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2002 INFINITI G20 P11 Series Service Manual PDF DOWNLOAD
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2002 INFINITI G20 P11 Series Service Manual PDF DOWNLOAD
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2002 INFINITI G20 P11 Series Service Manual PDF DOWNLOAD
Language : English
Pages : 2150
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
2002 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 TRUNK LID INSIDE RELEASE HANDLE................................................................................ 526 FRONT DOOR............................................................................................................. 527 Front Door Glass Limit Switch Reset (Driver side only)............................................................. 527 RESET CONDITIONS............................................................................................... 527 RESET PROCEDURES............................................................................................... 527 Overhaul........................................................................................................... 528 REAR DOOR.............................................................................................................. 529 Overhaul........................................................................................................... 529 INSTRUMENT PANEL ASSEMBLY.............................................................................................. 530 Removal and Installation........................................................................................... 530 SIDE AND FLOOR TRIM.................................................................................................... 534 Removal and Installation........................................................................................... 534 DOOR TRIM.............................................................................................................. 536 Removal and Installation........................................................................................... 536 ROOF TRIM.............................................................................................................. 538 Removal and Installation........................................................................................... 538 TRUNK ROOM TRIM........................................................................................................ 540 Removal and Installation........................................................................................... 540 EXTERIOR............................................................................................................... 541 Removal and Installation........................................................................................... 541 FRONT SEAT............................................................................................................. 547 Removal and Installation........................................................................................... 547 POWER SEAT..................................................................................................... 548 HEATED SEAT.................................................................................................... 549 REAR SEAT.............................................................................................................. 550 Removal and Installation........................................................................................... 550 FOLDING SEAT................................................................................................... 550 SUNROOF................................................................................................................ 551 Adjustment......................................................................................................... 551 Removal and Installation........................................................................................... 552 Trouble Diagnoses.................................................................................................. 556 DIAGNOSTIC TABLE............................................................................................... 556 WIND DEFLECTOR................................................................................................. 556 ADJUSTMENT..................................................................................................... 557 DRAIN HOSES.................................................................................................... 558 WEATHERSTRIP................................................................................................... 558 LINK AND WIRE ASSEMBLY......................................................................................... 559 WINDSHIELD AND WINDOWS................................................................................................. 560 Removal and Installation........................................................................................... 560 REMOVAL........................................................................................................ 560 INSTALLATION................................................................................................... 560 WINDSHIELD..................................................................................................... 561 DOOR MIRROR............................................................................................................ 562 Removal and Installation........................................................................................... 562 REAR VIEW MIRROR....................................................................................................... 563 Removal and Installation........................................................................................... 563 REMOVAL........................................................................................................ 563 INSTALLATION................................................................................................... 563 BODY (ALIGNMENT)....................................................................................................... 564 Alignment.......................................................................................................... 564 ENGINE COMPARTMENT............................................................................................. 565 UNDERBODY...................................................................................................... 567 cl......................................................................................................................... 570 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents...................................................................................................... 570 PRECAUTIONS............................................................................................................ 571 Precautions........................................................................................................ 571 PREPARATION............................................................................................................ 572 Special Service Tools.............................................................................................. 572 Commercial Service Tool............................................................................................ 572 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING................................................................... 573 NVH Troubleshooting Chart.......................................................................................... 573 CLUTCH SYSTEM.......................................................................................................... 574 Components......................................................................................................... 574 Inspection and Adjustment.......................................................................................... 575 ADJUSTING CLUTCH PEDAL......................................................................................... 575 BLEEDING PROCEDURE............................................................................................. 576 CLUTCH MASTER CYLINDER................................................................................................. 577 Components......................................................................................................... 577 Removal............................................................................................................ 577 Installation....................................................................................................... 578 Disassembly........................................................................................................ 578 Inspection......................................................................................................... 578 Assembly........................................................................................................... 578 CLUTCH DAMPER.......................................................................................................... 580 Components......................................................................................................... 580 Removal............................................................................................................ 580 Disassembly........................................................................................................ 580 Inspection......................................................................................................... 581 Assembly........................................................................................................... 581 Installation....................................................................................................... 581 OPERATING CYLINDER..................................................................................................... 582 Components......................................................................................................... 582 Removal............................................................................................................ 582 Disassembly........................................................................................................ 582 Inspection......................................................................................................... 583 Assembly........................................................................................................... 583 Installation....................................................................................................... 583 PIPING................................................................................................................. 584 Removal............................................................................................................ 584 Installation....................................................................................................... 584 CLUTCH RELEASE MECHANISM............................................................................................... 585 Components......................................................................................................... 585 Removal............................................................................................................ 585 Inspection......................................................................................................... 585 Installation....................................................................................................... 585 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL................................................................................. 588 Components......................................................................................................... 588 Inspection and Adjustment.......................................................................................... 588 CLUTCH DISC.................................................................................................... 588 CLUTCH COVER AND FLYWHEEL...................................................................................... 588 FLYWHEEL INSPECTION............................................................................................ 589 Installation....................................................................................................... 589 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................. 590 Clutch Control System.............................................................................................. 590 Clutch Master Cylinder............................................................................................. 590 Clutch Operating Cylinder.......................................................................................... 590 Clutch Damper...................................................................................................... 590 Clutch Disc........................................................................................................ 590 Clutch Cover....................................................................................................... 590 Clutch Pedal....................................................................................................... 590 ec......................................................................................................................... 592 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents...................................................................................................... 592 TROUBLE DIAGNOSIS - INDEX.............................................................................................. 599 Alphabetical & P No. Index for DTC................................................................................. 599 PRECAUTIONS............................................................................................................ 605 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................ 605 Precautions for On Board Diagnostic (OBD) System of Engine and A/T................................................. 605 Engine Fuel & Emission Control System.............................................................................. 606 Precautions........................................................................................................ 607 Wiring Diagrams and Trouble Diagnosis.............................................................................. 608 PREPARATION............................................................................................................ 609 Special Service Tools.............................................................................................. 609 Commercial Service Tools........................................................................................... 609 ENGINE AND EMISSION CONTROL OVERALL SYSTEM............................................................................. 611 Engine Control Component Parts Location............................................................................ 611 Circuit Diagram.................................................................................................... 615 System Diagram..................................................................................................... 617 Vacuum Hose Drawing................................................................................................ 618 System Chart....................................................................................................... 619 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION................................................................... 620 Multiport Fuel Injection (MFI) System.............................................................................. 620 Distributor Ignition (DI) System................................................................................... 622 Air Conditioning Cut Control....................................................................................... 623 Fuel Cut Control (at no load & high engine speed).................................................................. 624 Evaporative Emission System........................................................................................ 624 On Board Refueling Vapor Recovery (ORVR)........................................................................... 630 Positive Crankcase Ventilation..................................................................................... 639 BASIC SERVICE PROCEDURE................................................................................................ 641 Fuel Pressure Release.............................................................................................. 641 Fuel Pressure Check................................................................................................ 641 Fuel Pressure Regulator Check...................................................................................... 642 Injector........................................................................................................... 642 Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment........................................................... 644 Idle Air Volume Learning........................................................................................... 656 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION................................................................................. 658 Introduction....................................................................................................... 658 Two Trip Detection Logic........................................................................................... 658 Emission-related Diagnostic Information............................................................................ 659 Malfunction Indicator Lamp (MIL)................................................................................... 672 OBD System Operation Chart......................................................................................... 674 CONSULT-II......................................................................................................... 679 Generic Scan Tool (GST)............................................................................................ 692 TROUBLE DIAGNOSIS - INTRODUCTION....................................................................................... 694 Introduction....................................................................................................... 694 Work Flow.......................................................................................................... 696 TROUBLE DIAGNOSIS - BASIC INSPECTION................................................................................... 698 Basic Inspection................................................................................................... 698 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION................................................................................ 714 DTC Inspection Priority Chart...................................................................................... 714 Fail-safe Chart.................................................................................................... 715 Symptom Matrix Chart............................................................................................... 716 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 720 Major Sensor Reference Graph in Data Monitor Mode.................................................................. 722 ECM Terminals and Reference Value.................................................................................. 725 TROUBLE DIAGNOSIS - SPECIFICATION VALUE................................................................................ 733 Description........................................................................................................ 733 Testing Condition.................................................................................................. 733 Inspection Procedure............................................................................................... 733 Diagnostic Procedure............................................................................................... 734 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT............................................................................ 737 Description........................................................................................................ 737 Diagnostic Procedure............................................................................................... 737 TROUBLE DIAGNOSIS FOR POWER SUPPLY..................................................................................... 738 Main Power Supply and Ground Circuit............................................................................... 738 DTC P0100 MASS AIR FLOW SENSOR (MAFS).................................................................................. 745 Component Description.............................................................................................. 745 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 745 ECM Terminals and Reference Value.................................................................................. 745 On Board Diagnosis Logic........................................................................................... 746 DTC Confirmation Procedure......................................................................................... 746 Overall Function Check............................................................................................. 748 Wiring Diagram..................................................................................................... 749 Diagnostic Procedure............................................................................................... 750 Component Inspection............................................................................................... 753 DTC P0105 ABSOLUTE PRESSURE SENSOR..................................................................................... 754 Component Description.............................................................................................. 754 On Board Diagnosis Logic........................................................................................... 754 DTC Confirmation Procedure......................................................................................... 754 Diagnostic Procedure............................................................................................... 755 DTC P0110 INTAKE AIR TEMPERATURE SENSOR................................................................................ 756 Component Description.............................................................................................. 756 On Board Diagnosis Logic........................................................................................... 756 DTC Confirmation Procedure......................................................................................... 756 Wiring Diagram..................................................................................................... 758 Diagnostic Procedure............................................................................................... 759 Component Inspection............................................................................................... 761 DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR (ECTS) (CIRCUIT)........................................................... 762 Component Description.............................................................................................. 