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2002 NISSAN QUEST V41 Series Service Manual PDF DOWNLOAD
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Description
2002 NISSAN QUEST V41 Series Service Manual PDF DOWNLOAD
FILE DETAILS:
2002 NISSAN QUEST V41 Series Service Manual PDF DOWNLOAD
Language : English
Pages : 1986
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
2002 NISSAN QUEST V41 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 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............................................................................................................. 2 FUSE AND FUSIBLE LINK BOX.............................................................................................. 3 JOINT CONNECTOR........................................................................................................ 4 ELECTRICAL UNITS....................................................................................................... 5 QUICK REFERENCE CHART.................................................................................................. 6 COMMENT SHEET.......................................................................................................... 3 GST Mode 6 - Test Value & Test Limit Chart............................................................................. 5 at......................................................................................................................... 6 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS...................................................................................................... 6 TROUBLE DIAGNOSIS - INDEX.............................................................................................. 9 Alphabetical & P No. Index for DTC................................................................................. 9 PRECAUTIONS............................................................................................................ 11 Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELTPRE-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............................................................................................... 21 Hydraulic Control Circuit.......................................................................................... 22 Shift Mechanism.................................................................................................... 23 Control System..................................................................................................... 32 Control Mechanism.................................................................................................. 34 Control Valve...................................................................................................... 39 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION................................................................................. 40 Introduction....................................................................................................... 40 OBD-II Function for A/T System..................................................................................... 40 One or Two Trip Detection Logic of OBD-II.......................................................................... 40 OBD-II Diagnostic Trouble Code (DTC)............................................................................... 40 Malfunction Indicator Lamp (MIL)................................................................................... 43 CONSULT-II......................................................................................................... 44 Diagnostic Procedure Without CONSULT-II............................................................................ 53 TROUBLE DIAGNOSIS - INTRODUCTION....................................................................................... 60 Introduction....................................................................................................... 60 Work Flow.......................................................................................................... 64 TROUBLE DIAGNOSIS - BASIC INSPECTION................................................................................... 66 A/T Fluid Check.................................................................................................... 66 Stall Test......................................................................................................... 66 Line Pressure Test................................................................................................. 70 Road Test.......................................................................................................... 71 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION................................................................................ 88 Symptom Chart...................................................................................................... 88 TCM Terminals and Reference Value.................................................................................. 100 TROUBLE DIAGNOSIS FOR POWER SUPPLY..................................................................................... 105 Wiring Diagram - AT - MAIN......................................................................................... 105 DTC P0705 PARK/NEUTRAL POSITION SWITCH................................................................................. 108 Description........................................................................................................ 108 Wiring Diagram - AT - PNP/SW....................................................................................... 110 Diagnostic Procedure............................................................................................... 111 Component Inspection............................................................................................... 114 DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT......................................................................... 115 Description........................................................................................................ 115 Wiring Diagram - AT - FTS.......................................................................................... 117 Diagnostic Procedure............................................................................................... 118 Component Inspection............................................................................................... 121 DTC P0720 VEHICLE SPEED SENSOR A/T (REVOLUTION SENSOR)................................................................. 122 Description........................................................................................................ 122 Wiring Diagram - AT - VSSA/T....................................................................................... 124 Diagnostic Procedure............................................................................................... 125 Component Inspection............................................................................................... 127 DTC P0725 ENGINE SPEED SIGNAL.......................................................................................... 128 Description........................................................................................................ 128 Wiring Diagram - AT - ENGSS........................................................................................ 129 Diagnostic Procedure............................................................................................... 130 DTC P0731 A/T 1ST GEAR FUNCTION........................................................................................ 132 Description........................................................................................................ 132 Wiring Diagram - AT - 1ST.......................................................................................... 135 Diagnostic Procedure............................................................................................... 136 Component Inspection............................................................................................... 137 DTC P0732 A/T 2ND GEAR FUNCTION........................................................................................ 138 Description........................................................................................................ 138 Wiring Diagram - AT - 2ND.......................................................................................... 141 Diagnostic Procedure............................................................................................... 142 Component Inspection............................................................................................... 143 DTC P0733 A/T 3RD GEAR FUNCTION........................................................................................ 144 Description........................................................................................................ 144 Wiring Diagram - AT - 3RD.......................................................................................... 147 Diagnostic Procedure............................................................................................... 148 Component Inspection............................................................................................... 149 DTC P0734 A/T 4TH GEAR FUNCTION........................................................................................ 150 Description........................................................................................................ 150 Wiring Diagram - AT - 4TH.......................................................................................... 154 Diagnostic Procedure............................................................................................... 155 Component Inspection............................................................................................... 158 DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE....................................................................... 159 Description........................................................................................................ 159 Wiring Diagram - AT - TCV.......................................................................................... 161 Diagnostic Procedure............................................................................................... 162 Component Inspection............................................................................................... 163 DTC P0744 A/T TCC S/V FUNCTION (LOCK-UP)............................................................................... 164 Description........................................................................................................ 164 Wiring Diagram - AT - TCCSIG....................................................................................... 166 Diagnostic Procedure............................................................................................... 167 Component Inspection............................................................................................... 171 DTC P0745 LINE PRESSURE SOLENOID VALVE................................................................................. 172 Description........................................................................................................ 172 Wiring Diagram - AT - LPSV......................................................................................... 174 Diagnostic Procedure............................................................................................... 175 Component Inspection............................................................................................... 177 DTC P0750 SHIFT SOLENOID VALVE A....................................................................................... 178 Description........................................................................................................ 178 Wiring Diagram - AT - SSV/A........................................................................................ 180 Diagnostic Procedure............................................................................................... 181 Component Inspection............................................................................................... 183 DTC P0755 SHIFT SOLENOID VALVE B....................................................................................... 184 Description........................................................................................................ 184 Wiring Diagram - AT - SSV/B........................................................................................ 186 Diagnostic Procedure............................................................................................... 187 Component Inspection............................................................................................... 189 DTC P1705 THROTTLE POSITION SENSOR..................................................................................... 190 Description........................................................................................................ 190 Wiring Diagram - AT - TPS.......................................................................................... 192 Diagnostic Procedure............................................................................................... 193 Component Inspection............................................................................................... 196 DTC P1760 OVERRUN CLUTCH SOLENOID VALVE................................................................................ 197 Description........................................................................................................ 197 Wiring Diagram - AT - OVRCSV....................................................................................... 199 Diagnostic Procedure............................................................................................... 200 Component Inspection............................................................................................... 202 DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE)........................................... 203 Description........................................................................................................ 203 Wiring Diagram - AT - BA/FTS....................................................................................... 205 Diagnostic Procedure............................................................................................... 206 Component Inspection............................................................................................... 209 DTC VEHICLE SPEED SENSOR MTR........................................................................................... 210 Description........................................................................................................ 210 Wiring Diagram - AT - VSSMTR....................................................................................... 212 Diagnostic Procedure............................................................................................... 213 CONTROL UNIT (RAM), CONTROL UNIT (ROM)................................................................................. 214 Description........................................................................................................ 214 On Board Diagnosis Logic........................................................................................... 214 DTC Confirmation Procedure......................................................................................... 214 Diagnostic Procedure............................................................................................... 215 CONTROL UNIT (EEP ROM)................................................................................................. 216 Description........................................................................................................ 216 On Board Diagnosis Logic........................................................................................... 216 DTC Confirmation Procedure......................................................................................... 216 Diagnostic Procedure............................................................................................... 217 TROUBLE DIAGNOSES FOR SYMPTOMS......................................................................................... 218 Wiring Diagram - AT - NONDTC....................................................................................... 218 1. O/D OFF Indicator Lamp Does Not Come On......................................................................... 221 2. Engine Cannot Be Started In P and N Position.................................................................... 223 3. In P Position, Vehicle Moves Forward or Backward When Pushed.................................................... 224 4. In N Position, Vehicle Moves.................................................................................... 225 5. Large Shock. N -> R Position.................................................................................... 227 6. Vehicle Does Not Creep Backward In R Position................................................................... 229 7. Vehicle Does Not Creep Forward in D, 2 or 1 Position............................................................ 233 8. Vehicle Cannot Be Started From D1............................................................................... 236 9. A/T Does Not Shift: D1 -> D2 or Does Not Kickdown: D4 -> D2..................................................... 239 10. A/T Does Not Shift: D2 -> D3................................................................................... 242 11. A/T Does Not Shift: D3 -> D4................................................................................... 245 12. A/T Does Not Perform Lock-up................................................................................... 248 13. A/T Does Not Hold Lock-up Condition............................................................................ 250 14. Lock-up Is Not Released........................................................................................ 252 15. Engine Speed Does Not Return To Idle (Light Braking D4 -> D3).................................................. 253 16. Vehicle Does Not Start From D1................................................................................. 255 17. A/T Does Not Shift: D4 -> D3, When Overdrive Control Switch ON -> OFF.......................................... 256 18. A/T Does Not Shift: D3 -> 22, When Selector Lever D -> 2 Position.............................................. 257 19. A/T Does Not Shift: 22 -> 11, When Selector Lever 2 -> 1 Position.............................................. 258 20. Vehicle Does Not Decelerate By Engine Brake.................................................................... 259 21. TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control and Throttle Position Switches Circuit Checks).... 259 A/T SHIFT LOCK SYSTEM.................................................................................................. 268 Description........................................................................................................ 268 Wiring Diagram - SHIFT -........................................................................................... 269 Shift Lock System Electrical Parts Location........................................................................ 270 Removal............................................................................................................ 270 Diagnostic Procedure............................................................................................... 271 Installation and Adjustment........................................................................................ 273 Component Check.................................................................................................... 274 ON-VEHICLE SERVICE..................................................................................................... 275 Control Valve Assembly and Accumulators............................................................................ 275 Revolution Sensor Replacement...................................................................................... 276 Park/Neutral Position (PNP) Switch Adjustment...................................................................... 276 Control Cable Adjustment........................................................................................... 277 Differential Side Oil Seal Replacement............................................................................. 277 REMOVAL AND INSTALLATION............................................................................................... 278 Removal............................................................................................................ 278 Installation....................................................................................................... 279 OVERHAUL............................................................................................................... 281 Components......................................................................................................... 281 Oil Channel........................................................................................................ 284 Locations of Adjusting Shims, Needle Bearings, Thrust Washers and Snap Rings....................................... 285 DISASSEMBLY............................................................................................................ 286 REPAIR FOR COMPONENT PARTS............................................................................................. 300 Manual Shaft....................................................................................................... 300 Oil Pump........................................................................................................... 303 Control Valve Assembly............................................................................................. 307 Control Valve Upper Body........................................................................................... 315 Control Valve Lower Body........................................................................................... 319 Reverse Clutch..................................................................................................... 321 High Clutch........................................................................................................ 324 Forward and Overrun Clutches....................................................................................... 329 Low & Reverse Brake................................................................................................ 334 Rear Internal Gear, Forward Clutch Hub and Overrun Clutch Hub...................................................... 337 Output Shaft, Idler Gear, Reduction Pinion Gear and Bearing Retainer............................................... 341 Band Servo Piston Assembly......................................................................................... 346 Final Drive........................................................................................................ 351 ASSEMBLY............................................................................................................... 355 Assembly (1)....................................................................................................... 355 Adjustment (1)..................................................................................................... 355 Assembly (2)....................................................................................................... 360 Adjustment (2)..................................................................................................... 366 Assembly (3)....................................................................................................... 368 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................. 375 General Specifications............................................................................................. 375 Shift Schedule..................................................................................................... 375 Stall Revolution................................................................................................... 375 Line Pressure...................................................................................................... 375 Control Valves..................................................................................................... 376 Accumulator........................................................................................................ 376 Clutch and Brakes.................................................................................................. 377 Final Drive........................................................................................................ 378 Planetary Carrier and Oil Pump..................................................................................... 379 Input Shaft........................................................................................................ 380 Reduction Pinion Gear.............................................................................................. 380 Band Servo......................................................................................................... 381 Output Shaft....................................................................................................... 381 Bearing Retainer................................................................................................... 382 Total End Play..................................................................................................... 382 Reverse Clutch End Play............................................................................................ 382 Removal and Installation........................................................................................... 383 Shift Solenoid Valves.............................................................................................. 383 Solenoid Valves.................................................................................................... 383 A/T Fluid Temperature Sensor....................................................................................... 383 Revolution Sensor.................................................................................................. 383 Dropping Resistor.................................................................................................. 383 SUPER MULTIPLE JUNCTION (SMJ).......................................................................................... 0 FUSE BLOCK............................................................................................................. 2 FUSE AND FUSIBLE LINK BOX.............................................................................................. 3 JOINT CONNECTOR........................................................................................................ 4 ELECTRICAL UNITS....................................................................................................... 5 ax......................................................................................................................... 384 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS...................................................................................................... 384 FRONT AXLE............................................................................................................. 385 Precautions........................................................................................................ 385 PRECAUTIONS.................................................................................................... 385 Preparation........................................................................................................ 385 SPECIAL SERVICE TOOLS.......................................................................................... 385 COMMERCIAL SERVICE TOOL........................................................................................ 385 Noise, Vibration and Harshness (NVH)Troubleshooting................................................................ 