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2003 NISSAN PATHFINDER R50 Series Service Manual PDF DOWNLOAD
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Description
2003 NISSAN PATHFINDER R50 Series Service Manual PDF DOWNLOAD
FILE DETAILS:
2003 NISSAN PATHFINDER R50 Series Service Manual PDF DOWNLOAD
Language : English
Pages : 2935
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
2003 NISSAN PATHFINDER R50 Series Service Manual PDF DOWNLOAD
fwd........................................................................................................................... 1 Exit...................................................................................................................... 0 QUICK REFERENCE INDEX..................................................................................................... 1 FOREWORD.................................................................................................................. 2 GI - General Information.................................................................................................. 0 MA - Maintenance.......................................................................................................... 0 EM - Engine Mechanical.................................................................................................... 0 LC - Engine Lubrication & Cooling Systems................................................................................. 0 EC - Engine Control System................................................................................................ 0 FE - Accelerator Control, Fuel & Exhaust Systems.......................................................................... 0 CL - Clutch............................................................................................................... 0 MT - Manual Transmission.................................................................................................. 0 AT - Automatic Transmission............................................................................................... 0 TF - Transfer............................................................................................................. 0 PD - Propeller Shaft & Differential Carrier............................................................................... 0 AX - Front & Rear Axle.................................................................................................... 0 SU - Front & Rear Suspension.............................................................................................. 0 BR - Brake System......................................................................................................... 0 ST - Steering System...................................................................................................... 0 RS - Restraint System..................................................................................................... 0 BT - Body & Trim.......................................................................................................... 0 HA - Heater & Air Conditioner............................................................................................. 0 SC - Starting & Charging System........................................................................................... 0 EL - Electrical System.................................................................................................... 0 IDX - Alphabetical Index.................................................................................................. 1 SUPER MULTIPLE JUNCTION (SMJ)............................................................................................. 0 FUSE BLOCK - JUNCTION BOX (J/B)........................................................................................... 2 FUSE AND FUSIBLE LINK BOX................................................................................................. 3 ELECTRICAL UNITS.......................................................................................................... 4 JOINT CONNECTOR (J/C)..................................................................................................... 5 QUICK REFERENCE CHART..................................................................................................... 6 Comment Sheet............................................................................................................. 3 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 BELT PRE-TENSIONER"........................... 11 Precautions for On Board Diagnostic (OBD) System of A/T and Engine.................................................... 11 Precautions........................................................................................................... 11 Service Notice or Precautions......................................................................................... 13 Wiring Diagrams and Trouble Diagnosis................................................................................. 14 PREPARATION............................................................................................................... 15 Special Service Tools................................................................................................. 15 OVERALL SYSTEM............................................................................................................ 17 A/T Electrical Parts Location......................................................................................... 17 Circuit Diagram....................................................................................................... 18 Cross-sectional View.................................................................................................. 19 Hydraulic Control Circuit............................................................................................. 20 Shift Mechanism....................................................................................................... 21 Control System........................................................................................................ 30 Control Mechanism..................................................................................................... 31 Control Valve......................................................................................................... 36 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION.................................................................................... 38 Introduction.......................................................................................................... 38 OBD-II Function for A/T System........................................................................................ 38 One or Two Trip Detection Logic of OBD-II............................................................................. 38 OBD-II Diagnostic Trouble Code (DTC).................................................................................. 38 Malfunction Indicator Lamp (MIL)...................................................................................... 42 CONSULT-II............................................................................................................ 42 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.................................................................................................... 69 Road Test............................................................................................................. 70 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION................................................................................... 88 Symptom Chart......................................................................................................... 88 TCM Terminals and Reference Value..................................................................................... 100 CAN COMMUNICATION......................................................................................................... 103 System Description.................................................................................................... 103 CAN Communication Unit................................................................................................ 103 TROUBLE DIAGNOSIS FOR POWER SUPPLY........................................................................................ 107 Wiring Diagram - AT - MAIN............................................................................................ 107 Diagnostic Procedure.................................................................................................. 108 DTC P0705 PARK/NEUTRAL POSITION SWITCH.................................................................................... 110 Description........................................................................................................... 110 Wiring Diagram - AT - PNP/SW.......................................................................................... 112 Diagnostic Procedure.................................................................................................. 113 Component Inspection.................................................................................................. 114 DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT............................................................................ 116 Description........................................................................................................... 116 Wiring Diagram - AT - FTS............................................................................................. 118 Diagnostic Procedure.................................................................................................. 119 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.................................................................................................. 126 DTC P0725 ENGINE SPEED SIGNAL............................................................................................. 127 Description........................................................................................................... 127 Wiring Diagram - AT - ENGSS........................................................................................... 128 Diagnostic Procedure.................................................................................................. 129 DTC P0731 IMPROPER SHIFTING TO 1ST GEAR POSITION.......................................................................... 131 Description........................................................................................................... 131 Wiring Diagram - AT - 1ST............................................................................................. 134 Diagnostic Procedure.................................................................................................. 135 Component Inspection.................................................................................................. 136 DTC P0732 IMPROPER SHIFTING TO 2ND GEAR POSITION.......................................................................... 137 Description........................................................................................................... 137 Wiring Diagram - AT - 2ND............................................................................................. 140 Diagnostic Procedure.................................................................................................. 141 Component Inspection.................................................................................................. 142 DTC P0733 IMPROPER SHIFTING TO 3RD GEAR POSITION.......................................................................... 143 Description........................................................................................................... 143 Wiring Diagram - AT - 3RD............................................................................................. 146 Diagnostic Procedure.................................................................................................. 147 Component Inspection.................................................................................................. 148 DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION.......................................................................... 149 Description........................................................................................................... 149 Wiring Diagram - AT - 4TH............................................................................................. 153 Diagnostic Procedure.................................................................................................. 154 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 IMPROPER LOCK-UP OPERATION...................................................................................... 164 Description........................................................................................................... 164 Wiring Diagram - AT - TCCSIG.......................................................................................... 167 Diagnostic Procedure.................................................................................................. 168 Component Inspection.................................................................................................. 172 DTC P0745 LINE PRESSURE SOLENOID VALVE.................................................................................... 173 Description........................................................................................................... 173 Wiring Diagram - AT - LPSV............................................................................................ 175 Diagnostic Procedure.................................................................................................. 176 Component Inspection.................................................................................................. 178 DTC P0750 SHIFT SOLENOID VALVE A.......................................................................................... 179 Description........................................................................................................... 179 Wiring Diagram - AT - SSV/A........................................................................................... 180 Diagnostic Procedure.................................................................................................. 181 Component Inspection.................................................................................................. 182 DTC P0755 SHIFT SOLENOID VALVE B.......................................................................................... 183 Description........................................................................................................... 183 Wiring Diagram - AT - SSV/B........................................................................................... 184 Diagnostic Procedure.................................................................................................. 185 Component Inspection.................................................................................................. 186 DTC P1705 ACCELERATOR PEDAL POSITION SENSOR (THROTTLE POSITION SENSOR).................................................... 187 Description........................................................................................................... 187 On Board Diagnosis Logic.............................................................................................. 188 Possible Cause........................................................................................................ 188 Diagnostic Trouble Code (DTC) Confirmation Procedure.................................................................. 189 Wiring Diagram - AT - TPS............................................................................................. 190 Diagnostic Procedure.................................................................................................. 191 DTC P1760 OVERRUN CLUTCH SOLENOID VALVE................................................................................... 193 Description........................................................................................................... 193 Wiring Diagram - AT - OVRCSV.......................................................................................... 195 Diagnostic Procedure.................................................................................................. 196 Component Inspection.................................................................................................. 197 DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE).............................................. 198 Description........................................................................................................... 198 Wiring Diagram - AT - BA/FTS.......................................................................................... 200 Diagnostic Procedure.................................................................................................. 201 Component Inspection.................................................................................................. 204 DTC VEHICLE SPEED SENSOR.MTR.............................................................................................. 205 Description........................................................................................................... 205 Wiring Diagram - AT - VSSMTR.......................................................................................... 207 Diagnostic Procedure.................................................................................................. 208 DTC U1000 CAN COMMUNICATION LINE.......................................................................................... 210 Description........................................................................................................... 210 On Board Diagnosis Logic.............................................................................................. 210 Possible Cause........................................................................................................ 210 Diagnostic Trouble Code (DTC) Confirmation Procedure.................................................................. 211 Wiring Diagram - AT - CAN............................................................................................. 212 Diagnostic Procedure.................................................................................................. 213 DTC TURBINE REVOLUTION SENSOR............................................................................................. 214 Description........................................................................................................... 214 Wiring Diagram - AT - TRSA/T.......................................................................................... 216 Diagnostic Procedure.................................................................................................. 217 Component Inspection.................................................................................................. 218 DTC CONTROL UNIT (RAM), CONTROL UNIT (ROM)................................................................................ 219 Description........................................................................................................... 219 Diagnostic Procedure.................................................................................................. 