" Or "1" Position...................................................... 242 8. Vehicle Cannot Be Started From D1............................................................................... 245 9. A/T Does Not Shift: D1 -> D2 Or Does Not Kickdown: D4 -> D2..................................................... 248 10. A/T Does Not Shift: D2 -> D3................................................................................... 251 11. A/T Does Not Shift: D3 -> D4................................................................................... 254 12. A/T Does Not Perform Lock-up................................................................................... 257 13. A/T Does Not Hold Lock-up Condition............................................................................ 259 14. Lock-up Is Not Released........................................................................................ 261 15. Engine Speed Does Not Return To Idle (Light Braking D4 -> D3).................................................. 262 16. Vehicle Does Not Start From D1................................................................................. 264 17. A/T Does Not Shift: D4 -> D3, When Overdrive Control Switch "ON" -> "OFF"...................................... 265 18. A/T Does Not Shift: D3 -> 22, When Selector Lever "D" -> "2" Position.......................................... 266 19. A/T Does Not Shift: 22 -> 11, When Selector Lever "2" -> "1" Position.......................................... 267 20. Vehicle Does Not Decelerate By Engine Brake.................................................................... 268 21. TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control and Throttle Position Switches Circuit Checks).... 268 A/T SHIFT LOCK SYSTEM.................................................................................................. 277 Description........................................................................................................ 277 Shift Lock System Electrical Parts Location........................................................................ 277 Wiring Diagram - SHIFT -........................................................................................... 278 Diagnostic Procedure............................................................................................... 279 KEY INTERLOCK CABLE.................................................................................................... 283 Components......................................................................................................... 283 Removal............................................................................................................ 283 Installation....................................................................................................... 284 ON-VEHICLE SERVICE..................................................................................................... 285 Control Valve Assembly and Accumulators............................................................................ 285 Control Cable Adjustment........................................................................................... 286 Park/Neutral Position (PNP) Switch Adjustment...................................................................... 286 Differential Side Oil Seal Replacement............................................................................. 287 Revolution Sensor Replacement...................................................................................... 287 REMOVAL AND INSTALLATION............................................................................................... 288 Removal............................................................................................................ 288 Installation....................................................................................................... 289 OVERHAUL............................................................................................................... 291 Components......................................................................................................... 291 Oil Channel........................................................................................................ 294 Locations of Adjusting Shims, Needle Bearings, Thrust Washers and Snap Rings....................................... 295 DISASSEMBLY............................................................................................................ 296 REPAIR FOR COMPONENT PARTS............................................................................................. 310 Manual Shaft....................................................................................................... 310 Oil Pump........................................................................................................... 313 Control Valve Assembly............................................................................................. 317 Control Valve Upper Body........................................................................................... 326 Control Valve Lower Body........................................................................................... 330 Reverse Clutch..................................................................................................... 332 High Clutch........................................................................................................ 336 Forward Clutch and Overrun Clutch.................................................................................. 341 Low & Reverse Brake................................................................................................ 348 Rear Internal Gear, Forward Clutch Hub and Overrun Clutch Hub...................................................... 352 Output Shaft, Idler Gear, Reduction Pinion Gear and Bearing Retainer............................................... 356 Band Servo Piston Assembly......................................................................................... 361 Final Drive........................................................................................................ 366 ASSEMBLY............................................................................................................... 373 Assembly (1)....................................................................................................... 373 Adjustment (1)..................................................................................................... 374 Assembly (2)....................................................................................................... 379 Adjustment (2)..................................................................................................... 383 Assembly (3)....................................................................................................... 387 Assembly (4)....................................................................................................... 389 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................. 394 General Specifications............................................................................................. 394 Shift Schedule..................................................................................................... 394 Stall Revolution................................................................................................... 394 Line Pressure...................................................................................................... 394 Control Valves..................................................................................................... 395 Clutch and Brakes.................................................................................................. 395 Clutch and Brake Return Springs.................................................................................... 397 Oil Pump........................................................................................................... 397 Input Shaft........................................................................................................ 398 Planetary Carrier.................................................................................................. 398 Final Drive........................................................................................................ 398 Reduction Pinion Gear.............................................................................................. 401 Output Shaft....................................................................................................... 403 Bearing Retainer................................................................................................... 403 Total End Play..................................................................................................... 404 Reverse Clutch End Play............................................................................................ 404 Accumulator........................................................................................................ 404 Band Servo......................................................................................................... 404 Removal and Installation........................................................................................... 405 Shift Solenoid Valves.............................................................................................. 405 Solenoid Valves.................................................................................................... 405 A/T Fluid Temperature Sensor....................................................................................... 405 Revolution Sensor.................................................................................................. 405 Dropping Resistor.................................................................................................. 405 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 ax......................................................................................................................... 406 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents...................................................................................................... 406 FRONT AXLE............................................................................................................. 407 Precautions........................................................................................................ 407 PRECAUTIONS.................................................................................................... 407 Preparation........................................................................................................ 407 SPECIAL SERVICE TOOLS.......................................................................................... 407 COMMERCIAL SERVICE TOOLS....................................................................................... 407 Noise, Vibration and Harshness (NVH) Troubleshooting............................................................... 408 NVH TROUBLESHOOTING CHART...................................................................................... 408 On-vehicle Service................................................................................................. 408 FRONT AXLE PARTS............................................................................................... 408 FRONT WHEEL BEARING............................................................................................ 408 DRIVE SHAFT.................................................................................................... 409 Wheel Hub and Knuckle.............................................................................................. 410 COMPONENTS..................................................................................................... 410 REMOVAL........................................................................................................ 410 INSTALLATION................................................................................................... 411 DISASSEMBLY.................................................................................................... 412 INSPECTION..................................................................................................... 413 ASSEMBLY....................................................................................................... 413 Drive Shaft........................................................................................................ 415 COMPONENTS..................................................................................................... 415 REMOVAL........................................................................................................ 416 INSTALLATION................................................................................................... 417 DISASSEMBLY.................................................................................................... 418 INSPECTION..................................................................................................... 420 ASSEMBLY....................................................................................................... 420 Service Data and Specifications (SDS).............................................................................. 424 DRIVE SHAFT.................................................................................................... 424 WHEEL BEARING (FRONT).......................................................................................... 424 REAR AXLE.............................................................................................................. 425 Precautions........................................................................................................ 425 PRECAUTIONS.................................................................................................... 425 Preparation........................................................................................................ 425 COMMERCIAL SERVICE TOOLS....................................................................................... 425 Noise, Vibration and Harshness (NVH) Troubleshooting............................................................... 425 On-vehicle Service................................................................................................. 425 REAR AXLE PARTS................................................................................................ 425 REAR WHEEL BEARING............................................................................................. 426 Wheel Hub.......................................................................................................... 426 COMPONENTS..................................................................................................... 426 REMOVAL........................................................................................................ 426 INSTALLATION................................................................................................... 427 Service Data and Specifications (SDS).............................................................................. 427 WHEEL BEARING (REAR)........................................................................................... 427 br......................................................................................................................... 428 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents...................................................................................................... 428 PRECAUTIONS............................................................................................................ 430 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................ 430 Precautions for Brake System....................................................................................... 430 Wiring Diagrams and Trouble Diagnosis.............................................................................. 431 PREPARATION............................................................................................................ 432 Commercial Service Tools........................................................................................... 432 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING................................................................... 433 NVH Troubleshooting Chart.......................................................................................... 433 ON-VEHICLE SERVICE..................................................................................................... 434 Checking Brake Fluid Level......................................................................................... 434 Checking Brake Line................................................................................................ 434 Changing Brake Fluid............................................................................................... 434 Brake Burnishing Procedure......................................................................................... 434 Bleeding Brake System.............................................................................................. 435 BRAKE HYDRAULIC LINE................................................................................................... 436 Hydraulic Circuit.................................................................................................. 436 Removal............................................................................................................ 436 Inspection......................................................................................................... 436 Installation....................................................................................................... 437 DUAL PROPORTIONING VALVE............................................................................................... 438 Inspection......................................................................................................... 438 BRAKE PEDAL AND BRACKET................................................................................................ 439 Removal and Installation........................................................................................... 439 Inspection......................................................................................................... 439 Adjustment......................................................................................................... 439 MASTER CYLINDER........................................................................................................ 441 Removal............................................................................................................ 441 Disassembly........................................................................................................ 441 Inspection......................................................................................................... 442 Assembly........................................................................................................... 442 Installation....................................................................................................... 443 BRAKE BOOSTER.......................................................................................................... 444 On-vehicle Service................................................................................................. 444 OPERATING CHECK................................................................................................ 444 AIRTIGHT CHECK................................................................................................. 444 Removal............................................................................................................ 444 Inspection......................................................................................................... 444 OUTPUT ROD LENGTH CHECK........................................................................................ 444 Installation....................................................................................................... 445 VACUUM HOSE............................................................................................................ 446 Removal and Installation........................................................................................... 446 Inspection......................................................................................................... 446 HOSES AND CONNECTORS........................................................................................... 446 CHECK VALVE.................................................................................................... 446 FRONT DISC BRAKE....................................................................................................... 447 Component.......................................................................................................... 447 Pad Replacement.................................................................................................... 447 Removal............................................................................................................ 448 Disassembly........................................................................................................ 448 Inspection......................................................................................................... 448 CALIPER........................................................................................................ 448 ROTOR.......................................................................................................... 449 Assembly........................................................................................................... 450 Installation....................................................................................................... 450 REAR DISC BRAKE........................................................................................................ 451 Component.......................................................................................................... 451 Pad Replacement.................................................................................................... 451 Removal............................................................................................................ 453 Disassembly........................................................................................................ 454 Inspection......................................................................................................... 455 CALIPER........................................................................................................ 455 ROTOR.......................................................................................................... 455 Assembly........................................................................................................... 456 Installation....................................................................................................... 458 PARKING BRAKE CONTROL.................................................................................................. 459 Components......................................................................................................... 459 Removal and Installation........................................................................................... 459 Inspection......................................................................................................... 460 Adjustment......................................................................................................... 460 ABS.................................................................................................................... 461 DESCRIPTION........................................................................................................ 461 Purpose........................................................................................................ 461 ABS (Anti-Lock Brake System) Operation......................................................................... 461 ABS Hydraulic Circuit.......................................................................................... 461 System Components.............................................................................................. 462 System Description............................................................................................. 462 SENSOR..................................................................................................... 462 CONTROL UNIT............................................................................................... 462 ABS ACTUATOR AND ELECTRIC UNIT............................................................................. 462 Component Parts and Harness Connector Location................................................................. 464 Schematic...................................................................................................... 465 Wiring Diagram - ABS -......................................................................................... 466 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION............................................................................. 469 Self-diagnosis................................................................................................. 469 FUNCTION................................................................................................... 469 SELF-DIAGNOSIS PROCEDURE................................................................................... 469 HOW TO READ SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES).................................................... 469 HOW TO ERASE SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES)................................................... 470 CONSULT-II..................................................................................................... 471 CONSULT-II APPLICATION TO ABS.............................................................................. 471 ECU (ABS CONTROL UNIT) PART NUMBER MODE.................................................................... 471 CONSULT-II Inspection Procedure................................................................................ 471 SELF-DIAGNOSIS PROCEDURE................................................................................... 471 SELF-DIAGNOSTIC RESULTS MODE............................................................................... 473 DATA MONITOR PROCEDURE..................................................................................... 474 ACTIVE TEST PROCEDURE...................................................................................... 475 DATA MONITOR MODE.......................................................................................... 476 ACTIVE TEST MODE........................................................................................... 476 TROUBLE DIAGNOSIS - INTRODUCTION................................................................................... 477 How to Perform Trouble Diagnoses for Quick and Accurate Repair................................................. 477 INTRODUCTION............................................................................................... 477 TROUBLE DIAGNOSIS - BASIC INSPECTION............................................................................... 478 Preliminary Check.............................................................................................. 478 Ground Circuit Check........................................................................................... 481 ABS ACTUATOR AND ELECTRIC UNIT GROUND...................................................................... 481 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION............................................................................ 482 Malfunction Code/Symptom Chart................................................................................. 482 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS........................................................................ 483 Wheel Sensor or Rotor.......................................................................................... 483 DIAGNOSTIC PROCEDURE....................................................................................... 483 ABS Actuator Solenoid Valve or Solenoid Valve Relay............................................................ 486 DIAGNOSTIC PROCEDURE....................................................................................... 486 Motor Relay or Motor........................................................................................... 489 DIAGNOSTIC PROCEDURE....................................................................................... 