386 NVH TROUBLESHOOTING CHART...................................................................................... 386 On-vehicle Service................................................................................................. 386 FRONT AXLE PARTS............................................................................................... 386 FRONT WHEEL BEARING............................................................................................ 387 DRIVE SHAFT.................................................................................................... 387 Wheel Hub and Knuckle.............................................................................................. 388 COMPONENTS..................................................................................................... 388 REMOVAL........................................................................................................ 389 INSTALLATION................................................................................................... 390 DISASSEMBLY.................................................................................................... 390 INSPECTION..................................................................................................... 391 ASSEMBLY....................................................................................................... 391 Drive Shaft........................................................................................................ 392 COMPONENTS..................................................................................................... 392 REMOVAL........................................................................................................ 393 DISASSEMBLY.................................................................................................... 394 INSPECTION..................................................................................................... 396 ASSEMBLY....................................................................................................... 396 INSTALLATION................................................................................................... 399 Service Data and Specifications (SDS).............................................................................. 400 WHEEL BEARING (FRONT).......................................................................................... 400 DRIVE SHAFT.................................................................................................... 400 REAR AXLE.............................................................................................................. 401 Precautions........................................................................................................ 401 PRECAUTIONS.................................................................................................... 401 Preparation........................................................................................................ 401 COMMERCIAL SERVICE TOOL........................................................................................ 401 Noise, Vibration and Harshness (NVH)Troubleshooting................................................................ 401 On-vehicle Service................................................................................................. 401 REAR AXLE PARTS................................................................................................ 401 REAR WHEEL HUB BEARING......................................................................................... 401 Wheel Hub.......................................................................................................... 402 COMPONENTS..................................................................................................... 402 REMOVAL........................................................................................................ 402 INSTALLATION................................................................................................... 403 Service Data and Specifications (SDS).............................................................................. 403 WHEEL BEARING (REAR)........................................................................................... 403 br......................................................................................................................... 404 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS...................................................................................................... 404 PRECAUTIONS............................................................................................................ 406 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................ 406 Precautions for Brake System....................................................................................... 406 Wiring Diagrams and Trouble Diagnosis.............................................................................. 406 PREPARATION............................................................................................................ 407 Commercial Service Tools........................................................................................... 407 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING................................................................... 408 NVH Troubleshooting Chart.......................................................................................... 408 ON-VEHICLE SERVICE..................................................................................................... 409 Checking Brake Fluid Level......................................................................................... 409 Checking Brake Line................................................................................................ 409 Changing Brake Fluid............................................................................................... 409 Bleeding Brake System.............................................................................................. 410 Brake Burnishing Procedure......................................................................................... 410 BRAKE HYDRAULIC LINE................................................................................................... 411 Hydraulic Circuit.................................................................................................. 411 Removal............................................................................................................ 411 Inspection......................................................................................................... 412 Installation....................................................................................................... 412 DUAL LOAD SENSING VALVE................................................................................................ 413 Inspection......................................................................................................... 413 Removal and Installation........................................................................................... 415 BRAKE PEDAL AND BRACKET................................................................................................ 416 Removal and Installation........................................................................................... 416 Inspection......................................................................................................... 416 Adjustment......................................................................................................... 416 MASTER CYLINDER........................................................................................................ 418 Removal............................................................................................................ 418 Disassembly........................................................................................................ 418 Inspection......................................................................................................... 419 Assembly........................................................................................................... 419 Installation....................................................................................................... 420 BRAKE BOOSTER.......................................................................................................... 421 On-vehicle Service................................................................................................. 421 OPERATING CHECK................................................................................................ 421 AIRTIGHT CHECK................................................................................................. 421 Removal............................................................................................................ 421 Inspection......................................................................................................... 422 OUTPUT ROD LENGTH CHECK........................................................................................ 422 Installation....................................................................................................... 422 VACUUM PIPING.......................................................................................................... 423 Removal and Installation........................................................................................... 423 Inspection......................................................................................................... 423 HOSES AND CONNECTORS........................................................................................... 423 CHECK VALVE.................................................................................................... 423 FRONT DISC BRAKE....................................................................................................... 424 Components......................................................................................................... 424 Pad Replacement.................................................................................................... 425 Removal............................................................................................................ 426 Disassembly........................................................................................................ 426 Inspection......................................................................................................... 426 CALIPER........................................................................................................ 426 ROTOR.......................................................................................................... 427 Assembly........................................................................................................... 427 Installation....................................................................................................... 427 REAR DRUM BRAKE........................................................................................................ 428 Components......................................................................................................... 428 Removal............................................................................................................ 429 Inspection......................................................................................................... 430 WHEEL CYLINDER................................................................................................. 430 WHEEL CYLINDER OVERHAUL........................................................................................ 430 DRUM........................................................................................................... 430 LINING......................................................................................................... 430 Installation....................................................................................................... 431 PARKING BRAKE CONTROL.................................................................................................. 432 Components......................................................................................................... 432 Removal and Installation........................................................................................... 432 Inspection......................................................................................................... 433 Adjustment......................................................................................................... 433 ABS.................................................................................................................... 434 DESCRIPTION........................................................................................................ 434 Purpose........................................................................................................ 434 Operation...................................................................................................... 434 ABS Hydraulic Circuit.......................................................................................... 434 System Components.............................................................................................. 435 System Description............................................................................................. 435 SENSOR..................................................................................................... 435 CONTROL UNIT (BUILT-IN ABS ACTUATOR AND ELECTRIC UNIT)..................................................... 435 ABS ACTUATOR AND ELECTRIC UNIT............................................................................. 436 Component Parts and Harness ConnectorLocation.................................................................. 437 Schematic...................................................................................................... 438 Wiring Diagram - ABS -......................................................................................... 439 ON BOARD DIAGNOSTIC SYSTEMDESCRIPTION.............................................................................. 442 Self-diagnosis................................................................................................. 442 FUNCTION................................................................................................... 442 SELF-DIAGNOSIS PROCEDURE................................................................................... 442 HOW TO READ SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES).................................................... 443 HOW TO ERASE SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES)................................................... 443 CONSULT-II..................................................................................................... 444 CONSULT-II APPLICATION TO ABS.............................................................................. 444 ECU (ABS CONTROL UNIT) PART NUMBER MODE.................................................................... 444 CONSULT-II Inspection Procedure................................................................................ 445 SELF-DIAGNOSIS PROCEDURE................................................................................... 445 SELF-DIAGNOSTIC RESULTS MODE............................................................................... 446 DATA MONITOR PROCEDURE..................................................................................... 447 ACTIVE TEST PROCEDURE...................................................................................... 447 DATA MONITOR MODE.......................................................................................... 448 ACTIVE TEST MODE........................................................................................... 449 TROUBLE DIAGNOSIS - INTRODUCTION................................................................................... 450 How to Perform Trouble Diagnoses for Quick and Accurate Repair................................................. 450 INTRODUCTION............................................................................................... 450 TROUBLE DIAGNOSIS - BASIC INSPECTION............................................................................... 451 Preliminary Check.............................................................................................. 451 Ground Circuit Check........................................................................................... 454 ABS ACTUATOR AND ELECTRIC UNIT GROUND...................................................................... 454 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION............................................................................ 455 Malfunction Code/Symptom Chart................................................................................. 455 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS........................................................................ 456 Wheel Sensor or Rotor.......................................................................................... 456 DIAGNOSTIC PROCEDURE....................................................................................... 456 ABS Actuator Solenoid Valve and Solenoid Valve Relay........................................................... 459 DIAGNOSTIC PROCEDURE....................................................................................... 459 Motor Relay or Motor........................................................................................... 461 DIAGNOSTIC PROCEDURE....................................................................................... 461 Low Voltage.................................................................................................... 463 DIAGNOSTIC PROCEDURE....................................................................................... 463 Control Unit................................................................................................... 465 DIAGNOSTIC PROCEDURE....................................................................................... 465 TROUBLE DIAGNOSES FOR SYMPTOMS..................................................................................... 466 1. ABS Works Frequently........................................................................................ 466 2. Unexpected Pedal Action..................................................................................... 466 3. Long Stopping Distance...................................................................................... 467 4. ABS Does Not Work........................................................................................... 469 5. Pedal Vibration and Noise................................................................................... 469 6. Warning Lamp Does Not Come On When Ignition Switch Is Turned On............................................. 470 7. Warning Lamp Stays On When Ignition Switch Is Turned On..................................................... 472 REMOVAL AND INSTALLATION........................................................................................... 476 Front Wheel Sensor............................................................................................. 476 Rear Wheel Sensor.............................................................................................. 476 Sensor Rotor................................................................................................... 477 REMOVAL.................................................................................................... 477 INSTALLATION............................................................................................... 477 Actuator....................................................................................................... 478 REMOVAL.................................................................................................... 478 INSTALLATION............................................................................................... 478 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................. 479 General Specifications............................................................................................. 479 Disc Brake......................................................................................................... 479 Drum Brake......................................................................................................... 479 Brake Pedal........................................................................................................ 479 Parking Brake Control.............................................................................................. 479 SUPER MULTIPLE JUNCTION (SMJ).......................................................................................... 0 FUSE BLOCK............................................................................................................. 2 FUSE AND FUSIBLE LINK BOX.............................................................................................. 3 JOINT CONNECTOR........................................................................................................ 4 ELECTRICAL UNITS....................................................................................................... 5 bt......................................................................................................................... 480 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS...................................................................................................... 480 PRECAUTIONS............................................................................................................ 482 Service Notice..................................................................................................... 482 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................ 482 PREPARATION............................................................................................................ 483 Special Service Tools.............................................................................................. 483 SQUEAK AND RATTLE TROUBLE DIAGNOSES.................................................................................... 484 Work Flow.......................................................................................................... 484 CUSTOMER INTERVIEW............................................................................................. 484 DUPLICATE THE NOISE AND TEST DRIVE............................................................................. 485 CHECK RELATED SERVICE BULLETINS................................................................................ 485 LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE................................................................... 485 REPAIR THE CAUSE............................................................................................... 485 CONFIRM THE REPAIR............................................................................................. 486 Generic Squeak and Rattle Troubleshooting.......................................................................... 486 INSTRUMENT PANEL............................................................................................... 486 CENTER CONSOLE................................................................................................. 486 DOORS.......................................................................................................... 486 TRUNK.......................................................................................................... 486 SUNROOF/HEADLINER.............................................................................................. 487 SEATS.......................................................................................................... 487 UNDERHOOD...................................................................................................... 487 Diagnostic Worksheet............................................................................................... 488 CLIP AND FASTENER...................................................................................................... 490 Description........................................................................................................ 490 BODY FRONT END......................................................................................................... 493 Removal and Installation........................................................................................... 493 FRONT BUMPER ASSEMBLY.......................................................................................... 493 BODY REAR END AND OPENER............................................................................................... 496 Removal and Installation........................................................................................... 496 REAR BUMPER ASSEMBLY........................................................................................... 496 FRONT DOOR............................................................................................................. 499 Overhaul........................................................................................................... 499 SLIDING DOOR........................................................................................................... 500 Overhaul........................................................................................................... 500 INSTRUMENT PANEL ASSEMBLY.............................................................................................. 502 Removal and Installation........................................................................................... 502 SIDE AND FLOOR TRIM.................................................................................................... 507 Removal and Installation........................................................................................... 507 DOOR TRIM.............................................................................................................. 510 Front Door Trim.................................................................................................... 510 REMOVAL AND INSTALLATION....................................................................................... 510 Siding Door Trim................................................................................................... 511 REMOVAL AND INSTALLATION....................................................................................... 511 BACK DOOR TRIM......................................................................................................... 512 Removal and Installation........................................................................................... 512 ROOF TRIM.............................................................................................................. 513 Removal and Installation........................................................................................... 513 EXTERIOR............................................................................................................... 515 Removal and Installation........................................................................................... 515 FRONT SEAT............................................................................................................. 519 Removal and Installation........................................................................................... 519 POWER SEAT..................................................................................................... 519 MANUAL SEAT.................................................................................................... 520 2ND SEAT............................................................................................................... 521 Removal and Installation........................................................................................... 521 CAPTAIN’S CHAIR................................................................................................ 521 BENCH.......................................................................................................... 