220 DTC CONTROL UNIT (EEP ROM)................................................................................................ 221 Description........................................................................................................... 221 Diagnostic Procedure.................................................................................................. 222 TROUBLE DIAGNOSES FOR SYMPTOMS............................................................................................ 223 Wiring Diagram - AT - NONDTC.......................................................................................... 223 O/D OFF Indicator Lamp Does Not Come On............................................................................... 226 Engine Cannot Be Started In "P" and "N" Position...................................................................... 228 In "P" Position, Vehicle Moves Forward Or Backward When Pushed........................................................ 229 In "N" Position, Vehicle Moves........................................................................................ 230 Large Shock. "N" -> "R" Position...................................................................................... 232 Vehicle Does Not Creep Backward In "R" Position....................................................................... 234 Vehicle Does Not Creep Forward In "D", "2" Or "1" Position............................................................ 237 Vehicle Cannot Be Started From D1..................................................................................... 240 A/T Does Not Shift: D1 -> D2 Or Does Not Kickdown: D4 -> D2........................................................... 243 A/T Does Not Shift: D2 -> D3.......................................................................................... 246 A/T Does Not Shift: D3 -> D4.......................................................................................... 249 A/T Does Not Perform Lock-up.......................................................................................... 252 A/T Does Not Hold Lock-up Condition................................................................................... 254 Lock-up Is Not Released............................................................................................... 256 Engine Speed Does Not Return To Idle (Light Braking D4 -> D3)......................................................... 257 Vehicle Does Not Start From D1........................................................................................ 259 A/T Does Not Shift: D4 -> D3, When Overdrive Control Switch "ON" -> "OFF"............................................. 260 A/T Does Not Shift: D3 -> 22, When Selector Lever "D" -> "2" Position................................................. 261 A/T Does Not Shift: 22 -> 11, When Selector Lever "2" -> "1" Position................................................. 262 Vehicle Does Not Decelerate By Engine Brake........................................................................... 263 TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control and Accelerator Pedal Position Sensor Circuit Checks).... 263 A/T SHIFT LOCK SYSTEM..................................................................................................... 270 Description........................................................................................................... 270 Wiring Diagram - SHIFT -.............................................................................................. 271 Diagnostic Procedure.................................................................................................. 272 KEY INTERLOCK CABLE....................................................................................................... 275 Components............................................................................................................ 275 Removal............................................................................................................... 275 Installation.......................................................................................................... 276 ON-VEHICLE SERVICE........................................................................................................ 277 Control Valve Assembly and Accumulators............................................................................... 277 Revolution Sensor Replacement......................................................................................... 278 Turbine Revolution Sensor Replacement................................................................................. 278 Rear Oil Seal Replacement............................................................................................. 278 Rear Oil Seal and Companion Flange Oil Seal Replacement............................................................... 279 Parking Components Inspection......................................................................................... 279 Park/Neutral Position Switch Adjustment............................................................................... 280 Manual Control Linkage Adjustment..................................................................................... 280 REMOVAL AND INSTALLATION.................................................................................................. 281 Removal............................................................................................................... 281 Installation.......................................................................................................... 282 OVERHAUL.................................................................................................................. 286 Components............................................................................................................ 286 Oil Channel........................................................................................................... 289 Locations of Needle Bearings, Thrust Washers and Snap Rings........................................................... 290 DISASSEMBLY............................................................................................................... 291 REPAIR FOR COMPONENT PARTS................................................................................................ 302 Oil Pump.............................................................................................................. 302 Control Valve Assembly................................................................................................ 306 Control Valve Upper Body.............................................................................................. 312 Control Valve Lower Body.............................................................................................. 317 Reverse Clutch........................................................................................................ 319 High Clutch........................................................................................................... 322 Forward and Overrun Clutches.......................................................................................... 325 Low & Reverse Brake................................................................................................... 329 Forward Clutch Drum Assembly.......................................................................................... 333 Rear Internal Gear and Forward Clutch Hub............................................................................. 335 Band Servo Piston Assembly............................................................................................ 338 Parking Pawl Components............................................................................................... 342 ASSEMBLY.................................................................................................................. 344 Assembly (1).......................................................................................................... 344 Adjustment............................................................................................................ 352 Assembly (2).......................................................................................................... 354 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................... 361 General Specifications................................................................................................ 361 Shift Schedule........................................................................................................ 361 Stall Revolution...................................................................................................... 361 Line Pressure......................................................................................................... 361 Return Springs........................................................................................................ 362 Accumulator O-ring.................................................................................................... 363 Clutches and Brakes................................................................................................... 363 Oil Pump and Low One-way Clutch....................................................................................... 365 Total End Play........................................................................................................ 365 Reverse Clutch Drum End Play.......................................................................................... 366 Removal and Installation.............................................................................................. 366 Shift Solenoid Valves................................................................................................. 366 Solenoid Valves....................................................................................................... 366 A/T Fluid Temperature Sensor.......................................................................................... 366 Turbine Revolution Sensor............................................................................................. 366 Revolution Sensor..................................................................................................... 367 Dropping Resistor..................................................................................................... 367 SUPER MULTIPLE JUNCTION (SMJ)............................................................................................. 0 FUSE BLOCK - JUNCTION BOX (J/B)........................................................................................... 2 FUSE AND FUSIBLE LINK BOX................................................................................................. 3 ELECTRICAL UNITS.......................................................................................................... 4 JOINT CONNECTOR (J/C)..................................................................................................... 5 ax............................................................................................................................ 368 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents......................................................................................................... 368 FRONT AXLE................................................................................................................ 369 Precautions........................................................................................................... 369 PRECAUTIONS....................................................................................................... 369 Preparation........................................................................................................... 369 SPECIAL SERVICE TOOLS............................................................................................. 369 COMMERCIAL SERVICE TOOLS.......................................................................................... 369 Noise, Vibration and Harshness (NVH) Troubleshooting.................................................................. 370 NVH TROUBLESHOOTING CHART......................................................................................... 370 On-vehicle Service.................................................................................................... 370 FRONT AXLE PARTS.................................................................................................. 370 FRONT WHEEL BEARING............................................................................................... 371 DRIVE SHAFT (4WD)................................................................................................. 372 Wheel Hub and Rotor Disc.............................................................................................. 373 COMPONENTS........................................................................................................ 373 REMOVAL........................................................................................................... 374 INSTALLATION...................................................................................................... 376 DISASSEMBLY....................................................................................................... 376 INSPECTION........................................................................................................ 376 ASSEMBLY.......................................................................................................... 377 Knuckle Spindle....................................................................................................... 377 REMOVAL........................................................................................................... 377 INSPECTION........................................................................................................ 378 INSTALLATION...................................................................................................... 378 Drive Shaft (4WD)..................................................................................................... 379 COMPONENTS........................................................................................................ 379 REMOVAL........................................................................................................... 379 DISASSEMBLY....................................................................................................... 380 INSPECTION........................................................................................................ 381 ASSEMBLY.......................................................................................................... 381 INSTALLATION...................................................................................................... 382 Service Data and Specifications (SDS)................................................................................. 383 WHEEL BEARING (FRONT)............................................................................................. 383 DRIVE SHAFT (4WD)................................................................................................. 383 REAR AXLE................................................................................................................. 385 Precautions........................................................................................................... 385 PRECAUTIONS....................................................................................................... 385 Preparation........................................................................................................... 385 SPECIAL SERVICE TOOLS............................................................................................. 385 COMMERCIAL SERVICE TOOLS.......................................................................................... 386 Noise, Vibration and Harshness (NVH) Troubleshooting.................................................................. 386 On-vehicle Service.................................................................................................... 386 REAR AXLE PARTS................................................................................................... 386 REAR WHEEL BEARING................................................................................................ 386 Components............................................................................................................ 387 Removal............................................................................................................... 387 Inspection............................................................................................................ 389 AXLE SHAFT........................................................................................................ 389 BEARING CAGE...................................................................................................... 389 REAR AXLE HOUSING................................................................................................. 389 Installation.......................................................................................................... 389 Service Data and Specifications (SDS)................................................................................. 390 WHEEL BEARING (REAR).............................................................................................. 390 br............................................................................................................................ 392 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents......................................................................................................... 392 PRECAUTIONS............................................................................................................... 395 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................... 395 Precautions for SRS "Air Bag" and "SEAT BELT PRE-TENSIONER" Service................................................... 395 Precautions for Brake System.......................................................................................... 395 Wiring Diagrams and Trouble Diagnoses................................................................................. 396 PREPARATION............................................................................................................... 397 Special Service Tools................................................................................................. 397 Commercial Service Tools.............................................................................................. 397 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................... 398 NVH Troubleshooting Chart............................................................................................. 398 ON-VEHICLE SERVICE........................................................................................................ 399 Checking Brake Fluid Level............................................................................................ 399 Checking Brake Line................................................................................................... 399 Changing Brake Fluid.................................................................................................. 399 Bleeding Brake System................................................................................................. 