762 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 762 On Board Diagnosis Logic........................................................................................... 762 DTC Confirmation Procedure......................................................................................... 763 Wiring Diagram..................................................................................................... 764 Diagnostic Procedure............................................................................................... 765 Component Inspection............................................................................................... 767 DTC P0120 THROTTLE POSITION SENSOR..................................................................................... 768 Component Description.............................................................................................. 768 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 768 ECM Terminals and Reference Value.................................................................................. 769 On Board Diagnosis Logic........................................................................................... 769 DTC Confirmation Procedure......................................................................................... 770 Wiring Diagram..................................................................................................... 774 Diagnostic Procedure............................................................................................... 775 Component Inspection............................................................................................... 779 DTC P0125 ENGINE COOLANT TEMPERATURE (ECT) SENSOR...................................................................... 781 Component Description.............................................................................................. 781 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 781 On Board Diagnosis Logic........................................................................................... 781 DTC Confirmation Procedure......................................................................................... 782 Wiring Diagram..................................................................................................... 783 Diagnostic Procedure............................................................................................... 784 Component Inspection............................................................................................... 786 DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)..................................................................... 787 Component Description.............................................................................................. 787 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 787 ECM Terminals and Reference Value.................................................................................. 787 On Board Diagnosis Logic........................................................................................... 788 DTC Confirmation Procedure......................................................................................... 788 Overall Function Check............................................................................................. 789 Wiring Diagram..................................................................................................... 790 Diagnostic Procedure............................................................................................... 791 Component Inspection............................................................................................... 793 DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING)....................................................... 795 Component Description.............................................................................................. 795 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 795 ECM Terminals and Reference Value.................................................................................. 795 On Board Diagnosis Logic........................................................................................... 796 DTC Confirmation Procedure......................................................................................... 796 Overall Function Check............................................................................................. 797 Diagnostic Procedure............................................................................................... 797 Component Inspection............................................................................................... 799 DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING)....................................................... 801 Component Description.............................................................................................. 801 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 801 ECM Terminals and Reference Value.................................................................................. 801 On Board Diagnosis Logic........................................................................................... 802 DTC Confirmation Procedure......................................................................................... 802 Overall Function Check............................................................................................. 803 Diagnostic Procedure............................................................................................... 804 Component Inspection............................................................................................... 806 DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)......................................................... 808 Component Description.............................................................................................. 808 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 808 ECM Terminals and Reference Value.................................................................................. 808 On Board Diagnosis Logic........................................................................................... 809 DTC Confirmation Procedure......................................................................................... 809 Overall Function Check............................................................................................. 810 Wiring Diagram..................................................................................................... 811 Diagnostic Procedure............................................................................................... 812 Component Inspection............................................................................................... 815 DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)................................................................ 817 Component Description.............................................................................................. 817 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 817 ECM Terminals and Reference Value.................................................................................. 817 On Board Diagnosis Logic........................................................................................... 818 DTC Confirmation Procedure......................................................................................... 818 Wiring Diagram..................................................................................................... 819 Diagnostic Procedure............................................................................................... 820 Component Inspection............................................................................................... 821 DTC P0135 HEATED OXYGEN SENSOR 1 HEATER (FRONT)........................................................................ 823 Description........................................................................................................ 823 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 823 ECM Terminals and Reference Value.................................................................................. 823 On Board Diagnosis Logic........................................................................................... 823 DTC Confirmation Procedure......................................................................................... 824 Wiring Diagram..................................................................................................... 825 Diagnostic Procedure............................................................................................... 826 Component Inspection............................................................................................... 827 DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)...................................................... 828 Component Description.............................................................................................. 828 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 828 ECM Terminals and Reference Value.................................................................................. 828 On Board Diagnosis Logic........................................................................................... 828 DTC Confirmation Procedure......................................................................................... 829 Overall Function Check............................................................................................. 829 Wiring Diagram..................................................................................................... 830 Diagnostic Procedure............................................................................................... 831 Component Inspection............................................................................................... 834 DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)...................................................... 836 Component Description.............................................................................................. 836 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 836 ECM Terminals and Reference Value.................................................................................. 836 On Board Diagnosis Logic........................................................................................... 836 DTC Confirmation Procedure......................................................................................... 837 Overall Function Check............................................................................................. 837 Wiring Diagram..................................................................................................... 838 Diagnostic Procedure............................................................................................... 839 Component Inspection............................................................................................... 842 DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING).......................................................... 844 Component Description.............................................................................................. 844 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 844 ECM Terminals and Reference Value.................................................................................. 844 On Board Diagnosis Logic........................................................................................... 844 DTC Confirmation Procedure......................................................................................... 845 Overall Function Check............................................................................................. 845 Wiring Diagram..................................................................................................... 846 Diagnostic Procedure............................................................................................... 847 Component Inspection............................................................................................... 850 DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE)................................................................. 852 Component Description.............................................................................................. 852 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 852 ECM Terminals and Reference Value.................................................................................. 852 On Board Diagnosis Logic........................................................................................... 852 DTC Confirmation Procedure......................................................................................... 853 Overall Function Check............................................................................................. 853 Wiring Diagram..................................................................................................... 854 Diagnostic Procedure............................................................................................... 855 Component Inspection............................................................................................... 856 DTC P0141 HEATED OXYGEN SENSOR 2 HEATER (REAR)......................................................................... 858 Description........................................................................................................ 858 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 858 ECM Terminals and Reference Value.................................................................................. 858 On Board Diagnosis Logic........................................................................................... 858 DTC Confirmation Procedure......................................................................................... 859 Wiring Diagram..................................................................................................... 860 Diagnostic Procedure............................................................................................... 861 Component Inspection............................................................................................... 862 DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)................................................................... 863 On Board Diagnosis Logic........................................................................................... 863 DTC Confirmation Procedure......................................................................................... 863 Wiring Diagram..................................................................................................... 865 Diagnostic Procedure............................................................................................... 866 DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)................................................................... 870 On Board Diagnosis Logic........................................................................................... 870 DTC Confirmation Procedure......................................................................................... 870 Wiring Diagram..................................................................................................... 872 Diagnostic Procedure............................................................................................... 873 DTC P0180 FUEL TANK TEMPERATURE SENSOR................................................................................. 877 Component Description.............................................................................................. 877 On Board Diagnosis Logic........................................................................................... 877 DTC Confirmation Procedure......................................................................................... 877 Wiring Diagram..................................................................................................... 879 Diagnostic Procedure............................................................................................... 880 Component Inspection............................................................................................... 881 DTC P0217 COOLANT OVERTEMPERATURE ENRICHMENT PROTECTION................................................................ 882 System Description................................................................................................. 882 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 882 ECM Terminals and Reference Value.................................................................................. 883 On Board Diagnosis Logic........................................................................................... 883 Possible Cause..................................................................................................... 883 Overall Function Check............................................................................................. 884 Wiring Diagram..................................................................................................... 887 Diagnostic Procedure (A/T Models).................................................................................. 889 Diagnostic Procedure (M/T Models).................................................................................. 900 Main 12 Causes of Overheating...................................................................................... 912 DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE................................................ 913 On Board Diagnosis Logic........................................................................................... 913 DTC Confirmation Procedure......................................................................................... 913 Diagnostic Procedure............................................................................................... 914 Component Inspection............................................................................................... 919 DTC P0325 KNOCK SENSOR (KS)............................................................................................ 920 Component Description.............................................................................................. 920 ECM Terminals and Reference Value.................................................................................. 920 On Board Diagnosis Logic........................................................................................... 920 DTC Confirmation Procedure......................................................................................... 920 Wiring Diagram..................................................................................................... 921 Diagnostic Procedure............................................................................................... 922 Component Inspection............................................................................................... 923 DTC P0335 CRANKSHAFT POSITION SENSOR (CKPS) (OBD)...................................................................... 924 Component Description.............................................................................................. 924 ECM Terminals and Reference Value.................................................................................. 924 On Board Diagnosis Logic........................................................................................... 924 DTC Confirmation Procedure......................................................................................... 925 Wiring Diagram..................................................................................................... 926 Diagnostic Procedure............................................................................................... 927 Component Inspection............................................................................................... 929 DTC P0340 CAMSHAFT POSITION SENSOR (CMPS).............................................................................. 930 Component Description.............................................................................................. 930 ECM Terminals and Reference Value.................................................................................. 930 On Board Diagnosis Logic........................................................................................... 931 DTC Confirmation Procedure......................................................................................... 931 Wiring Diagram..................................................................................................... 933 Diagnostic Procedure............................................................................................... 934 Component Inspection............................................................................................... 937 DTC P0400 EGR FUNCTION (CLOSE)......................................................................................... 938 Description........................................................................................................ 938 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 939 ECM Terminals and Reference Value.................................................................................. 939 On Board Diagnosis Logic........................................................................................... 939 Possible Cause..................................................................................................... 940 DTC Confirmation Procedure......................................................................................... 940 Wiring Diagram..................................................................................................... 942 Diagnostic Procedure............................................................................................... 943 DTC P0403 EGR VOLUME CONTROL VALVE (CIRCUIT)........................................................................... 948 Description........................................................................................................ 948 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 949 ECM Terminals and Reference Value.................................................................................. 949 On Board Diagnosis Logic........................................................................................... 949 Possible Cause..................................................................................................... 950 DTC Confirmation Procedure......................................................................................... 950 Wiring Diagram..................................................................................................... 951 Diagnostic Procedure............................................................................................... 952 DTC P0420 THREE WAY CATALYST FUNCTION.................................................................................. 955 On Board Diagnosis Logic........................................................................................... 955 DTC Confirmation Procedure......................................................................................... 955 Overall Function Check............................................................................................. 956 Diagnostic Procedure............................................................................................... 956 DTC P0440 EVAP CONTROL SYSTEM (SMALL LEAK) (NEGATIVE PRESSURE)......................................................... 959 On Board Diagnosis Logic........................................................................................... 959 Possible Cause..................................................................................................... 959 DTC Confirmation Procedure......................................................................................... 