522 3RD SEAT............................................................................................................... 523 Removal and Installation........................................................................................... 523 BENCH.......................................................................................................... 523 3RD SEAT SLIDING RAIL.......................................................................................... 524 SUNROOF................................................................................................................ 528 Adjustment......................................................................................................... 528 Removal and Installation........................................................................................... 529 Trouble Diagnoses.................................................................................................. 531 DIAGNOSTIC TABLE............................................................................................... 531 ADJUSTMENT..................................................................................................... 531 DRAIN HOSES.................................................................................................... 532 WEATHERSTRIP................................................................................................... 533 GUIDE RAIL ASSEMBLY............................................................................................ 533 WINDSHIELD AND WINDOWS................................................................................................. 534 Removal and Installation........................................................................................... 534 REMOVAL........................................................................................................ 534 INSTALLATION................................................................................................... 534 WINDSHIELD AND REAR WINDOW..................................................................................... 535 REAR SIDE WINDOW............................................................................................... 535 DOOR MIRROR............................................................................................................ 537 Removal and Installation........................................................................................... 537 REAR VIEW MIRROR....................................................................................................... 538 Removal............................................................................................................ 538 Installation....................................................................................................... 538 BODY (ALIGNMENT)....................................................................................................... 539 Alignment.......................................................................................................... 539 ENGINE COMPARTMENT............................................................................................. 540 UNDERBODY...................................................................................................... 542 ec......................................................................................................................... 544 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS...................................................................................................... 544 TROUBLE DIAGNOSIS - INDEX.............................................................................................. 550 Alphabetical & P No. Index for DTC................................................................................. 550 PRECAUTIONS............................................................................................................ 555 Supplemental Restraint System (SRS) "AIR BAG"...................................................................... 555 Precautions for On Board Diagnostic (OBD) System of Engine and A/T................................................. 555 Engine Fuel & Emission Control System.............................................................................. 556 Precautions........................................................................................................ 557 Wiring Diagrams and Trouble Diagnosis.............................................................................. 558 PREPARATION............................................................................................................ 559 Special Service Tools.............................................................................................. 559 Commercial Service Tools........................................................................................... 559 ENGINE AND EMISSION CONTROL OVERALL SYSTEM............................................................................. 561 Engine Control Component Parts Location............................................................................ 561 Circuit Diagram.................................................................................................... 563 System Diagram..................................................................................................... 564 Vacuum Hose Drawing................................................................................................ 565 System Chart....................................................................................................... 566 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION................................................................... 567 Multiport Fuel Injection (MFI) System.............................................................................. 567 Distributor Ignition (DI) System................................................................................... 569 Air Conditioning Cut Control....................................................................................... 570 Fuel Cut Control (at no load & high engine speed).................................................................. 571 Evaporative Emission System........................................................................................ 571 Positive Crankcase Ventilation..................................................................................... 577 BASIC SERVICE PROCEDURE................................................................................................ 578 Fuel Pressure Release.............................................................................................. 578 Fuel Pressure Check................................................................................................ 578 Fuel Pressure Regulator Check...................................................................................... 579 Injector........................................................................................................... 579 Fast Idle Cam (FIC)................................................................................................ 580 Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment........................................................... 582 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION................................................................................. 593 Introduction....................................................................................................... 593 Two Trip Detection Logic........................................................................................... 593 Emission-related Diagnostic Information............................................................................ 594 Malfunction Indicator Lamp (MIL)................................................................................... 606 OBD System Operation Chart......................................................................................... 606 CONSULT-II......................................................................................................... 612 Generic Scan Tool (GST)............................................................................................ 625 TROUBLE DIAGNOSIS - INTRODUCTION....................................................................................... 627 Introduction....................................................................................................... 627 Work Flow.......................................................................................................... 629 TROUBLE DIAGNOSIS - BASIC INSPECTION................................................................................... 631 Basic Inspection................................................................................................... 631 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION................................................................................ 645 DTC Inspection Priority Chart...................................................................................... 645 Fail-safe Chart.................................................................................................... 646 Symptom Matrix Chart............................................................................................... 647 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 651 Major Sensor Reference Graph in Data Monitor Mode.................................................................. 653 ECM Terminals and Reference Value.................................................................................. 656 TROUBLE DIAGNOSIS - SPECIFICATION VALUE................................................................................ 665 Description........................................................................................................ 665 Testing Condition.................................................................................................. 665 Inspection Procedure............................................................................................... 665 Diagnostic Procedure............................................................................................... 666 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT............................................................................ 669 Description........................................................................................................ 669 Diagnostic Procedure............................................................................................... 669 TROUBLE DIAGNOSIS FOR POWER SUPPLY..................................................................................... 670 Main Power Supply and Ground Circuit............................................................................... 670 DTC P0100 MASS AIR FLOW SENSOR (MAFS).................................................................................. 677 Component Description.............................................................................................. 677 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 677 ECM Terminals and Reference Value.................................................................................. 677 On Board Diagnosis Logic........................................................................................... 678 DTC Confirmation Procedure......................................................................................... 678 Overall Function Check............................................................................................. 680 Wiring Diagram..................................................................................................... 681 Diagnostic Procedure............................................................................................... 682 Component Inspection............................................................................................... 685 DTC P0105 ABSOLUTE PRESSURE SENSOR..................................................................................... 686 Component Description.............................................................................................. 686 On Board Diagnosis Logic........................................................................................... 686 DTC Confirmation Procedure......................................................................................... 687 Overall Function Check............................................................................................. 688 Wiring Diagram..................................................................................................... 689 Diagnostic Procedure............................................................................................... 690 Component Inspection............................................................................................... 696 DTC P0110 INTAKE AIR TEMPERATURE SENSOR................................................................................ 697 Component Description.............................................................................................. 697 On Board Diagnosis Logic........................................................................................... 697 DTC Confirmation Procedure......................................................................................... 697 Wiring Diagram..................................................................................................... 699 Diagnostic Procedure............................................................................................... 700 Component Inspection............................................................................................... 701 DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR (ECTS) (CIRCUIT)........................................................... 703 Component Description.............................................................................................. 703 On Board Diagnosis Logic........................................................................................... 703 DTC Confirmation Procedure......................................................................................... 704 Wiring Diagram..................................................................................................... 705 Diagnostic Procedure............................................................................................... 706 Component Inspection............................................................................................... 708 DTC P0120 THROTTLE POSITION SENSOR..................................................................................... 709 Description........................................................................................................ 709 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 709 ECM Terminals and Reference Value.................................................................................. 710 On Board Diagnosis Logic........................................................................................... 710 DTC Confirmation Procedure......................................................................................... 711 Wiring Diagram..................................................................................................... 714 Diagnostic Procedure............................................................................................... 715 Component Inspection............................................................................................... 718 DTC P0125 ENGINE COOLANT TEMPERATURE (ECT) SENSOR...................................................................... 720 Description........................................................................................................ 720 On Board Diagnosis Logic........................................................................................... 720 DTC Confirmation Procedure......................................................................................... 721 Wiring Diagram..................................................................................................... 722 Diagnostic Procedure............................................................................................... 723 Component Inspection............................................................................................... 725 DTC P0130 HEATED OXYGEN SENSOR 1 (FRONT) (CIRCUIT)..................................................................... 726 Component Description.............................................................................................. 726 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 726 ECM Terminals and Reference Value.................................................................................. 726 On Board Diagnosis Logic........................................................................................... 727 DTC Confirmation Procedure......................................................................................... 727 Overall Function Check............................................................................................. 728 Wiring Diagram..................................................................................................... 729 Diagnostic Procedure............................................................................................... 730 Component Inspection............................................................................................... 732 DTC P0131 HEATED OXYGEN SENSOR 1 (FRONT) (LEAN SHIFT MONITORING)....................................................... 734 Component Description.............................................................................................. 734 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 734 ECM Terminals and Reference Value.................................................................................. 734 On Board Diagnosis Logic........................................................................................... 735 DTC Confirmation Procedure......................................................................................... 735 Overall Function Check............................................................................................. 736 Diagnostic Procedure............................................................................................... 736 Component Inspection............................................................................................... 738 DTC P0132 HEATED OXYGEN SENSOR 1 (FRONT) (RICH SHIFT MONITORING)....................................................... 740 Component Description.............................................................................................. 740 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 740 ECM Terminals and Reference Value.................................................................................. 740 On Board Diagnosis Logic........................................................................................... 741 DTC Confirmation Procedure......................................................................................... 741 Overall Function Check............................................................................................. 742 Diagnostic Procedure............................................................................................... 742 Component Inspection............................................................................................... 745 DTC P0133 HEATED OXYGEN SENSOR 1 (FRONT) (RESPONSE MONITORING)......................................................... 747 Component Description.............................................................................................. 747 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 747 ECM Terminals and Reference Value.................................................................................. 747 On Board Diagnosis Logic........................................................................................... 748 DTC Confirmation Procedure......................................................................................... 748 Overall Function Check............................................................................................. 749 Wiring Diagram..................................................................................................... 750 Diagnostic Procedure............................................................................................... 751 Component Inspection............................................................................................... 755 DTC P0134 HEATED OXYGEN SENSOR 1 (FRONT) (HIGH VOLTAGE)................................................................ 757 Component Description.............................................................................................. 757 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 757 ECM Terminals and Reference Value.................................................................................. 757 On Board Diagnosis Logic........................................................................................... 758 DTC Confirmation Procedure......................................................................................... 758 Wiring Diagram..................................................................................................... 759 Diagnostic Procedure............................................................................................... 760 Component Inspection............................................................................................... 761 DTC P0135 HEATED OXYGEN SENSOR 1 HEATER (FRONT)........................................................................ 763 Description........................................................................................................ 763 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 763 ECM Terminals and Reference Value.................................................................................. 763 On Board Diagnosis Logic........................................................................................... 763 DTC Confirmation Procedure......................................................................................... 764 Wiring Diagram..................................................................................................... 765 Diagnostic Procedure............................................................................................... 766 Component Inspection............................................................................................... 767 DTC P0137 HEATED OXYGEN SENSOR 2 (REAR) (MIN. VOLTAGE MONITORING)...................................................... 769 Component Description.............................................................................................. 769 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 769 ECM Terminals and Reference Value.................................................................................. 769 On Board Diagnosis Logic........................................................................................... 769 DTC Confirmation Procedure......................................................................................... 770 Overall Function Check............................................................................................. 770 Wiring Diagram..................................................................................................... 772 Diagnostic Procedure............................................................................................... 773 Component Inspection............................................................................................... 776 DTC P0138 HEATED OXYGEN SENSOR 2 (REAR) (MAX. VOLTAGE MONITORING)...................................................... 778 Component Description.............................................................................................. 778 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 778 ECM Terminals and Reference Value.................................................................................. 778 On Board Diagnosis Logic........................................................................................... 778 DTC Confirmation Procedure......................................................................................... 779 Overall Function Check............................................................................................. 779 Wiring Diagram..................................................................................................... 781 Diagnostic Procedure............................................................................................... 782 Component Inspection............................................................................................... 785 DTC P0139 HEATED OXYGEN SENSOR 2 (REAR) (RESPONSE MONITORING).......................................................... 787 Component Description.............................................................................................. 787 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 787 ECM Terminals and Reference Value.................................................................................. 787 On Board Diagnosis Logic........................................................................................... 787 DTC Confirmation Procedure......................................................................................... 788 Overall Function Check............................................................................................. 788 Wiring Diagram..................................................................................................... 789 Diagnostic Procedure............................................................................................... 790 Component Inspection............................................................................................... 793 DTC P0140 HEATED OXYGEN SENSOR 2 (REAR) (HIGH VOLTAGE)................................................................. 795 Component Description.............................................................................................. 795 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 795 ECM Terminals and Reference Value.................................................................................. 795 On Board Diagnosis Logic........................................................................................... 795 DTC Confirmation Procedure......................................................................................... 796 Overall Function Check............................................................................................. 796 Wiring Diagram..................................................................................................... 797 Diagnostic Procedure............................................................................................... 798 Component Inspection............................................................................................... 800 DTC P0141 HEATED OXYGEN SENSOR 2 HEATER (REAR)......................................................................... 802 Description........................................................................................................ 802 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 802 ECM Terminals and Reference Value.................................................................................. 802 On Board Diagnosis Logic........................................................................................... 802 DTC Confirmation Procedure......................................................................................... 803 Wiring Diagram..................................................................................................... 804 Diagnostic Procedure............................................................................................... 805 Component Inspection............................................................................................... 807 DTC P0171 FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)................................................................... 808 On Board Diagnosis Logic........................................................................................... 808 DTC Confirmation Procedure......................................................................................... 