400 BRAKE HYDRAULIC LINE...................................................................................................... 401 Hydraulic Circuit..................................................................................................... 401 Removal............................................................................................................... 402 Inspection............................................................................................................ 402 Installation.......................................................................................................... 402 PROPORTIONING VALVE....................................................................................................... 403 Inspection............................................................................................................ 403 Removal and Installation.............................................................................................. 403 BRAKE PEDAL AND BRACKET................................................................................................... 404 Removal and Installation.............................................................................................. 404 Inspection............................................................................................................ 404 Adjustment............................................................................................................ 404 MASTER CYLINDER........................................................................................................... 406 Removal............................................................................................................... 406 Disassembly........................................................................................................... 407 MODELS WITHOUT VDC................................................................................................ 407 MODELS WITH VDC................................................................................................... 407 Inspection............................................................................................................ 407 Assembly.............................................................................................................. 408 MODELS WITHOUT VDC................................................................................................ 408 MODELS WITH VDC................................................................................................... 408 Installation.......................................................................................................... 409 BRAKE BOOSTER............................................................................................................. 410 On-vehicle Service.................................................................................................... 410 OPERATING CHECK................................................................................................... 410 AIRTIGHT CHECK.................................................................................................... 410 Removal............................................................................................................... 410 Inspection............................................................................................................ 410 OUTPUT ROD LENGTH CHECK........................................................................................... 410 Installation.......................................................................................................... 411 VACUUM PIPING............................................................................................................. 412 Vacuum Hose........................................................................................................... 412 Removal and Installation.............................................................................................. 412 Inspection............................................................................................................ 412 HOSES AND CONNECTORS.............................................................................................. 412 CHECK VALVE....................................................................................................... 412 FRONT DISC BRAKE.......................................................................................................... 413 Components............................................................................................................ 413 Pad Replacement....................................................................................................... 413 Removal............................................................................................................... 414 Disassembly........................................................................................................... 415 Inspection............................................................................................................ 415 CALIPER........................................................................................................... 415 ROTOR............................................................................................................. 415 Assembly.............................................................................................................. 416 Installation.......................................................................................................... 416 Brake Burnishing Procedure............................................................................................ 416 REAR DRUM BRAKE........................................................................................................... 417 Components............................................................................................................ 417 Removal............................................................................................................... 417 Inspection............................................................................................................ 418 WHEEL CYLINDER.................................................................................................... 418 Wheel Cylinder Overhaul............................................................................................... 419 Inspection............................................................................................................ 419 DRUM.............................................................................................................. 419 LINING............................................................................................................ 419 Installation.......................................................................................................... 419 PARKING BRAKE CONTROL..................................................................................................... 421 Components............................................................................................................ 421 Removal and Installation.............................................................................................. 421 Inspection............................................................................................................ 421 Adjustment............................................................................................................ 422 ABS....................................................................................................................... 423 DESCRIPTION........................................................................................................... 423 Purpose........................................................................................................... 423 Operation......................................................................................................... 423 ABS Hydraulic Circuit............................................................................................. 423 System Components................................................................................................. 424 System Description................................................................................................ 424 SENSOR........................................................................................................ 424 CONTROL UNIT (BUILT-IN ABS ACTUATOR AND ELECTRIC UNIT)........................................................ 424 ABS ACTUATOR AND ELECTRIC UNIT................................................................................ 424 G SENSOR (4WD MODELS ONLY).................................................................................... 425 Component Parts and Harness Connector Location.................................................................... 426 Schematic......................................................................................................... 427 Wiring Diagram - ABS -............................................................................................ 428 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION................................................................................ 432 Self-diagnosis.................................................................................................... 432 FUNCTION...................................................................................................... 432 SELF-DIAGNOSIS PROCEDURE...................................................................................... 432 HOW TO READ SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES)....................................................... 433 HOW TO ERASE SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES)...................................................... 433 CONSULT-II........................................................................................................ 434 CONSULT-II APPLICATION TO ABS................................................................................. 434 ECU (ABS CONTROL UNIT) PART NUMBER MODE....................................................................... 434 CONSULT-II Inspection Procedure................................................................................... 435 SELF-DIAGNOSIS PROCEDURE...................................................................................... 435 SELF-DIAGNOSTIC RESULTS MODE.................................................................................. 436 DATA MONITOR PROCEDURE........................................................................................ 437 ACTIVE TEST PROCEDURE......................................................................................... 438 DATA MONITOR MODE............................................................................................. 439 ACTIVE TEST MODE.............................................................................................. 439 TROUBLE DIAGNOSIS - INTRODUCTION...................................................................................... 440 How to Perform Trouble Diagnoses for Quick and Accurate Repair.................................................... 440 INTRODUCTION.................................................................................................. 440 TROUBLE DIAGNOSIS - BASIC INSPECTION.................................................................................. 441 Preliminary Check................................................................................................. 441 Ground Circuit Check.............................................................................................. 444 ABS ACTUATOR AND ELECTRIC UNIT GROUND......................................................................... 444 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION............................................................................... 445 Malfunction Code/Symptom Chart.................................................................................... 445 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS........................................................................... 447 Wheel Sensor or Rotor............................................................................................. 447 DIAGNOSTIC PROCEDURE.......................................................................................... 447 ABS Actuator Solenoid Valve or Solenoid Valve Relay............................................................... 450 DIAGNOSTIC PROCEDURE.......................................................................................... 450 Motor Relay or Motor.............................................................................................. 452 DIAGNOSTIC PROCEDURE.......................................................................................... 452 Low Voltage....................................................................................................... 454 DIAGNOSTIC PROCEDURE.......................................................................................... 454 G Sensor and Circuit.............................................................................................. 456 DIAGNOSTIC PROCEDURE.......................................................................................... 456 Control Unit...................................................................................................... 458 DIAGNOSTIC PROCEDURE.......................................................................................... 458 TROUBLE DIAGNOSES FOR SYMPTOMS........................................................................................ 459 1. ABS Works Frequently........................................................................................... 459 2. Unexpected Pedal Action........................................................................................ 459 3. Long Stopping Distance......................................................................................... 461 4. ABS Does Not Work.............................................................................................. 461 5. Pedal Vibration and Noise...................................................................................... 462 6. Warning Lamp Does Not Come On When Ignition Switch Is Turned On................................................ 463 7. Warning Lamp Stays On When Ignition Switch Is Turned On........................................................ 465 8. Vehicle Vibrates Excessively When ABS Is Operating............................................................. 468 REMOVAL AND INSTALLATION.............................................................................................. 471 Front Wheel Sensor................................................................................................ 471 Rear Wheel Sensor................................................................................................. 471 Front Sensor Rotor................................................................................................ 472 REMOVAL....................................................................................................... 472 INSTALLATION.................................................................................................. 472 Rear Sensor Rotor................................................................................................. 472 REMOVAL....................................................................................................... 472 INSTALLATION.................................................................................................. 472 G Sensor.......................................................................................................... 472 ABS Actuator and Electric Unit.................................................................................... 473 REMOVAL....................................................................................................... 473 INSTALLATION.................................................................................................. 473 VDC/TCS/ABS............................................................................................................... 474 PRECAUTIONS........................................................................................................... 474 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"....................................... 474 Precautions for SRS "Air Bag" and "SEAT BELT PRE-TENSIONER" Service............................................... 474 Precautions for Brake System...................................................................................... 474 Precautions for Brake Control..................................................................................... 475 Diagnosis Precaution.............................................................................................. 475 CAN SYSTEM.................................................................................................... 475 Precaution for Harness Repair..................................................................................... 475 CAN SYSTEM.................................................................................................... 475 PREPARATION........................................................................................................... 477 Commercial Service Tools.......................................................................................... 477 ON-VEHICLE SERVICE.................................................................................................... 478 Adjustment of Steering Angle Sensor Neutral Position.............................................................. 478 Calibration of Decel G Sensor..................................................................................... 478 GENERAL INFORMATION................................................................................................... 480 Fail-Safe......................................................................................................... 480 ABS SYSTEM.................................................................................................... 480 VDC/TCS SYSTEM................................................................................................ 480 Hydraulic Circuit Diagram......................................................................................... 480 ABS Function...................................................................................................... 480 TCS Function...................................................................................................... 481 VDC Function...................................................................................................... 481 System Diagram.................................................................................................... 481 CAN COMMUNICATION..................................................................................................... 482 System Description................................................................................................ 482 CAN Communication Unit............................................................................................ 482 TYPE 1 (ALL-MODE 4WD MODELS).................................................................................. 482 TYPE 2 (EXCEPT ALL-MODE 4WD MODELS)........................................................................... 484 TROUBLE DIAGNOSES..................................................................................................... 