489 Low Voltage.................................................................................................... 491 DIAGNOSTIC PROCEDURE....................................................................................... 491 Control Unit................................................................................................... 493 DIAGNOSTIC PROCEDURE....................................................................................... 493 TROUBLE DIAGNOSES FOR SYMPTOMS..................................................................................... 494 1. ABS Works Frequently........................................................................................ 494 2. Unexpected Pedal Action..................................................................................... 494 3. Long Stopping Distance...................................................................................... 495 4. ABS Does Not Work........................................................................................... 496 5. Pedal Vibration and Noise................................................................................... 497 6. ABS Warning Lamp Does Not Come On When Ignition Switch Is Turned On......................................... 498 7. ABS Warning Lamp Stays On When Ignition Switch Is Turned On................................................. 500 REMOVAL AND INSTALLATION........................................................................................... 502 Front Wheel Sensors............................................................................................ 502 Rear Wheel Sensors............................................................................................. 503 ABS Actuator and Electric Unit................................................................................. 504 REMOVAL.................................................................................................... 504 INSTALLATION............................................................................................... 504 Sensor Rotor................................................................................................... 505 REMOVAL.................................................................................................... 505 INSTALLATION............................................................................................... 505 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................. 506 General Specifications............................................................................................. 506 Disc Brake......................................................................................................... 506 Brake Pedal........................................................................................................ 506 Parking Brake...................................................................................................... 506 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......................................................................................................................... 508 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents...................................................................................................... 508 PRECAUTIONS............................................................................................................ 510 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................ 510 PREPARATION............................................................................................................ 511 Special Service Tools.............................................................................................. 511 Commercial Service Tool............................................................................................ 511 SQUEAK AND RATTLE TROUBLE DIAGNOSES.................................................................................... 512 Work Flow.......................................................................................................... 512 CUSTOMER INTERVIEW............................................................................................. 512 DUPLICATE THE NOISE AND TEST DRIVE............................................................................. 513 CHECK RELATED SERVICE BULLETINS................................................................................ 513 LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE................................................................... 513 REPAIR THE CAUSE............................................................................................... 513 CONFIRM THE REPAIR............................................................................................. 514 Generic Squeak and Rattle Troubleshooting.......................................................................... 514 INSTRUMENT PANEL............................................................................................... 514 CENTER CONSOLE................................................................................................. 514 DOORS.......................................................................................................... 514 TRUNK.......................................................................................................... 515 SUNROOF/HEADLINER.............................................................................................. 515 SEATS.......................................................................................................... 515 UNDERHOOD...................................................................................................... 515 Diagnostic Worksheet............................................................................................... 516 CLIP AND FASTENER...................................................................................................... 518 Description........................................................................................................ 518 BODY FRONT END......................................................................................................... 520 Removal and Installation........................................................................................... 520 FRONT BUMPER ASSEMBLY.......................................................................................... 520 BODY REAR END AND OPENER............................................................................................... 523 Removal and Installation........................................................................................... 523 REAR BUMPER ASSEMBLY........................................................................................... 523 FRONT DOOR............................................................................................................. 526 Front Door Glass Limit Switch Reset (Driver side only)............................................................. 526 RESET CONDITIONS............................................................................................... 526 RESET PROCEDURES............................................................................................... 526 Overhaul........................................................................................................... 527 REAR DOOR.............................................................................................................. 528 Overhaul........................................................................................................... 528 INSTRUMENT PANEL ASSEMBLY.............................................................................................. 529 Removal and Installation........................................................................................... 529 SIDE AND FLOOR TRIM.................................................................................................... 533 Removal and Installation........................................................................................... 533 DOOR TRIM.............................................................................................................. 535 Removal and Installation........................................................................................... 535 ROOF TRIM.............................................................................................................. 537 Removal and Installation........................................................................................... 537 TRUNK ROOM TRIM........................................................................................................ 539 Removal and Installation........................................................................................... 539 EXTERIOR............................................................................................................... 540 Removal and Installation........................................................................................... 540 FRONT SEAT............................................................................................................. 546 Removal and Installation........................................................................................... 546 POWER SEAT..................................................................................................... 547 HEATED SEAT.................................................................................................... 548 REAR SEAT.............................................................................................................. 549 Removal and Installation........................................................................................... 549 FOLDING SEAT................................................................................................... 549 SUNROOF................................................................................................................ 550 Adjustment......................................................................................................... 550 Removal and Installation........................................................................................... 551 Trouble Diagnoses.................................................................................................. 555 DIAGNOSTIC TABLE............................................................................................... 555 WIND DEFLECTOR................................................................................................. 555 ADJUSTMENT..................................................................................................... 556 DRAIN HOSES.................................................................................................... 557 WEATHERSTRIP................................................................................................... 557 LINK AND WIRE ASSEMBLY......................................................................................... 558 WINDSHIELD AND WINDOWS................................................................................................. 559 Removal and Installation........................................................................................... 559 REMOVAL........................................................................................................ 559 INSTALLATION................................................................................................... 559 WINDSHIELD..................................................................................................... 560 DOOR MIRROR............................................................................................................ 561 Removal and Installation........................................................................................... 561 REAR VIEW MIRROR....................................................................................................... 562 Removal and Installation........................................................................................... 562 REMOVAL........................................................................................................ 562 INSTALLATION................................................................................................... 562 BODY (ALIGNMENT)....................................................................................................... 563 Alignment.......................................................................................................... 563 ENGINE COMPARTMENT............................................................................................. 564 UNDERBODY...................................................................................................... 566 cl......................................................................................................................... 568 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents...................................................................................................... 568 PRECAUTIONS............................................................................................................ 569 Precautions........................................................................................................ 569 PREPARATION............................................................................................................ 570 Special Service Tools.............................................................................................. 570 Commercial Service Tool............................................................................................ 570 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING................................................................... 571 NVH Troubleshooting Chart.......................................................................................... 571 CLUTCH SYSTEM.......................................................................................................... 572 Components......................................................................................................... 572 Inspection and Adjustment.......................................................................................... 573 ADJUSTING CLUTCH PEDAL......................................................................................... 573 BLEEDING PROCEDURE............................................................................................. 574 CLUTCH MASTER CYLINDER................................................................................................. 575 Components......................................................................................................... 575 Removal............................................................................................................ 575 Installation....................................................................................................... 576 Disassembly........................................................................................................ 576 Inspection......................................................................................................... 576 Assembly........................................................................................................... 576 CLUTCH DAMPER.......................................................................................................... 578 Components......................................................................................................... 578 Removal............................................................................................................ 578 Disassembly........................................................................................................ 578 Inspection......................................................................................................... 579 Assembly........................................................................................................... 579 Installation....................................................................................................... 579 OPERATING CYLINDER..................................................................................................... 580 Components......................................................................................................... 580 Removal............................................................................................................ 580 Disassembly........................................................................................................ 580 Inspection......................................................................................................... 581 Assembly........................................................................................................... 581 Installation....................................................................................................... 581 PIPING................................................................................................................. 582 Removal............................................................................................................ 582 Installation....................................................................................................... 582 CLUTCH RELEASE MECHANISM............................................................................................... 583 Components......................................................................................................... 583 Removal............................................................................................................ 583 Inspection......................................................................................................... 583 Installation....................................................................................................... 583 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL................................................................................. 586 Components......................................................................................................... 586 Inspection and Adjustment.......................................................................................... 586 CLUTCH DISC.................................................................................................... 586 CLUTCH COVER AND FLYWHEEL...................................................................................... 586 FLYWHEEL INSPECTION............................................................................................ 587 Installation....................................................................................................... 587 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................. 588 Clutch Control System.............................................................................................. 588 Clutch Master Cylinder............................................................................................. 588 Clutch Operating Cylinder.......................................................................................... 588 Clutch Damper...................................................................................................... 588 Clutch Disc........................................................................................................ 588 Clutch Cover....................................................................................................... 588 Clutch Pedal....................................................................................................... 588 ec......................................................................................................................... 590 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents...................................................................................................... 590 TROUBLE DIAGNOSIS - INDEX.............................................................................................. 597 Alphabetical & P No. Index for DTC................................................................................. 597 PRECAUTIONS............................................................................................................ 603 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................ 603 Precautions for On Board Diagnostic (OBD) System of Engine and A/T................................................. 603 Engine Fuel & Emission Control System.............................................................................. 604 Precautions........................................................................................................ 605 Wiring Diagrams and Trouble Diagnosis.............................................................................. 606 PREPARATION............................................................................................................ 607 Special Service Tools.............................................................................................. 607 Commercial Service Tools........................................................................................... 607 ENGINE AND EMISSION CONTROL OVERALL SYSTEM............................................................................. 609 Engine Control Component Parts Location............................................................................ 609 Circuit Diagram.................................................................................................... 613 System Diagram..................................................................................................... 615 Vacuum Hose Drawing................................................................................................ 616 System Chart....................................................................................................... 617 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION................................................................... 618 Multiport Fuel Injection (MFI) System.............................................................................. 618 Distributor Ignition (DI) System................................................................................... 620 Air Conditioning Cut Control....................................................................................... 621 Fuel Cut Control (at no load & high engine speed).................................................................. 622 Evaporative Emission System........................................................................................ 622 On Board Refueling Vapor Recovery (ORVR)........................................................................... 628 Positive Crankcase Ventilation..................................................................................... 637 BASIC SERVICE PROCEDURE................................................................................................ 639 Fuel Pressure Release.............................................................................................. 639 Fuel Pressure Check................................................................................................ 639 Fuel Pressure Regulator Check...................................................................................... 640 Injector........................................................................................................... 640 Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment........................................................... 642 Idle Air Volume Learning........................................................................................... 654 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION................................................................................. 656 Introduction....................................................................................................... 656 Two Trip Detection Logic........................................................................................... 656 Emission-related Diagnostic Information............................................................................ 657 Malfunction Indicator Lamp (MIL)................................................................................... 670 OBD System Operation Chart......................................................................................... 672 CONSULT-II......................................................................................................... 677 Generic Scan Tool (GST)............................................................................................ 690 TROUBLE DIAGNOSIS - INTRODUCTION....................................................................................... 692 Introduction....................................................................................................... 692 Work Flow.......................................................................................................... 694 TROUBLE DIAGNOSIS - BASIC INSPECTION................................................................................... 696 Basic Inspection................................................................................................... 696 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION................................................................................ 712 DTC Inspection Priority Chart...................................................................................... 712 Fail-safe Chart.................................................................................................... 713 Symptom Matrix Chart............................................................................................... 714 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 718 Major Sensor Reference Graph in Data Monitor Mode.................................................................. 720 ECM Terminals and Reference Value.................................................................................. 723 TROUBLE DIAGNOSIS - SPECIFICATION VALUE................................................................................ 731 Description........................................................................................................ 731 Testing Condition.................................................................................................. 731 Inspection Procedure............................................................................................... 731 Diagnostic Procedure............................................................................................... 732 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT............................................................................ 735 Description........................................................................................................ 735 Diagnostic Procedure............................................................................................... 735 TROUBLE DIAGNOSIS FOR POWER SUPPLY..................................................................................... 736 Main Power Supply and Ground Circuit............................................................................... 736 DTC P0100 MASS AIR FLOW SENSOR (MAFS).................................................................................. 743 Component Description.............................................................................................. 743 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 743 ECM Terminals and Reference Value.................................................................................. 743 On Board Diagnosis Logic........................................................................................... 744 DTC Confirmation Procedure......................................................................................... 744 Overall Function Check............................................................................................. 746 Wiring Diagram..................................................................................................... 747 Diagnostic Procedure............................................................................................... 748 Component Inspection............................................................................................... 751 DTC P0105 ABSOLUTE PRESSURE SENSOR..................................................................................... 752 Component Description.............................................................................................. 752 On Board Diagnosis Logic........................................................................................... 752 DTC Confirmation Procedure......................................................................................... 