960 Diagnostic Procedure............................................................................................... 961 DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE (CIRCUIT).................................................. 973 Description........................................................................................................ 973 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 973 ECM Terminals and Reference Value.................................................................................. 974 On Board Diagnosis Logic........................................................................................... 974 Possible Cause..................................................................................................... 974 DTC Confirmation Procedure......................................................................................... 975 Wiring Diagram..................................................................................................... 976 Diagnostic Procedure............................................................................................... 977 DTC P0446 EVAPORATIVE EMISSION (EVAP) CANISTER VENT CONTROL VALVE (CIRCUIT)............................................ 980 Component Description.............................................................................................. 980 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 980 ECM Terminals and Reference Value.................................................................................. 980 On Board Diagnosis Logic........................................................................................... 980 Possible Cause..................................................................................................... 981 DTC Confirmation Procedure......................................................................................... 981 Wiring Diagram..................................................................................................... 982 Diagnostic Procedure............................................................................................... 983 DTC P0450 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PRESSURE SENSOR................................................... 987 Component Description.............................................................................................. 987 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 987 ECM Terminals and Reference Value.................................................................................. 987 On Board Diagnosis Logic........................................................................................... 988 Possible Cause..................................................................................................... 988 DTC Confirmation Procedure......................................................................................... 988 Wiring Diagram..................................................................................................... 990 Diagnostic Procedure............................................................................................... 991 DTC P0455 EVAP CONTROL SYSTEM (GROSS LEAK).............................................................................1000 On Board Diagnosis Logic...........................................................................................1000 Possible Cause.....................................................................................................1000 DTC Confirmation Procedure.........................................................................................1001 Diagnostic Procedure...............................................................................................1002 DTC P0460 FUEL LEVEL SENSOR FUNCTION (SLOSH)...........................................................................1011 Component Description..............................................................................................1011 ECM Terminals and Reference Value..................................................................................1011 On Board Diagnostic Logic..........................................................................................1011 Possible Cause.....................................................................................................1011 DTC Confirmation Procedure.........................................................................................1012 Wiring Diagram.....................................................................................................1013 Diagnostic Procedure...............................................................................................1014 DTC P0461 FUEL LEVEL SENSOR FUNCTION...................................................................................1016 Component Description..............................................................................................1016 On Board Diagnostic Logic..........................................................................................1016 Possible Cause.....................................................................................................1016 Overall Function Check.............................................................................................1016 DTC P0464 FUEL LEVEL SENSOR CIRCUIT....................................................................................1018 Component Description..............................................................................................1018 ECM Terminals and Reference Value..................................................................................1018 On Board Diagnostic Logic..........................................................................................1018 Possible Cause.....................................................................................................1018 DTC Confirmation Procedure.........................................................................................1019 Wiring Diagram.....................................................................................................1020 Diagnostic Procedure...............................................................................................1021 DTC P0500 VEHICLE SPEED SENSOR (VSS)...................................................................................1023 Component Description..............................................................................................1023 ECM Terminals and Reference Value..................................................................................1023 On Board Diagnosis Logic...........................................................................................1023 DTC Confirmation Procedure.........................................................................................1023 Overall Function Check.............................................................................................1024 Wiring Diagram.....................................................................................................1025 Diagnostic Procedure...............................................................................................1026 DTC P0505 IDLE AIR CONTROL VALVE (IACV) - AUXILIARY AIR CONTROL (AAC) VALVE............................................1027 Description........................................................................................................1027 CONSULT-II Reference Value in Data Monitor Mode....................................................................1028 ECM Terminals and Reference Value..................................................................................1028 On Board Diagnosis Logic...........................................................................................1028 DTC Confirmation Procedure.........................................................................................1028 Wiring Diagram.....................................................................................................1030 Diagnostic Procedure...............................................................................................1031 DTC P0510 CLOSED THROTTLE POSITION SWITCH..............................................................................1036 Component Description..............................................................................................1036 CONSULT-II Reference Value in Data Monitor Mode....................................................................1036 ECM Terminals and Reference Value..................................................................................1036 On Board Diagnosis Logic...........................................................................................1036 DTC Confirmation Procedure.........................................................................................1037 Overall Function Check.............................................................................................1037 Wiring Diagram.....................................................................................................1038 Diagnostic Procedure...............................................................................................1039 DTC P0600 A/T CONTROL..................................................................................................1044 System Description.................................................................................................1044 ECM Terminals and Reference Value..................................................................................1044 On Board Diagnosis Logic...........................................................................................1044 DTC Confirmation Procedure.........................................................................................1044 Wiring Diagram.....................................................................................................1045 Diagnostic Procedure...............................................................................................1046 DTC P0605 ECM..........................................................................................................1047 Component Description..............................................................................................1047 On Board Diagnosis Logic...........................................................................................1047 DTC Confirmation Procedure.........................................................................................1047 Diagnostic Procedure...............................................................................................1048 DTC P1126 THERMOSTAT FUNCTION..........................................................................................1049 On Board Diagnosis Logic...........................................................................................1049 Possible Cause.....................................................................................................1049 DTC Confirmation Procedure.........................................................................................1049 Diagnostic Procedure...............................................................................................1050 DTC P1148 CLOSED LOOP CONTROL..........................................................................................1051 On Board Diagnosis Logic...........................................................................................1051 DTC Confirmation Procedure.........................................................................................1051 Overall Function Check.............................................................................................1052 Diagnostic Procedure...............................................................................................1052 DTC P1217 ENGINE OVER TEMPERATURE (OVERHEAT)...........................................................................1053 System Description.................................................................................................1053 CONSULT-II Reference Value in Data Monitor Mode....................................................................1053 ECM Terminals and Reference Value..................................................................................1054 On Board Diagnosis Logic...........................................................................................1054 Overall Function Check.............................................................................................1055 Wiring Diagram.....................................................................................................1056 Diagnostic Procedure (A/T Models)..................................................................................1058 Diagnostic Procedure (M/T Models)..................................................................................1069 Main 12 Causes of Overheating......................................................................................1081 DTC P1336 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) (COG)................................................................1082 Component Description..............................................................................................1082 ECM Terminals and Reference Value..................................................................................1082 On Board Diagnosis Logic...........................................................................................1082 DTC Confirmation Procedure.........................................................................................1083 Wiring Diagram.....................................................................................................1084 Diagnostic Procedure...............................................................................................1085 Component Inspection...............................................................................................1087 DTC P1401 EGR TEMPERATURE SENSOR.......................................................................................1088 Component Description..............................................................................................1088 On Board Diagnosis Logic...........................................................................................1088 Possible Cause.....................................................................................................1088 DTC Confirmation Procedure.........................................................................................1089 Wiring Diagram.....................................................................................................1091 Diagnostic Procedure...............................................................................................1092 DTC P1402 EGR FUNCTION (OPEN)..........................................................................................1096 Description........................................................................................................1096 CONSULT-II Reference Value in Data Monitor Mode....................................................................1097 ECM Terminals and Reference Value..................................................................................1097 On Board Diagnosis Logic...........................................................................................1097 Possible Cause.....................................................................................................1098 DTC Confirmation Procedure.........................................................................................1098 Wiring Diagram.....................................................................................................1100 Diagnostic Procedure...............................................................................................1101 DTC P1440 EVAP CONTROL SYSTEM (SMALL LEAK) (POSITIVE PRESSURE).........................................................1106 On Board Diagnosis Logic...........................................................................................1106 Possible Cause.....................................................................................................1106 DTC Confirmation Procedure.........................................................................................1107 Diagnostic Procedure...............................................................................................1107 DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE............................................................1108 Description........................................................................................................1108 CONSULT-II Reference Value in Data Monitor Mode....................................................................1108 ECM Terminals and Reference Value..................................................................................1109 On Board Diagnosis Logic...........................................................................................1109 Possible Cause.....................................................................................................1109 DTC Confirmation Procedure.........................................................................................1110 Wiring Diagram.....................................................................................................1111 Diagnostic Procedure...............................................................................................1112 DTC P1446 EVAPORATIVE EMISSION (EVAP) CANISTER VENT CONTROL VALVE (CLOSE)..............................................1120 Component Description..............................................................................................1120 CONSULT-II Reference Value in Data Monitor Mode....................................................................1120 ECM Terminals and Reference Value..................................................................................1120 On Board Diagnosis Logic...........................................................................................1120 Possible Cause.....................................................................................................1121 DTC Confirmation Procedure.........................................................................................1121 Wiring Diagram.....................................................................................................1122 Diagnostic Procedure...............................................................................................1123 DTC P1447 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PURGE FLOW MONITORING.............................................1128 System Description.................................................................................................1128 On Board Diagnosis Logic...........................................................................................1128 Possible Cause.....................................................................................................1128 DTC Confirmation Procedure.........................................................................................1129 Overall Function Check.............................................................................................1129 Diagnostic Procedure...............................................................................................1131 DTC P1448 EVAPORATIVE EMISSION (EVAP) CANISTER VENT CONTROL VALVE (OPEN)...............................................1140 Component Description..............................................................................................1140 CONSULT-II Reference Value in Data Monitor Mode....................................................................1140 ECM Terminals and Reference Value..................................................................................1140 On Board Diagnosis Logic...........................................................................................1140 Possible Cause.....................................................................................................1141 DTC Confirmation Procedure.........................................................................................1141 Overall Function Check.............................................................................................1142 Wiring Diagram.....................................................................................................1143 Diagnostic Procedure...............................................................................................1144 DTC P1464 FUEL LEVEL SENSOR CIRCUIT (GROUND SIGNAL)....................................................................1149 Component Description..............................................................................................1149 ECM Terminals and Reference Value..................................................................................1149 On Board Diagnostic Logic..........................................................................................1149 Possible Cause.....................................................................................................1149 DTC Confirmation Procedure.........................................................................................1150 Wiring Diagram.....................................................................................................1151 Diagnostic Procedure...............................................................................................1152 DTC P1490 VACUUM CUT VALVE BYPASS VALVE (CIRCUIT)......................................................................1153 Description........................................................................................................1153 CONSULT-II Reference Value in Data Monitor Mode....................................................................1153 ECM Terminals and Reference Value..................................................................................1153 On Board Diagnosis Logic...........................................................................................1154 Possible Cause.....................................................................................................1154 DTC Confirmation Procedure.........................................................................................1154 Wiring Diagram.....................................................................................................1155 Diagnostic Procedure...............................................................................................1156 DTC P1491 VACUUM CUT VALVE BYPASS VALVE................................................................................1159 Description........................................................................................................1159 CONSULT-II Reference Value in Data Monitor Mode....................................................................1159 ECM Terminals and Reference Value..................................................................................1159 On Board Diagnosis Logic...........................................................................................1160 Possible Cause.....................................................................................................1160 DTC Confirmation Procedure.........................................................................................1160 Overall Function Check.............................................................................................1161 Wiring Diagram.....................................................................................................1162 Diagnostic Procedure...............................................................................................1163 DTC P1605 A/T DIAGNOSIS COMMUNICATION LINE.............................................................................1171 System Description.................................................................................................1171 ECM Terminals and Reference Value..................................................................................1171 On Board Diagnosis Logic...........................................................................................1171 DTC Confirmation Procedure.........................................................................................1171 Wiring Diagram.....................................................................................................1172 Diagnostic Procedure...............................................................................................1173 DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH...........................................................................1174 Component Description..............................................................................................1174 CONSULT-II Reference Value in Data Monitor Mode....................................................................1174 ECM Terminals and Reference Value..................................................................................1174 On Board Diagnosis Logic...........................................................................................1174 DTC Confirmation Procedure.........................................................................................1174 Overall Function Check.............................................................................................1175 Wiring Diagram.....................................................................................................1176 Diagnostic Procedure For M/T Models................................................................................1177 Diagnostic Procedure For A/T Models................................................................................1179 IGNITION SIGNAL........................................................................................................