485 How to Proceed with Diagnosis..................................................................................... 485 BASIC CONCEPT................................................................................................. 485 DIAGNOSIS FLOWCHART........................................................................................... 486 ASKING COMPLAINTS............................................................................................. 487 EXAMPLE OF DIAGNOSIS SHEET.................................................................................... 487 Component Installation Location................................................................................... 488 Schematic......................................................................................................... 489 Wiring Diagram - VDC -............................................................................................ 490 Control Unit Input/Output Signal Standard......................................................................... 495 STANDARDS BY CONSULT-II....................................................................................... 495 CONSULT-II Functions.............................................................................................. 497 CONSULT-II MAIN FUNCTION...................................................................................... 497 SELF-DIAGNOSIS................................................................................................ 499 DATA MONITOR.................................................................................................. 502 ACTIVE TEST................................................................................................... 505 For Fast and Accurate Diagnosis................................................................................... 507 PRECAUTIONS FOR DIAGNOSIS..................................................................................... 507 Basic Inspection.................................................................................................. 509 BASIC INSPECTION 1: BRAKE FLUID LEVEL AND LEAK INSPECTION..................................................... 509 BASIC INSPECTION 2: INSPECTION FOR LOOSENESS OF POWER SYSTEM TERMINALS........................................ 509 BASIC INSPECTION 3: INSPECTION OF ABS WARNING LAMP, VDC OFF INDICATOR LAMP AND SLIP INDICATOR LAMP............ 509 Inspection 1 Wheel Sensor System.................................................................................. 510 INSPECTION PROCEDURE.......................................................................................... 510 Inspection 2 Engine System........................................................................................ 512 Inspection 3 VDC/TCS/ABS Control Unit System...................................................................... 512 Inspection 4 VDC Pressure Sensor System........................................................................... 513 Inspection 5 Steering Angle Sensor System......................................................................... 514 Inspection 6 Yaw Rate/Side/Decel G Sensor System.................................................................. 515 Inspection 7 Solenoid Valve, VDC Switch-over Solenoid Valve and Circuit........................................... 517 Inspection 8 ABS Actuator Relay or ABS Motor Relay Power System................................................... 519 Inspection 9 Stop Lamp Switch and Circuit......................................................................... 520 Inspection 10 ABS Actuator and Electric Unit (Control Unit) Power Circuit......................................... 521 Inspection 11 When "SHIFT POSITION ERROR" Appears in Self-Diagnosis Results Display............................... 523 Inspection 12 When "ST ANG SEN COM CIR" Appears on Self-Diagnosis Results Display................................. 524 Inspection 13 Brake Fluid Level of Reservoir Tank................................................................. 524 Inspection 14 CAN Communications System........................................................................... 525 Inspecting Components............................................................................................. 525 VDC OFF SWITCH................................................................................................ 525 Symptom 1 ABS Works Frequently.................................................................................... 526 Symptom 2 Unexpected Pedal Reaction............................................................................... 526 Symptom 3 Long Stopping Distance.................................................................................. 527 Symptom 4 ABS Does Not Work....................................................................................... 528 Symptom 5 Pedal Vibration and Noise............................................................................... 528 Symptom 6 VDC OFF Indicator Lamp Does Not Illuminate.............................................................. 529 Symptom 7 SLIP Indicator Lamp Does Not Illuminate................................................................. 530 Symptom 8 Vehicle Behaves Jerkily During VDC/TCS/ABS Operation.................................................... 531 WHEEL SENSORS......................................................................................................... 533 Removal and Installation.......................................................................................... 533 REMOVAL....................................................................................................... 533 INSTALLATION.................................................................................................. 533 SENSOR ROTOR.......................................................................................................... 535 Removal and Installation.......................................................................................... 535 REMOVAL....................................................................................................... 535 INSTALLATION.................................................................................................. 535 VDC/TCS/ABS ACTUATOR.................................................................................................. 536 Removal and Installation.......................................................................................... 536 G SENSOR.............................................................................................................. 537 Removal and Installation.......................................................................................... 537 REMOVAL....................................................................................................... 537 INSTALLATION.................................................................................................. 537 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................... 538 General Specifications................................................................................................ 538 Disc Brake............................................................................................................ 538 Drum Brake............................................................................................................ 538 Brake Pedal........................................................................................................... 538 Parking Brake Control................................................................................................. 539 SUPER MULTIPLE JUNCTION (SMJ)............................................................................................. 0 FUSE BLOCK - JUNCTION BOX (J/B)........................................................................................... 2 FUSE AND FUSIBLE LINK BOX................................................................................................. 3 ELECTRICAL UNITS.......................................................................................................... 4 JOINT CONNECTOR (J/C)..................................................................................................... 5 bt............................................................................................................................ 540 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents......................................................................................................... 540 PRECAUTIONS............................................................................................................... 542 Service Notice........................................................................................................ 542 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................... 542 PREPARATION............................................................................................................... 543 Special Service Tools................................................................................................. 543 Commercial Service Tool............................................................................................... 543 SQUEAK AND RATTLE TROUBLE DIAGNOSES....................................................................................... 544 Work Flow............................................................................................................. 544 CUSTOMER INTERVIEW................................................................................................ 544 DUPLICATE THE NOISE AND TEST DRIVE................................................................................ 545 CHECK RELATED SERVICE BULLETINS................................................................................... 545 LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE...................................................................... 545 REPAIR THE CAUSE.................................................................................................. 545 CONFIRM THE REPAIR................................................................................................ 546 Generic Squeak and Rattle Troubleshooting............................................................................. 546 INSTRUMENT PANEL.................................................................................................. 546 CENTER CONSOLE.................................................................................................... 546 DOORS............................................................................................................. 546 TRUNK............................................................................................................. 547 SUNROOF/HEADLINER................................................................................................. 547 SEATS............................................................................................................. 547 UNDERHOOD......................................................................................................... 547 Diagnostic Worksheet.................................................................................................. 548 CLIP AND FASTENER......................................................................................................... 550 Description........................................................................................................... 550 BODY FRONT END............................................................................................................ 552 Removal and Installation.............................................................................................. 552 FRONT BUMPER ASSEMBLY............................................................................................. 552 BODY REAR END AND OPENER.................................................................................................. 555 Removal and Installation.............................................................................................. 555 REAR BUMPER ASSEMBLY.............................................................................................. 555 FRONT DOOR................................................................................................................ 558 Overhaul.............................................................................................................. 558 Front Door Limit Switch Reset......................................................................................... 559 RESET CONDITIONS.................................................................................................. 559 RESET PROCEDURES.................................................................................................. 559 REAR DOOR................................................................................................................. 560 Overhaul.............................................................................................................. 560 INSTRUMENT PANEL ASSEMBLY................................................................................................. 561 Removal and Installation.............................................................................................. 561 SIDE AND FLOOR TRIM....................................................................................................... 568 Removal and Installation.............................................................................................. 568 DOOR TRIM................................................................................................................. 570 Removal and Installation.............................................................................................. 570 TYPE A............................................................................................................ 570 TYPE B............................................................................................................ 571 ROOF TRIM................................................................................................................. 573 Removal and Installation.............................................................................................. 573 BACK DOOR TRIM............................................................................................................ 574 Removal and Installation.............................................................................................. 574 EXTERIOR.................................................................................................................. 575 Removal and Installation.............................................................................................. 575 FRONT SEAT................................................................................................................ 582 Removal and Installation.............................................................................................. 582 POWER SEAT........................................................................................................ 583 MANUAL SEAT....................................................................................................... 584 HEATED SEAT....................................................................................................... 585 REAR SEAT................................................................................................................. 586 Removal and Installation.............................................................................................. 586 SUNROOF................................................................................................................... 587 Adjustment............................................................................................................ 587 Contents of Working................................................................................................... 588 Contents of Switch Working............................................................................................ 589 JAM PROTECTION.................................................................................................... 589 Removal and Installation.............................................................................................. 589 Trouble Diagnoses..................................................................................................... 593 DIAGNOSTIC TABLE.................................................................................................. 593 WIND DEFLECTOR.................................................................................................... 593 ADJUSTMENT........................................................................................................ 594 DRAIN HOSES....................................................................................................... 595 WEATHERSTRIP...................................................................................................... 596 LINK AND WIRE ASSEMBLY............................................................................................ 596 WINDSHIELD AND WINDOWS.................................................................................................... 597 Removal and Installation.............................................................................................. 597 REMOVAL........................................................................................................... 597 INSTALLATION...................................................................................................... 597 WINDSHIELD........................................................................................................ 598 REAR SIDE WINDOW.................................................................................................. 599 DOOR MIRROR............................................................................................................... 600 Removal and Installation.............................................................................................. 600 BODY (ALIGNMENT).......................................................................................................... 601 Alignment............................................................................................................. 601 ENGINE COMPARTMENT................................................................................................ 602 UNDERBODY......................................................................................................... 604 cl............................................................................................................................ 606 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents......................................................................................................... 606 PRECAUTIONS............................................................................................................... 607 Precautions........................................................................................................... 607 PREPARATION............................................................................................................... 608 Special Service Tools................................................................................................. 608 Commercial Service Tools.............................................................................................. 