752 Diagnostic Procedure............................................................................................... 753 DTC P0110 INTAKE AIR TEMPERATURE SENSOR................................................................................ 754 Component Description.............................................................................................. 754 On Board Diagnosis Logic........................................................................................... 754 DTC Confirmation Procedure......................................................................................... 754 Wiring Diagram..................................................................................................... 756 Diagnostic Procedure............................................................................................... 757 Component Inspection............................................................................................... 759 DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR (ECTS) (CIRCUIT)........................................................... 760 Component Description.............................................................................................. 760 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 760 On Board Diagnosis Logic........................................................................................... 760 DTC Confirmation Procedure......................................................................................... 761 Wiring Diagram..................................................................................................... 762 Diagnostic Procedure............................................................................................... 763 Component Inspection............................................................................................... 765 DTC P0120 THROTTLE POSITION SENSOR..................................................................................... 766 Component Description.............................................................................................. 766 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 766 ECM Terminals and Reference Value.................................................................................. 767 On Board Diagnosis Logic........................................................................................... 767 DTC Confirmation Procedure......................................................................................... 768 Wiring Diagram..................................................................................................... 772 Diagnostic Procedure............................................................................................... 773 Component Inspection............................................................................................... 777 DTC P0125 ENGINE COOLANT TEMPERATURE (ECT) SENSOR...................................................................... 779 Component Description.............................................................................................. 779 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 779 On Board Diagnosis Logic........................................................................................... 779 DTC Confirmation Procedure......................................................................................... 780 Wiring Diagram..................................................................................................... 781 Diagnostic Procedure............................................................................................... 782 Component Inspection............................................................................................... 784 DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)..................................................................... 785 Component Description.............................................................................................. 785 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 785 ECM Terminals and Reference Value.................................................................................. 785 On Board Diagnosis Logic........................................................................................... 786 DTC Confirmation Procedure......................................................................................... 786 Overall Function Check............................................................................................. 787 Wiring Diagram..................................................................................................... 788 Diagnostic Procedure............................................................................................... 789 Component Inspection............................................................................................... 791 DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING)....................................................... 793 Component Description.............................................................................................. 793 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 793 ECM Terminals and Reference Value.................................................................................. 793 On Board Diagnosis Logic........................................................................................... 794 DTC Confirmation Procedure......................................................................................... 794 Overall Function Check............................................................................................. 795 Diagnostic Procedure............................................................................................... 795 Component Inspection............................................................................................... 797 DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING)....................................................... 799 Component Description.............................................................................................. 799 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 799 ECM Terminals and Reference Value.................................................................................. 799 On Board Diagnosis Logic........................................................................................... 800 DTC Confirmation Procedure......................................................................................... 800 Overall Function Check............................................................................................. 801 Diagnostic Procedure............................................................................................... 802 Component Inspection............................................................................................... 804 DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)......................................................... 806 Component Description.............................................................................................. 806 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 806 ECM Terminals and Reference Value.................................................................................. 806 On Board Diagnosis Logic........................................................................................... 807 DTC Confirmation Procedure......................................................................................... 807 Overall Function Check............................................................................................. 808 Wiring Diagram..................................................................................................... 809 Diagnostic Procedure............................................................................................... 810 Component Inspection............................................................................................... 813 DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)................................................................ 815 Component Description.............................................................................................. 815 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 815 ECM Terminals and Reference Value.................................................................................. 815 On Board Diagnosis Logic........................................................................................... 816 DTC Confirmation Procedure......................................................................................... 816 Wiring Diagram..................................................................................................... 817 Diagnostic Procedure............................................................................................... 818 Component Inspection............................................................................................... 819 DTC P0135 HEATED OXYGEN SENSOR 1 HEATER (FRONT)........................................................................ 821 Description........................................................................................................ 821 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 821 ECM Terminals and Reference Value.................................................................................. 821 On Board Diagnosis Logic........................................................................................... 821 DTC Confirmation Procedure......................................................................................... 822 Wiring Diagram..................................................................................................... 823 Diagnostic Procedure............................................................................................... 824 Component Inspection............................................................................................... 825 DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)...................................................... 826 Component Description.............................................................................................. 826 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 826 ECM Terminals and Reference Value.................................................................................. 826 On Board Diagnosis Logic........................................................................................... 826 DTC Confirmation Procedure......................................................................................... 827 Overall Function Check............................................................................................. 827 Wiring Diagram..................................................................................................... 828 Diagnostic Procedure............................................................................................... 829 Component Inspection............................................................................................... 832 DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)...................................................... 834 Component Description.............................................................................................. 834 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 834 ECM Terminals and Reference Value.................................................................................. 834 On Board Diagnosis Logic........................................................................................... 834 DTC Confirmation Procedure......................................................................................... 835 Overall Function Check............................................................................................. 835 Wiring Diagram..................................................................................................... 836 Diagnostic Procedure............................................................................................... 837 Component Inspection............................................................................................... 840 DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING).......................................................... 842 Component Description.............................................................................................. 842 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 842 ECM Terminals and Reference Value.................................................................................. 842 On Board Diagnosis Logic........................................................................................... 842 DTC Confirmation Procedure......................................................................................... 843 Overall Function Check............................................................................................. 843 Wiring Diagram..................................................................................................... 844 Diagnostic Procedure............................................................................................... 845 Component Inspection............................................................................................... 848 DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE)................................................................. 850 Component Description.............................................................................................. 850 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 850 ECM Terminals and Reference Value.................................................................................. 850 On Board Diagnosis Logic........................................................................................... 850 DTC Confirmation Procedure......................................................................................... 851 Overall Function Check............................................................................................. 851 Wiring Diagram..................................................................................................... 852 Diagnostic Procedure............................................................................................... 853 Component Inspection............................................................................................... 854 DTC P0141 HEATED OXYGEN SENSOR 2 HEATER (REAR)......................................................................... 856 Description........................................................................................................ 856 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 856 ECM Terminals and Reference Value.................................................................................. 856 On Board Diagnosis Logic........................................................................................... 856 DTC Confirmation Procedure......................................................................................... 857 Wiring Diagram..................................................................................................... 858 Diagnostic Procedure............................................................................................... 859 Component Inspection............................................................................................... 860 DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)................................................................... 861 On Board Diagnosis Logic........................................................................................... 861 DTC Confirmation Procedure......................................................................................... 861 Wiring Diagram..................................................................................................... 863 Diagnostic Procedure............................................................................................... 864 DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)................................................................... 868 On Board Diagnosis Logic........................................................................................... 868 DTC Confirmation Procedure......................................................................................... 868 Wiring Diagram..................................................................................................... 870 Diagnostic Procedure............................................................................................... 871 DTC P0180 FUEL TANK TEMPERATURE SENSOR................................................................................. 875 Component Description.............................................................................................. 875 On Board Diagnosis Logic........................................................................................... 875 DTC Confirmation Procedure......................................................................................... 875 Wiring Diagram..................................................................................................... 877 Diagnostic Procedure............................................................................................... 878 Component Inspection............................................................................................... 879 DTC P0217 COOLANT OVERTEMPERATURE ENRICHMENT PROTECTION................................................................ 880 System Description................................................................................................. 880 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 880 ECM Terminals and Reference Value.................................................................................. 881 On Board Diagnosis Logic........................................................................................... 881 Possible Cause..................................................................................................... 881 Overall Function Check............................................................................................. 882 Wiring Diagram..................................................................................................... 885 Diagnostic Procedure............................................................................................... 886 Main 12 Causes of Overheating...................................................................................... 897 DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE................................................ 898 On Board Diagnosis Logic........................................................................................... 898 DTC Confirmation Procedure......................................................................................... 898 Diagnostic Procedure............................................................................................... 899 Component Inspection............................................................................................... 904 DTC P0325 KNOCK SENSOR (KS)............................................................................................ 905 Component Description.............................................................................................. 905 ECM Terminals and Reference Value.................................................................................. 905 On Board Diagnosis Logic........................................................................................... 905 DTC Confirmation Procedure......................................................................................... 905 Wiring Diagram..................................................................................................... 906 Diagnostic Procedure............................................................................................... 907 Component Inspection............................................................................................... 908 DTC P0335 CRANKSHAFT POSITION SENSOR (CKPS) (OBD)...................................................................... 909 Component Description.............................................................................................. 909 ECM Terminals and Reference Value.................................................................................. 909 On Board Diagnosis Logic........................................................................................... 909 DTC Confirmation Procedure......................................................................................... 910 Wiring Diagram..................................................................................................... 911 Diagnostic Procedure............................................................................................... 912 Component Inspection............................................................................................... 914 DTC P0340 CAMSHAFT POSITION SENSOR (CMPS).............................................................................. 915 Component Description.............................................................................................. 915 ECM Terminals and Reference Value.................................................................................. 915 On Board Diagnosis Logic........................................................................................... 916 DTC Confirmation Procedure......................................................................................... 916 Wiring Diagram..................................................................................................... 918 Diagnostic Procedure............................................................................................... 919 Component Inspection............................................................................................... 922 DTC P0400 EGR FUNCTION (CLOSE)......................................................................................... 923 Description........................................................................................................ 923 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 924 ECM Terminals and Reference Value.................................................................................. 924 On Board Diagnosis Logic........................................................................................... 924 Possible Cause..................................................................................................... 925 DTC Confirmation Procedure......................................................................................... 925 Wiring Diagram..................................................................................................... 927 Diagnostic Procedure............................................................................................... 928 DTC P0403 EGR VOLUME CONTROL VALVE (CIRCUIT)........................................................................... 933 Description........................................................................................................ 933 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 934 ECM Terminals and Reference Value.................................................................................. 934 On Board Diagnosis Logic........................................................................................... 934 Possible Cause..................................................................................................... 935 DTC Confirmation Procedure......................................................................................... 935 Wiring Diagram..................................................................................................... 936 Diagnostic Procedure............................................................................................... 937 DTC P0420 THREE WAY CATALYST FUNCTION.................................................................................. 940 On Board Diagnosis Logic........................................................................................... 940 DTC Confirmation Procedure......................................................................................... 940 Overall Function Check............................................................................................. 941 Diagnostic Procedure............................................................................................... 941 DTC P0440 EVAP CONTROL SYSTEM (SMALL LEAK) (NEGATIVE PRESSURE)......................................................... 944 On Board Diagnosis Logic........................................................................................... 944 Possible Cause..................................................................................................... 944 DTC Confirmation Procedure......................................................................................... 945 Diagnostic Procedure............................................................................................... 946 DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE (CIRCUIT).................................................. 958 Description........................................................................................................ 958 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 958 ECM Terminals and Reference Value.................................................................................. 959 On Board Diagnosis Logic........................................................................................... 959 Possible Cause..................................................................................................... 959 DTC Confirmation Procedure......................................................................................... 960 Wiring Diagram..................................................................................................... 961 Diagnostic Procedure............................................................................................... 962 DTC P0446 EVAPORATIVE EMISSION (EVAP) CANISTER VENT CONTROL VALVE (CIRCUIT)............................................ 965 Component Description.............................................................................................. 965 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 965 ECM Terminals and Reference Value.................................................................................. 965 On Board Diagnosis Logic........................................................................................... 965 Possible Cause..................................................................................................... 966 DTC Confirmation Procedure......................................................................................... 966 Wiring Diagram..................................................................................................... 967 Diagnostic Procedure............................................................................................... 968 DTC P0450 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PRESSURE SENSOR................................................... 972 Component Description.............................................................................................. 972 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 972 ECM Terminals and Reference Value.................................................................................. 972 On Board Diagnosis Logic........................................................................................... 973 Possible Cause..................................................................................................... 973 DTC Confirmation Procedure......................................................................................... 973 Wiring Diagram..................................................................................................... 975 Diagnostic Procedure............................................................................................... 976 DTC P0455 EVAP CONTROL SYSTEM (GROSS LEAK)............................................................................. 985 On Board Diagnosis Logic........................................................................................... 985 Possible Cause..................................................................................................... 985 DTC Confirmation Procedure......................................................................................... 986 Diagnostic Procedure............................................................................................... 987 DTC P0460 FUEL LEVEL SENSOR FUNCTION (SLOSH)........................................................................... 