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...............................................................................................1186 INJECTOR...............................................................................................................1187 Component Description..............................................................................................1187 CONSULT-II Reference Value in Data Monitor Mode....................................................................1187 ECM Terminals and Reference Value..................................................................................1187 Wiring Diagram.....................................................................................................1188 Diagnostic Procedure...............................................................................................1189 START SIGNAL...........................................................................................................1192 CONSULT-II Reference Value in Data Monitor Mode....................................................................1192 ECM Terminals and Reference Value..................................................................................1192 Wiring Diagram.....................................................................................................1193 Diagnostic Procedure...............................................................................................1194 FUEL PUMP..............................................................................................................1196 System Description.................................................................................................1196 Component Description..............................................................................................1196 CONSULT-II Reference Value in Data Monitor Mode....................................................................1196 ECM Terminals and Reference Value..................................................................................1197 Wiring Diagram.....................................................................................................1198 Diagnostic Procedure...............................................................................................1199 Component Inspection...............................................................................................1204 POWER STEERING OIL PRESSURE SWITCH.....................................................................................1205 Component Description..............................................................................................1205 CONSULT-II Reference Value in Data Monitor Mode....................................................................1205 ECM Terminals and Reference Value..................................................................................1205 Wiring Diagram.....................................................................................................1206 Diagnostic Procedure...............................................................................................1207 Component Inspection...............................................................................................1209 REFRIGERANT PRESSURE SENSOR............................................................................................1210 Description........................................................................................................1210 ECM Terminals and Reference Value..................................................................................1210 Wiring Diagram.....................................................................................................1211 Diagnostic Procedure...............................................................................................1212 ELECTRICAL LOAD SIGNAL.................................................................................................1215 CONSULT-II Reference Value in Data Monitor Mode....................................................................1215 ECM Terminals and Reference Value..................................................................................1215 Wiring Diagram.....................................................................................................1216 Diagnostic Procedure...............................................................................................1218 MIL & DATA LINK CONNECTORS.............................................................................................1222 Wiring Diagram.....................................................................................................1222 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1223 Fuel Pressure Regulator............................................................................................1223 Idle Speed and Ignition Timing.....................................................................................1223 Ignition Coil......................................................................................................1223 Mass Air Flow Sensor...............................................................................................1223 Engine Coolant Temperature Sensor..................................................................................1223 EGR Volume Control Valve...........................................................................................1223 EGR Temperature Sensor.............................................................................................1223 Fuel Pump..........................................................................................................1224 IACV-AAC Valve.....................................................................................................1224 Injector...........................................................................................................1224 Resistor...........................................................................................................1224 Throttle Position Sensor...........................................................................................1224 Heated Oxygen Sensor 1 Heater (Front)..............................................................................1224 Calculated Load Value..............................................................................................1224 Intake Air Temperature Sensor......................................................................................1224 EVAP Canister Purge Volume Control Valve...........................................................................1224 Heated Oxygen Sensor 2 Heater (Rear)...............................................................................1224 Crankshaft Position Sensor (OBD)...................................................................................1224 Fuel Tank Temperature Sensor.......................................................................................1225 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.........................................................................................................................1226 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1226 PRECAUTIONS............................................................................................................1229 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................1229 Wiring Diagrams and Trouble Diagnosis..............................................................................1229 HARNESS CONNECTOR......................................................................................................1230 Description........................................................................................................1230 STANDARDIZED RELAY.....................................................................................................1232 Description........................................................................................................1232 POWER SUPPLY ROUTING...................................................................................................1234 Schematic..........................................................................................................1234 Wiring Diagram - POWER -...........................................................................................1235 Inspection.........................................................................................................1242 GROUND.................................................................................................................1243 Ground Distribution................................................................................................1243 COMBINATION SWITCH.....................................................................................................1251 Check..............................................................................................................1251 Replacement........................................................................................................1252 STEERING SWITCH........................................................................................................1253 Check..............................................................................................................1253 HEADLAMP (FOR USA).....................................................................................................1254 Component Parts and Harness Connector Location.....................................................................1254 System Description.................................................................................................1254 Schematic..........................................................................................................1257 Wiring Diagram - H/LAMP -..........................................................................................1258 Trouble Diagnoses..................................................................................................1261 Bulb Replacement...................................................................................................1264 Aiming Adjustment..................................................................................................1264 HEADLAMP (FOR CANADA) - DAYTIME LIGHT SYSTEM -.........................................................................1266 Component Parts and Harness Connector Location.....................................................................1266 System Description.................................................................................................1266 Schematic..........................................................................................................1269 Wiring Diagram - DTRL -............................................................................................1270 Trouble Diagnoses..................................................................................................1274 Bulb Replacement...................................................................................................1277 Aiming Adjustment..................................................................................................1277 PARKING, LICENSE AND TAIL LAMPS........................................................................................1278 System Description.................................................................................................1278 Schematic..........................................................................................................1279 Wiring Diagram - TAIL/L -..........................................................................................1280 Trouble Diagnoses..................................................................................................1283 STOP LAMP..............................................................................................................1284 Wiring Diagram - STOP/L -..........................................................................................1284 BACK-UP LAMP...........................................................................................................1285 Wiring Diagram - BACK/L -..........................................................................................1285 FRONT FOG LAMP.........................................................................................................1286 System Description.................................................................................................1286 Wiring Diagram - F/FOG -...........................................................................................1288 Aiming Adjustment..................................................................................................1290 TURN SIGNAL AND HAZARD WARNING LAMPS...................................................................................1291 System Description.................................................................................................1291 Wiring Diagram - TURN -............................................................................................1293 Trouble Diagnoses..................................................................................................1295 Electrical Components Inspection...................................................................................1295 ILLUMINATION...........................................................................................................1296 System Description.................................................................................................1296 Schematic..........................................................................................................1298 Wiring Diagram - ILL -.............................................................................................1299 INTERIOR ROOM LAMP.....................................................................................................1303 System Description.................................................................................................1303 Wiring Diagram - ROOM/L -..........................................................................................1305 VANITY MIRROR AND TRUNK ROOM LAMPS.....................................................................................1307 System Description.................................................................................................1307 Wiring Diagram - INT/L -...........................................................................................1308 METERS AND GAUGES......................................................................................................1309 Component Parts and Harness Connector Location.....................................................................1309 System Description.................................................................................................1309 Combination Meter..................................................................................................1311 Schematic..........................................................................................................1313 Wiring Diagram - METER -...........................................................................................1314 Meter/Gauge Operation and Odo/Trip Meter Segment Check in Diagnosis Mode...........................................1315 Trouble Diagnoses..................................................................................................1316 Electrical Components Inspection...................................................................................1322 WARNING LAMPS..........................................................................................................1323 Schematic..........................................................................................................1323 Wiring Diagram - WARN -............................................................................................1324 Electrical Components Inspection...................................................................................1328 A/T INDICATOR..........................................................................................................1329 Wiring Diagram - AT/IND -..........................................................................................1329 WARNING CHIME..........................................................................................................1330 Component Parts and Harness Connector Location.....................................................................1330 System Description.................................................................................................1330 Wiring Diagram - CHIME -...........................................................................................1332 Trouble Diagnoses..................................................................................................1334 FRONT WIPER AND WASHER.................................................................................................1339 System Description.................................................................................................1339 Wiring Diagram - WIPER -...........................................................................................1341 Removal and Installation...........................................................................................1342 Washer Nozzle Adjustment...........................................................................................1343 Washer Tube Layout.................................................................................................1343 HORN...................................................................................................................1344 Wiring Diagram - HORN -............................................................................................1344 CIGARETTE LIGHTER......................................................................................................1345 Wiring Diagram - CIGAR -...........................................................................................1345 REAR WINDOW DEFOGGER...................................................................................................1346 Component Parts and Harness Connector Location.....................................................................1346 System Description.................................................................................................1346 Wiring Diagram - DEF -.............................................................................................1348 Trouble Diagnoses..................................................................................................1350 Electrical Components Inspection...................................................................................1352 Filament Check.....................................................................................................1352 Filament Repair....................................................................................................1353 AUDIO..................................................................................................................1355 System Description.................................................................................................1355 Wiring Diagram - AUDIO -...........................................................................................1356 Trouble Diagnoses..................................................................................................1358 Inspection.........................................................................................................1359 AUDIO ANTENNA..........................................................................................................1360 System Description.................................................................................................1360 Wiring Diagram - P/ANT -...........................................................................................1361 Trouble Diagnoses..................................................................................................1362 Location of Antenna................................................................................................1362 Antenna Rod Replacement............................................................................................1363 TRUNK LID AND FUEL FILLER LID OPENER...................................................................................1364 Wiring Diagram - TLID -............................................................................................1364 POWER SUNROOF..........................................................................................................1365 System Description.................................................................................................1365 Wiring Diagram - SROOF -...........................................................................................1366 DOOR MIRROR............................................................................................................1368 Wiring Diagram - MIRROR -..........................................................................................1368 POWER SEAT.............................................................................................................1369 Wiring Diagram - SEAT -............................................................................................1369 HEATED SEAT............................................................................................................1370 Wiring Diagram - HSEAT -...........................................................................................1370 AUTOMATIC SPEED CONTROL DEVICE (ASCD)..................................................................................1371 Component Parts and Harness Connector Location.....................................................................1371 