608 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................... 609 NVH Troubleshooting Chart............................................................................................. 609 CLUTCH............................................................................................................ 609 CLUTCH SYSTEM - HYDRAULIC TYPE............................................................................................ 610 Components............................................................................................................ 610 On-Vehicle Inspection and Adjustment.................................................................................. 611 ADJUSTING CLUTCH PEDAL............................................................................................ 611 Air Bleeding Procedure................................................................................................ 612 CLUTCH MASTER CYLINDER.................................................................................................... 613 Components............................................................................................................ 613 Disassembly and Assembly.............................................................................................. 613 Inspection............................................................................................................ 613 OPERATING CYLINDER........................................................................................................ 614 Components............................................................................................................ 614 Inspection............................................................................................................ 614 CLUTCH RELEASE MECHANISM.................................................................................................. 615 Components............................................................................................................ 615 Removal............................................................................................................... 615 Inspection............................................................................................................ 616 Installation.......................................................................................................... 616 Lubrication........................................................................................................... 616 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL.................................................................................... 617 Components............................................................................................................ 617 Removal............................................................................................................... 617 Inspection and Adjustment............................................................................................. 617 CLUTCH DISC....................................................................................................... 617 CLUTCH COVER...................................................................................................... 618 FLYWHEEL INSPECTION............................................................................................... 618 Installation.......................................................................................................... 618 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................... 620 Clutch Control System................................................................................................. 620 Clutch Master Cylinder (With damper).................................................................................. 620 Clutch Operating Cylinder............................................................................................. 620 Clutch Disc........................................................................................................... 620 Clutch Cover.......................................................................................................... 620 Clutch Pedal.......................................................................................................... 620 ec............................................................................................................................ 622 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents......................................................................................................... 622 MODIFICATION NOTICE....................................................................................................... 630 Modification Notice................................................................................................... 630 How to Check Vehicle Type............................................................................................. 630 TROUBLE DIAGNOSIS - INDEX................................................................................................. 631 Alphabetical Index.................................................................................................... 631 DTC No. Index......................................................................................................... 635 PRECAUTIONS............................................................................................................... 640 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................... 640 Precautions for On Board Diagnostic (OBD) System of Engine and A/T.................................................... 640 Engine Fuel & Emission Control System................................................................................. 641 Precautions........................................................................................................... 642 Wiring Diagrams and Trouble Diagnosis................................................................................. 643 PREPARATION............................................................................................................... 644 Special Service Tools................................................................................................. 644 Commercial Service Tools.............................................................................................. 645 ENGINE AND EMISSION CONTROL OVERALL SYSTEM................................................................................ 647 Engine Control Component Parts Location............................................................................... 647 Circuit Diagram....................................................................................................... 652 System Diagram........................................................................................................ 655 Vacuum Hose Drawing................................................................................................... 656 System Chart.......................................................................................................... 657 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION...................................................................... 658 Multiport Fuel Injection (MFI) System................................................................................. 658 Electronic Ignition (EI) System....................................................................................... 660 Air Conditioning Cut Control.......................................................................................... 661 Fuel Cut Control (at no load & high engine speed)..................................................................... 662 Evaporative Emission System........................................................................................... 662 On Board Refueling Vapor Recovery (ORVR).............................................................................. 668 Positive Crankcase Ventilation........................................................................................ 677 CAN Communication..................................................................................................... 678 Automatic Speed Control Device (ASCD) System.......................................................................... 683 BASIC SERVICE PROCEDURE................................................................................................... 685 Fuel Pressure Release................................................................................................. 685 Fuel Pressure Check................................................................................................... 685 Fuel Pressure Regulator Check......................................................................................... 686 Injector.............................................................................................................. 687 How to Check Idle Speed and Ignition Timing........................................................................... 688 Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment.............................................................. 690 Accelerator Pedal Released Position Learning.......................................................................... 702 Throttle Valve Closed Position Learning............................................................................... 702 Idle Air Volume Learning.............................................................................................. 702 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION.................................................................................... 706 Introduction.......................................................................................................... 706 Two Trip Detection Logic.............................................................................................. 706 Emission-related Diagnostic Information............................................................................... 707 Malfunction Indicator Lamp (MIL)...................................................................................... 723 OBD System Operation Chart............................................................................................ 726 CONSULT-II............................................................................................................ 732 Generic Scan Tool (GST)............................................................................................... 746 TROUBLE DIAGNOSIS - INTRODUCTION.......................................................................................... 748 Introduction.......................................................................................................... 748 Work Flow............................................................................................................. 750 TROUBLE DIAGNOSIS - BASIC INSPECTION...................................................................................... 752 Basic Inspection...................................................................................................... 752 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION................................................................................... 758 DTC Inspection Priority Chart......................................................................................... 758 Fail-safe Chart....................................................................................................... 759 Symptom Matrix Chart.................................................................................................. 760 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 764 Major Sensor Reference Graph in Data Monitor Mode..................................................................... 768 ECM Terminals and Reference Value..................................................................................... 770 TROUBLE DIAGNOSIS - SPECIFICATION VALUE................................................................................... 780 Description........................................................................................................... 780 Testing Condition..................................................................................................... 780 Inspection Procedure.................................................................................................. 780 Diagnostic Procedure.................................................................................................. 781 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT............................................................................... 784 Description........................................................................................................... 784 Diagnostic Procedure.................................................................................................. 784 TROUBLE DIAGNOSIS FOR POWER SUPPLY........................................................................................ 785 ECM Terminals and Reference Value..................................................................................... 785 Main Power Supply and Ground Circuit.................................................................................. 786 DTC U1000, U1001 CAN COMMUNICATION LINE................................................................................... 793 Description........................................................................................................... 793 On Board Diagnosis Logic.............................................................................................. 793 DTC Confirmation Procedure............................................................................................ 793 Wiring Diagram........................................................................................................ 794 Diagnostic Procedure.................................................................................................. 795 DTC P0011, P0021 IVT CONTROL.............................................................................................. 796 Description........................................................................................................... 796 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 797 On Board Diagnosis Logic.............................................................................................. 797 DTC Confirmation Procedure............................................................................................ 797 Diagnostic Procedure.................................................................................................. 798 Component Inspection.................................................................................................. 799 DTC P0031, P0032, P0051, P0052 HO2S1 HEATER............................................................................... 800 Description........................................................................................................... 800 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 800 ECM Terminals and Reference Value..................................................................................... 800 On Board Diagnosis Logic.............................................................................................. 801 DTC Confirmation Procedure............................................................................................ 801 Wiring Diagram........................................................................................................ 803 Diagnostic Procedure.................................................................................................. 805 DTC P0037, P0038, P0057, P0058 HO2S2 HEATER............................................................................... 808 Description........................................................................................................... 808 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 808 ECM Terminals and Reference Value..................................................................................... 808 On Board Diagnosis Logic.............................................................................................. 809 DTC Confirmation Procedure............................................................................................ 809 Wiring Diagram........................................................................................................ 811 Diagnostic Procedure.................................................................................................. 813 DTC P0101 MAF SENSOR (TYPE I)............................................................................................. 815 Application Notice.................................................................................................... 815 Component Description................................................................................................. 815 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 815 ECM Terminals and Reference Value..................................................................................... 815 On Board Diagnosis Logic.............................................................................................. 816 DTC Confirmation Procedure............................................................................................ 816 Overall Function Check................................................................................................ 817 Wiring Diagram........................................................................................................ 819 Diagnostic Procedure.................................................................................................. 820 DTC P0101 MAF SENSOR (TYPE II)............................................................................................ 824 Application Notice.................................................................................................... 824 Component Description................................................................................................. 824 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 824 ECM Terminals and Reference Value..................................................................................... 824 On Board Diagnosis Logic.............................................................................................. 825 DTC Confirmation Procedure............................................................................................ 825 Overall Function Check................................................................................................ 827 Wiring Diagram........................................................................................................ 828 Diagnostic Procedure.................................................................................................. 829 DTC P0102, P0103 MAF SENSOR (TYPE I)...................................................................................... 832 Application Notice.................................................................................................... 832 Component Description................................................................................................. 832 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 832 ECM Terminals and Reference Value..................................................................................... 