996 Component Description.............................................................................................. 996 ECM Terminals and Reference Value.................................................................................. 996 On Board Diagnostic Logic.......................................................................................... 996 Possible Cause..................................................................................................... 996 DTC Confirmation Procedure......................................................................................... 997 Wiring Diagram..................................................................................................... 998 Diagnostic Procedure............................................................................................... 999 DTC P0461 FUEL LEVEL SENSOR FUNCTION...................................................................................1001 Component Description..............................................................................................1001 On Board Diagnostic Logic..........................................................................................1001 Possible Cause.....................................................................................................1001 Overall Function Check.............................................................................................1001 DTC P0464 FUEL LEVEL SENSOR CIRCUIT....................................................................................1003 Component Description..............................................................................................1003 ECM Terminals and Reference Value..................................................................................1003 On Board Diagnostic Logic..........................................................................................1003 Possible Cause.....................................................................................................1003 DTC Confirmation Procedure.........................................................................................1004 Wiring Diagram.....................................................................................................1005 Diagnostic Procedure...............................................................................................1006 DTC P0500 VEHICLE SPEED SENSOR (VSS)...................................................................................1008 Component Description..............................................................................................1008 ECM Terminals and Reference Value..................................................................................1008 On Board Diagnosis Logic...........................................................................................1008 DTC Confirmation Procedure.........................................................................................1008 Overall Function Check.............................................................................................1009 Wiring Diagram.....................................................................................................1010 Diagnostic Procedure...............................................................................................1011 DTC P0505 IDLE AIR CONTROL VALVE (IACV) - AUXILIARY AIR CONTROL (AAC) VALVE............................................1012 Description........................................................................................................1012 CONSULT-II Reference Value in Data Monitor Mode....................................................................1013 ECM Terminals and Reference Value..................................................................................1013 On Board Diagnosis Logic...........................................................................................1013 DTC Confirmation Procedure.........................................................................................1013 Wiring Diagram.....................................................................................................1015 Diagnostic Procedure...............................................................................................1016 DTC P0510 CLOSED THROTTLE POSITION SWITCH..............................................................................1021 Component Description..............................................................................................1021 CONSULT-II Reference Value in Data Monitor Mode....................................................................1021 ECM Terminals and Reference Value..................................................................................1021 On Board Diagnosis Logic...........................................................................................1021 DTC Confirmation Procedure.........................................................................................1022 Overall Function Check.............................................................................................1022 Wiring Diagram.....................................................................................................1023 Diagnostic Procedure...............................................................................................1024 DTC P0600 A/T CONTROL..................................................................................................1029 System Description.................................................................................................1029 ECM Terminals and Reference Value..................................................................................1029 On Board Diagnosis Logic...........................................................................................1029 DTC Confirmation Procedure.........................................................................................1029 Wiring Diagram.....................................................................................................1030 Diagnostic Procedure...............................................................................................1031 DTC P0605 ECM..........................................................................................................1032 Component Description..............................................................................................1032 On Board Diagnosis Logic...........................................................................................1032 DTC Confirmation Procedure.........................................................................................1032 Diagnostic Procedure...............................................................................................1033 DTC P1126 THERMOSTAT FUNCTION..........................................................................................1034 On Board Diagnosis Logic...........................................................................................1034 Possible Cause.....................................................................................................1034 DTC Confirmation Procedure.........................................................................................1034 Diagnostic Procedure...............................................................................................1035 DTC P1148 CLOSED LOOP CONTROL..........................................................................................1036 On Board Diagnosis Logic...........................................................................................1036 DTC Confirmation Procedure.........................................................................................1036 Overall Function Check.............................................................................................1037 Diagnostic Procedure...............................................................................................1037 DTC P1217 ENGINE OVER TEMPERATURE (OVERHEAT)...........................................................................1038 System Description.................................................................................................1038 CONSULT-II Reference Value in Data Monitor Mode....................................................................1038 ECM Terminals and Reference Value..................................................................................1039 On Board Diagnosis Logic...........................................................................................1039 Overall Function Check.............................................................................................1040 Wiring Diagram.....................................................................................................1041 Diagnostic Procedure...............................................................................................1042 Main 12 Causes of Overheating......................................................................................1054 Component Inspection...............................................................................................1054 DTC P1336 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) (COG)................................................................1056 Component Description..............................................................................................1056 ECM Terminals and Reference Value..................................................................................1056 On Board Diagnosis Logic...........................................................................................1056 DTC Confirmation Procedure.........................................................................................1057 Wiring Diagram.....................................................................................................1058 Diagnostic Procedure...............................................................................................1059 Component Inspection...............................................................................................1061 DTC P1401 EGR TEMPERATURE SENSOR.......................................................................................1062 Component Description..............................................................................................1062 On Board Diagnosis Logic...........................................................................................1062 Possible Cause.....................................................................................................1062 DTC Confirmation Procedure.........................................................................................1063 Wiring Diagram.....................................................................................................1065 Diagnostic Procedure...............................................................................................1066 DTC P1402 EGR FUNCTION (OPEN)..........................................................................................1070 Description........................................................................................................1070 CONSULT-II Reference Value in Data Monitor Mode....................................................................1071 ECM Terminals and Reference Value..................................................................................1071 On Board Diagnosis Logic...........................................................................................1071 Possible Cause.....................................................................................................1072 DTC Confirmation Procedure.........................................................................................1072 Wiring Diagram.....................................................................................................1074 Diagnostic Procedure...............................................................................................1075 DTC P1440 EVAP CONTROL SYSTEM (SMALL LEAK) (POSITIVE PRESSURE).........................................................1080 On Board Diagnosis Logic...........................................................................................1080 Possible Cause.....................................................................................................1080 DTC Confirmation Procedure.........................................................................................1081 Diagnostic Procedure...............................................................................................1081 DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE............................................................1082 Description........................................................................................................1082 CONSULT-II Reference Value in Data Monitor Mode....................................................................1082 ECM Terminals and Reference Value..................................................................................1083 On Board Diagnosis Logic...........................................................................................1083 Possible Cause.....................................................................................................1083 DTC Confirmation Procedure.........................................................................................1084 Wiring Diagram.....................................................................................................1085 Diagnostic Procedure...............................................................................................1086 DTC P1446 EVAPORATIVE EMISSION (EVAP) CANISTER VENT CONTROL VALVE (CLOSE)..............................................1094 Component Description..............................................................................................1094 CONSULT-II Reference Value in Data Monitor Mode....................................................................1094 ECM Terminals and Reference Value..................................................................................1094 On Board Diagnosis Logic...........................................................................................1094 Possible Cause.....................................................................................................1095 DTC Confirmation Procedure.........................................................................................1095 Wiring Diagram.....................................................................................................1096 Diagnostic Procedure...............................................................................................1097 DTC P1447 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PURGE FLOW MONITORING.............................................1102 System Description.................................................................................................1102 On Board Diagnosis Logic...........................................................................................1102 Possible Cause.....................................................................................................1102 DTC Confirmation Procedure.........................................................................................1103 Overall Function Check.............................................................................................1103 Diagnostic Procedure...............................................................................................1105 DTC P1448 EVAPORATIVE EMISSION (EVAP) CANISTER VENT CONTROL VALVE (OPEN)...............................................1114 Component Description..............................................................................................1114 CONSULT-II Reference Value in Data Monitor Mode....................................................................1114 ECM Terminals and Reference Value..................................................................................1114 On Board Diagnosis Logic...........................................................................................1114 Possible Cause.....................................................................................................1115 DTC Confirmation Procedure.........................................................................................1115 Overall Function Check.............................................................................................1116 Wiring Diagram.....................................................................................................1117 Diagnostic Procedure...............................................................................................1118 DTC P1464 FUEL LEVEL SENSOR CIRCUIT (GROUND SIGNAL)....................................................................1123 Component Description..............................................................................................1123 ECM Terminals and Reference Value..................................................................................1123 On Board Diagnostic Logic..........................................................................................1123 Possible Cause.....................................................................................................1123 DTC Confirmation Procedure.........................................................................................1124 Wiring Diagram.....................................................................................................1125 Diagnostic Procedure...............................................................................................1126 DTC P1490 VACUUM CUT VALVE BYPASS VALVE (CIRCUIT)......................................................................1127 Description........................................................................................................1127 CONSULT-II Reference Value in Data Monitor Mode....................................................................1127 ECM Terminals and Reference Value..................................................................................1127 On Board Diagnosis Logic...........................................................................................1128 Possible Cause.....................................................................................................1128 DTC Confirmation Procedure.........................................................................................1128 Wiring Diagram.....................................................................................................1129 Diagnostic Procedure...............................................................................................1130 DTC P1491 VACUUM CUT VALVE BYPASS VALVE................................................................................1133 Description........................................................................................................1133 CONSULT-II Reference Value in Data Monitor Mode....................................................................1133 ECM Terminals and Reference Value..................................................................................1133 On Board Diagnosis Logic...........................................................................................1134 Possible Cause.....................................................................................................1134 DTC Confirmation Procedure.........................................................................................1134 Overall Function Check.............................................................................................1135 Wiring Diagram.....................................................................................................1136 Diagnostic Procedure...............................................................................................1137 DTC P1605 A/T DIAGNOSIS COMMUNICATION LINE.............................................................................1145 System Description.................................................................................................1145 ECM Terminals and Reference Value..................................................................................1145 On Board Diagnosis Logic...........................................................................................1145 DTC Confirmation Procedure.........................................................................................1145 Wiring Diagram.....................................................................................................1146 Diagnostic Procedure...............................................................................................1147 DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH...........................................................................1148 Component Description..............................................................................................1148 CONSULT-II Reference Value in Data Monitor Mode....................................................................1148 ECM Terminals and Reference Value..................................................................................1148 On Board Diagnosis Logic...........................................................................................1148 DTC Confirmation Procedure.........................................................................................1148 Overall Function Check.............................................................................................1149 Wiring Diagram.....................................................................................................1150 Diagnostic Procedure For M/T Models................................................................................1151 Diagnostic Procedure For A/T Models................................................................................1153 IGNITION SIGNAL........................................................................................................1155 Component Description..............................................................................................1155 CONSULT-II Reference Value in Data Monitor Mode....................................................................1155 ECM Terminals and Reference Value..................................................................................1155 Wiring Diagram.....................................................................................................1157 Diagnostic Procedure...............................................................................................1158 Component Inspection...............................................................................................1162 INJECTOR...............................................................................................................1163 Component Description..............................................................................................1163 CONSULT-II Reference Value in Data Monitor Mode....................................................................1163 ECM Terminals and Reference Value..................................................................................1163 Wiring Diagram.....................................................................................................1164 Diagnostic Procedure...............................................................................................1165 START SIGNAL...........................................................................................................1168 CONSULT-II Reference Value in Data Monitor Mode....................................................................1168 ECM Terminals and Reference Value..................................................................................1168 Wiring Diagram.....................................................................................................1169 Diagnostic Procedure...............................................................................................1170 FUEL PUMP..............................................................................................................1172 System Description.................................................................................................1172 Component Description..............................................................................................1172 CONSULT-II Reference Value in Data Monitor Mode....................................................................1172 ECM Terminals and Reference Value..................................................................................1173 Wiring Diagram.....................................................................................................1174 Diagnostic Procedure...............................................................................................1175 Component Inspection...............................................................................................1180 POWER STEERING OIL PRESSURE SWITCH.....................................................................................1181 Component Description..............................................................................................1181 CONSULT-II Reference Value in Data Monitor Mode....................................................................1181 ECM Terminals and Reference Value..................................................................................1181 Wiring Diagram.....................................................................................................1182 Diagnostic Procedure...............................................................................................1183 Component Inspection...............................................................................................1185 REFRIGERANT PRESSURE SENSOR............................................................................................1186 Description........................................................................................................1186 ECM Terminals and Reference Value..................................................................................1186 Wiring Diagram.....................................................................................................1187 Diagnostic Procedure...............................................................................................1188 ELECTRICAL LOAD SIGNAL.................................................................................................1191 CONSULT-II Reference Value in Data Monitor Mode....................................................................1191 ECM Terminals and Reference Value..................................................................................1191 Wiring Diagram.....................................................................................................1192 Diagnostic Procedure...............................................................................................1194 MIL & DATA LINK CONNECTORS.............................................................................................1198 Wiring Diagram.....................................................................................................1198 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1199 Fuel Pressure Regulator............................................................................................1199 Idle Speed and Ignition Timing.....................................................................................1199 Ignition Coil......................................................................................................1199 Mass Air Flow Sensor...............................................................................................1199 Engine Coolant Temperature Sensor..................................................................................1199 EGR Volume Control Valve...........................................................................................1199 EGR Temperature Sensor.............................................................................................1199 Fuel Pump..........................................................................................................1200 IACV-AAC Valve.....................................................................................................1200 Injector...........................................................................................................1200 Resistor...........................................................................................................1200 Throttle Position Sensor...........................................................................................1200 Heated Oxygen Sensor 1 Heater (Front)..............................................................................1200 Calculated Load Value..............................................................................................1200 Intake Air Temperature Sensor......................................................................................1200 EVAP Canister Purge Volume Control Valve...........................................................................1200 Heated Oxygen Sensor 2 Heater (Rear)...............................................................................1200 Crankshaft Position Sensor (OBD)...................................................................................1200 Fuel Tank Temperature Sensor.......................................................................................1201 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.........................................................................................................................1202 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1202 PRECAUTIONS............................................................................................................1205 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................1205 Wiring Diagrams and Trouble Diagnosis..............................................................................1205 HARNESS CONNECTOR......................................................................................................1206 Description........................................................................................................1206 STANDARDIZED RELAY.....................................................................................................1208 Description........................................................................................................1208 POWER SUPPLY ROUTING...................................................................................................1210 Schematic..........................................................................................................1210 Wiring Diagram - POWER -...........................................................................................1211 Inspection.........................................................................................................1218 GROUND.................................................................................................................1219 Ground Distribution................................................................................................1219 COMBINATION SWITCH.....................................................................................................1227 Check..............................................................................................................1227 Replacement........................................................................................................1228 STEERING SWITCH........................................................................................................1229 Check..............................................................................................................1229 HEADLAMP (FOR USA).....................................................................................................1231 Component Parts and Harness Connector Location.....................................................................1231 System Description.................................................................................................1231 Schematic..........................................................................................................1234 Wiring Diagram - H/LAMP -..........................................................................................1235 Trouble Diagnoses..................................................................................................1238 Bulb Replacement...................................................................................................1241 Aiming Adjustment..................................................................................................1241 HEADLAMP (FOR CANADA) - DAYTIME LIGHT SYSTEM -.........................................................................1243 Component Parts and Harness Connector Location.....................................................................1243 System Description.................................................................................................1243 Schematic..........................................................................................................1246 Wiring Diagram - DTRL -............................................................................................1247 Trouble Diagnoses..................................................................................................1251 Bulb Replacement...................................................................................................1252 Aiming Adjustment..................................................................................................1252 PARKING, LICENSE AND TAIL LAMPS........................................................................................1253 System Description.................................................................................................1253 Schematic..........................................................................................................1254 Wiring Diagram - TAIL/L -..........................................................................................1255 Trouble Diagnoses..................................................................................................1258 STOP LAMP..............................................................................................................1259 Wiring Diagram - STOP/L -..........................................................................................1259 BACK-UP LAMP...........................................................................................................1260 Wiring Diagram - BACK/L -..........................................................................................1260 FRONT FOG LAMP.........................................................................................................1261 System Description.................................................................................................1261 Wiring Diagram - F/FOG -...........................................................................................1263 Aiming Adjustment..................................................................................................1265 TURN SIGNAL AND HAZARD WARNING LAMPS...................................................................................1266 System Description.................................................................................................1266 Wiring Diagram - TURN -............................................................................................1268 Trouble Diagnoses..................................................................................................1270 Electrical Components Inspection...................................................................................1270 ILLUMINATION...........................................................................................................1271 System Description.................................................................................................1271 Schematic..........................................................................................................1273 Wiring Diagram - ILL -.............................................................................................1274 INTERIOR ROOM LAMP.....................................................................................................1278 System Description.................................................................................................1278 Wiring Diagram - ROOM/L -..........................................................................................1280 VANITY MIRROR AND TRUNK ROOM LAMPS.....................................................................................1282 System Description.................................................................................................1282 Wiring Diagram - INT/L -...........................................................................................1283 METERS AND GAUGES......................................................................................................1284 Component Parts and Harness Connector Location.....................................................................1284 System Description.................................................................................................1284 Combination Meter..................................................................................................1286 Wiring Diagram - METER -...........................................................................................1287 Meter/Gauge Operation and Odo/Trip Meter Segment Check in Diagnosis Mode...........................................1288 Flexible Print Circuit (FPC).......................................................................................1289 Trouble Diagnoses..................................................................................................1290 Electrical Components Inspection...................................................................................1297 WARNING LAMPS..........................................................................................................1299 Schematic..........................................................................................................1299 Wiring Diagram - WARN -............................................................................................1300 Electrical Components Inspection...................................................................................1304 A/T INDICATOR..........................................................................................................1305 Wiring Diagram - AT/IND -..........................................................................................1305 WARNING CHIME..........................................................................................................1306 Component Parts and Harness Connector Location.....................................................................1306 System Description.................................................................................................1306 Wiring Diagram - CHIME -...........................................................................................1308 Trouble Diagnoses..................................................................................................1310 FRONT WIPER AND WASHER.................................................................................................1315 System Description.................................................................................................1315 Wiring Diagram - WIPER -...........................................................................................1317 Removal and Installation...........................................................................................1318 Washer Nozzle Adjustment...........................................................................................1319 Washer Tube Layout.................................................................................................1319 HORN...................................................................................................................1320 Wiring Diagram - HORN -............................................................................................1320 CIGARETTE LIGHTER......................................................................................................1321 Wiring Diagram - CIGAR -...........................................................................................1321 REAR WINDOW DEFOGGER...................................................................................................1322 Component Parts and Harness Connector Location.....................................................................1322 System Description.................................................................................................1322 Wiring Diagram - DEF -.............................................................................................1324 Trouble Diagnoses..................................................................................................1326 Electrical Components Inspection...................................................................................1328 Filament Check.....................................................................................................1328 Filament Repair....................................................................................................1329 AUDIO..................................................................................................................1331 System Description.................................................................................................1331 Wiring Diagram - AUDIO -...........................................................................................1332 Trouble Diagnoses..................................................................................................1334 Inspection.........................................................................................................1335 AUDIO ANTENNA..........................................................................................................1336 System Description.................................................................................................1336 Wiring Diagram - P/ANT -...........................................................................................1337 Trouble Diagnoses..................................................................................................1338 Location of Antenna................................................................................................1338 Antenna Rod Replacement............................................................................................1338 TRUNK LID AND FUEL FILLER LID OPENER...................................................................................1340 Wiring Diagram - TLID -............................................................................................1340 POWER SUNROOF..........................................................................................................1341 System Description.................................................................................................1341 Wiring Diagram - SROOF -...........................................................................................1342 DOOR MIRROR............................................................................................................1344 Wiring Diagram - MIRROR -..........................................................................................1344 POWER SEAT.............................................................................................................1345 Wiring Diagram - SEAT -............................................................................................1345 HEATED SEAT............................................................................................................1346 Wiring Diagram - HSEAT -...........................................................................................1346 AUTOMATIC SPEED CONTROL DEVICE (ASCD)..................................................................................1347 Component Parts and Harness Connector Location.....................................................................1347 System Description.................................................................................................1348 Schematic..........................................................................................................1350 Wiring Diagram - ASCD -............................................................................................1351 Fail-safe System...................................................................................................1355 Trouble Diagnoses..................................................................................................1356 Electrical Component Inspection....................................................................................1365 ASCD Wire Adjustment...............................................................................................1366 POWER WINDOW...........................................................................................................1367 System Description.................................................................................................1367 Schematic..........................................................................................................1369 Wiring Diagram - WINDOW -..........................................................................................1370 Trouble Diagnoses..................................................................................................1374 POWER DOOR LOCK........................................................................................................1377 Component Parts and Harness Connector Location.....................................................................1377 System Description.................................................................................................1377 Schematic..........................................................................................................1378 Wiring Diagram - D/LOCK -..........................................................................................1379 Trouble Diagnoses..................................................................................................1382 MULTI-REMOTE CONTROL SYSTEM............................................................................................1391 Component Parts and Harness Connector Location.....................................................................1391 System Description.................................................................................................1391 Schematic..........................................................................................................1394 Wiring Diagram - MULTI -...........................................................................................1395 Trouble Diagnoses..................................................................................................1398 ID Code Entry Procedure............................................................................................1411 Remote Controller Battery Replacement..............................................................................1415 VEHICLE SECURITY (THEFT WARNING) SYSTEM................................................................................1416 Component Parts and Harness Connector Location.....................................................................1416 System Description.................................................................................................1417 Schematic..........................................................................................................1420 Wiring Diagram - VEHSEC -..........................................................................................1421 Trouble Diagnoses..................................................................................................1425 SMART ENTRANCE CONTROL UNIT............................................................................................1444 Description........................................................................................................1444 Schematic..........................................................................................................1447 Smart Entrance Control Unit Inspection Table.......................................................................1449 IVIS (INFINITI VEHICLE IMMOBILIZER SYSTEM - NATS)......................................................................1450 Component Parts and Harness Connetor Location......................................................................1450 System Description.................................................................................................1451 System Composition.................................................................................................1451 Wiring Diagram - NATS -............................................................................................1452 CONSULT-II.........................................................................................................1453 Trouble Diagnoses..................................................................................................1456 How to Replace IVIS (NATS) IMMU....................................................................................1469 INTEGRATED HOMELINK TRANSMITTER........................................................................................1470 Wiring Diagram - TRNSMT -..........................................................................................1470 Trouble Diagnoses..................................................................................................1471 INFINITI COMMUNICATOR (IVCS)...........................................................................................1473 Precaution.........................................................................................................1473 Communicator Response Center Telephone Number for Technicians......................................................1473 Component Parts and Harness Connector Location.....................................................................1474 System Description.................................................................................................1475 Schematic..........................................................................................................1483 Wiring Diagram - IVCS -............................................................................................1484 CONSULT-II.........................................................................................................1488 Trouble Diagnoses..................................................................................................1493 Trouble Diagnoses for Intermittent Incident........................................................................1503 Demonstration Mode.................................................................................................1505 System Setting (When IVCS Unit is Replaced)........................................................................1507 ELECTRICAL UNITS LOCATION..............................................................................................1511 Engine Compartment.................................................................................................1511 Luggage Compartment................................................................................................1512 Passenger Compartment..............................................................................................1513 HARNESS LAYOUT.........................................................................................................1515 How to Read Harness Layout.........................................................................................1515 Outline............................................................................................................1516 Main Harness.......................................................................................................1517 Engine Room Harness................................................................................................1519 Engine Control Harness.............................................................................................1522 Body Harness.......................................................................................................1523 Body No. 2 Harness.................................................................................................1524 Tail & Tail No. 2 Harness..........................................................................................1525 Engine Harness.....................................................................................................1526 Room Lamp Harness..................................................................................................1527 Air Bag Harness....................................................................................................1528 Front Door Harness.................................................................................................1529 Rear Door Harness..................................................................................................1530 BULB SPECIFICATIONS....................................................................................................1531 Headlamp...........................................................................................................1531 Exterior Lamp......................................................................................................1531 Interior Lamp......................................................................................................1531 WIRING DIAGRAM CODES (CELL CODES)......................................................................................1532 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.........................................................................................................................1534 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1534 PRECAUTIONS............................................................................................................1536 Parts Requiring Angular Tightening.................................................................................1536 Liquid Gasket Application Procedure................................................................................1536 PREPARATION............................................................................................................1537 Special Service Tools..............................................................................................1537 Commercial Service Tools...........................................................................................1539 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................1541 NVH Troubleshooting - Engine Noise.................................................................................1542 OUTER COMPONENT PARTS..................................................................................................1543 Removal and Installation...........................................................................................1543 MEASUREMENT OF COMPRESSION PRESSURE....................................................................................1546 OIL PAN................................................................................................................1547 Components.........................................................................................................1547 Removal............................................................................................................1547 Installation.......................................................................................................1549 TIMING CHAIN...........................................................................................................1552 Components.........................................................................................................1552 Removal............................................................................................................1553 Inspection.........................................................................................................1556 Installation.......................................................................................................1556 OIL SEAL...............................................................................................................1561 Replacement........................................................................................................1561 VALVE OIL SEAL.................................................................................................1561 FRONT OIL SEAL.................................................................................................1561 REAR OIL SEAL..................................................................................................1562 CYLINDER HEAD..........................................................................................................1563 Components.........................................................................................................1563 