808 Wiring Diagram..................................................................................................... 810 Diagnostic Procedure............................................................................................... 811 DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)................................................................... 816 On Board Diagnosis Logic........................................................................................... 816 DTC Confirmation Procedure......................................................................................... 816 Wiring Diagram..................................................................................................... 818 Diagnostic Procedure............................................................................................... 819 DTC P0180 FUEL TANK TEMPERATURE SENSOR................................................................................. 823 Component Description.............................................................................................. 823 On Board Diagnosis Logic........................................................................................... 823 DTC Confirmation Procedure......................................................................................... 823 Wiring Diagram..................................................................................................... 825 Diagnostic Procedure............................................................................................... 826 Component Inspection............................................................................................... 827 DTC P0300 - P0306 NO. 6 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE................................................ 828 On Board Diagnosis Logic........................................................................................... 828 DTC Confirmation Procedure......................................................................................... 828 Diagnostic Procedure............................................................................................... 829 Component Inspection............................................................................................... 833 DTC P0325 KNOCK SENSOR (KS)............................................................................................ 834 Component Description.............................................................................................. 834 ECM Terminals and Reference Value.................................................................................. 834 On Board Diagnosis Logic........................................................................................... 834 DTC Confirmation Procedure......................................................................................... 834 Wiring Diagram..................................................................................................... 835 Diagnostic Procedure............................................................................................... 836 Component Inspection............................................................................................... 838 DTC P0335 CRANKSHAFT POSITION SENSOR (CKPS) (OBD)...................................................................... 839 Component Description.............................................................................................. 839 ECM Terminals and Reference Value.................................................................................. 839 On Board Diagnosis Logic........................................................................................... 840 DTC Confirmation Procedure......................................................................................... 840 Wiring Diagram..................................................................................................... 841 Diagnostic Procedure............................................................................................... 842 Component Inspection............................................................................................... 844 DTC P0340 CAMSHAFT POSITION SENSOR (CMPS).............................................................................. 845 Component Description.............................................................................................. 845 ECM Terminals and Reference Value.................................................................................. 845 On Board Diagnosis Logic........................................................................................... 846 DTC Confirmation Procedure......................................................................................... 846 Wiring Diagram..................................................................................................... 848 Diagnostic Procedure............................................................................................... 849 Component Inspection............................................................................................... 851 DTC P0420 THREE WAY CATALYST FUNCTION.................................................................................. 853 On Board Diagnosis Logic........................................................................................... 853 DTC Confirmation Procedure......................................................................................... 853 Overall Function Check............................................................................................. 854 Diagnostic Procedure............................................................................................... 854 DTC P0440 EVAP CONTROL SYSTEM (SMALL LEAK) (NEGATIVE PRESSURE)......................................................... 858 On Board Diagnosis Logic........................................................................................... 858 DTC Confirmation Procedure......................................................................................... 859 Diagnostic Procedure............................................................................................... 860 DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE (CIRCUIT).................................................. 869 Description........................................................................................................ 869 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 869 ECM Terminals and Reference Value.................................................................................. 870 On Board Diagnosis Logic........................................................................................... 870 DTC Confirmation Procedure......................................................................................... 871 Wiring Diagram..................................................................................................... 872 Diagnostic Procedure............................................................................................... 873 Component Inspection............................................................................................... 875 DTC P0446 EVAPORATIVE EMISSION (EVAP) CANISTER VENT CONTROL VALVE (CIRCUIT)............................................ 876 Component Description.............................................................................................. 876 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 876 ECM Terminals and Reference Value.................................................................................. 876 On Board Diagnosis Logic........................................................................................... 876 DTC Confirmation Procedure......................................................................................... 877 Wiring Diagram..................................................................................................... 878 Diagnostic Procedure............................................................................................... 879 Component Inspection............................................................................................... 881 DTC P0450 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PRESSURE SENSOR................................................... 883 Component Description.............................................................................................. 883 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 883 ECM Terminals and Reference Value.................................................................................. 883 On Board Diagnosis Logic........................................................................................... 884 DTC Confirmation Procedure......................................................................................... 884 Wiring Diagram..................................................................................................... 885 Diagnostic Procedure............................................................................................... 886 Component Inspection............................................................................................... 890 DTC P0455 EVAP CONTROL SYSTEM (GROSS LEAK)............................................................................. 891 On Board Diagnosis Logic........................................................................................... 891 DTC Confirmation Procedure......................................................................................... 892 Diagnostic Procedure............................................................................................... 893 DTC P0500 VEHICLE SPEED SENSOR (VSS)................................................................................... 901 Component Description.............................................................................................. 901 ECM Terminals and Reference Value.................................................................................. 901 On Board Diagnosis Logic........................................................................................... 901 DTC Confirmation Procedure......................................................................................... 901 Overall Function Check............................................................................................. 902 Wiring Diagram..................................................................................................... 903 Diagnostic Procedure............................................................................................... 904 DTC P0505 IDLE AIR CONTROL VALVE (IACV) - AUXILIARY AIR CONTROL (AAC) VALVE............................................ 905 Description........................................................................................................ 905 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 906 ECM Terminals and Reference Value.................................................................................. 906 On Board Diagnosis Logic........................................................................................... 906 DTC Confirmation Procedure......................................................................................... 907 Wiring Diagram..................................................................................................... 908 Diagnostic Procedure............................................................................................... 909 Component Inspection............................................................................................... 911 DTC P0510 CLOSED THROTTLE POSITION SWITCH.............................................................................. 912 Component Description.............................................................................................. 912 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 912 ECM Terminals and Reference Value.................................................................................. 912 On Board Diagnosis Logic........................................................................................... 912 DTC Confirmation Procedure......................................................................................... 913 Overall Function Check............................................................................................. 914 Wiring Diagram..................................................................................................... 915 Diagnostic Procedure............................................................................................... 916 Component Inspection............................................................................................... 918 DTC P0600 A/T CONTROL.................................................................................................. 920 System Description................................................................................................. 920 ECM Terminals and Reference Value.................................................................................. 920 On Board Diagnosis Logic........................................................................................... 920 DTC Confirmation Procedure......................................................................................... 920 Overall Function Check............................................................................................. 921 Wiring Diagram..................................................................................................... 922 Diagnostic Procedure............................................................................................... 923 DTC P0605 ECM.......................................................................................................... 925 Component Description.............................................................................................. 925 On Board Diagnosis Logic........................................................................................... 925 DTC Confirmation Procedure......................................................................................... 925 Diagnostic Procedure............................................................................................... 926 DTC P1105 MAP/BARO SWITCH SOLENOID VALVE............................................................................... 927 Description........................................................................................................ 927 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 927 ECM Terminals and Reference Value.................................................................................. 928 On Board Diagnosis Logic........................................................................................... 928 DTC Confirmation Procedure......................................................................................... 928 Wiring Diagram..................................................................................................... 930 Diagnostic Procedure............................................................................................... 931 Component Inspection............................................................................................... 937 DTC P1148 CLOSED LOOP CONTROL.......................................................................................... 939 On Board Diagnosis Logic........................................................................................... 939 DTC Confirmation Procedure......................................................................................... 939 Overall Function Check............................................................................................. 940 Diagnostic Procedure............................................................................................... 940 DTC P1217 ENGINE OVER TEMPERATURE (OVERHEAT)........................................................................... 941 System Description................................................................................................. 941 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 941 ECM Terminals and Reference Value.................................................................................. 942 On Board Diagnosis Logic........................................................................................... 942 Overall Function Check............................................................................................. 943 Wiring Diagram..................................................................................................... 944 Diagnostic Procedure............................................................................................... 945 Main 12 Causes of Overheating...................................................................................... 955 Component Inspection............................................................................................... 955 DTC P1320 IGNITION SIGNAL.............................................................................................. 957 Component Description.............................................................................................. 957 ECM Terminals and Reference Value.................................................................................. 957 On Board Diagnosis Logic........................................................................................... 958 DTC Confirmation Procedure......................................................................................... 958 Wiring Diagram..................................................................................................... 959 Diagnostic Procedure............................................................................................... 960 Component Inspection............................................................................................... 963 DTC P1336 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) (COG)................................................................ 964 Component Description.............................................................................................. 964 ECM Terminals and Reference Value.................................................................................. 964 On Board Diagnosis Logic........................................................................................... 965 DTC Confirmation Procedure......................................................................................... 965 Wiring Diagram..................................................................................................... 966 Diagnostic Procedure............................................................................................... 967 Component Inspection............................................................................................... 969 DTC P1440 EVAP CONTROL SYSTEM (SMALL LEAK) (POSITIVE PRESSURE)......................................................... 970 On Board Diagnosis Logic........................................................................................... 970 DTC Confirmation Procedure......................................................................................... 971 DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE............................................................ 972 Description........................................................................................................ 972 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 972 ECM Terminals and Reference Value.................................................................................. 973 On Board Diagnosis Logic........................................................................................... 973 DTC Confirmation Procedure......................................................................................... 974 Wiring Diagram..................................................................................................... 975 Diagnostic Procedure............................................................................................... 976 Component Inspection............................................................................................... 980 DTC P1446 EVAPORATIVE EMISSION (EVAP) CANISTER VENT CONTROL VALVE (CLOSE).............................................. 981 Component Description.............................................................................................. 981 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 981 ECM Terminals and Reference Value.................................................................................. 981 On Board Diagnosis Logic........................................................................................... 981 DTC Confirmation Procedure......................................................................................... 982 Wiring Diagram..................................................................................................... 983 Diagnostic Procedure............................................................................................... 984 Component Inspection............................................................................................... 986 DTC P1447 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PURGE FLOW MONITORING............................................. 987 System Description................................................................................................. 987 On Board Diagnosis Logic........................................................................................... 987 DTC Confirmation Procedure......................................................................................... 988 Overall Function Check............................................................................................. 988 Diagnostic Procedure............................................................................................... 989 DTC P1448 EVAPORATIVE EMISSION (EVAP) CANISTER VENT CONTROL VALVE (OPEN)............................................... 995 Component Description.............................................................................................. 995 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 995 ECM Terminals and Reference Value.................................................................................. 995 On Board Diagnosis Logic........................................................................................... 995 DTC Confirmation Procedure......................................................................................... 996 Overall Function Check............................................................................................. 997 Wiring Diagram..................................................................................................... 998 Diagnostic Procedure............................................................................................... 999 Component Inspection...............................................................................................1001 DTC P1490 VACUUM CUT VALVE BYPASS VALVE (CIRCUIT)......................................................................1002 Description........................................................................................................1002 CONSULT-II Reference Value in Data Monitor Mode....................................................................1002 ECM Terminals and Reference Value..................................................................................1002 On Board Diagnosis Logic...........................................................................................1003 DTC Confirmation Procedure.........................................................................................1003 Wiring Diagram.....................................................................................................1004 Diagnostic Procedure...............................................................................................1005 Component Inspection...............................................................................................1008 DTC P1491 VACUUM CUT VALVE BYPASS VALVE................................................................................1009 Description........................................................................................................1009 CONSULT-II Reference Value in Data Monitor Mode....................................................................1009 ECM Terminals and Reference Value..................................................................................1009 On Board Diagnosis Logic...........................................................................................1010 DTC Confirmation Procedure.........................................................................................1010 Overall Function Check.............................................................................................1011 Wiring Diagram.....................................................................................................1012 Diagnostic Procedure...............................................................................................1013 Component Inspection...............................................................................................1016 DTC P1605 A/T DIAGNOSIS COMMUNICATION LINE.............................................................................1017 Component Description..............................................................................................1017 ECM Terminals and Reference Value..................................................................................1017 On Board Diagnosis Logic...........................................................................................1017 DTC Confirmation Procedure.........................................................................................1017 Wiring Diagram.....................................................................................................1018 Diagnostic Procedure...............................................................................................1019 DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH...........................................................................1020 Component Description..............................................................................................1020 CONSULT-II Reference Value in Data Monitor Mode....................................................................1020 ECM Terminals and Reference Value..................................................................................1020 On Board Diagnosis Logic...........................................................................................1020 DTC Confirmation Procedure.........................................................................................1020 Overall Function Check.............................................................................................1021 Wiring Diagram.....................................................................................................1022 Diagnostic Procedure...............................................................................................1023 INJECTOR...............................................................................................................1028 Component Description..............................................................................................1028 CONSULT-II Reference Value in Data Monitor Mode....................................................................1028 ECM Terminals and Reference Value..................................................................................1028 Wiring Diagram.....................................................................................................1029 Diagnostic Procedure...............................................................................................1030 Component Inspection...............................................................................................1032 START SIGNAL...........................................................................................................1033 CONSULT-II Reference Value in Data Monitor Mode....................................................................1033 ECM Terminals and Reference