832 On Board Diagnosis Logic.............................................................................................. 833 DTC Confirmation Procedure............................................................................................ 833 Wiring Diagram........................................................................................................ 835 Diagnostic Procedure.................................................................................................. 836 DTC P0102, P0103 MAF SENSOR (TYPE II)..................................................................................... 840 Application Notice.................................................................................................... 840 Component Description................................................................................................. 840 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 840 ECM Terminals and Reference Value..................................................................................... 840 On Board Diagnosis Logic.............................................................................................. 841 DTC Confirmation Procedure............................................................................................ 841 Wiring Diagram........................................................................................................ 843 Diagnostic Procedure.................................................................................................. 844 DTC P0112, P0113 IAT SENSOR (TYPE I)...................................................................................... 847 Application Notice.................................................................................................... 847 Component Description................................................................................................. 847 On Board Diagnosis Logic.............................................................................................. 847 DTC Confirmation Procedure............................................................................................ 847 Wiring Diagram........................................................................................................ 849 Diagnostic Procedure.................................................................................................. 850 Component Inspection.................................................................................................. 851 DTC P0112, P0113 IAT SENSOR (TYPE II)..................................................................................... 852 Application Notice.................................................................................................... 852 Component Description................................................................................................. 852 On Board Diagnosis Logic.............................................................................................. 852 DTC Confirmation Procedure............................................................................................ 852 Wiring Diagram........................................................................................................ 854 Diagnostic Procedure.................................................................................................. 855 Component Inspection.................................................................................................. 856 DTC P0117, P0118 ECT SENSOR............................................................................................... 857 Component Description................................................................................................. 857 On Board Diagnosis Logic.............................................................................................. 857 DTC Confirmation Procedure............................................................................................ 858 Wiring Diagram........................................................................................................ 859 Diagnostic Procedure.................................................................................................. 860 DTC P0122, P0123 TP SENSOR................................................................................................ 862 Component Description................................................................................................. 862 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 862 ECM Terminals and Reference Value..................................................................................... 862 On Board Diagnosis Logic.............................................................................................. 863 DTC Confirmation Procedure............................................................................................ 863 Wiring Diagram........................................................................................................ 865 Diagnostic Procedure.................................................................................................. 866 Component Inspection.................................................................................................. 868 DTC P0125 ECT SENSOR...................................................................................................... 870 Description........................................................................................................... 870 On Board Diagnosis Logic.............................................................................................. 870 DTC Confirmation Procedure............................................................................................ 871 Diagnostic Procedure.................................................................................................. 871 DTC P0127 IAT SENSOR...................................................................................................... 873 Component Description................................................................................................. 873 On Board Diagnosis Logic.............................................................................................. 873 DTC Confirmation Procedure............................................................................................ 873 Diagnostic Procedure.................................................................................................. 874 DTC P0128 THERMOSTAT FUNCTION............................................................................................. 875 On Board Diagnosis Logic.............................................................................................. 875 DTC Confirmation Procedure............................................................................................ 875 Diagnostic Procedure.................................................................................................. 876 DTC P0132, P0152 HO2S1.................................................................................................... 877 Component Description................................................................................................. 877 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 877 ECM Terminals and Reference Value..................................................................................... 877 On Board Diagnosis Logic.............................................................................................. 878 DTC Confirmation Procedure............................................................................................ 878 Wiring Diagram........................................................................................................ 879 Diagnostic Procedure.................................................................................................. 881 DTC P0133, P0153 HO2S1.................................................................................................... 885 Component Description................................................................................................. 885 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 885 ECM Terminals and Reference Value..................................................................................... 885 On Board Diagnosis Logic.............................................................................................. 886 DTC Confirmation Procedure............................................................................................ 886 Overall Function Check................................................................................................ 887 Wiring Diagram........................................................................................................ 888 Diagnostic Procedure.................................................................................................. 890 DTC P0134, P0154 HO2S1.................................................................................................... 899 Component Description................................................................................................. 899 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 899 ECM Terminals and Reference Value..................................................................................... 899 On Board Diagnosis Logic.............................................................................................. 900 DTC Confirmation Procedure............................................................................................ 900 Overall Function Check................................................................................................ 901 Wiring Diagram........................................................................................................ 902 Diagnostic Procedure.................................................................................................. 904 DTC P0138, P0158 HO2S2.................................................................................................... 908 Component Description................................................................................................. 908 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 908 ECM Terminals and Reference Value..................................................................................... 908 On Board Diagnosis Logic.............................................................................................. 908 DTC Confirmation Procedure............................................................................................ 909 Wiring Diagram........................................................................................................ 910 Diagnostic Procedure.................................................................................................. 912 DTC P0139, P0159 HO2S2.................................................................................................... 916 Component Description................................................................................................. 916 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 916 ECM Terminals and Reference Value..................................................................................... 916 On Board Diagnosis Logic.............................................................................................. 916 DTC Confirmation Procedure............................................................................................ 917 Overall Function Check................................................................................................ 917 Wiring Diagram........................................................................................................ 919 Diagnostic Procedure.................................................................................................. 921 DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION........................................................................... 925 On Board Diagnosis Logic.............................................................................................. 925 DTC Confirmation Procedure............................................................................................ 925 Wiring Diagram........................................................................................................ 927 Diagnostic Procedure.................................................................................................. 929 DTC P0172, P0175 FUEL INJECTION SYSTEM FUNCTION........................................................................... 933 On Board Diagnosis Logic.............................................................................................. 933 DTC Confirmation Procedure............................................................................................ 933 Wiring Diagram........................................................................................................ 935 Diagnostic Procedure.................................................................................................. 937 DTC P0181 FTT SENSOR...................................................................................................... 940 Component Description................................................................................................. 940 On Board Diagnosis Logic.............................................................................................. 940 DTC Confirmation Procedure............................................................................................ 940 Diagnostic Procedure.................................................................................................. 941 DTC P0182, P0183 FTT SENSOR............................................................................................... 943 Component Description................................................................................................. 943 On Board Diagnosis Logic.............................................................................................. 943 DTC Confirmation Procedure............................................................................................ 943 Wiring Diagram........................................................................................................ 945 Diagnostic Procedure.................................................................................................. 946 DTC P0222, P0223 TP SENSOR................................................................................................ 948 Component Description................................................................................................. 948 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 948 ECM Terminals and Reference Value..................................................................................... 948 On Board Diagnosis Logic.............................................................................................. 949 DTC Confirmation Procedure............................................................................................ 949 Wiring Diagram........................................................................................................ 951 Diagnostic Procedure.................................................................................................. 952 Component Inspection.................................................................................................. 954 DTC P0300 - P0306 MULTIPLE CYLINDER MISFIRE, NO. 1 - 6 CYLINDER MISFIRE................................................... 956 On Board Diagnosis Logic.............................................................................................. 956 DTC Confirmation Procedure............................................................................................ 957 Diagnostic Procedure.................................................................................................. 958 DTC P0327, P0328 KS....................................................................................................... 966 Component Description................................................................................................. 966 ECM Terminals and Reference Value..................................................................................... 966 On Board Diagnosis Logic.............................................................................................. 966 DTC Confirmation Procedure............................................................................................ 966 Wiring Diagram........................................................................................................ 967 Diagnostic Procedure.................................................................................................. 968 DTC P0335 CKP SENSOR (POS)................................................................................................ 971 Component Description................................................................................................. 971 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 971 On Board Diagnosis Logic.............................................................................................. 971 DTC Confirmation Procedure............................................................................................ 972 Wiring Diagram........................................................................................................ 973 Diagnostic Procedure.................................................................................................. 974 Component Inspection.................................................................................................. 977 DTC P0340, P0345 CMP SENSOR (PHASE)....................................................................................... 978 Component Description................................................................................................. 978 On Board Diagnosis Logic.............................................................................................. 978 DTC Confirmation Procedure............................................................................................ 978 Wiring Diagram........................................................................................................ 980 Diagnostic Procedure.................................................................................................. 982 Component Inspection.................................................................................................. 986 DTC P0420, P0430 THREE WAY CATALYST FUNCTION.............................................................................. 987 On Board Diagnosis Logic.............................................................................................. 987 DTC Confirmation Procedure............................................................................................ 987 Overall Function Check................................................................................................ 988 Diagnostic Procedure.................................................................................................. 988 DTC P0441 EVAP CONTROL SYSTEM............................................................................................. 992 System Description.................................................................................................... 992 On Board Diagnosis Logic.............................................................................................. 