Removal............................................................................................................1564 Disassembly........................................................................................................1567 Inspection.........................................................................................................1569 CYLINDER HEAD DISTORTION.......................................................................................1569 CAMSHAFT VISUAL CHECK..........................................................................................1569 CAMSHAFT RUNOUT................................................................................................1569 CAMSHAFT CAM HEIGHT............................................................................................1569 CAMSHAFT JOURNAL CLEARANCE.....................................................................................1570 CAMSHAFT END PLAY..............................................................................................1570 CAMSHAFT SPROCKET RUNOUT.......................................................................................1571 VALVE GUIDE CLEARANCE..........................................................................................1571 VALVE GUIDE REPLACEMENT........................................................................................1571 VALVE SEATS....................................................................................................1572 REPLACING VALVE SEAT FOR SERVICE PARTS.........................................................................1573 VALVE DIMENSIONS...............................................................................................1574 VALVE SPRING...................................................................................................1574 HYDRAULIC LASH ADJUSTER........................................................................................1574 ROCKER ARM, SHIM AND ROCKER ARM GUIDE..........................................................................1575 Assembly...........................................................................................................1575 Installation.......................................................................................................1579 ENGINE ASSEMBLY........................................................................................................1588 Removal and Installation...........................................................................................1588 REMOVAL........................................................................................................1589 INSTALLATION...................................................................................................1590 CYLINDER BLOCK.........................................................................................................1591 Components.........................................................................................................1591 Removal and Installation...........................................................................................1592 Disassembly........................................................................................................1592 PISTON AND CRANKSHAFT..........................................................................................1592 Inspection.........................................................................................................1592 PISTON AND PISTON PIN CLEARANCE................................................................................1592 PISTON RING SIDE CLEARANCE.....................................................................................1593 PISTON RING END GAP............................................................................................1594 CONNECTING ROD BEND AND TORSION................................................................................1594 CYLINDER BLOCK DISTORTION AND WEAR.............................................................................1594 PISTON-TO-BORE CLEARANCE.......................................................................................1595 CRANKSHAFT.....................................................................................................1596 BEARING CLEARANCE..............................................................................................1596 CONNECTING ROD BUSHING CLEARANCE (SMALL END)...................................................................1599 REPLACEMENT OF CONNECTING ROD BUSHING (SMALL END)..............................................................1599 REPLACEMENT OF PILOT BUSHING (M/T) OR PILOT CONVERTER (A/T)....................................................1599 FLYWHEEL/DRIVE PLATE RUNOUT....................................................................................1600 Assembly...........................................................................................................1600 PISTON.........................................................................................................1600 CRANKSHAFT.....................................................................................................1601 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1604 General Specifications.............................................................................................1604 Compression Pressure...............................................................................................1604 Cylinder Head......................................................................................................1604 Valve..............................................................................................................1605 VALVE..........................................................................................................1605 VALVE SPRING...................................................................................................1605 HYDRAULIC LASH ADJUSTER (HLA)..................................................................................1605 VALVE GUIDE....................................................................................................1606 VALVE SHIM CLEARANCE ADJUSTMENT................................................................................1606 AVAILABLE SHIM.................................................................................................1607 VALVE SEAT.....................................................................................................1608 VALVE SEAT RESURFACE LIMIT.....................................................................................1609 Camshaft and Camshaft Bearing......................................................................................1609 Cylinder Block.....................................................................................................1610 Piston, Piston Ring and Piston pin.................................................................................1611 PISTON.........................................................................................................1611 PISTON RING....................................................................................................1611 PISTON PIN.....................................................................................................1611 Connecting Rod.....................................................................................................1612 Crankshaft.........................................................................................................1613 Main Bearing.......................................................................................................1614 STANDARD.......................................................................................................1614 UNDERSIZE......................................................................................................1614 Connecting Rod Bearing.............................................................................................1614 STANDARD SIZE..................................................................................................1614 UNDERSIZE......................................................................................................1614 Bearing Clearance..................................................................................................1615 Miscellaneous Components...........................................................................................1615 fe.........................................................................................................................1616 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1616 PREPARATION............................................................................................................1617 Special Service Tool...............................................................................................1617 Commercial Service Tools...........................................................................................1617 ACCELERATOR CONTROL SYSTEM.............................................................................................1618 Removal and Installation...........................................................................................1618 Adjusting Accelerator Wire.........................................................................................1618 FUEL SYSTEM............................................................................................................1620 Removal and Installation...........................................................................................1620 FUEL PUMP AND GAUGE............................................................................................1621 EXHAUST SYSTEM.........................................................................................................1623 Removal and Installation...........................................................................................1623 foldout....................................................................................................................1626 QUICK REFERENCE INDEX.................................................................................................. 0 SUPER MULTIPLE JUNCTION (SMJ)..........................................................................................1626 FUSE BLOCK - JUNCTION BOX (J/B)........................................................................................1628 FUSE AND FUSIBLE LINK BOX..............................................................................................1629 ELECTRICAL UNITS.......................................................................................................1630 JOINT CONNECTOR (J/C)..................................................................................................1631 QUICK REFERENCE CHART..................................................................................................1632 gi.........................................................................................................................1633 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1633 PRECAUTIONS............................................................................................................1635 Precautions........................................................................................................1635 PRECAUTIONS FOR SUPPLEMENTAL RESTRAINT SYSTEM (SRS) "AIR BAG" AND "SEAT BELT PRE-TENSIONER"....................1635 PRECAUTIONS FOR IVIS (INFINITI VEHICLE IMMOBILIZER SYSTEM - NATS)..............................................1635 GENERAL PRECAUTIONS............................................................................................1636 PRECAUTIONS FOR MULTIPORT FUEL INJECTION SYSTEM OR ENGINE CONTROL SYSTEM.......................................1638 PRECAUTIONS FOR THREE WAY CATALYST.............................................................................1638 PRECAUTIONS FOR HOSES..........................................................................................1638 PRECAUTIONS FOR ENGINE OILS....................................................................................1639 PRECAUTIONS FOR FUEL...........................................................................................1640 PRECAUTIONS FOR AIR CONDITIONING...............................................................................1640 HOW TO USE THIS MANUAL.................................................................................................1641 HOW TO READ WIRING DIAGRAMS............................................................................................1643 Sample/Wiring Diagram - EXAMPL -...................................................................................1643 OPTIONAL SPLICE................................................................................................1644 CONTROL UNIT TERMINALS AND REFERENCE VALUE CHART...............................................................1645 Description........................................................................................................1646 CONNECTOR SYMBOLS..............................................................................................1648 SWITCH POSITIONS...............................................................................................1649 DETECTABLE LINES AND NON-DETECTABLE LINES......................................................................1649 MULTIPLE SWITCH................................................................................................1650 REFERENCE AREA.................................................................................................1651 HOW TO CHECK TERMINAL..................................................................................................1653 Connector and Terminal Pin Kit.....................................................................................1653 How to Probe Connectors............................................................................................1653 PROBING FROM HARNESS SIDE......................................................................................1653 PROBING FROM TERMINAL SIDE.....................................................................................1653 How to Check Enlarged Contact Spring of Terminal...................................................................1654 Waterproof Connector Inspection....................................................................................1655 RUBBER SEAL INSPECTION.........................................................................................1655 WIRE SEAL INSPECTION...........................................................................................1655 Terminal Lock Inspection...........................................................................................1655 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT..........................................................1656 Work Flow..........................................................................................................1656 Incident Simulation Tests..........................................................................................1657 INTRODUCTION...................................................................................................1657 VEHICLE VIBRATION..............................................................................................1657 HEAT SENSITIVE.................................................................................................1658 FREEZING.......................................................................................................1658 WATER INTRUSION................................................................................................1659 ELECTRICAL LOAD................................................................................................1659 COLD OR HOT START UP...........................................................................................1659 Circuit Inspection.................................................................................................1659 INTRODUCTION...................................................................................................1659 TESTING FOR "OPENS" IN THE CIRCUIT.............................................................................1660 TESTING FOR "SHORTS" IN THE CIRCUIT............................................................................1661 GROUND INSPECTION..............................................................................................1662 VOLTAGE DROP TESTS.............................................................................................1662 CONTROL UNIT CIRCUIT TEST......................................................................................1664 HOW TO FOLLOW TROUBLE DIAGNOSES........................................................................................1666 How to Follow Test Groups in Trouble Diagnoses.....................................................................1667 Harness Wire Color and Connector Number Indication.................................................................1668 TYPE 1: HARNESS WIRE COLOR AND CONNECTOR NUMBER ARE SHOWN IN ILLUSTRATION......................................1668 TYPE 2: HARNESS WIRE COLOR AND CONNECTOR NUMBER ARE SHOWN IN TEXT..............................................1668 Key to Symbols Signifying Measurements or Procedures...............................................................1669 CONSULT-II CHECKING SYSTEM.............................................................................................1671 Function and System Application....................................................................................1671 Nickel Metal Hydride Battery Replacement...........................................................................1672 Checking Equipment.................................................................................................1672 CONSULT-II Data Link Connector (DLC) Circuit.......................................................................1673 INSPECTION PROCEDURE...........................................................................................1673 IDENTIFICATION INFORMATION.............................................................................................1674 Model Variation....................................................................................................1674 Identification Number..............................................................................................1675 VEHICLE IDENTIFICATION NUMBER ARRANGEMENT......................................................................1675 IDENTIFICATION PLATE...........................................................................................1676 ENGINE SERIAL NUMBER...........................................................................................1676 AUTOMATIC TRANSAXLE NUMBER.....................................................................................1676 MANUAL TRANSAXLE NUMBER........................................................................................1676 Dimensions.........................................................................................................1677 Wheels & Tires.....................................................................................................1677 LIFTING POINTS AND TOW TRUCK TOWING....................................................................................1678 Preparation........................................................................................................1678 SPECIAL SERVICE TOOLS..........................................................................................1678 Boad-on Lift.......................................................................................................1678 Garage Jack and Safety Stand.......................................................................................1679 2-pole Lift........................................................................................................1680 Tow Truck Towing...................................................................................................1681 VEHICLE RECOVERY (FREEING A STUCK VEHICLE).....................................................................1682 TIGHTENING TORQUE OF STANDARD BOLTS....................................................................................1683 SAE J1930 TERMINOLOGY LIST.............................................................................................1684 SAE J1930 Terminology List.........................................................................................1684 ha.........................................................................................................................1689 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1689 AUTO...................................................................................................................1689 PRECAUTIONS........................................................................................................1691 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"....................................1691 Precautions for Working with HFC-134a (R-134a).................................................................1691 General Refrigerant Precautions................................................................................1692 Precautions for Leak Detection Dye.............................................................................1692 Identification.................................................................................................1693 Precautions for Refrigerant Connection.........................................................................1693 Precautions for Servicing Compressor...........................................................................1695 Precautions for Service Equipment..............................................................................1695 Wiring Diagrams and Trouble Diagnosis..........................................................................1697 PREPARATION........................................................................................................1698 Special Service Tools..........................................................................................1698 HFC-134a (R-134a) Service Tools and Equipment..................................................................1699 DESCRIPTION........................................................................................................1702 Refrigeration System...........................................................................................1702 Component Layout...............................................................................................1703 Introduction...................................................................................................1704 Features.......................................................................................................1704 Overview of Control System.....................................................................................1707 Control Operation..............................................................................................1707 Discharge Air Flow.............................................................................................1709 TROUBLE DIAGNOSES..................................................................................................1711 Component Location.............................................................................................1711 Circuit Diagram................................................................................................1713 Wiring Diagram - A/C, A -......................................................................................1714 Auto Amp. Terminals and Reference Value........................................................................1717 Self-diagnosis.................................................................................................1719 How to Perform Trouble Diagnoses for Quick and Accurate Repair.................................................1729 Operational Check..............................................................................................1730 A/C System.....................................................................................................1733 Mode Door Motor................................................................................................1736 Air Mix Door Motor.............................................................................................1742 Intake Door Motor..............................................................................................1746 Blower Motor...................................................................................................1753 Magnet Clutch..................................................................................................1761 Insufficient Cooling...........................................................................................1768 Insufficient Heating...........................................................................................1776 Noise..........................................................................................................1777 Self-diagnosis.................................................................................................1778 Memory Function................................................................................................1779 ECON (ECONOMY) Mode............................................................................................1780 Ambient Sensor Circuit.........................................................................................1780 In-vehicle Sensor Circuit......................................................................................1783 Sunload Sensor Circuit.........................................................................................1787 Intake Sensor Circuit..........................................................................................1790 Air Mix Door Motor PBR Circuit.................................................................................1792 SERVICE PROCEDURE..................................................................................................1793 HFC-134a (R-134a) Service Procedure............................................................................1793 Maintenance of Lubricant Quantity in Compressor................................................................1795 Compressor.....................................................................................................1798 Compressor Clutch..............................................................................................1799 Thermal Protector..............................................................................................1802 Heater Unit (Heater Core)......................................................................................1802 Blower Unit....................................................................................................1803 Cooling Unit (A/C Evaporator)..................................................................................1804 Refrigerant Lines..............................................................................................1805 Belt...........................................................................................................1810 Idle Air Control Valve (IACV) - Auxiliary Air Control (AAC) Valve..............................................1810 Ventilation Air Filter.........................................................................................1810 SERVICE DATA AND SPECIFICATIONS (SDS)..............................................................................1811 Auto...........................................................................................................1811 MANUAL.................................................................................................................1689 PRECAUTIONS........................................................................................................1812 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"....................................1812 Precautions for Working with HFC-134a (R-134a).................................................................1812 General Refrigerant Precautions................................................................................1813 Precautions for Leak Detection Dye.............................................................................1813 Identification.................................................................................................1814 Precautions for Refrigerant Connection.........................................................................1814 Precautions for