Value..................................................................................1033 Wiring Diagram.....................................................................................................1034 Diagnostic Procedure...............................................................................................1035 FUEL PUMP..............................................................................................................1037 System Description.................................................................................................1037 Component Description..............................................................................................1037 CONSULT-II Reference Value in Data Monitor Mode....................................................................1037 ECM Terminals and Reference Value..................................................................................1038 Wiring Diagram.....................................................................................................1039 Diagnostic Procedure...............................................................................................1040 Component Inspection...............................................................................................1044 POWER STEERING OIL PRESSURE SWITCH.....................................................................................1045 Component Description..............................................................................................1045 CONSULT-II Reference Value in Data Monitor Mode....................................................................1045 ECM Terminals and Reference Value..................................................................................1045 Wiring Diagram.....................................................................................................1046 Diagnostic Procedure...............................................................................................1047 Component Inspection...............................................................................................1048 IACV-FICD SOLENOID VALVE...............................................................................................1049 Component Description..............................................................................................1049 ECM Terminals and Reference Value..................................................................................1049 Wiring Diagram.....................................................................................................1050 Diagnostic Procedure...............................................................................................1051 Component Inspection...............................................................................................1053 AIR CONDITIONER HIGH PRESSURE SWITCH...................................................................................1055 System Description.................................................................................................1055 ECM Terminals and Reference Value..................................................................................1055 Wiring Diagram.....................................................................................................1056 Diagnostic Procedure...............................................................................................1057 Component Inspection...............................................................................................1058 MIL & DATA LINK CONNECTORS.............................................................................................1059 Wiring Diagram.....................................................................................................1059 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1060 Fuel Pressure Regulator............................................................................................1060 Idle Speed and Ignition Timing.....................................................................................1060 Ignition Coil......................................................................................................1060 Mass Air Flow Sensor...............................................................................................1060 Engine Coolant Temperature Sensor..................................................................................1060 Heated Oxygen Sensor 1 Heater (Front)..............................................................................1060 Fuel Pump..........................................................................................................1060 IACV-AAC Valve.....................................................................................................1060 Injector...........................................................................................................1061 Resistor...........................................................................................................1061 Throttle Position Sensor...........................................................................................1061 Calculated Load Value..............................................................................................1061 Intake Air Temperature Sensor......................................................................................1061 Heated Oxygen Sensor 2 Heater (Rear)...............................................................................1061 Crankshaft Position Sensor (OBD)...................................................................................1061 Fuel Tank Temperature Sensor.......................................................................................1061 SUPER MULTIPLE JUNCTION (SMJ).......................................................................................... 0 FUSE BLOCK............................................................................................................. 2 FUSE AND FUSIBLE LINK BOX.............................................................................................. 3 JOINT CONNECTOR........................................................................................................ 4 ELECTRICAL UNITS....................................................................................................... 5 el.........................................................................................................................1062 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS......................................................................................................1062 PRECAUTIONS............................................................................................................1065 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................1065 Wiring Diagrams and Trouble Diagnosis..............................................................................1065 PREPARATION............................................................................................................1066 Special Service Tools..............................................................................................1066 HARNESS CONNECTOR......................................................................................................1067 Description........................................................................................................1067 STANDARDIZED RELAY.....................................................................................................1069 Description........................................................................................................1069 POWER SUPPLY ROUTING...................................................................................................1071 Schematic..........................................................................................................1071 Wiring Diagram - POWER -...........................................................................................1073 Inspection.........................................................................................................1080 GROUND.................................................................................................................1081 Ground Distribution................................................................................................1081 COMBINATION SWITCH.....................................................................................................1092 Check..............................................................................................................1092 Replacement........................................................................................................1093 STEERING SWITCH........................................................................................................1094 Check..............................................................................................................1094 HEADLAMP (FOR USA).....................................................................................................1095 Component Parts and Harness Connector Location.....................................................................1095 System Description.................................................................................................1095 Wiring Diagram - H/LAMP -..........................................................................................1097 Trouble Diagnoses..................................................................................................1099 Bulb Replacement...................................................................................................1107 Aiming Adjustment..................................................................................................1107 HEADLAMP (FOR CANADA) - DAYTIME LIGHT SYSTEM -.........................................................................1109 Component Parts and Harness Connector Location.....................................................................1109 System Description.................................................................................................1109 Wiring Diagram - DTRL -............................................................................................1112 Trouble Diagnoses..................................................................................................1114 Bulb Replacement...................................................................................................1115 Aiming Adjustment..................................................................................................1115 PARKING, LICENSE AND TAIL LAMPS........................................................................................1116 Wiring Diagram - TAIL/L -..........................................................................................1116 STOP LAMP..............................................................................................................1117 Wiring Diagram - STOP/L -..........................................................................................1117 BACK-UP LAMP...........................................................................................................1118 Wiring Diagram - BACK/L -..........................................................................................1118 FRONT FOG LAMP.........................................................................................................1119 System Description.................................................................................................1119 Wiring Diagram - F/FOG -...........................................................................................1120 Aiming Adjustment..................................................................................................1121 CORNERING LAMP.........................................................................................................1122 System Description.................................................................................................1122 Wiring Diagram - CORNER -..........................................................................................1123 TURN SIGNAL AND HAZARD WARNING LAMPS...................................................................................1124 System Description.................................................................................................1124 Wiring Diagram - TURN -............................................................................................1125 Trouble Diagnoses..................................................................................................1127 Electrical Components Inspection...................................................................................1127 TRAILER TOW............................................................................................................1128 System Description.................................................................................................1128 Wiring Diagram - T/TOW -...........................................................................................1129 Trouble Diagnoses..................................................................................................1130 ILLUMINATION...........................................................................................................1131 System Description.................................................................................................1131 Schematic..........................................................................................................1133 Wiring Diagram - ILL -.............................................................................................1134 INTERIOR ROOM LAMP.....................................................................................................1138 System Description.................................................................................................1138 Schematic..........................................................................................................1140 Wiring Diagram - INT/L -...........................................................................................1141 Trouble Diagnoses..................................................................................................1144 METERS AND GAUGES......................................................................................................1146 Component Parts and Harness Connector Location.....................................................................1146 System Description.................................................................................................1146 Combination Meter..................................................................................................1148 Wiring Diagram - METER -...........................................................................................1150 Combination Meter Self-Diagnosis Mode..............................................................................1151 Trouble Diagnoses..................................................................................................1154 Electrical Component Inspection....................................................................................1160 WARNING LAMPS..........................................................................................................1162 System Description.................................................................................................1162 Schematic..........................................................................................................1164 Wiring Diagram - WARN -............................................................................................1165 Electrical Component Inspection....................................................................................1169 WARNING CHIME..........................................................................................................1170 Component Parts and Harness Connector Location.....................................................................1170 System Description.................................................................................................1170 Wiring Diagram - CHIME -...........................................................................................1172 Trouble Diagnoses..................................................................................................1173 FRONT WIPER AND WASHER.................................................................................................1178 System Description.................................................................................................1178 Wiring Diagram - WIPER -...........................................................................................1179 Trouble Diagnoses..................................................................................................1180 Removal and Installation...........................................................................................1180 Washer Nozzle Adjustment...........................................................................................1181 REAR WIPER AND WASHER..................................................................................................1183 System Description/Except for Glass Hatch Model....................................................................1183 Wiring Diagram - WIP/R - /Except for Glass Hatch Model.............................................................1184 System Description/For Glass Hatch Model...........................................................................1185 Wiring Diagram - WIP/R - /For Glass Hatch Model....................................................................1186 Removal and Installation...........................................................................................1187 Washer Fluid and Check Valve.......................................................................................1188 HORN...................................................................................................................1189 Wiring Diagram - HORN -............................................................................................1189 CIGARETTE LIGHTER......................................................................................................1190 Wiring Diagram - CIGAR -...........................................................................................1190 REAR WINDOW DEFOGGER...................................................................................................1191 Component Parts and Harness Connector Location.....................................................................1191 System Description.................................................................................................1191 Wiring Diagram - DEF -.............................................................................................1193 Trouble Diagnoses..................................................................................................1194 Electrical Components Inspection...................................................................................1196 Filament Check.....................................................................................................1196 Filament Repair....................................................................................................1197 AUDIO..................................................................................................................1199 System Description.................................................................................................1199 Schematic - Midgrade and Premium System............................................................................1200 Wiring Diagram - AUDIO - /Base System..............................................................................1201 Wiring Diagram - AUDIO - /Midgrade and Premium System..............................................................1202 Trouble Diagnoses..................................................................................................1206 AUDIO ANTENNA..........................................................................................................1213 Location of Antenna................................................................................................1213 Removal and Installation...........................................................................................1213 FAMILY ENTERTAINMENT SYSTEM............................................................................................1214 System Description.................................................................................................1214 Schematic..........................................................................................................1215 Wiring Diagram - FES...............................................................................................1216 Trouble Diagnoses..................................................................................................1221 POWER SUNROOF..........................................................................................................1229 System Description.................................................................................................1229 Wiring Diagram - SROOF -...........................................................................................1230 POWER DOOR MIRROR......................................................................................................1231 Wiring Diagram - MIRROR - /Without Automatic Drive Positioner......................................................1231 HEATED MIRROR..........................................................................................................1232 Wiring Diagram - H/MIRR -..........................................................................................1232 AUTOMATIC DRIVE POSITIONER.............................................................................................1233 Component Parts and Harness Connector Location.....................................................................1233 System Description.................................................................................................1233 Schematic..........................................................................................................1236 Wiring Diagram - AUT/DP -..........................................................................................1237 Trouble Diagnosis..................................................................................................1242 POWER SEAT.............................................................................................................1270 Wiring Diagram - SEAT -............................................................................................1270 HEATED SEAT............................................................................................................1272 System Description.................................................................................................1272 Schematic..........................................................................................................1273 Wiring Diagram - H/SEAT............................................................................................1274 Trouble Diagnoses..................................................................................................1277 AUTOMATIC SPEED CONTROL DEVICE (ASCD)..................................................................................1278 Components Parts and Harness Connector Location....................................................................1278 System Description.................................................................................................1279 Schematic..........................................................................................................1281 Wiring Diagram - ASCD -............................................................................................1282 Fail-safe System...................................................................................................1286 Trouble Diagnoses..................................................................................................1287 Electrical Component Inspection....................................................................................1295 ASCD Wire Adjustment...............................................................................................1297 POWER WINDOW...........................................................................................................1298 System Description.................................................................................................1298 Wiring Diagram - WINDOW -..........................................................................................1300 Trouble Diagnoses..................................................................................................1302 POWER DOOR LOCK........................................................................................................1303 Component Parts and Harness Connector Location.....................................................................1303 System Description.................................................................................................1304 Schematic..........................................................................................................1306 Wiring Diagram - D/LOCK -..........................................................................................1307 Trouble Diagnosis..................................................................................................1312 REMOTE KEYLESS ENTRY SYSTEM............................................................................................1323 Component Parts and Harness Connector Location.....................................................................1323 System Description.................................................................................................1323 Schematic..........................................................................................................1326 Wiring Diagram - KEYLES -..........................................................................................1327 Trouble Diagnoses..................................................................................................1331 ID Code Entry Procedure............................................................................................1340 Keyfob Battery Replacement.........................................................................................1341 VEHICLE SECURITY (THEFT WARNING) SYSTEM................................................................................1342 Component Parts and Harness Connector Location.....................................................................1342 System Description.................................................................................................1344 Schematic..........................................................................................................1347 Wiring Diagram - VEHSEC -..........................................................................................1348 Trouble Diagnoses..................................................................................................1355 SMART ENTRANCE CONTROL UNIT............................................................................................1365 Description........................................................................................................1365 Schematic..........................................................................................................1367 Smart Entrance Control Unit Inspection Table.......................................................................1369 INTEGRATED HOMELINK TRANSMITTER........................................................................................1371 Wiring Diagram - TRNSMT -..........................................................................................1371 Trouble Diagnoses..................................................................................................1372 ELECTRICAL UNITS LOCATION..............................................................................................1374 Engine Compartment.................................................................................................1374 Passenger Compartment..............................................................................................1375 HARNESS LAYOUT.........................................................................................................1377 How to Read Harness Layout.........................................................................................1377 Outline............................................................................................................1378 Main Harness and Body No. 2 Harness................................................................................1379 Engine Room Harness................................................................................................1383 Engine Control Harness.............................................................................................1386 Body Harness.......................................................................................................1390 Back Door Harness..................................................................................................1391 Back Door No. 2 Harness............................................................................................1392 Room Lamp Harness..................................................................................................1393 Air Bag Harness....................................................................................................1394 Front Door Harness.................................................................................................1395 Sliding Door Harness...............................................................................................1396 BULB SPECIFICATIONS....................................................................................................1397 Headlamp...........................................................................................................1397 Exterior Lamp......................................................................................................1397 Interior Lamp......................................................................................................1397 WIRING DIAGRAM CODES (CELL CODES)......................................................................................1398 SUPER MULTIPLE JUNCTION (SMJ).......................................................................................... 