992 DTC Confirmation Procedure............................................................................................ 993 Overall Function Check................................................................................................ 993 Diagnostic Procedure.................................................................................................. 995 DTC P0442 EVAP CONTROL SYSTEM.............................................................................................1002 On Board Diagnosis Logic..............................................................................................1002 DTC Confirmation Procedure............................................................................................1003 Diagnostic Procedure..................................................................................................1004 DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE........................................................1017 Description...........................................................................................................1017 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1017 ECM Terminals and Reference Value.....................................................................................1018 On Board Diagnosis Logic..............................................................................................1018 DTC Confirmation Procedure............................................................................................1019 Wiring Diagram........................................................................................................1020 Diagnostic Procedure..................................................................................................1021 DTC P0447 EVAP CANISTER VENT CONTROL VALVE................................................................................1024 Component Description.................................................................................................1024 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1024 ECM Terminals and Reference Value.....................................................................................1024 On Board Diagnosis Logic..............................................................................................1024 DTC Confirmation Procedure............................................................................................1025 Wiring Diagram........................................................................................................1026 Diagnostic Procedure..................................................................................................1027 DTC P0452 EVAP SYSTEM PRESSURE SENSOR.....................................................................................1031 Component Description.................................................................................................1031 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1031 ECM Terminals and Reference Value.....................................................................................1031 On Board Diagnosis Logic..............................................................................................1032 DTC Confirmation Procedure............................................................................................1032 Wiring Diagram........................................................................................................1033 Diagnostic Procedure..................................................................................................1034 DTC P0453 EVAP SYSTEM PRESSURE SENSOR.....................................................................................1037 Component Description.................................................................................................1037 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1037 ECM Terminals and Reference Value.....................................................................................1037 On Board Diagnosis Logic..............................................................................................1038 DTC Confirmation Procedure............................................................................................1038 Wiring Diagram........................................................................................................1039 Diagnostic Procedure..................................................................................................1040 DTC P0455 EVAP CONTROL SYSTEM.............................................................................................1046 On Board Diagnosis Logic..............................................................................................1046 DTC Confirmation Procedure............................................................................................1047 Diagnostic Procedure..................................................................................................1048 DTC P0456 EVAP CONTROL SYSTEM.............................................................................................1059 On Board Diagnosis Logic..............................................................................................1059 DTC Confirmation Procedure............................................................................................1060 Overall Function Check................................................................................................1061 Diagnostic Procedure..................................................................................................1062 DTC P0460 FUEL LEVEL SENSOR...............................................................................................1075 Component Description.................................................................................................1075 On Board Diagnostic Logic.............................................................................................1075 DTC Confirmation Procedure............................................................................................1075 Diagnostic Procedure..................................................................................................1076 DTC P0461 FUEL LEVEL SENSOR...............................................................................................1077 Component Description.................................................................................................1077 On Board Diagnostic Logic.............................................................................................1077 Overall Function Check................................................................................................1077 Diagnostic Procedure..................................................................................................1078 DTC P0462, P0463 FUEL LEVEL SENSOR........................................................................................1079 Component Description.................................................................................................1079 On Board Diagnostic Logic.............................................................................................1079 DTC Confirmation Procedure............................................................................................1079 Diagnostic Procedure..................................................................................................1080 DTC P0500 VSS.............................................................................................................1081 Description...........................................................................................................1081 On Board Diagnosis Logic..............................................................................................1081 DTC Confirmation Procedure............................................................................................1081 Overall Function Check................................................................................................1082 Diagnostic Procedure..................................................................................................1082 DTC P0506 ISC SYSTEM......................................................................................................1083 Description...........................................................................................................1083 On Board Diagnosis Logic..............................................................................................1083 DTC Confirmation Procedure............................................................................................1083 Diagnostic Procedure..................................................................................................1084 DTC P0507 ISC SYSTEM......................................................................................................1085 Description...........................................................................................................1085 On Board Diagnosis Logic..............................................................................................1085 DTC Confirmation Procedure............................................................................................1085 Diagnostic Procedure..................................................................................................1086 DTC P0550 PSP SENSOR......................................................................................................1087 Component Description.................................................................................................1087 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1087 On Board Diagnosis Logic..............................................................................................1087 DTC Confirmation Procedure............................................................................................1087 Wiring Diagram........................................................................................................1088 Diagnostic Procedure..................................................................................................1089 Component Inspection..................................................................................................1091 DTC P0605 ECM.............................................................................................................1092 Component Description.................................................................................................1092 On Board Diagnosis Logic..............................................................................................1092 DTC Confirmation Procedure............................................................................................1092 Diagnostic Procedure..................................................................................................1093 DTC P1065 ECM POWER SUPPLY (BACK UP)......................................................................................1094 Component Description.................................................................................................1094 ECM Terminals and Reference Value.....................................................................................1094 On Board Diagnosis Logic..............................................................................................1094 DTC Confirmation Procedure............................................................................................1094 Wiring Diagram........................................................................................................1096 Diagnostic Procedure..................................................................................................1097 DTC P1102 MAF SENSOR (TYPE I).............................................................................................1099 Application Notice....................................................................................................1099 Component Description.................................................................................................1099 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1099 ECM Terminals and Reference Value.....................................................................................1099 On Board Diagnosis Logic..............................................................................................1100 DTC Confirmation Procedure............................................................................................1100 Wiring Diagram........................................................................................................1101 Diagnostic Procedure..................................................................................................1102 DTC P1110, P1135 IVT CONTROL..............................................................................................1106 Description...........................................................................................................1106 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1106 On Board Diagnosis Logic..............................................................................................1107 DTC Confirmation Procedure............................................................................................1107 Diagnostic Procedure..................................................................................................1108 DTC P1111, P1136 IVT CONTROL SOLENOID VALVE...............................................................................1109 Component Description.................................................................................................1109 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1109 ECM Terminals and Reference Value.....................................................................................1109 On Board Diagnosis Logic..............................................................................................1110 DTC Confirmation Procedure............................................................................................1110 Wiring Diagram........................................................................................................1111 Diagnostic Procedure..................................................................................................1113 DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR..............................................................................1115 Component Description.................................................................................................1115 On Board Diagnosis Logic..............................................................................................1115 DTC Confirmation Procedure............................................................................................1115 Diagnostic Procedure..................................................................................................1116 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION..............................................................................1117 Description...........................................................................................................1117 ECM Terminals and Reference Value.....................................................................................1117 On Board Diagnosis Logic..............................................................................................1118 DTC Confirmation Procedure............................................................................................1118 Wiring Diagram........................................................................................................1119 Diagnostic Procedure..................................................................................................1120 Component Inspection..................................................................................................1124 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY.............................................................................1125 Component Description.................................................................................................1125 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1125 ECM Terminals and Reference Value.....................................................................................1125 On Board Diagnosis Logic..............................................................................................1125 DTC Confirmation Procedure............................................................................................1126 Wiring Diagram........................................................................................................1127 Diagnostic Procedure..................................................................................................1128 Component Inspection..................................................................................................1129 DTC P1128 THROTTLE CONTROL MOTOR..........................................................................................1130 Component Description.................................................................................................1130 ECM Terminals and Reference Value.....................................................................................1130 On Board Diagnosis Logic..............................................................................................1130 DTC Confirmation Procedure............................................................................................1130 Wiring Diagram........................................................................................................1132 Diagnostic Procedure..................................................................................................1133 Component Inspection..................................................................................................1134 DTC P1130 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE......................................................................1135 Description...........................................................................................................1135 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1136 ECM Terminals and Reference Value.....................................................................................1136 On Board Diagnosis Logic..............................................................................................1137 DTC Confirmation Procedure............................................................................................1137 Wiring Diagram........................................................................................................1139 Diagnostic Procedure..................................................................................................1140 DTC P1131 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE......................................................................1156 Component Description.................................................................................................1156 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1156 ECM Terminals and Reference Value.....................................................................................1156 On Board Diagnosis Logic..............................................................................................1156 DTC Confirmation Procedure............................................................................................1157 Wiring