Servicing Compressor...........................................................................1816 Precautions for Service Equipment..............................................................................1816 Wiring Diagrams and Trouble Diagnosis..........................................................................1818 PREPARATION........................................................................................................1819 Special Service Tools..........................................................................................1819 HFC-134a (R-134a) Service Tools and Equipment..................................................................1820 DESCRIPTION........................................................................................................1823 Refrigeration System...........................................................................................1823 Component Layout...............................................................................................1824 Control Operation..............................................................................................1825 Discharge Air Flow.............................................................................................1826 System Description.............................................................................................1827 TROUBLE DIAGNOSES..................................................................................................1828 Component Location.............................................................................................1828 Circuit Diagram - Air Conditioner..............................................................................1830 Wiring Diagram - A/C, M -......................................................................................1831 How to Perform Trouble Diagnoses for Quick and Accurate Repair.................................................1835 Operational Check..............................................................................................1836 A/C System.....................................................................................................1838 Intake Door....................................................................................................1840 Mode Door Motor................................................................................................1844 Air Mix Door...................................................................................................1850 Blower Motor...................................................................................................1855 Magnet Clutch..................................................................................................1862 Insufficient Cooling...........................................................................................1870 Insufficient Heating...........................................................................................1877 Noise..........................................................................................................1878 SERVICE PROCEDURE..................................................................................................1879 HFC-134a (R-134a) Service Procedure............................................................................1879 Maintenance of Lubricant Quantity in Compressor................................................................1881 Compressor.....................................................................................................1884 Compressor Clutch..............................................................................................1885 Thermal Protector..............................................................................................1888 Heater Unit (Heater Core)......................................................................................1888 Blower Unit....................................................................................................1889 Cooling Unit (A/C Evaporator)..................................................................................1890 Refrigerant Lines..............................................................................................1891 Belt...........................................................................................................1896 Idle Air Control Valve (IACV) - Auxiliary Air Control (AAC) Valve..............................................1896 Ventilation Air Filter.........................................................................................1896 SERVICE DATA AND SPECIFICATIONS (SDS)..............................................................................1897 Manual.........................................................................................................1897 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........................................................................................................................1899 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 Transaxle.................................................................................................. 0 AT - Automatic Transaxle............................................................................................... 0 AX - Front & Rear Axle................................................................................................. 0 SU - Front & Rear Suspension........................................................................................... 0 BR - Brake System...................................................................................................... 0 ST - Steering System................................................................................................... 0 RS - Restraint System.................................................................................................. 0 BT - Body & Trim....................................................................................................... 0 HA - Heater & Air Conditioner.......................................................................................... 0 SC - Starting & Charging System........................................................................................ 0 EL - Electrical System................................................................................................. 0 lc.........................................................................................................................1907 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1907 ENGINE LUBRICATION SYSTEM..............................................................................................1908 Precautions........................................................................................................1908 LIQUID GASKET APPLICATION PROCEDURE............................................................................1908 Preparation........................................................................................................1908 SPECIAL SERVICE TOOLS..........................................................................................1908 Lubrication Circuit................................................................................................1909 Oil Pressure Check.................................................................................................1910 Oil Pump...........................................................................................................1910 REMOVAL........................................................................................................1910 DISASSEMBLY AND ASSEMBLY.......................................................................................1911 INSPECTION.....................................................................................................1911 REGULATOR VALVE INSPECTION.....................................................................................1912 INSTALLATION...................................................................................................1913 Oil Filter.........................................................................................................1913 Service Data and Specifications (SDS)..............................................................................1913 OIL PRESSURE CHECK.............................................................................................1913 REGULATOR VALVE INSPECTION.....................................................................................1913 OIL PUMP INSPECTION............................................................................................1913 ENGINE COOLING SYSTEM..................................................................................................1914 Precautions........................................................................................................1914 LIQUID GASKET APPLICATION PROCEDURE............................................................................1914 Preparation........................................................................................................1914 SPECIAL SERVICE TOOL...........................................................................................1914 Cooling Circuit....................................................................................................1915 System Check.......................................................................................................1915 CHECKING COOLING SYSTEM HOSES..................................................................................1915 CHECKING COOLING SYSTEM FOR LEAKS..............................................................................1915 CHECKING RADIATOR..............................................................................................1916 CHECKING RADIATOR CAP..........................................................................................1916 Water Pump.........................................................................................................1916 REMOVAL........................................................................................................1916 INSPECTION.....................................................................................................1917 INSTALLATION...................................................................................................1917 Thermostat.........................................................................................................1918 REMOVAL AND INSTALLATION.......................................................................................1918 INSPECTION.....................................................................................................1919 Water Outlet.......................................................................................................1919 INSPECTION.....................................................................................................1919 INSTALLATION...................................................................................................1919 Radiator...........................................................................................................1920 COMPONENTS.....................................................................................................1920 Cooling Fan Control System.........................................................................................1920 Refilling Engine Coolant...........................................................................................1921 Overheating Cause Analysis.........................................................................................1921 Service Data and Specifications (SDS)..............................................................................1922 THERMOSTAT.....................................................................................................1922 RADIATOR.......................................................................................................1922 ma.........................................................................................................................1923 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1923 PRECAUTIONS............................................................................................................1924 Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................1924 PREPARATION............................................................................................................1925 Special Service Tool...............................................................................................1925 Commercial Service Tool............................................................................................1925 GENERAL MAINTENANCE....................................................................................................1926 PERIODIC MAINTENANCE...................................................................................................1928 Schedule 1.........................................................................................................1929 EMISSION CONTROL SYSTEM MAINTENANCE............................................................................1929 CHASSIS AND BODY MAINTENANCE...................................................................................1930 Schedule 2.........................................................................................................1931 EMISSION CONTROL SYSTEM MAINTENANCE............................................................................1931 CHASSIS AND BODY MAINTENANCE...................................................................................1932 RECOMMENDED FLUIDS AND LUBRICANTS......................................................................................1933 Fluids and Lubricants..............................................................................................1933 SAE Viscosity Number...............................................................................................1933 GASOLINE ENGINE OIL............................................................................................1933 Anti-freeze Coolant Mixture Ratio..................................................................................1934 ENGINE MAINTENANCE.....................................................................................................1935 Checking Drive Belts...............................................................................................1935 Changing Engine Coolant............................................................................................1936 -DRAINING ENGINE COOLANT-......................................................................................1936 -REFILLING ENGINE COOLANT-.....................................................................................1937 -FLUSHING COOLING SYSTEM-......................................................................................1938 Checking Fuel Lines................................................................................................1938 Changing Fuel Filter...............................................................................................1939 WITH CONSULT-II................................................................................................1939 WITHOUT CONSULT-II.............................................................................................1939 Changing Air Cleaner Filter........................................................................................1940 VISCOUS PAPER TYPE.............................................................................................1940 Changing Engine Oil................................................................................................1940 Changing Oil Filter................................................................................................1941 Changing Spark Plugs (Platinum-tipped type)........................................................................1941 Changing Spark Plugs (Conventional type)...........................................................................1942 Checking EVAP Vapor Lines..........................................................................................1943 CHASSIS AND BODY MAINTENANCE...........................................................................................1944 Checking Exhaust System............................................................................................1944 Checking Clutch Fluid Level and Leaks..............................................................................1944 Checking M/T Oil...................................................................................................1944 Changing M/T Oil...................................................................................................1944 Checking A/T Fluid.................................................................................................1945 Changing A/T Fluid.................................................................................................1945 Balancing Wheels...................................................................................................1946 Tire Rotation......................................................................................................1946 Checking Brake Fluid Level and Leaks...............................................................................1946 Checking Brake Lines and Cables....................................................................................1946 Checking Disc Brake................................................................................................1946 ROTOR..........................................................................................................1946 CALIPER........................................................................................................1947 PAD............................................................................................................1947 Checking Steering Gear and Linkage.................................................................................1947 STEERING GEAR..................................................................................................1947 STEERING LINKAGE...............................................................................................1947 Checking Power Steering Fluid and Lines............................................................................1947 CHECKING FLUID LEVEL...........................................................................................1947 CHECKING LINES.................................................................................................1947 Lubricating Locks, Hinges and Hood Latches.........................................................................1948 Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters....................................................1948 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1949 Engine Maintenance.................................................................................................1949 DRIVE BELT DEFLECTION AND TENSION..............................................................................1949 SPARK PLUG TYPE................................................................................................1949 Chassis and Body Maintenance.......................................................................................1949 WHEEL BALANCE..................................................................................................1949 mt.........................................................................................................................1951 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1951 PREPARATION............................................................................................................1952 Special Service Tools..............................................................................................1952 Commercial Service Tools...........................................................................................1954 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................1956 NVH Troubleshooting Chart..........................................................................................1956 DESCRIPTION............................................................................................................1957 Cross-sectional View...............................................................................................1957 DOUBLE-CONE SYNCHRONIZER.......................................................................................1958 ON-VEHICLE SERVICE.....................................................................................................1959 Replacing Oil Seal.................................................................................................1959 DIFFERENTIAL OIL SEAL..........................................................................................1959 STRIKING ROD OIL SEAL..........................................................................................1959 Position Switch Check..............................................................................................1960 BACK-UP LAMP SWITCH............................................................................................1960 PNP SWITCH.....................................................................................................1960 Viscous Coupling Check.............................................................................................1961 REMOVAL AND INSTALLATION...............................................................................................1962 Removal............................................................................................................1962 Installation.......................................................................................................1964 OVERHAUL...............................................................................................................1965 Transaxle Gear Control.............................................................................................1965 Case Components....................................................................................................1966 Gear Components....................................................................................................1967 Shift Control Components...........................................................................................1968 Final Drive Components.............................................................................................1969 DISASSEMBLY............................................................................................................1970 Transaxle Case.....................................................................................................1970 Clutch Housing.....................................................................................................1972 REPAIR FOR COMPONENT PARTS.............................................................................................1976 Input Shaft and Gears..............................................................................................1976 DISASSEMBLY....................................................................................................1976 INSPECTION.....................................................................................................1977 ASSEMBLY.......................................................................................................1978 Mainshaft and Gears................................................................................................1981 DISASSEMBLY....................................................................................................1981 INSPECTION.....................................................................................................1982 ASSEMBLY.......................................................................................................1984 Final Drive........................................................................................................1989 PRE-INSPECTION.................................................................................................1989 DISASSEMBLY....................................................................................................1990 INSPECTION.....................................................................................................1991 ASSEMBLY.......................................................................................................1992 Shift Control Components...........................................................................................1995 INSPECTION.....................................................................................................1995 ASSEMBLY...............................................................................................................1996 Clutch Housing.....................................................................................................1996 Transaxle Case.....................................................................................................2000 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................2006 General Specifications.............................................................................................2006 TRANSAXLE......................................................................................................2006 FINAL GEAR.....................................................................................................2006 Gear End Play......................................................................................................2007 Clearance Between Baulk Ring and Gear..............................................................................2007 3RD, 4TH, 5TH, REVERSE BAULK RING..............................................................................2007 1ST AND 2ND BAULK RING.........................................................................................2007 Available Snap Rings...............................................................................................2007 SNAP RING......................................................................................................2007 Available C-rings..................................................................................................2008 4TH INPUT GEAR C-RING..........................................................................................2008 5TH INPUT GEAR REAR C-RING.....................................................................................2008 MAINSHAFT C-RING...............................................................................................2008 Available Adjusting Shims..........................................................................................2009 INPUT SHAFT REAR BEARING ADJUSTING SHIM........................................................................2009 MAINSHAFT ADJUSTING SHIM.......................................................................................2010 MAINSHAFT REAR BEARING ADJUSTING SHIM..........................................................................2010 Available Thrust Washer............................................................................................2011 MAINSHAFT THRUST WASHER........................................................................................2011 Available Washers..................................................................................................2011 DIFFERENTIAL SIDE GEAR THRUST WASHER...........................................................................2011 Available Shims - Differential Side Bearing Preload and Adjusting Shim.............................................2012 BEARING PRELOAD................................................................................................2012 DIFFERENTIAL SIDE BEARING ADJUSTING SHIMS......................................................................2012 rs.........................................................................................................................2015 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................2015 SEAT BELTS.............................................................................................................2017 Precautions........................................................................................................2017 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) "AIR BAG" AND "SEAT BELT PRE-TENSIONER"....................................2017 PRECAUTION FOR SEAT BELT SERVICE...............................................................................2017 Front Seat Belt....................................................................................................2019 REMOVAL AND