0 FUSE BLOCK............................................................................................................. 2 FUSE AND FUSIBLE LINK BOX.............................................................................................. 3 JOINT CONNECTOR........................................................................................................ 4 ELECTRICAL UNITS....................................................................................................... 5 em.........................................................................................................................1400 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS......................................................................................................1400 PRECAUTIONS............................................................................................................1402 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................1402 Parts Requiring Angular Tightening.................................................................................1402 Liquid Gasket Application Procedure................................................................................1402 PREPARATION............................................................................................................1403 Special Service Tools..............................................................................................1403 Commercial Service Tools...........................................................................................1405 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................1407 NVH Troubleshooting Chart - Engine Noise...........................................................................1408 OUTER COMPONENT PARTS..................................................................................................1409 Removal and Installation...........................................................................................1409 MEASUREMENT OF COMPRESSION PRESSURE....................................................................................1412 OIL PAN................................................................................................................1413 Removal............................................................................................................1413 Installation.......................................................................................................1415 TIMING BELT............................................................................................................1416 Components.........................................................................................................1416 Removal............................................................................................................1417 Inspection.........................................................................................................1419 BELT TENSIONER AND TENSIONER SPRING............................................................................1419 Installation.......................................................................................................1420 Tension Adjustment.................................................................................................1421 AFTER BELT REPLACEMENT.........................................................................................1421 AFTER ENGINE OVERHAUL OR ENGINE REASSEMBLY (WITH ROCKER COVERS REMOVED)........................................1422 OIL SEAL...............................................................................................................1424 Replacement........................................................................................................1424 VALVE OIL SEAL.................................................................................................1424 OIL SEAL INSTALLING DIRECTION..................................................................................1424 CAMSHAFT OIL SEAL..............................................................................................1425 FRONT OIL SEAL.................................................................................................1425 REAR OIL SEAL..................................................................................................1425 CYLINDER HEAD..........................................................................................................1426 Components.........................................................................................................1426 Removal............................................................................................................1427 Disassembly........................................................................................................1429 Inspection.........................................................................................................1430 CYLINDER HEAD DISTORTION.......................................................................................1430 CAMSHAFT VISUAL CHECK..........................................................................................1431 CAMSHAFT RUNOUT................................................................................................1431 CAMSHAFT CAM HEIGHT............................................................................................1431 CAMSHAFT JOURNAL CLEARANCE.....................................................................................1431 CAMSHAFT END PLAY..............................................................................................1432 CAMSHAFT SPROCKET RUNOUT.......................................................................................1432 VALVE GUIDE CLEARANCE..........................................................................................1432 VALVE GUIDE REPLACEMENT........................................................................................1433 VALVE SEATS....................................................................................................1434 REPLACING VALVE SEAT FOR SERVICE PARTS.........................................................................1435 VALVE DIMENSIONS...............................................................................................1435 VALVE SPRING...................................................................................................1436 ROCKER SHAFT AND ROCKER ARM....................................................................................1436 HYDRAULIC VALVE LIFTER.........................................................................................1437 Assembly...........................................................................................................1437 Installation.......................................................................................................1438 ENGINE ASSEMBLY........................................................................................................1442 Removal and Installation...........................................................................................1442 ENGINE MOUNTING................................................................................................1443 CYLINDER BLOCK.........................................................................................................1446 Components.........................................................................................................1446 Removal and Installation...........................................................................................1447 Disassembly........................................................................................................1447 PISTON AND CRANKSHAFT..........................................................................................1447 Inspection.........................................................................................................1448 PISTON AND PISTON PIN CLEARANCE................................................................................1448 PISTON RING SIDE CLEARANCE.....................................................................................1448 PISTON RING END GAP............................................................................................1448 CONNECTING ROD BEND AND TORSION................................................................................1449 CYLINDER BLOCK DISTORTION AND WEAR.............................................................................1449 PISTON-TO-BORE CLEARANCE.......................................................................................1450 CRANKSHAFT.....................................................................................................1451 BEARING CLEARANCE..............................................................................................1452 CONNECTING ROD BUSHING CLEARANCE (SMALL END)...................................................................1454 REPLACEMENT OF CONNECTING ROD BUSHING (SMALL END)..............................................................1454 Assembly...........................................................................................................1455 PISTON.........................................................................................................1455 CRANKSHAFT.....................................................................................................1455 REPLACING PILOT CONVERTER......................................................................................1457 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1458 General Specifications.............................................................................................1458 Cylinder Head......................................................................................................1459 Valve..............................................................................................................1459 VALVE..........................................................................................................1459 VALVE SPRING...................................................................................................1460 HYDRAULIC VALVE LIFTER.........................................................................................1460 VALVE GUIDE....................................................................................................1460 ROCKER SHAFT AND ROCKER ARM....................................................................................1460 Valve Seat.........................................................................................................1461 INTAKE VALVE SEAT..............................................................................................1461 EXHAUST VALVE SEAT.............................................................................................1462 Camshaft and Camshaft Bearing......................................................................................1463 Cylinder Block.....................................................................................................1464 Piston, Piston Ring and Piston Pin.................................................................................1465 AVAILABLE PISTON...............................................................................................1465 PISTON RING....................................................................................................1465 PISTON PIN.....................................................................................................1466 Connecting Rod.....................................................................................................1466 Crankshaft.........................................................................................................1466 Available Main Bearing.............................................................................................1467 NO. 1 MAIN BEARING.............................................................................................1467 NO. 2 AND 3 MAIN BEARING.......................................................................................1467 NO. 4 MAIN BEARING.............................................................................................1467 UNDER SIZE.....................................................................................................1467 Available Connecting Rod Bearing...................................................................................1468 CONNECTING ROD BEARING UNDERSIZE...............................................................................1468 Miscellaneous Components...........................................................................................1468 BEARING CLEARANCE..............................................................................................1468 fe.........................................................................................................................1470 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS......................................................................................................1470 PREPARATION............................................................................................................1471 Special Service Tool...............................................................................................1471 Commercial Service Tool............................................................................................1471 ACCELERATOR CONTROL SYSTEM.............................................................................................1472 Removal and Installation...........................................................................................1472 Adjusting Accelerator Wire.........................................................................................1472 FUEL SYSTEM............................................................................................................1473 Removal and Installation...........................................................................................1473 FUEL TANK......................................................................................................1474 FUEL PUMP AND GAUGE............................................................................................1475 EXHAUST SYSTEM.........................................................................................................1477 Removal and Installation...........................................................................................1477 foldout....................................................................................................................1480 QUICK REFERENCE INDEX.................................................................................................. 0 SUPER MULTIPLE JUNCTION (SMJ)..........................................................................................1480 FUSE BLOCK.............................................................................................................1482 FUSE AND FUSIBLE LINK BOX..............................................................................................1483 JOINT CONNECTOR........................................................................................................1484 ELECTRICAL UNITS.......................................................................................................1485 gi.........................................................................................................................1487 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS......................................................................................................1487 PRECAUTIONS............................................................................................................1489 Precautions........................................................................................................1489 PRECAUTIONS FOR SUPPLEMENTAL RESTRAINT SYSTEM (SRS) "AIR BAG" AND "SEAT BELT PRE-TENSIONER"....................1489 GENERAL PRECAUTIONS............................................................................................1489 PRECAUTIONS FOR MULTIPORT FUEL INJECTION SYSTEM OR ENGINE CONTROL SYSTEM.......................................1491 PRECAUTIONS FOR THREE WAY CATALYST.............................................................................1491 PRECAUTIONS FOR HOSES..........................................................................................1492 PRECAUTIONS FOR ENGINE OILS....................................................................................1492 PRECAUTIONS FOR FUEL...........................................................................................1493 PRECAUTIONS FOR AIR CONDITIONING...............................................................................1493 HOW TO USE THIS MANUAL.................................................................................................1494 HOW TO READ WIRING DIAGRAMS............................................................................................1496 Sample/Wiring Diagram - EXAMPL -...................................................................................1496 OPTIONAL SPLICE................................................................................................1497 Description........................................................................................................1498 CONNECTOR SYMBOLS..............................................................................................1500 SWITCH POSITIONS...............................................................................................1501 DETECTABLE LINES AND NON-DETECTABLE LINES......................................................................1501 MULTIPLE SWITCH................................................................................................1502 REFERENCE AREA.................................................................................................1503 HOW TO CHECK TERMINAL..................................................................................................1505 Connector and Terminal Pin Kit.....................................................................................1505 How to Probe Connectors............................................................................................1505 PROBING FROM HARNESS SIDE......................................................................................1505 PROBING FROM TERMINAL SIDE.....................................................................................1505 How to Check Enlarged Contact Spring of Terminal...................................................................1506 Waterproof Connector Inspection....................................................................................1507 RUBBER SEAL INSPECTION.........................................................................................1507 WIRE SEAL INSPECTION...........................................................................................1507 Terminal Lock Inspection...........................................................................................1507 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT..........................................................1508 Work Flow..........................................................................................................1508 Incident Simulation Tests..........................................................................................1509 INTRODUCTION...................................................................................................1509 VEHICLE VIBRATION..............................................................................................1509 HEAT SENSITIVE.................................................................................................1510 FREEZING.......................................................................................................1510 WATER INTRUSION................................................................................................1511 ELECTRICAL LOAD................................................................................................1511 COLD OR HOT START UP...........................................................................................1511 Circuit Inspection.................................................................................................1511 INTRODUCTION...................................................................................................1511 TESTING FOR "OPENS" IN THE CIRCUIT.............................................................................1512 TESTING FOR "SHORTS" IN THE CIRCUIT............................................................................1513 GROUND INSPECTION..............................................................................................1514 VOLTAGE DROP TESTS.............................................................................................1514 CONTROL UNIT CIRCUIT TEST......................................................................................1516 HOW TO FOLLOW TROUBLE DIAGNOSES........................................................................................1518 How to Follow Test Groups in Trouble Diagnoses.....................................................................1519 Harness Wire Color and Connector Number Indication.................................................................1520 TYPE 1: HARNESS WIRE COLOR AND CONNECTOR NUMBER ARE SHOWN IN ILLUSTRATION......................................1520 TYPE 2: HARNESS WIRE COLOR AND CONNECTOR NUMBER ARE SHOWN IN TEXT..............................................1521 Key to Symbols Signifying Measurements or Procedures...............................................................1521 CONSULT-II CHECKING SYSTEM.............................................................................................1523 Function and System Application....................................................................................1523 Nickel Metal Hydride Battery Replacement...........................................................................1524 Checking Equipment.................................................................................................1524 CONSULT-II Data Link Connector (DLC) Circuit.......................................................................1524 INSPECTION PROCEDURE...........................................................................................1525 IDENTIFICATION INFORMATION.............................................................................................1526 Model Variation....................................................................................................1526 Identification Number..............................................................................................1527 VEHICLE IDENTIFICATION NUMBER ARRANGEMENT......................................................................1527 ENGINE SERIAL NUMBER...........................................................................................1528 AUTOMATIC TRANSAXLE NUMBER.....................................................................................1528 Dimensions.........................................................................................................1528 Wheels & Tires.....................................................................................................1528 LIFTING POINTS AND TOW TRUCK TOWING....................................................................................1529 Preparation........................................................................................................1529 SPECIAL SERVICE TOOLS..........................................................................................1529 Pantograph Jack....................................................................................................1529 Board-on Lift......................................................................................................1530 Garage Jack and Safety Stand.......................................................................................1530 2-pole Lift........................................................................................................1531 Tow Truck Towing...................................................................................................1531 VEHICLE RECOVERY (FREEING A STUCK VEHICLE).....................................................................1532 TIGHTENING TORQUE OF STANDARD BOLTS....................................................................................1533 RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS.............................................................................1534 SAE J1930 TERMINOLOGY LIST.............................................................................................1535 SAE J1930 Terminology List.........................................................................................1535 ha.........................................................................................................................1539 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS......................................................................................................1539 AUTO...................................................................................................................1551 PRECAUTIONS........................................................................................................1541 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"....................................1541 Precautions for Working with HFC-134a (R-134a).................................................................1542 Contaminated Refrigerant.......................................................................................1542 General Refrigerant Precautions................................................................................1542 Precautions for Leak Detection Dye.............................................................................1543 