System Description.................................................................................................1372 Schematic..........................................................................................................1374 Wiring Diagram - ASCD -............................................................................................1375 Fail-safe System...................................................................................................1379 Trouble Diagnoses..................................................................................................1380 Electrical Component Inspection....................................................................................1389 ASCD Wire Adjustment...............................................................................................1390 POWER WINDOW...........................................................................................................1391 System Description.................................................................................................1391 Schematic..........................................................................................................1393 Wiring Diagram - WINDOW -..........................................................................................1394 Trouble Diagnoses..................................................................................................1398 POWER DOOR LOCK........................................................................................................1401 Component Parts and Harness Connector Location.....................................................................1401 System Description.................................................................................................1401 Schematic..........................................................................................................1402 Wiring Diagram - D/LOCK -..........................................................................................1403 Trouble Diagnoses..................................................................................................1406 MULTI-REMOTE CONTROL SYSTEM............................................................................................1415 Component Parts and Harness Connector Location.....................................................................1415 System Description.................................................................................................1415 Schematic..........................................................................................................1418 Wiring Diagram - MULTI -...........................................................................................1419 Trouble Diagnoses..................................................................................................1422 ID Code Entry Procedure............................................................................................1434 Remote Controller Battery Replacement..............................................................................1438 VEHICLE SECURITY (THEFT WARNING) SYSTEM................................................................................1439 Component Parts and Harness Connector Location.....................................................................1439 System Description.................................................................................................1440 Schematic..........................................................................................................1443 Wiring Diagram - VEHSEC -..........................................................................................1444 Trouble Diagnoses..................................................................................................1448 SMART ENTRANCE CONTROL UNIT............................................................................................1467 Description........................................................................................................1467 Schematic..........................................................................................................1469 Smart Entrance Control Unit Inspection Table.......................................................................1471 IVIS (INFINITI VEHICLE IMMOBILIZER SYSTEM - NATS)......................................................................1472 Component Parts and Harness Connetor Location......................................................................1472 System Description.................................................................................................1473 System Composition.................................................................................................1473 Wiring Diagram - NATS -............................................................................................1474 CONSULT-II.........................................................................................................1475 Trouble Diagnoses..................................................................................................1478 How to Replace IVIS (NATS) IMMU....................................................................................1491 INTEGRATED HOMELINK TRANSMITTER........................................................................................1492 Wiring Diagram - TRNSMT -..........................................................................................1492 Trouble Diagnoses..................................................................................................1493 ELECTRICAL UNITS LOCATION..............................................................................................1495 Engine Compartment.................................................................................................1495 Passenger Compartment..............................................................................................1497 HARNESS LAYOUT.........................................................................................................1499 How to Read Harness Layout.........................................................................................1499 Outline............................................................................................................1500 Main Harness.......................................................................................................1501 Engine Room Harness................................................................................................1503 Engine Control Harness.............................................................................................1506 Body Harness.......................................................................................................1507 Body No. 2 Harness.................................................................................................1508 Tail & Tail No. 2 Harness..........................................................................................1509 Engine Harness.....................................................................................................1510 Room Lamp Harness..................................................................................................1511 Air Bag Harness....................................................................................................1512 Front Door Harness.................................................................................................1513 Rear Door Harness..................................................................................................1514 BULB SPECIFICATIONS....................................................................................................1515 Headlamp...........................................................................................................1515 Exterior Lamp......................................................................................................1515 Interior Lamp......................................................................................................1515 WIRING DIAGRAM CODES (CELL CODES)......................................................................................1516 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.........................................................................................................................1518 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1518 PRECAUTIONS............................................................................................................1520 Parts Requiring Angular Tightening.................................................................................1520 Liquid Gasket Application Procedure................................................................................1520 PREPARATION............................................................................................................1521 Special Service Tools..............................................................................................1521 Commercial Service Tools...........................................................................................1523 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................1525 NVH Troubleshooting - Engine Noise.................................................................................1526 OUTER COMPONENT PARTS..................................................................................................1527 Removal and Installation...........................................................................................1527 MEASUREMENT OF COMPRESSION PRESSURE....................................................................................1530 OIL PAN................................................................................................................1531 Components.........................................................................................................1531 Removal............................................................................................................1531 Installation.......................................................................................................1533 TIMING CHAIN...........................................................................................................1536 Components.........................................................................................................1536 Removal............................................................................................................1537 Inspection.........................................................................................................1540 Installation.......................................................................................................1540 OIL SEAL...............................................................................................................1545 Replacement........................................................................................................1545 VALVE OIL SEAL.................................................................................................1545 FRONT OIL SEAL.................................................................................................1545 REAR OIL SEAL..................................................................................................1546 CYLINDER HEAD..........................................................................................................1547 Components.........................................................................................................1547 Removal............................................................................................................1548 Disassembly........................................................................................................1551 Inspection.........................................................................................................1553 CYLINDER HEAD DISTORTION.......................................................................................1553 CAMSHAFT VISUAL CHECK..........................................................................................1553 CAMSHAFT RUNOUT................................................................................................1553 CAMSHAFT CAM HEIGHT............................................................................................1553 CAMSHAFT JOURNAL CLEARANCE.....................................................................................1554 CAMSHAFT END PLAY..............................................................................................1554 CAMSHAFT SPROCKET RUNOUT.......................................................................................1555 VALVE GUIDE CLEARANCE..........................................................................................1555 VALVE GUIDE REPLACEMENT........................................................................................1555 VALVE SEATS....................................................................................................1556 REPLACING VALVE SEAT FOR SERVICE PARTS.........................................................................1557 VALVE DIMENSIONS...............................................................................................1558 VALVE SPRING...................................................................................................1558 HYDRAULIC LASH ADJUSTER........................................................................................1558 ROCKER ARM, SHIM AND ROCKER ARM GUIDE..........................................................................1559 Assembly...........................................................................................................1559 Installation.......................................................................................................1563 ENGINE ASSEMBLY........................................................................................................1569 Removal and Installation...........................................................................................1569 REMOVAL........................................................................................................1570 INSTALLATION...................................................................................................1571 CYLINDER BLOCK.........................................................................................................1572 Components.........................................................................................................1572 Removal and Installation...........................................................................................1573 Disassembly........................................................................................................1573 PISTON AND CRANKSHAFT..........................................................................................1573 Inspection.........................................................................................................1573 PISTON AND PISTON PIN CLEARANCE................................................................................1573 PISTON RING SIDE CLEARANCE.....................................................................................1574 PISTON RING END GAP............................................................................................1575 CONNECTING ROD BEND AND TORSION................................................................................1575 CYLINDER BLOCK DISTORTION AND WEAR.............................................................................1575 PISTON-TO-BORE CLEARANCE.......................................................................................1576 CRANKSHAFT.....................................................................................................1577 BEARING CLEARANCE..............................................................................................1577 CONNECTING ROD BUSHING CLEARANCE (SMALL END)...................................................................1580 REPLACEMENT OF CONNECTING ROD BUSHING (SMALL END)..............................................................1580 REPLACEMENT OF PILOT BUSHING (M/T) OR PILOT CONVERTER (A/T)....................................................1580 FLYWHEEL/DRIVE PLATE RUNOUT....................................................................................1581 Assembly...........................................................................................................1581 PISTON.........................................................................................................1581 CRANKSHAFT.....................................................................................................1582 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1585 General Specifications.............................................................................................1585 Compression Pressure...............................................................................................1585 Cylinder Head......................................................................................................1585 Valve..............................................................................................................1586 VALVE..........................................................................................................1586 VALVE SPRING...................................................................................................1586 HYDRAULIC LASH ADJUSTER (HLA)..................................................................................1586 VALVE GUIDE....................................................................................................1587 VALVE SHIM CLEARANCE ADJUSTMENT................................................................................1587 AVAILABLE SHIM.................................................................................................1588 VALVE SEAT.....................................................................................................1589 VALVE SEAT RESURFACE LIMIT.....................................................................................1590 Camshaft and Camshaft Bearing......................................................................................1590 Cylinder Block.....................................................................................................1591 Piston, Piston Ring and Piston pin.................................................................................1592 PISTON.........................................................................................................1592 PISTON RING....................................................................................................1592 PISTON PIN.....................................................................................................1592 Connecting Rod.....................................................................................................1593 Crankshaft.........................................................................................................1594 Main Bearing.......................................................................................................1595 STANDARD.......................................................................................................1595 UNDERSIZE......................................................................................................1595 Connecting Rod Bearing.............................................................................................1595 STANDARD SIZE..................................................................................................1595 UNDERSIZE......................................................................................................1595 Bearing Clearance..................................................................................................1596 Miscellaneous Components...........................................................................................1596 fe.........................................................................................................................1598 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1598 PREPARATION............................................................................................................1599 Special Service Tool...............................................................................................1599 Commercial Service Tools...........................................................................................1599 ACCELERATOR CONTROL SYSTEM.............................................................................................1600 Removal and Installation...........................................................................................1600 Adjusting Accelerator Wire.........................................................................................1600 FUEL SYSTEM............................................................................................................1602 Removal and Installation...........................................................................................1602 FUEL PUMP AND GAUGE............................................................................................1603 EXHAUST SYSTEM.........................................................................................................1605 Removal and Installation...........................................................................................1605 foldout....................................................................................................................1608 QUICK REFERENCE INDEX.................................................................................................. 