INSTALLATION.......................................................................................2019 Rear Seat Belt.....................................................................................................2021 REMOVAL AND INSTALLATION.......................................................................................2021 Seat Belt Inspection...............................................................................................2023 AFTER A COLLISION..............................................................................................2023 PRELIMINARY CHECKS.............................................................................................2023 SEAT BELT RETRACTOR ON-VEHICLE CHECK...........................................................................2024 SEAT BELT RETRACTOR OFF-VEHICLE CHECK..........................................................................2024 Tether Anchor Plate................................................................................................2026 REMOVAL AND INSTALLATION.......................................................................................2026 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)....................................................................................2027 Precautions........................................................................................................2027 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) "AIR BAG" AND "SEAT BELT PRE-TENSIONER"....................................2027 PRECAUTIONS FOR SRS "AIR BAG" AND "SEAT BELT PRE-TENSIONER" SERVICE............................................2027 WIRING DIAGRAMS AND TROUBLE DIAGNOSIS..........................................................................2027 Preparation........................................................................................................2028 SPECIAL SERVICE TOOLS..........................................................................................2028 SRS Configuration..................................................................................................2029 Seat Belt Pre-tensioner with Load Limiter..........................................................................2030 Built-in Type Side Air Bag.........................................................................................2030 SRS Component Parts Location.......................................................................................2031 Maintenance Items..................................................................................................2031 Diagnosis Sensor Unit..............................................................................................2032 REMOVAL AND INSTALLATION.......................................................................................2032 Seat Belt Pre-tensioner............................................................................................2033 REMOVAL AND INSTALLATION.......................................................................................2033 Satellite Sensor...................................................................................................2033 REMOVAL AND INSTALLATION.......................................................................................2033 Driver Air Bag Module and Spiral Cable.............................................................................2034 REMOVAL AND INSTALLATION.......................................................................................2034 REMOVAL........................................................................................................2034 INSTALLATION...................................................................................................2036 Front Passenger Air Bag Module.....................................................................................2037 REMOVAL........................................................................................................2037 INSTALLATION...................................................................................................2037 Side Air Bag Module................................................................................................2038 REMOVAL........................................................................................................2038 INSTALLATION...................................................................................................2039 Disposal of Air Bag Module and Seat Belt Pre-tensioner.............................................................2040 CHECKING DEPLOYMENT TOOL.......................................................................................2040 DEPLOYMENT PROCEDURES FOR AIR BAG MODULE (OUTSIDE OF VEHICLE)..................................................2041 DEPLOYMENT PROCEDURES FOR SEAT BELT PRE-TENSIONER (OUTSIDE OF VEHICLE).........................................2044 DEPLOYMENT OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER WHILE MOUNTED IN VEHICLE..............................2044 DISPOSING OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER........................................................2045 Trouble Diagnoses Introduction.....................................................................................2046 DIAGNOSIS FUNCTION.............................................................................................2046 DIAGNOSIS MODE FOR CONSULT-II..................................................................................2046 HOW TO CHANGE SELF-DIAGNOSIS MODE WITH CONSULT-II..............................................................2047 HOW TO CHANGE SELF-DIAGNOSIS MODE WITHOUT CONSULT-II...........................................................2047 HOW TO ERASE SELF-DIAGNOSIS RESULTS............................................................................2047 How to Perform Trouble Diagnoses for Quick and Accurate Repair.....................................................2049 INFORMATION FROM CUSTOMER......................................................................................2049 PRELIMINARY CHECK..............................................................................................2049 WORK FLOW......................................................................................................2050 Schematic..........................................................................................................2051 Wiring Diagram - SRS -.............................................................................................2052 SRS Operation Check................................................................................................2055 DIAGNOSTIC PROCEDURE 1.........................................................................................2055 Trouble Diagnoses with CONSULT-II..................................................................................2057 DIAGNOSTIC PROCEDURE 2.........................................................................................2057 DIAGNOSTIC PROCEDURE 3.........................................................................................2060 DIAGNOSTIC PROCEDURE 4 (CONTINUED FROM DIAGNOSTIC PROCEDURE 2).................................................2062 DIAGNOSTIC PROCEDURE 5.........................................................................................2062 Trouble Diagnoses without CONSULT-II...............................................................................2066 DIAGNOSTIC PROCEDURE 6.........................................................................................2066 DIAGNOSTIC PROCEDURE 7.........................................................................................2069 DIAGNOSTIC PROCEDURE 8 (CONTINUED FROM DIAGNOSTIC PROCEDURE 6).................................................2071 Trouble Diagnoses: "AIR BAG" Warning Lamp Does Not Turn Off........................................................2072 DIAGNOSTIC PROCEDURE 9.........................................................................................2072 Trouble Diagnoses: "AIR BAG" Warning Lamp Does Not Turn On.........................................................2074 DIAGNOSTIC PROCEDURE 10........................................................................................2074 Trouble Diagnoses: SRS Does Not Enter Diagnosis Mode Using Door Switch.............................................2075 DIAGNOSTIC PROCEDURE 11........................................................................................2075 Trouble Diagnoses: "SEAT BELT" Warning Lamp Does Not Turn Off......................................................2076 DIAGNOSTIC PROCEDURE 12........................................................................................2076 Trouble Diagnoses: "SEAT BELT" Warning Lamp Does Not Turn On.......................................................2078 DIAGNOSTIC PROCEDURE 13........................................................................................2078 Collision Diagnosis................................................................................................2079 FOR FRONTAL COLLISION..........................................................................................2079 FOR SIDE COLLISION.............................................................................................2081 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 sc.........................................................................................................................2083 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................2083 PRECAUTIONS............................................................................................................2084 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................2084 Wiring Diagrams and Trouble Diagnosis..............................................................................2084 PREPARATION............................................................................................................2085 Special Service Tool...............................................................................................2085 BATTERY................................................................................................................2086 How to Handle Battery..............................................................................................2086 METHODS OF PREVENTING OVER-DISCHARGE...........................................................................2086 CHECKING ELECTROLYTE LEVEL.....................................................................................2086 SPECIFIC GRAVITY CHECK.........................................................................................2087 CHARGING THE BATTERY...........................................................................................2088 Trouble Diagnoses with Battery/Starting/Charging System Tester.....................................................2089 DIAGNOSTIC RESULT ITEM CHART...................................................................................2091 STARTING SYSTEM........................................................................................................2092 System Description.................................................................................................2092 M/T MODELS.....................................................................................................2092 A/T MODELS.....................................................................................................2092 Wiring Diagram - START -...........................................................................................2093 M/T MODELS.....................................................................................................2093 A/T MODELS.....................................................................................................2094 Trouble Diagnoses with Battery/Starting/Charging System Tester.....................................................2095 DIAGNOSTIC RESULT ITEM CHART...................................................................................2096 WORK FLOW......................................................................................................2097 DIAGNOSTIC PROCEDURE 1.........................................................................................2098 DIAGNOSTIC PROCEDURE 2.........................................................................................2100 MINIMUM SPECIFICATION OF CRANKING VOLTAGE REFERENCING COOLANT TEMPERATURE......................................2101 Construction.......................................................................................................2101 Removal and Installation...........................................................................................2101 Pinion/Clutch Check................................................................................................2102 CHARGING SYSTEM........................................................................................................2103 System Description.................................................................................................2103 Wiring Diagram - CHARGE -..........................................................................................2104 Trouble Diagnoses with Battery/Starting/Charging System Tester.....................................................2105 DIAGNOSTIC RESULT ITEM CHART...................................................................................2107 WORK FLOW......................................................................................................2108 DIAGNOSTIC PROCEDURE 1.........................................................................................2109 DIAGNOSTIC PROCEDURE 2.........................................................................................2110 DIAGNOSTIC PROCEDURE 3.........................................................................................2111 MALFUNCTION INDICATOR..........................................................................................2111 Construction.......................................................................................................2112 Removal and Installation...........................................................................................2112 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................2113 Battery............................................................................................................2113 Starter............................................................................................................2113 Alternator.........................................................................................................2113 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.........................................................................................................................2115 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................2115 PRECAUTIONS............................................................................................................2116 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................2116 Precautions for Steering System....................................................................................2116 PREPARATION............................................................................................................2117 Special Service Tools..............................................................................................2117 Commercial Service Tools...........................................................................................2118 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................2119 NVH Troubleshooting Chart..........................................................................................2119 ON-VEHICLE SERVICE.....................................................................................................2120 Checking Steering Wheel Play.......................................................................................2120 Checking Neutral Position on Steering Wheel........................................................................2120 PRE-CHECKING...................................................................................................2120 CHECKING.......................................................................................................2120 Front Wheel Turning Angle..........................................................................................2120 Checking Gear Housing Movement.....................................................................................2120 Checking and Adjusting Drive Belts.................................................................................2121 Checking Fluid Level...............................................................................................2121 Checking Fluid Leakage.............................................................................................2121 Bleeding Hydraulic System..........................................................................................2121 Checking Steering Wheel Turning Force..............................................................................2122 Checking Hydraulic System..........................................................................................2122 STEERING WHEEL AND STEERING COLUMN.....................................................................................2124 Components.........................................................................................................2124 Removal and Installation...........................................................................................2124 STEERING WHEEL.................................................................................................2124 STEERING COLUMN................................................................................................2125 Disassembly and Assembly...........................................................................................2127 Inspection.........................................................................................................2128 TILT MECHANISM.................................................................................................2128 POWER STEERING GEAR AND LINKAGE........................................................................................2129 Components.........................................................................................................2129 Removal and Installation...........................................................................................2130 Disassembly........................................................................................................2132 Inspection.........................................................................................................2132 BOOT...........................................................................................................2132 RACK...........................................................................................................2132 PINION ASSEMBLY................................................................................................2133 GEAR HOUSING CYLINDER..........................................................................................2133 TIE-ROD OUTER AND INNER SOCKETS................................................................................2133 Assembly...........................................................................................................2133 Adjustment.........................................................................................................2138 POWER STEERING OIL PUMP................................................................................................2140 Components.........................................................................................................2140 Pre-disassembly Inspection.........................................................................................2140 Disassembly........................................................................................................2140 Inspection.........................................................................................................2141 Assembly...........................................................................................................2142 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................2145 General Specifications.............................................................................................2145 Steering Wheel.....................................................................................................2145 Steering Column....................................................................................................2145 Steering Gear and Linkage..........................................................................................2146 Power Steering.....................................................................................................2147 su.........................................................................................................................2149 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................2149 FRONT SUSPENSION.......................................................................................................2150 Precautions........................................................................................................2150 PRECAUTIONS....................................................................................................2150 Preparation........................................................................................................2150 SPECIAL SERVICE TOOLS..........................................................................................2150 COMMERCIAL SERVICE TOOLS.......................................................................................2150 Noise, Vibration and Harshness (NVH) Troubleshooting...............................................................2151 NVH TROUBLESHOOTING CHART......................................................................................2151 Components.........................................................................................................2152 On-vehicle Service.................................................................................................2153 FRONT SUSPENSION PARTS.........................................................................................2153 FRONT WHEEL ALIGNMENT..........................................................................................2154 Coil Spring and Shock Absorber.....................................................................................2157 COMPONENTS.....................................................................................................2157 REMOVAL........................................................................................................2158 DISASSEMBLY....................................................................................................2158 INSPECTION.....................................................................................................2158 ASSEMBLY.......................................................................................................2159 Third Link and Upper Link..........................................................................................2159 REMOVAL........................................................................................................2159 INSTALLATION...................................................................................................2159 DISASSEMBLY....................................................................................................2160 ASSEMBLY.......................................................................................................2160 Stabilizer Bar.....................................................................................................2161 REMOVAL AND INSTALLATION.......................................................................................2161 Transverse Link and Lower Ball Joint...............................................................................2162 REMOVAL AND INSTALLATION.......................................................................................2162 INSPECTION.....................................................................................................2162 Service Data and Specifications (SDS)..............................................................................2162 GENERAL SPECIFICATIONS (FRONT).................................................................................2162 FRONT WHEEL ALIGNMENT (UNLADEN*1)..............................................................................2163 LOWER BALL JOINT...............................................................................................2163 WHEELARCH HEIGHT (UNLADEN*)....................................................................................2164 WHEEL RUNOUT...................................................................................................2164 REAR SUSPENSION........................................................................................................2165 Precautions........................................................................................................2165 PRECAUTIONS....................................................................................................2165 Preparation........................................................................................................2165 COMMERCIAL SERVICE TOOLS.......................................................................................2165 Noise, Vibration and Harshness (NVH) Troubleshooting...............................................................2165 Components.........................................................................................................2166 On-vehicle Service.................................................................................................2167 REAR SUSPENSION PARTS..........................................................................................2167 REAR WHEEL ALIGNMENT...........................................................................................2167 Removal and Installation...........................................................................................2169 REMOVAL........................................................................................................2170 INSTALLATION...................................................................................................2170 Coil Spring and Shock Absorber.....................................................................................2170 REMOVAL........................................................................................................2170 DISASSEMBLY....................................................................................................2171 INSPECTION.....................................................................................................2171 ASSEMBLY.......................................................................................................2171 Torsion Beam, Lateral Link and Control Rod.........................................................................2172 DISASSEMBLY....................................................................................................2172 INSPECTION.....................................................................................................2172 ASSEMBLY.......................................................................................................2172 Service Data and Specifications (SDS)..............................................................................2173 GENERAL SPECIFICATIONS (REAR)..................................................................................2173 REAR WHEEL ALIGNMENT (UNLADEN*)................................................................................2173
DESCRIPTION:
2001 INFINITI G20 P11 Series Service Manual PDF DOWNLOAD
FOREWORD
- This manual contains maintenance and repair procedures for the 2001 INFINITI G20.
- In order to assure your safety and the efficient functioning of the vehicle, this manual should be read thoroughly.
- It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task.
- All information in this manual is based on the latest product 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 INFINITI must first completely satisfy himself that neither his safety nor the vehicle’s safety will be jeopardized by the service method selected.
Questions? Email us: [email protected]
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PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
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