A/C Identification Label.......................................................................................1543 Precautions for Refrigerant Connection.........................................................................1543 Precautions for Servicing Compressor...........................................................................1547 Precautions for Service Equipment..............................................................................1547 Wiring Diagrams and Trouble Diagnosis..........................................................................1550 PREPARATION........................................................................................................1551 HFC-134a (R-134a) Service Tools and Equipment..................................................................1551 Commercial Service Tools.......................................................................................1554 DESCRIPTION........................................................................................................1556 Refrigeration System...........................................................................................1556 Component Layout...............................................................................................1558 Introduction...................................................................................................1560 Features.......................................................................................................1560 Overview of Control System.....................................................................................1561 Control Operation..............................................................................................1562 Discharge Air Flow.............................................................................................1564 TROUBLE DIAGNOSES..................................................................................................1565 Component Location.............................................................................................1565 Circuit Diagram - Auto Air Conditioner.........................................................................1568 Wiring Diagram - A/C, A -......................................................................................1569 How to Perform Trouble Diagnoses for Quick and Accurate Repair.................................................1573 Operational Check..............................................................................................1574 Self-diagnosis.................................................................................................1576 Malfunction Code/Symptom Chart.................................................................................1578 A/C System.....................................................................................................1580 Air Mix Door...................................................................................................1584 Intake Door....................................................................................................1592 Mode Door Motor................................................................................................1601 Front Blower Motor.............................................................................................1610 Memory Function................................................................................................1622 Rear Blower Motor..............................................................................................1623 Magnet Clutch..................................................................................................1636 Insufficient Cooling...........................................................................................1643 Insufficient Heating...........................................................................................1648 Noise..........................................................................................................1650 Ambient Temperature Sensor.....................................................................................1651 In-vehicle Temperature Sensor..................................................................................1654 Sunload Sensor.................................................................................................1657 SERVICE PROCEDURE..................................................................................................1660 HFC-134a (R-134a) Service Procedure............................................................................1660 Maintenance of Lubricant Quantity in Compressor................................................................1662 Compressor.....................................................................................................1665 Compressor Clutch..............................................................................................1666 Clutch Air Gap Adjustment......................................................................................1668 Magnet Clutch..................................................................................................1668 Shaft Seal.....................................................................................................1669 Refrigerant Lines..............................................................................................1672 Checking Refrigerant Leaks.....................................................................................1673 Electronic Refrigerant Leak Detector...........................................................................1673 Fluorescent Dye Leak Detector..................................................................................1676 Heater Core....................................................................................................1677 Front Evaporator Core..........................................................................................1679 Rear Evaporator Core...........................................................................................1680 Spring Lock Coupling...........................................................................................1680 Fast Idle Control Device (FICD)................................................................................1682 Belt...........................................................................................................1682 SERVICE DATA AND SPECIFICATIONS (SDS)..............................................................................1683 Auto...........................................................................................................1683 MANUAL.................................................................................................................1694 PRECAUTIONS........................................................................................................1684 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"....................................1684 Precautions for Working with HFC-134a (R-134a).................................................................1685 Contaminated Refrigerant.......................................................................................1685 General Refrigerant Precautions................................................................................1685 Precautions for Leak Detection Dye.............................................................................1686 A/C Identification Label.......................................................................................1686 Precautions for Refrigerant Connection.........................................................................1686 Precautions for Servicing Compressor...........................................................................1690 Precautions for Service Equipment..............................................................................1691 Wiring Diagrams and Trouble Diagnosis..........................................................................1693 PREPARATION........................................................................................................1694 HFC-134a (R-134a) Service Tools and Equipment..................................................................1694 Commercial Service Tools.......................................................................................1697 DESCRIPTION........................................................................................................1699 Refrigeration System...........................................................................................1699 Component Layout...............................................................................................1701 Control Operation..............................................................................................1703 Discharge Air Flow.............................................................................................1704 TROUBLE DIAGNOSES..................................................................................................1705 Component Location.............................................................................................1705 Circuit Diagram - Manual Air Conditioner.......................................................................1708 Wiring Diagram - A/C, M -......................................................................................1709 How to Perform Trouble Diagnoses for Quick and Accurate Repair.................................................1713 Operational Check..............................................................................................1714 Symptom Chart..................................................................................................1716 A/C System.....................................................................................................1718 Air Mix Door...................................................................................................1720 Intake Door....................................................................................................1724 Mode Door Motor................................................................................................1729 Front Blower Motor.............................................................................................1732 Rear Blower Motor..............................................................................................1741 Magnet Clutch..................................................................................................1752 Insufficient Cooling...........................................................................................1759 Insufficient Heating...........................................................................................1764 Noise..........................................................................................................1766 SERVICE PROCEDURE..................................................................................................1767 HFC-134a (R-134a) Service Procedure............................................................................1767 Maintenance of Lubricant Quantity in Compressor................................................................1769 Compressor.....................................................................................................1772 Compressor Clutch..............................................................................................1773 Clutch Air Gap Adjustment......................................................................................1775 Magnet Clutch..................................................................................................1775 Shaft Seal.....................................................................................................1776 Refrigerant Lines..............................................................................................1779 Checking Refrigerant Leaks.....................................................................................1781 Electronic Refrigerant Leak Detector...........................................................................1781 Fluorescent Dye Leak Detector..................................................................................1784 Heater Core....................................................................................................1785 Front Evaporator Core..........................................................................................1787 Rear Evaporator Core...........................................................................................1788 Spring Lock Coupling...........................................................................................1788 Fast Idle Control Device (FICD)................................................................................1790 Belt...........................................................................................................1790 SERVICE DATA AND SPECIFICATIONS (SDS)..............................................................................1791 Manual.........................................................................................................1791 SUPER MULTIPLE JUNCTION (SMJ).......................................................................................... 0 FUSE BLOCK............................................................................................................. 2 FUSE AND FUSIBLE LINK BOX.............................................................................................. 3 JOINT CONNECTOR........................................................................................................ 4 ELECTRICAL UNITS....................................................................................................... 5 idx........................................................................................................................1793 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 AT - Automatic Transmission............................................................................................ 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.........................................................................................................................1801 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS......................................................................................................1801 ENGINE LUBRICATION SYSTEM..............................................................................................1802 Precautions........................................................................................................1802 LIQUID GASKET APPLICATION PROCEDURE............................................................................1802 Preparation........................................................................................................1802 SPECIAL SERVICE TOOLS..........................................................................................1802 Lubrication Circuit................................................................................................1803 Oil Pressure Check.................................................................................................1803 Oil Pump...........................................................................................................1804 REMOVAL AND INSTALLATION.......................................................................................1804 DISASSEMBLY AND ASSEMBLY.......................................................................................1804 INSPECTION.....................................................................................................1805 REGULATOR VALVE INSPECTION.....................................................................................1805 OIL FILTER.....................................................................................................1806 Service Data and Specifications (SDS)..............................................................................1806 OIL PRESSURE...................................................................................................1806 REGULATOR VALVE................................................................................................1806 OIL PUMP.......................................................................................................1806 ENGINE COOLING SYSTEM..................................................................................................1807 Precautions........................................................................................................1807 LIQUID GASKET APPLICATION PROCEDURE............................................................................1807 Preparation........................................................................................................1807 SPECIAL SERVICE TOOLS..........................................................................................1807 Cooling Circuit....................................................................................................1808 System Check.......................................................................................................1808 CHECKING COOLING SYSTEM HOSES..................................................................................1808 CHECKING RADIATOR CAP..........................................................................................1808 CHECKING COOLING SYSTEM FOR LEAKS..............................................................................1809 Water Pump.........................................................................................................1809 REMOVAL........................................................................................................1809 INSPECTION.....................................................................................................1810 INSTALLATION...................................................................................................1810 Thermostat.........................................................................................................1811 REMOVAL........................................................................................................1811 INSPECTION.....................................................................................................1811 INSTALLATION...................................................................................................1812 Radiator...........................................................................................................1812 REMOVAL AND INSTALLATION.......................................................................................1812 INSPECTION.....................................................................................................1813 Refilling Engine Coolant...........................................................................................1814 Overheating Cause Analysis.........................................................................................1814 Cooling Fan Control System.........................................................................................1815 Service Data and Specifications (SDS)..............................................................................1815 THERMOSTAT.....................................................................................................1815 RADIATOR.......................................................................................................1816 ma.........................................................................................................................1817 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS......................................................................................................1817 PRECAUTIONS............................................................................................................1818 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................1818 PREPARATION............................................................................................................1819 Special Service Tool...............................................................................................1819 Commercial Service Tool............................................................................................1819 Preparation for Changing Engine Coolant............................................................................1819 GENERAL MAINTENANCE....................................................................................................1820 PERIODIC MAINTENANCE...................................................................................................1822 Schedule 1.........................................................................................................1823 EMISSION CONTROL SYSTEM MAINTENANCE............................................................................1823 CHASSIS AND BODY MAINTENANCE...................................................................................1824 Schedule 2.........................................................................................................1825 EMISSION CONTROL SYSTEM MAINTENANCE............................................................................1825 CHASSIS AND BODY MAINTENANCE...................................................................................1826 RECOMMENDED FLUIDS AND LUBRICANTS......................................................................................1827 Fluids and Lubricants..............................................................................................1827 SAE Viscosity Number...............................................................................................1828 GASOLINE ENGINE OIL............................................................................................1828 Anti-freeze Coolant Mixture Ratio..................................................................................1828 ENGINE MAINTENANCE.....................................................................................................1829 Checking Drive Belts...............................................................................................1829 Changing Engine Coolant............................................................................................1830 DRAINING ENGINE COOLANT........................................................................................1830 REFILLING ENGINE COOLANT.......................................................................................1831 FLUSHING COOLING SYSTEM........................................................................................1833 Checking Fuel Lines................................................................................................1834 Changing Fuel Filter...............................................................................................1835 WITH CONSULT–II...............................................................................................1835 WITHOUT CONSULT–II............................................................................................1835 Changing Air Cleaner Filter........................................................................................1836 VISCOUS PAPER TYPE.............................................................................................1836 Changing Engine Oil................................................................................................1836 Changing Oil Filter................................................................................................1837 Changing Spark Plugs...............................................................................................1837 Checking EVAP Vapor Lines..........................................................................................1839 CHASSIS AND BODY MAINTENANCE...........................................................................................1840 Checking Exhaust System............................................................................................1840 Checking A/T Fluid.................................................................................................1840 Changing A/T Fluid.................................................................................................1841 Balancing Wheels...................................................................................................1841 Tire Rotation......................................................................................................1841 Checking Brake Fluid Level and Leaks...............................................................................1841 Checking Brake Lines and Cables....................................................................................1842 Checking Disc Brake................................................................................................1842 ROTOR..........................................................................................................1842 CALIPER........................................................................................................1842 PAD............................................................................................................1842 Checking Drum Brake................................................................................................1842 WHEEL CYLINDER.................................................................................................1842 DRUM...........................................................................................................1842 LINING.........................................................................................................1843 Checking Steering Gear, Linkage....................................................................................1843 STEERING GEAR..................................................................................................1843 STEERING LINKAGE...............................................................................................1843 Checking Power Steering Fluid and Lines............................................................................1843 CHECKING FLUID LEVEL...........................................................................................1843 CHECKING LINES.................................................................................................1843 Axle and Suspension Parts..........................................................................................1844 FRONT AND REAR AXLE AND SUSPENSION PARTS.......................................................................1844 DRIVE SHAFT....................................................................................................1844 Checking ASCD Vacuum Hoses.........................................................................................1845 Lubricating Locks, Hinges and Hood Latches.........................................................................1845 Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters....................................................1846 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1847 Engine Maintenance.................................................................................................1847 DRIVE BELT DEFLECTION..........................................................................................1847 DRIVE BELT TENSION.............................................................................................1847 SPARK PLUG TYPE................................................................................................1847 Chassis and Body Maintenance.......................................................................................1847 WHEEL BALANCE..................................................................................................1847 rs.........................................................................................................................1849 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS......................................................................................................1849 SEAT BELTS.............................................................................................................1851 Precautions........................................................................................................1851 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) "AIR