0 SUPER MULTIPLE JUNCTION (SMJ)..........................................................................................1608 FUSE BLOCK - JUNCTION BOX (J/B)........................................................................................1610 FUSE AND FUSIBLE LINK BOX..............................................................................................1611 ELECTRICAL UNITS.......................................................................................................1612 JOINT CONNECTOR (J/C)..................................................................................................1613 QUICK REFERENCE CHART..................................................................................................1614 gi.........................................................................................................................1615 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1615 PRECAUTIONS............................................................................................................1617 Precautions........................................................................................................1617 PRECAUTIONS FOR SUPPLEMENTAL RESTRAINT SYSTEM (SRS) "AIR BAG" AND "SEAT BELT PRE-TENSIONER"....................1617 PRECAUTIONS FOR IVIS (INFINITI VEHICLE IMMOBILIZER SYSTEM - NATS)..............................................1617 GENERAL PRECAUTIONS............................................................................................1618 PRECAUTIONS FOR MULTIPORT FUEL INJECTION SYSTEM OR ENGINE CONTROL SYSTEM.......................................1620 PRECAUTIONS FOR THREE WAY CATALYST.............................................................................1620 PRECAUTIONS FOR HOSES..........................................................................................1620 PRECAUTIONS FOR ENGINE OILS....................................................................................1621 PRECAUTIONS FOR FUEL...........................................................................................1622 PRECAUTIONS FOR AIR CONDITIONING...............................................................................1622 HOW TO USE THIS MANUAL.................................................................................................1623 HOW TO READ WIRING DIAGRAMS............................................................................................1625 Sample/Wiring Diagram - EXAMPL -...................................................................................1625 OPTIONAL SPLICE................................................................................................1626 CONTROL UNIT TERMINALS AND REFERENCE VALUE CHART...............................................................1627 Description........................................................................................................1628 CONNECTOR SYMBOLS..............................................................................................1630 SWITCH POSITIONS...............................................................................................1631 DETECTABLE LINES AND NON-DETECTABLE LINES......................................................................1631 MULTIPLE SWITCH................................................................................................1632 REFERENCE AREA.................................................................................................1633 HOW TO CHECK TERMINAL..................................................................................................1635 Connector and Terminal Pin Kit.....................................................................................1635 How to Probe Connectors............................................................................................1635 PROBING FROM HARNESS SIDE......................................................................................1635 PROBING FROM TERMINAL SIDE.....................................................................................1635 How to Check Enlarged Contact Spring of Terminal...................................................................1636 Waterproof Connector Inspection....................................................................................1637 RUBBER SEAL INSPECTION.........................................................................................1637 WIRE SEAL INSPECTION...........................................................................................1637 Terminal Lock Inspection...........................................................................................1637 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT..........................................................1638 Work Flow..........................................................................................................1638 Incident Simulation Tests..........................................................................................1639 INTRODUCTION...................................................................................................1639 VEHICLE VIBRATION..............................................................................................1639 HEAT SENSITIVE.................................................................................................1640 FREEZING.......................................................................................................1640 WATER INTRUSION................................................................................................1641 ELECTRICAL LOAD................................................................................................1641 COLD OR HOT START UP...........................................................................................1641 Circuit Inspection.................................................................................................1641 INTRODUCTION...................................................................................................1641 TESTING FOR "OPENS" IN THE CIRCUIT.............................................................................1642 TESTING FOR "SHORTS" IN THE CIRCUIT............................................................................1643 GROUND INSPECTION..............................................................................................1644 VOLTAGE DROP TESTS.............................................................................................1644 CONTROL UNIT CIRCUIT TEST......................................................................................1646 HOW TO FOLLOW TROUBLE DIAGNOSES........................................................................................1648 How to Follow Test Groups in Trouble Diagnoses.....................................................................1649 Harness Wire Color and Connector Number Indication.................................................................1650 TYPE 1: HARNESS WIRE COLOR AND CONNECTOR NUMBER ARE SHOWN IN ILLUSTRATION......................................1650 TYPE 2: HARNESS WIRE COLOR AND CONNECTOR NUMBER ARE SHOWN IN TEXT..............................................1650 Key to Symbols Signifying Measurements or Procedures...............................................................1651 CONSULT-II CHECKING SYSTEM.............................................................................................1653 Function and System Application....................................................................................1653 Nickel Metal Hydride Battery Replacement...........................................................................1653 Checking Equipment.................................................................................................1654 CONSULT-II Data Link Connector (DLC) Circuit.......................................................................1654 INSPECTION PROCEDURE...........................................................................................1654 IDENTIFICATION INFORMATION.............................................................................................1655 Model Variation....................................................................................................1655 Identification Number..............................................................................................1656 VEHICLE IDENTIFICATION NUMBER ARRANGEMENT......................................................................1656 IDENTIFICATION PLATE...........................................................................................1657 ENGINE SERIAL NUMBER...........................................................................................1657 AUTOMATIC TRANSAXLE NUMBER.....................................................................................1657 MANUAL TRANSAXLE NUMBER........................................................................................1657 Dimensions.........................................................................................................1658 Wheels & Tires.....................................................................................................1658 LIFTING POINTS AND TOW TRUCK TOWING....................................................................................1659 Preparation........................................................................................................1659 SPECIAL SERVICE TOOLS..........................................................................................1659 Board-on Lift......................................................................................................1659 Garage Jack and Safety Stand.......................................................................................1660 2-pole Lift........................................................................................................1661 Tow Truck Towing...................................................................................................1662 VEHICLE RECOVERY (FREEING A STUCK VEHICLE).....................................................................1663 TIGHTENING TORQUE OF STANDARD BOLTS....................................................................................1664 SAE J1930 TERMINOLOGY LIST.............................................................................................1665 SAE J1930 Terminology List.........................................................................................1665 ha.........................................................................................................................1669 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1669 AUTO...................................................................................................................1671 PRECAUTIONS........................................................................................................1671 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"....................................1671 Precautions for Working with HFC-134a (R-134a).................................................................1671 General Refrigerant Precautions................................................................................1672 Precautions for Leak Detection Dye.............................................................................1672 Identification.................................................................................................1673 Precautions for Refrigerant Connection.........................................................................1673 Precautions for Servicing Compressor...........................................................................1675 Precautions for Service Equipment..............................................................................1675 Wiring Diagrams and Trouble Diagnosis..........................................................................1677 PREPARATION........................................................................................................1678 Special Service Tools..........................................................................................1678 HFC-134a (R-134a) Service Tools and Equipment..................................................................1679 DESCRIPTION........................................................................................................1682 Refrigeration System...........................................................................................1682 Component Layout...............................................................................................1683 Introduction...................................................................................................1684 Features.......................................................................................................1684 Overview of Control System.....................................................................................1687 Control Operation..............................................................................................1687 Discharge Air Flow.............................................................................................1689 TROUBLE DIAGNOSES..................................................................................................1691 Component Location.............................................................................................1691 Circuit Diagram................................................................................................1693 Wiring Diagram - A/C, A -......................................................................................1694 Auto Amp. Terminals and Reference Value........................................................................1697 Self-diagnosis.................................................................................................1699 How to Perform Trouble Diagnoses for Quick and Accurate Repair.................................................1709 Operational Check..............................................................................................1710 A/C System.....................................................................................................1713 Mode Door Motor................................................................................................1716 Air Mix Door Motor.............................................................................................1722 Intake Door Motor..............................................................................................1726 Blower Motor...................................................................................................1733 Magnet Clutch..................................................................................................1741 Insufficient Cooling...........................................................................................1748 Insufficient Heating...........................................................................................1756 Noise..........................................................................................................1757 Self-diagnosis.................................................................................................1758 Memory Function................................................................................................1759 ECON (ECONOMY) Mode............................................................................................1760 Ambient Sensor Circuit.........................................................................................1760 In-vehicle Sensor Circuit......................................................................................1763 Sunload Sensor Circuit.........................................................................................1767 Intake Sensor Circuit..........................................................................................1770 Air Mix Door Motor PBR Circuit.................................................................................1772 SERVICE PROCEDURE..................................................................................................1773 HFC-134a (R-134a) Service Procedure............................................................................1773 Maintenance of Lubricant Quantity in Compressor................................................................1775 Compressor.....................................................................................................1778 Compressor Clutch..............................................................................................1779 Thermal Protector..............................................................................................1782 Heater Unit (Heater Core)......................................................................................1782 Blower Unit....................................................................................................1783 Cooling Unit (A/C Evaporator)..................................................................................1784 Refrigerant Lines..............................................................................................1785 Belt...........................................................................................................1790 Idle Air Control Valve (IACV) - Auxiliary Air Control (AAC) Valve..............................................1790 Ventilation Air Filter.........................................................................................1790 SERVICE DATA AND SPECIFICATIONS (SDS)..............................................................................1791 Auto...........................................................................................................1791 MANUAL.................................................................................................................1792 PRECAUTIONS........................................................................................................1792 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"....................................1792 Precautions for Working with HFC-134a (R-134a).................................................................1792 General Refrigerant Precautions................................................................................1793 Precautions for Leak Detection Dye.............................................................................1793 Identification.................................................................................................1794 Precautions for Refrigerant Connection.........................................................................1794 Precautions for Servicing Compressor...........................................................................1796 Precautions for Service Equipment..............................................................................1796 Wiring Diagrams and Trouble Diagnosis..........................................................................1798 PREPARATION........................................................................................................1799 Special Service Tools..........................................................................................1799 HFC-134a (R-134a) Service Tools and Equipment..................................................................1800 DESCRIPTION........................................................................................................1803 Refrigeration System...........................................................................................1803 Component Layout...............................................................................................1804 Control Operation..............................................................................................1805 Discharge Air Flow.............................................................................................1806 System Description.............................................................................................1807 TROUBLE DIAGNOSES..................................................................................................1808 Component Location.............................................................................................1808 Circuit Diagram - Air Conditioner..............................................................................1810 Wiring Diagram - A/C, M -......................................................................................1811 How to Perform Trouble Diagnoses for Quick and Accurate Repair.................................................1815 Operational Check..............................................................................................1816 A/C System.....................................................................................................1818 Intake Door....................................................................................................1820 Mode Door Motor................................................................................................1824 Air Mix Door...................................................................................................1830 Blower Motor...................................................................................................1835 Magnet Clutch..................................................................................................1842 Insufficient Cooling...........................................................................................1850 Insufficient Heating...........................................................................................1857 Noise..........................................................................................................1858 SERVICE PROCEDURE..................................................................................................1859 HFC-134a (R-134a) Service Procedure............................................................................1859 Maintenance of Lubricant Quantity in Compressor................................................................1861 Compressor.....................................................................................................1864 Compressor Clutch..............................................................................................1865 Thermal Protector..............................................................................................1868 Heater Unit (Heater Core)......................................................................................1868 Blower Unit....................................................................................................1869 Cooling Unit (A/C Evaporator)..................................................................................1870 Refrigerant Lines..............................................................................................1871 Belt...........................................................................................................1876 Idle Air Control Valve (IACV) - Auxiliary Air Control (AAC) Valve..............................................1876 Ventilation Air Filter.........................................................................................1876 SERVICE DATA AND SPECIFICATIONS (SDS)..............................................................................1877 Manual.........................................................................................................1877 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........................................................................................................................1879 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.........................................................................................................................1887 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1887 ENGINE LUBRICATION SYSTEM..............................................................................................1888 Precautions........................................................................................................1888 LIQUID GASKET APPLICATION PROCEDURE............................................................................1888 Preparation........................................................................................................1888 SPECIAL SERVICE TOOLS..........................................................................................1888 Lubrication Circuit................................................................................................1889 Oil Pressure Check.................................................................................................1890 Oil Pump...........................................................................................................1890 REMOVAL........................................................................................................1890 DISASSEMBLY AND ASSEMBLY.......................................................................................1891 INSPECTION.....................................................................................................1891 REGULATOR VALVE INSPECTION.....................................................................................1892 INSTALLATION...................................................................................................1893 Oil Filter.........................................................................................................1893 Service Data and Specifications (SDS)..............................................................................1893 OIL PRESSURE CHECK.............................................................................................1893 REGULATOR VALVE INSPECTION.....................................................................................1893 OIL PUMP INSPECTION............................................................................................1893 ENGINE COOLING SYSTEM..................................................................................................1894 Precautions........................................................................................................1894 LIQUID GASKET APPLICATION PROCEDURE............................................................................1894 Preparation........................................................................................................1894 SPECIAL SERVICE TOOL...........................................................................................1894 Cooling Circuit....................................................................................................1895 System Check.......................................................................................................1895 CHECKING COOLING SYSTEM HOSES..................................................................................1895 CHECKING COOLING SYSTEM FOR LEAKS..............................................................................1895 CHECKING RADIATOR..............................................................................................1896 CHECKING RADIATOR CAP..........................................................................................1896 Water Pump.........................................................................................................1896 REMOVAL........................................................................................................1896 INSPECTION.....................................................................................................1897 INSTALLATION...................................................................................................1897 Thermostat.........................................................................................................1898 REMOVAL AND INSTALLATION.......................................................................................1898 INSPECTION.....................................................................................................1899 Water Outlet.......................................................................................................1899 INSPECTION.....................................................................................................1899 INSTALLATION...................................................................................................1899 Radiator...........................................................................................................1900 COMPONENTS.....................................................................................................1900 Cooling Fan Control System.........................................................................................1900 Refilling Engine Coolant...........................................................................................1901 Overheating Cause Analysis.........................................................................................1901 Service Data and Specifications (SDS)..............................................................................1902 THERMOSTAT.....................................................................................................1902 RADIATOR.......................................................................................................1902 ma.........................................................................................................................1903 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1903 PRECAUTIONS............................................................................................................1904 Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................1904 PREPARATION............................................................................................................1905 Special Service Tool...............................................................................................1905 Commercial Service Tool............................................................................................1905 GENERAL MAINTENANCE....................................................................................................1906 PERIODIC MAINTENANCE...................................................................................................1908 Schedule 1.........................................................................................................1909 EMISSION CONTROL SYSTEM MAINTENANCE............................................................................1909 CHASSIS AND BODY MAINTENANCE...................................................................................1910 Schedule 2.........................................................................................................1911 EMISSION CONTROL SYSTEM MAINTENANCE............................................................................1911 CHASSIS AND BODY MAINTENANCE...................................................................................1912 RECOMMENDED FLUIDS AND LUBRICANTS......................................................................................1913 Fluids and Lubricants..............................................................................................1913 SAE Viscosity Number...............................................................................................1913 GASOLINE ENGINE OIL............................................................................................1913 Anti-freeze Coolant Mixture Ratio..................................................................................1914 ENGINE MAINTENANCE.....................................................................................................1915 Checking Drive Belts...............................................................................................1915 Changing Engine Coolant............................................................................................1916 -DRAINING ENGINE COOLANT-......................................................................................1916 -REFILLING ENGINE COOLANT-.....................................................................................1917 -FLUSHING COOLING SYSTEM-......................................................................................1918 Checking Fuel Lines................................................................................................1918 Changing Fuel Filter...............................................................................................1919 WITH CONSULT-II................................................................................................1919 WITHOUT CONSULT-II.............................................................................................1919 Changing Air Cleaner Filter........................................................................................1920 VISCOUS PAPER TYPE.............................................................................................1920 Changing Engine Oil................................................................................................1920 Changing Oil Filter................................................................................................1921 Changing Spark Plugs (Platinum-tipped type)........................................................................1921 Changing Spark Plugs (Conventional type)...........................................................................1922 Checking EVAP Vapor Lines..........................................................................................1923 CHASSIS AND BODY MAINTENANCE...........................................................................................1924 Checking Exhaust System............................................................................................1924 Checking Clutch Fluid Level and Leaks..............................................................................1924 Checking M/T Oil...................................................................................................1924 Changing M/T Oil...................................................................................................1924 Checking A/T Fluid.................................................................................................1925 Changing A/T Fluid.................................................................................................1925 Balancing Wheels...................................................................................................1926 Tire Rotation......................................................................................................1926 Checking Brake Fluid Level and Leaks...............................................................................1926 Checking Brake Lines and Cables....................................................................................1926 Checking Disc Brake................................................................................................1927 ROTOR..........................................................................................................1927 CALIPER........................................................................................................1927 PAD............................................................................................................1927 Checking Steering Gear and Linkage.................................................................................1927 STEERING GEAR..................................................................................................1927 STEERING LINKAGE...............................................................................................1927 Checking Power Steering Fluid and Lines............................................................................1927 Axle and Suspension Parts..........................................................................................1928 Drive Shaft........................................................................................................1928 Vacuum Hose........................................................................................................1928 Lubricating Locks, Hinges and Hood Latches.........................................................................1929 Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters....................................................1929 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1930 Engine Maintenance.................................................................................................1930 DRIVE BELT DEFLECTION AND TENSION..............................................................................1930 SPARK PLUG TYPE................................................................................................1930 Chassis and Body Maintenance.......................................................................................1930 WHEEL BALANCE..................................................................................................1930 mt.........................................................................................................................1931 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1931 PREPARATION............................................................................................................1932 Special Service Tools..............................................................................................1932 Commercial Service Tools...........................................................................................1934 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................1936 NVH Troubleshooting Chart..........................................................................................1936 DESCRIPTION............................................................................................................1937 Cross-sectional View...............................................................................................1937 DOUBLE-CONE SYNCHRONIZER.......................................................................................1938 ON-VEHICLE SERVICE.....................................................................................................1939 Replacing Oil Seal.................................................................................................1939 DIFFERENTIAL OIL SEAL..........................................................................................1939 STRIKING ROD OIL SEAL..........................................................................................1939 Position Switch Check..............................................................................................1940 BACK-UP LAMP SWITCH............................................................................................1940 PNP SWITCH.....................................................................................................1940 Viscous Coupling Check.............................................................................................1941 REMOVAL AND INSTALLATION...............................................................................................1942 Removal............................................................................................................1942 Installation.......................................................................................................1944 OVERHAUL...............................................................................................................1945 Transaxle Gear Control.............................................................................................1945 Case Components....................................................................................................1946 Gear Components....................................................................................................1947 Shift Control Components...........................................................................................1948 Final Drive Components.............................................................................................1949 DISASSEMBLY............................................................................................................1950 Transaxle Case.....................................................................................................1950 Clutch Housing.....................................................................................................1952 REPAIR FOR COMPONENT PARTS.............................................................................................1956 Input Shaft and Gears..............................................................................................1956 DISASSEMBLY....................................................................................................1956 INSPECTION.....................................................................................................1957 ASSEMBLY.......................................................................................................1958 Mainshaft and Gears................................................................................................1961 DISASSEMBLY....................................................................................................1961 INSPECTION.....................................................................................................1962 ASSEMBLY.......................................................................................................1964 Final Drive........................................................................................................1969 PRE-INSPECTION.................................................................................................1969 DISASSEMBLY....................................................................................................1970 INSPECTION.....................................................................................................1971 ASSEMBLY.......................................................................................................1972 Shift Control Components...........................................................................................1975 INSPECTION.....................................................................................................1975 ASSEMBLY...............................................................................................................1976 Clutch Housing.....................................................................................................1976 Transaxle Case.....................................................................................................1980 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1986 General Specifications.............................................................................................1986 TRANSAXLE......................................................................................................1986 FINAL GEAR.....................................................................................................1986 Gear End Play......................................................................................................1987 Clearance Between Baulk Ring and Gear..............................................................................1987 3RD, 4TH, 5TH, REVERSE BAULK RING..............................................................................1987 1ST AND 2ND BAULK RING.........................................................................................1987 Available Snap Rings...............................................................................................1987 SNAP RING......................................................................................................1987 Available C-rings..................................................................................................1988 4TH INPUT GEAR C-RING..........................................................................................1988 5TH INPUT GEAR REAR C-RING.....................................................................................1988 MAINSHAFT C-RING...............................................................................................1988 Available Adjusting Shims..........................................................................................1989 INPUT SHAFT REAR BEARING ADJUSTING SHIM........................................................................1989 MAINSHAFT ADJUSTING SHIM.......................................................................................1990 MAINSHAFT REAR BEARING ADJUSTING SHIM..........................................................................1990 Available Thrust Washer............................................................................................1991 MAINSHAFT THRUST WASHER........................................................................................1991 Available Washers..................................................................................................1991 DIFFERENTIAL SIDE GEAR THRUST WASHER...........................................................................1991 Available Shims - Differential Side Bearing Preload and Adjusting Shim.............................................1992 BEARING PRELOAD................................................................................................1992 DIFFERENTIAL SIDE BEARING ADJUSTING SHIMS......................................................................1992 rs.........................................................................................................................1995 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1995 SEAT BELTS.............................................................................................................1997 Precautions........................................................................................................1997 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) "AIR BAG" AND "SEAT BELT PRE-TENSIONER"....................................1997 PRECAUTION FOR SEAT BELT SERVICE...............................................................................1997 Front Seat Belt....................................................................................................1998 REMOVAL AND INSTALLATION.......................................................................................1998 Rear Seat Belt.....................................................................................................2000 REMOVAL AND INSTALLATION.......................................................................................2000 Seat Belt Inspection...............................................................................................2002 AFTER A COLLISION..............................................................................................2002 PRELIMINARY CHECKS.............................................................................................2002 SEAT BELT RETRACTOR ON-VEHICLE CHECK...........................................................................2003 SEAT BELT RETRACTOR OFF-VEHICLE CHECK..........................................................................2003 Tether Anchor Plate................................................................................................2005 REMOVAL AND INSTALLATION.......................................................................................2005 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)....................................................................................2006 Precautions........................................................................................................2006 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) "AIR BAG" AND "SEAT BELT PRE-TENSIONER"....................................2006 PRECAUTIONS FOR SRS "AIR BAG" AND "SEAT BELT PRE-TENSIONER" SERVICE............................................2006 WIRING DIAGRAMS AND TROUBLE DIAGNOSIS..........................................................................2006 Preparation........................................................................................................2007 SPECIAL SERVICE TOOLS..........................................................................................2007 SRS Configuration..................................................................................................2008 Seat Belt Pre-tensioner with Load Limiter..........................................................................2009 Side Air Bag.......................................................................................................2009 SRS Component Parts Location.......................................................................................2010 Maintenance Items..................................................................................................2010 Diagnosis Sensor Unit..............................................................................................2011 REMOVAL AND INSTALLATION.......................................................................................2011 Seat Belt Pre-tensioner............................................................................................2012 REMOVAL AND INSTALLATION.......................................................................................2012 Satellite Sensor...................................................................................................2012 REMOVAL AND INSTALLATION.......................................................................................2012 Driver Air Bag Module and Spiral Cable.............................................................................2013 REMOVAL AND INSTALLATION.......................................................................................2013 REMOVAL........................................................................................................2013 INSTALLATION...................................................................................................2015 