BAG" AND "SEAT BELT PRE-TENSIONER"....................................1851 PRECAUTION FOR SEAT BELT SERVICE...............................................................................1851 Front Seat Belt....................................................................................................1852 REMOVAL AND INSTALLATION.......................................................................................1852 Rear Seat Belt.....................................................................................................1854 REMOVAL AND INSTALLATION.......................................................................................1854 Built-in Child Seat................................................................................................1855 REMOVAL AND INSTALLATION.......................................................................................1855 Seat Belt Inspection...............................................................................................1857 AFTER A COLLISION..............................................................................................1857 PRELIMINARY CHECKS.............................................................................................1857 SEAT BELT RETRACTOR ON-VEHICLE CHECK...........................................................................1858 SEAT BELT RETRACTOR OFF-VEHICLE CHECK..........................................................................1859 TETHER ANCHOR PLATE............................................................................................1860 ISOFIX CHILD RESTRAINT ANCHORAGE...............................................................................1860 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)....................................................................................1861 Precautions........................................................................................................1861 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) "AIR BAG" AND "SEAT BELT PRE-TENSIONER"....................................1861 PRECAUTIONS FOR SRS "AIR BAG" SERVICE..........................................................................1861 WIRING DIAGRAMS AND TROUBLE DIAGNOSIS..........................................................................1861 Preparation........................................................................................................1862 SPECIAL SERVICE TOOLS..........................................................................................1862 Description........................................................................................................1863 SRS Component Parts Location.......................................................................................1864 Maintenance Items..................................................................................................1864 Diagnosis Sensor Unit..............................................................................................1865 REMOVAL AND INSTALLATION.......................................................................................1865 Seat Belt Pre-tensioner............................................................................................1867 REMOVAL AND INSTALLATION.......................................................................................1867 Driver Air Bag Module and Spiral Cable.............................................................................1867 REMOVAL AND INSTALLATION.......................................................................................1867 REMOVAL........................................................................................................1867 INSTALLATION...................................................................................................1869 Front Passenger Air Bag Module.....................................................................................1870 REMOVAL........................................................................................................1870 INSTALLATION...................................................................................................1872 Disposal of Air Bag Module and Seat Belt Pre-tensioner.............................................................1872 CHECKING DEPLOYMENT TOOL.......................................................................................1873 DEPLOYMENT PROCEDURES FOR AIR BAG MODULE (OUTSIDE OF VEHICLE)..................................................1874 DEPLOYMENT OF AIR BAG MODULE AND SEATBELT PRE-TENSIONER WHILE MOUNTED IN VEHICLE...............................1877 DISPOSING OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER........................................................1877 Trouble Diagnoses Introduction.....................................................................................1878 DIAGNOSIS FUNCTION.............................................................................................1878 DIAGNOSIS MODE FOR CONSULT-II..................................................................................1878 HOW TO CHANGE SELF-DIAGNOSIS MODE WITH CONSULT-II.............................................................1879 HOW TO CHANGE SELF-DIAGNOSIS MODE WITHOUT CONSULT-II..........................................................1879 HOW TO ERASE SELF-DIAGNOSIS RESULTS............................................................................1880 How to Perform Trouble Diagnoses for Quick and Accurate Repair.....................................................1881 INFORMATION FROM CUSTOMER......................................................................................1881 PRELIMINARY CHECK..............................................................................................1881 WORK FLOW......................................................................................................1881 Schematic..........................................................................................................1882 Wiring Diagram - SRS -.............................................................................................1883 SRS Operation Check................................................................................................1885 DIAGNOSTIC PROCEDURE 1.........................................................................................1885 Trouble Diagnoses with CONSULT-II.................................................................................1885 DIAGNOSTIC PROCEDURE 2.........................................................................................1885 DIAGNOSTIC PROCEDURE 3.........................................................................................1888 DIAGNOSTIC PROCEDURE 4 (CONTINUED FROM DIAGNOSTIC PROCEDURE 2).................................................1890 DIAGNOSTIC PROCEDURE 5.........................................................................................1890 Trouble Diagnoses without CONSULT-II..............................................................................1894 DIAGNOSTIC PROCEDURE 6.........................................................................................1894 DIAGNOSTIC PROCEDURE 7.........................................................................................1896 DIAGNOSTIC PROCEDURE 8 (CONTINUED FROM DIAGNOSTIC PROCEDURE 6).................................................1897 Trouble Diagnoses: "AIR BAG" Warning Lamp Does Not Turn Off........................................................1898 DIAGNOSTIC PROCEDURE 9.........................................................................................1898 Trouble Diagnoses: "AIR BAG" Warning Lamp Does Not Turn On.........................................................1900 DIAGNOSTIC PROCEDURE 10........................................................................................1900 Collision Diagnosis................................................................................................1901 SRS INSPECTION.................................................................................................1901 SUPER MULTIPLE JUNCTION (SMJ).......................................................................................... 0 FUSE BLOCK............................................................................................................. 2 FUSE AND FUSIBLE LINK BOX.............................................................................................. 3 JOINT CONNECTOR........................................................................................................ 4 ELECTRICAL UNITS....................................................................................................... 5 sc.........................................................................................................................1903 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS......................................................................................................1903 PRECAUTIONS............................................................................................................1904 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................1904 Wiring Diagrams and Trouble Diagnosis..............................................................................1904 PREPARATION............................................................................................................1905 Special Service Tool...............................................................................................1905 BATTERY................................................................................................................1906 How to Handle Battery..............................................................................................1906 METHODS OF PREVENTING OVER-DISCHARGE...........................................................................1906 CHECKING ELECTROLYTE LEVEL.....................................................................................1906 SPECIFIC GRAVITY CHECK.........................................................................................1907 CHARGING THE BATTERY...........................................................................................1908 Trouble Diagnoses with Battery/Starting/Charging System Tester.....................................................1909 DIAGNOSTIC RESULT ITEM CHART...................................................................................1911 STARTING SYSTEM........................................................................................................1912 System Description.................................................................................................1912 FOR MODELS WITH VEHICLE SECURITY SYSTEM........................................................................1912 FOR MODELS WITHOUT VEHICLE SECURITY SYSTEM.....................................................................1912 Wiring Diagram - START -...........................................................................................1913 Trouble Diagnoses with Battery/Starting/Charging System Tester.....................................................1915 DIAGNOSTIC RESULT ITEM CHART...................................................................................1916 WORK FLOW......................................................................................................1917 DIAGNOSTIC PROCEDURE 1.........................................................................................1918 DIAGNOSTIC PROCEDURE 2.........................................................................................1920 MINIMUM SPECIFICATION OF CRANKING VOLTAGE REFERENCING COOLANT TEMPERATURE......................................1921 Construction.......................................................................................................1922 Removal and Installation...........................................................................................1923 Pinion/Clutch Check................................................................................................1923 CHARGING SYSTEM........................................................................................................1924 System Description.................................................................................................1924 Wiring Diagram - CHARGE -..........................................................................................1925 Trouble Diagnoses with Battery/Starting/Charging System Tester.....................................................1926 DIAGNOSTIC RESULT ITEM CHART...................................................................................1928 WORK FLOW......................................................................................................1929 DIAGNOSTIC PROCEDURE 1.........................................................................................1930 DIAGNOSTIC PROCEDURE 2.........................................................................................1931 DIAGNOSTIC PROCEDURE 3.........................................................................................1932 MALFUNCTION INDICATOR..........................................................................................1933 Construction.......................................................................................................1933 Removal and Installation...........................................................................................1933 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1934 Battery............................................................................................................1934 Starter............................................................................................................1934 Generator..........................................................................................................1934 SUPER MULTIPLE JUNCTION (SMJ).......................................................................................... 0 FUSE BLOCK............................................................................................................. 2 FUSE AND FUSIBLE LINK BOX.............................................................................................. 3 JOINT CONNECTOR........................................................................................................ 4 ELECTRICAL UNITS....................................................................................................... 5 st.........................................................................................................................1935 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS......................................................................................................1935 PRECAUTIONS............................................................................................................1936 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................1936 Precautions for Steering System....................................................................................1936 PREPARATION............................................................................................................1937 Special Service Tools..............................................................................................1937 Commercial Service Tool............................................................................................1938 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................1939 NVH Troubleshooting Chart..........................................................................................1939 ON-VEHICLE SERVICE.....................................................................................................1940 Checking Steering Wheel Play.......................................................................................1940 Checking Neutral Position on Steering Wheel........................................................................1940 PRE-CHECKING...................................................................................................1940 CHECKING.......................................................................................................1940 Checking Front Wheel Turning Angle.................................................................................1940 Checking Gear Housing Movement.....................................................................................1940 Checking and Adjusting Drive Belts.................................................................................1941 Checking Fluid Level...............................................................................................1941 Checking Fluid Leakage.............................................................................................1941 Bleeding Hydraulic System..........................................................................................1941 Checking Steering Wheel Turning Force..............................................................................1942 Checking Hydraulic System..........................................................................................1942 STEERING WHEEL AND STEERING COLUMN.....................................................................................1944 Components.........................................................................................................1944 Removal and Installation...........................................................................................1944 STEERING WHEEL.................................................................................................1944 TURN SIGNAL CANCEL CAM.........................................................................................1945 STEERING COLUMN................................................................................................1946 Disassembly and Assembly...........................................................................................1947 STEERING LOCK..................................................................................................1948 IGNITION KEY CYLINDER..........................................................................................1948 TILT MECHANISM.................................................................................................1949 Inspection.........................................................................................................1949 POWER STEERING GEAR AND LINKAGE........................................................................................1950 Components.........................................................................................................1950 Removal and Installation...........................................................................................1951 Disassembly........................................................................................................1952 Inspection.........................................................................................................1953 BOOT...........................................................................................................1953 TIE-ROD OUTER AND INNER SOCKETS................................................................................1953 Assembly...........................................................................................................1953 POWER STEERING OIL PUMP................................................................................................1955 Components.........................................................................................................1955 Pre-disassembly Inspection.........................................................................................1955 Inspection.........................................................................................................1956 PULLEY AND PULLEY SHAFT........................................................................................1956 Disassembly........................................................................................................1956 Assembly...........................................................................................................1956 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1958 General Specifications.............................................................................................1958 Steering Wheel.....................................................................................................1958 Steering Column....................................................................................................1958 Steering Gear and Linkage..........................................................................................1959 Power Steering.....................................................................................................1959 su.........................................................................................................................1961 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS......................................................................................................1961 FRONT SUSPENSION.......................................................................................................1962 Precautions........................................................................................................1962 PRECAUTIONS....................................................................................................1962 Preparation........................................................................................................1962 SPECIAL SERVICE TOOL...........................................................................................1962 COMMERCIAL SERVICE TOOL........................................................................................1962 Noise, Vibration and Harshness (NVH) Troubleshooting...............................................................1963 NVH TROUBLESHOOTING CHART......................................................................................1963 Components.........................................................................................................1964 On-vehicle Service.................................................................................................1965 FRONT SUSPENSION PARTS.........................................................................................1965 FRONT WHEEL ALIGNMENT..........................................................................................1966 Coil Spring and Strut Assembly.....................................................................................1968 COMPONENTS.....................................................................................................1968 REMOVAL AND INSTALLATION.......................................................................................1969 DISASSEMBLY....................................................................................................1969 INSPECTION.....................................................................................................1969 ASSEMBLY.......................................................................................................1970 Stabilizer Bar.....................................................................................................1970 REMOVAL AND INSTALLATION.......................................................................................1970 INSPECTION.....................................................................................................1971 Transverse Link and Transverse Link Gusset.........................................................................1971 REMOVAL AND INSTALLATION.......................................................................................1971 INSPECTION.....................................................................................................1971 Lower Ball Joint...................................................................................................1971 REMOVAL AND INSTALLATION.......................................................................................1971 INSPECTION.....................................................................................................1972 Service Data and Specifications (SDS)..............................................................................1972 GENERAL SPECIFICATIONS (FRONT).................................................................................1972 FRONT WHEEL ALIGNMENT (UNLADEN*1)..............................................................................1973 LOWER BALL JOINT...............................................................................................1973 WHEELARCH HEIGHT (UNLADEN*)....................................................................................1974 WHEEL RUNOUT...................................................................................................1974 REAR SUSPENSION........................................................................................................1975 Precautions........................................................................................................1975 PRECAUTIONS....................................................................................................1975 Preparation........................................................................................................1975 COMMERCIAL SERVICE TOOL........................................................................................1975 Noise, Vibration and Harshness (NVH)Troubleshooting................................................................1975 Components.........................................................................................................1976 On-vehicle Service.................................................................................................1976 REAR SUSPENSION PARTS..........................................................................................1976 REAR WHEEL ALIGNMENT...........................................................................................1977 Removal and Installation...........................................................................................1979 Leaf Spring........................................................................................................1980 COMPONENTS.....................................................................................................1980 REMOVAL........................................................................................................1980 INSPECTION.....................................................................................................1981 INSTALLATION...................................................................................................1982 Shock Absorber.....................................................................................................1983 REMOVAL AND INSTALLATION.......................................................................................1983 INSPECTION.....................................................................................................1983 Stabilizer Bar.....................................................................................................1983 REMOVAL AND INSTALLATION.......................................................................................1983 INSPECTION.....................................................................................................1984 Service Data and Specifications (SDS)..............................................................................1984 GENERAL SPECIFICATIONS (REAR)..................................................................................1984 REAR WHEEL ALIGNMENT (UNLADEN*1)...............................................................................1985 WHEELARCH HEIGHT (UNLADEN*)....................................................................................1985 WHEEL RUNOUT...................................................................................................1985
DESCRIPTION:
2002 NISSAN QUEST V41 Series Service Manual PDF DOWNLOAD
FOREWORD
- This manual contains maintenance and repair procedures for the 2002 NISSAN QUEST.
- 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.
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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