Front Passenger Air Bag Module.....................................................................................2016 REMOVAL........................................................................................................2016 INSTALLATION...................................................................................................2017 Side Air Bag Module................................................................................................2017 REMOVAL........................................................................................................2017 INSTALLATION...................................................................................................2019 Disposal of Air Bag Module and Seat Belt Pre-tensioner.............................................................2019 CHECKING DEPLOYMENT TOOL.......................................................................................2020 DEPLOYMENT PROCEDURES FOR AIR BAG MODULE (OUTSIDE OF VEHICLE)..................................................2021 DEPLOYMENT PROCEDURES FOR SEAT BELT PRE-TENSIONER (OUTSIDE OF VEHICLE).........................................2023 DEPLOYMENT OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER WHILE MOUNTED IN VEHICLE..............................2024 DISPOSING OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER........................................................2024 Trouble Diagnoses Introduction.....................................................................................2026 DIAGNOSIS FUNCTION.............................................................................................2026 DIAGNOSIS MODE FOR CONSULT-II..................................................................................2026 HOW TO CHANGE SELF-DIAGNOSIS MODE WITH CONSULT-II..............................................................2027 HOW TO CHANGE SELF-DIAGNOSIS MODE WITHOUT CONSULT-II...........................................................2027 HOW TO ERASE SELF-DIAGNOSIS RESULTS............................................................................2027 How to Perform Trouble Diagnoses for Quick and Accurate Repair.....................................................2029 INFORMATION FROM CUSTOMER......................................................................................2029 PRELIMINARY CHECK..............................................................................................2029 WORK FLOW......................................................................................................2030 Wiring Diagram - SRS -.............................................................................................2031 SRS Operation Check................................................................................................2033 DIAGNOSTIC PROCEDURE 1.........................................................................................2033 Trouble Diagnoses with CONSULT-II..................................................................................2033 DIAGNOSTIC PROCEDURE 2.........................................................................................2033 DIAGNOSTIC PROCEDURE 3.........................................................................................2037 DIAGNOSTIC PROCEDURE 4 (CONTINUED FROM DIAGNOSTIC PROCEDURE 2).................................................2038 DIAGNOSTIC PROCEDURE 5.........................................................................................2039 Trouble Diagnoses without CONSULT-II...............................................................................2043 DIAGNOSTIC PROCEDURE 6.........................................................................................2043 DIAGNOSTIC PROCEDURE 7.........................................................................................2048 DIAGNOSTIC PROCEDURE 8 (CONTINUED FROM DIAGNOSTIC PROCEDURE 6).................................................2050 Trouble Diagnoses: "AIR BAG" Warning Lamp Does Not Turn Off........................................................2051 DIAGNOSTIC PROCEDURE 9.........................................................................................2051 Trouble Diagnoses: "AIR BAG" Warning Lamp Does Not Turn On.........................................................2053 DIAGNOSTIC PROCEDURE 10........................................................................................2053 Collision Diagnosis................................................................................................2054 FOR FRONTAL COLLISION..........................................................................................2054 FOR SIDE COLLISION.............................................................................................2056 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.........................................................................................................................2059 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................2059 PRECAUTIONS............................................................................................................2060 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................2060 Wiring Diagrams and Trouble Diagnosis..............................................................................2060 PREPARATION............................................................................................................2061 Special Service Tool...............................................................................................2061 BATTERY................................................................................................................2062 How to Handle Battery..............................................................................................2062 METHODS OF PREVENTING OVER-DISCHARGE...........................................................................2062 CHECKING ELECTROLYTE LEVEL.....................................................................................2062 SPECIFIC GRAVITY CHECK.........................................................................................2063 CHARGING THE BATTERY...........................................................................................2064 Trouble Diagnoses with Battery/Starting/Charging System Tester.....................................................2065 DIAGNOSTIC RESULT ITEM CHART...................................................................................2067 STARTING SYSTEM........................................................................................................2068 System Description.................................................................................................2068 M/T MODELS.....................................................................................................2068 A/T MODELS.....................................................................................................2068 Wiring Diagram - START -...........................................................................................2069 M/T MODELS.....................................................................................................2069 A/T MODELS.....................................................................................................2070 Trouble Diagnoses with Battery/Starting/Charging System Tester.....................................................2071 DIAGNOSTIC RESULT ITEM CHART...................................................................................2072 WORK FLOW......................................................................................................2073 DIAGNOSTIC PROCEDURE 1.........................................................................................2074 DIAGNOSTIC PROCEDURE 2.........................................................................................2076 MINIMUM SPECIFICATION OF CRANKING VOLTAGE REFERENCING COOLANT TEMPERATURE......................................2077 Construction.......................................................................................................2077 Removal and Installation...........................................................................................2077 Pinion/Clutch Check................................................................................................2078 CHARGING SYSTEM........................................................................................................2079 System Description.................................................................................................2079 Wiring Diagram - CHARGE -..........................................................................................2080 Trouble Diagnoses with Battery/Starting/Charging System Tester.....................................................2081 DIAGNOSTIC RESULT ITEM CHART...................................................................................2083 WORK FLOW......................................................................................................2084 DIAGNOSTIC PROCEDURE 1.........................................................................................2085 DIAGNOSTIC PROCEDURE 2.........................................................................................2086 DIAGNOSTIC PROCEDURE 3.........................................................................................2087 MALFUNCTION INDICATOR..........................................................................................2087 Construction.......................................................................................................2088 Removal and Installation...........................................................................................2088 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................2089 Battery............................................................................................................2089 Starter............................................................................................................2089 Alternator.........................................................................................................2089 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.........................................................................................................................2091 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................2091 PRECAUTIONS............................................................................................................2092 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................2092 Precautions for Steering System....................................................................................2092 PREPARATION............................................................................................................2093 Special Service Tools..............................................................................................2093 Commercial Service Tools...........................................................................................2094 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................2095 NVH Troubleshooting Chart..........................................................................................2095 ON-VEHICLE SERVICE.....................................................................................................2096 Checking Steering Wheel Play.......................................................................................2096 Checking Neutral Position on Steering Wheel........................................................................2096 PRE-CHECKING...................................................................................................2096 CHECKING.......................................................................................................2096 Front Wheel Turning Angle..........................................................................................2096 Checking Gear Housing Movement.....................................................................................2096 Checking and Adjusting Drive Belts.................................................................................2097 Checking Fluid Level...............................................................................................2097 Checking Fluid Leakage.............................................................................................2097 Bleeding Hydraulic System..........................................................................................2097 Checking Steering Wheel Turning Force..............................................................................2098 Checking Hydraulic System..........................................................................................2098 STEERING WHEEL AND STEERING COLUMN.....................................................................................2100 Components.........................................................................................................2100 Removal and Installation...........................................................................................2100 STEERING WHEEL.................................................................................................2100 STEERING COLUMN................................................................................................2101 Disassembly and Assembly...........................................................................................2103 Inspection.........................................................................................................2104 TILT MECHANISM.................................................................................................2104 POWER STEERING GEAR AND LINKAGE........................................................................................2105 Components.........................................................................................................2105 Removal and Installation...........................................................................................2106 Disassembly........................................................................................................2108 Inspection.........................................................................................................2108 BOOT...........................................................................................................2108 RACK...........................................................................................................2108 PINION ASSEMBLY................................................................................................2109 GEAR HOUSING CYLINDER..........................................................................................2109 TIE-ROD OUTER AND INNER SOCKETS................................................................................2109 Assembly...........................................................................................................2109 Adjustment.........................................................................................................2114 POWER STEERING OIL PUMP................................................................................................2116 Components.........................................................................................................2116 Pre-disassembly Inspection.........................................................................................2116 Disassembly........................................................................................................2116 Inspection.........................................................................................................2117 Assembly...........................................................................................................2118 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................2121 General Specifications.............................................................................................2121 Steering Wheel.....................................................................................................2121 Steering Column....................................................................................................2121 Steering Gear and Linkage..........................................................................................2122 Power Steering.....................................................................................................2123 su.........................................................................................................................2125 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................2125 FRONT SUSPENSION.......................................................................................................2126 Precautions........................................................................................................2126 PRECAUTIONS....................................................................................................2126 Preparation........................................................................................................2126 SPECIAL SERVICE TOOLS..........................................................................................2126 COMMERCIAL SERVICE TOOLS.......................................................................................2126 Noise, Vibration and Harshness (NVH) Troubleshooting...............................................................2127 NVH TROUBLESHOOTING CHART......................................................................................2127 Components.........................................................................................................2128 On-vehicle Service.................................................................................................2129 FRONT SUSPENSION PARTS.........................................................................................2129 FRONT WHEEL ALIGNMENT..........................................................................................2130 Coil Spring and Shock Absorber.....................................................................................2133 COMPONENTS.....................................................................................................2133 REMOVAL........................................................................................................2134 DISASSEMBLY....................................................................................................2134 INSPECTION.....................................................................................................2134 ASSEMBLY.......................................................................................................2135 Third Link and Upper Link..........................................................................................2135 REMOVAL........................................................................................................2135 INSTALLATION...................................................................................................2135 DISASSEMBLY....................................................................................................2136 ASSEMBLY.......................................................................................................2136 Stabilizer Bar.....................................................................................................2137 REMOVAL AND INSTALLATION.......................................................................................2137 Transverse Link and Lower Ball Joint...............................................................................2138 REMOVAL AND INSTALLATION.......................................................................................2138 INSPECTION.....................................................................................................2138 Service Data and Specifications (SDS)..............................................................................2138 GENERAL SPECIFICATIONS (FRONT).................................................................................2138 FRONT WHEEL ALIGNMENT (UNLADEN*1)..............................................................................2139 LOWER BALL JOINT...............................................................................................2139 WHEELARCH HEIGHT (UNLADEN*)....................................................................................2140 WHEEL RUNOUT...................................................................................................2140 REAR SUSPENSION........................................................................................................2141 Precautions........................................................................................................2141 PRECAUTIONS....................................................................................................2141 Preparation........................................................................................................2141 COMMERCIAL SERVICE TOOLS.......................................................................................2141 Noise, Vibration and Harshness (NVH) Troubleshooting...............................................................2141 Components.........................................................................................................2142 On-vehicle Service.................................................................................................2143 REAR SUSPENSION PARTS..........................................................................................2143 REAR WHEEL ALIGNMENT...........................................................................................2143 Removal and Installation...........................................................................................2145 REMOVAL........................................................................................................2146 INSTALLATION...................................................................................................2146 Coil Spring and Shock Absorber.....................................................................................2146 REMOVAL........................................................................................................2146 DISASSEMBLY....................................................................................................2147 INSPECTION.....................................................................................................2147 ASSEMBLY.......................................................................................................2147 Torsion Beam, Lateral Link and Control Rod.........................................................................2148 DISASSEMBLY....................................................................................................2148 INSPECTION.....................................................................................................2148 ASSEMBLY.......................................................................................................2148 Service Data and Specifications (SDS)..............................................................................2149 GENERAL SPECIFICATIONS (REAR)..................................................................................2149 REAR WHEEL ALIGNMENT (UNLADEN*)................................................................................2149
DESCRIPTION:
2002 INFINITI G20 P11 Series Service Manual PDF DOWNLOAD
FOREWORD
- This manual contains maintenance and repair procedures for the 2002 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.
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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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