Diagram........................................................................................................1158 Diagnostic Procedure..................................................................................................1159 DTC P1143, P1163 HO2S1....................................................................................................1162 Component Description.................................................................................................1162 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1162 ECM Terminals and Reference Value.....................................................................................1162 On Board Diagnosis Logic..............................................................................................1163 DTC Confirmation Procedure............................................................................................1163 Overall Function Check................................................................................................1164 Diagnostic Procedure..................................................................................................1165 DTC P1144, P1164 HO2S1....................................................................................................1170 Component Description.................................................................................................1170 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1170 ECM Terminals and Reference Value.....................................................................................1170 On Board Diagnosis Logic..............................................................................................1171 DTC Confirmation Procedure............................................................................................1171 Overall Function Check................................................................................................1172 Diagnostic Procedure..................................................................................................1173 DTC P1146, P1166 HO2S2....................................................................................................1178 Component Description.................................................................................................1178 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1178 ECM Terminals and Reference Value.....................................................................................1178 On Board Diagnosis Logic..............................................................................................1178 DTC Confirmation Procedure............................................................................................1179 Overall Function Check................................................................................................1179 Wiring Diagram........................................................................................................1181 Diagnostic Procedure..................................................................................................1183 DTC P1147, P1167 HO2S2....................................................................................................1187 Component Description.................................................................................................1187 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1187 ECM Terminals and Reference Value.....................................................................................1187 On Board Diagnosis Logic..............................................................................................1187 DTC Confirmation Procedure............................................................................................1188 Overall Function Check................................................................................................1188 Wiring Diagram........................................................................................................1190 Diagnostic Procedure..................................................................................................1192 DTC P1148, P1168 CLOSED LOOP CONTROL......................................................................................1196 On Board Diagnosis Logic..............................................................................................1196 DTC Confirmation Procedure............................................................................................1196 Overall Function Check................................................................................................1197 Diagnostic Procedure..................................................................................................1197 DTC P1165 SWIRL CONTROL VALVE CONTROL VACUUM CHECK SWITCH.................................................................1198 Component Description.................................................................................................1198 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1198 ECM Terminals and Reference Value.....................................................................................1198 On Board Diagnosis Logic..............................................................................................1199 DTC Confirmation Procedure............................................................................................1199 Wiring Diagram........................................................................................................1200 Diagnostic Procedure..................................................................................................1201 DTC P1211 ABS/TCS CONTROL UNIT............................................................................................1204 Description...........................................................................................................1204 On Board Diagnosis Logic..............................................................................................1204 DTC Confirmation Procedure............................................................................................1204 Diagnostic Procedure..................................................................................................1205 DTC P1212 ABS/TCS COMMUNICATION LINE......................................................................................1206 Description...........................................................................................................1206 On Board Diagnosis Logic..............................................................................................1206 DTC Confirmation Procedure............................................................................................1206 Diagnostic Procedure..................................................................................................1207 DTC P1217 ENGINE OVER TEMPERATURE.........................................................................................1208 On Board Diagnosis Logic..............................................................................................1208 Overall Function Check................................................................................................1208 Diagnostic Procedure..................................................................................................1209 Main 12 Causes of Overheating.........................................................................................1212 DTC P1225 TP SENSOR.......................................................................................................1213 Component Description.................................................................................................1213 On Board Diagnosis Logic..............................................................................................1213 DTC Confirmation Procedure............................................................................................1213 Diagnostic Procedure..................................................................................................1214 DTC P1226 TP SENSOR.......................................................................................................1215 Component Description.................................................................................................1215 On Board Diagnosis Logic..............................................................................................1215 DTC Confirmation Procedure............................................................................................1215 Diagnostic Procedure..................................................................................................1216 DTC P1229 SENSOR POWER SUPPLY.............................................................................................1217 ECM Terminals and Reference Value.....................................................................................1217 On Board Diagnosis Logic..............................................................................................1217 DTC Confirmation Procedure............................................................................................1217 Wiring Diagram........................................................................................................1219 Diagnostic Procedure..................................................................................................1220 DTC P1442 EVAP CONTROL SYSTEM.............................................................................................1222 On Board Diagnosis Logic..............................................................................................1222 DTC Confirmation Procedure............................................................................................1223 Diagnostic Procedure..................................................................................................1224 DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE...............................................................1237 Description...........................................................................................................1237 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1237 ECM Terminals and Reference Value.....................................................................................1238 On Board Diagnosis Logic..............................................................................................1238 DTC Confirmation Procedure............................................................................................1238 Wiring Diagram........................................................................................................1240 Diagnostic Procedure..................................................................................................1241 DTC P1446 EVAP CANISTER VENT CONTROL VALVE................................................................................1249 Component Description.................................................................................................1249 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1249 ECM Terminals and Reference Value.....................................................................................1249 On Board Diagnosis Logic..............................................................................................1249 DTC Confirmation Procedure............................................................................................1250 Wiring Diagram........................................................................................................1251 Diagnostic Procedure..................................................................................................1252 DTC P1448 EVAP CANISTER VENT CONTROL VALVE................................................................................1257 Component Description.................................................................................................1257 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1257 ECM Terminals and Reference Value.....................................................................................1257 On Board Diagnosis Logic..............................................................................................1257 DTC Confirmation Procedure............................................................................................1258 Overall Function Check................................................................................................1259 Wiring Diagram........................................................................................................1260 Diagnostic Procedure..................................................................................................1261 DTC P1456 EVAP CONTROL SYSTEM.............................................................................................1266 On Board Diagnosis Logic..............................................................................................1266 DTC Confirmation Procedure............................................................................................1267 Overall Function Check................................................................................................1268 Diagnostic Procedure..................................................................................................1269 DTC P1490 VACUUM CUT VALVE BYPASS VALVE...................................................................................1282 Description...........................................................................................................1282 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1282 ECM Terminals and Reference Value.....................................................................................1282 On Board Diagnosis Logic..............................................................................................1283 DTC Confirmation Procedure............................................................................................1283 Wiring Diagram........................................................................................................1284 Diagnostic Procedure..................................................................................................1285 DTC P1491 VACUUM CUT VALVE BYPASS VALVE...................................................................................1288 Description...........................................................................................................1288 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1288 ECM Terminals and Reference Value.....................................................................................1288 On Board Diagnosis Logic..............................................................................................1289 DTC Confirmation Procedure............................................................................................1289 Overall Function Check................................................................................................1290 Wiring Diagram........................................................................................................1291 Diagnostic Procedure..................................................................................................1292 DTC P1564 ASCD STEERING SWITCH............................................................................................1300 Component Description.................................................................................................1300 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1300 ECM Terminals and Reference Value.....................................................................................1300 On Board Diagnosis Procedure..........................................................................................1301 DTC Confirmation Procedure............................................................................................1301 Wiring Diagram........................................................................................................1302 Diagnostic Procedure..................................................................................................1303 Component Inspection..................................................................................................1305 DTC P1572 ASCD BRAKE SWITCH...............................................................................................1306 Component Description.................................................................................................1306 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1306 ECM Terminals and Reference Value.....................................................................................1306 On Board Diagnosis Procedure..........................................................................................1307 DTC Confirmation Procedure............................................................................................1307 Wiring Diagram........................................................................................................1309 Diagnostic Procedure..................................................................................................1310 Component Inspection..................................................................................................1315 DTC P1706 PNP SWITCH......................................................................................................1317 Component Description.................................................................................................1317 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1317 ECM Terminals and Reference Value.....................................................................................1317 On Board Diagnosis Logic..............................................................................................1317 DTC Confirmation Procedure............................................................................................1317 Overall Function Check................................................................................................1318 Wiring Diagram........................................................................................................1319 Diagnostic Procedure..................................................................................................1320 DTC P1805 BRAKE SWITCH....................................................................................................1323 Description...........................................................................................................1323 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1323 ECM Terminals and Reference Value.....................................................................................1323 On Board Diagnosis Logic..............................................................................................1323 DTC Confirmation Procedure............................................................................................1324 Wiring Diagram........................................................................................................1325 Diagnostic Procedure..................................................................................................1326 Component Inspection..................................................................................................1328 DTC P2122, P2123 APP SENSOR...............................................................................................1329 Component Description.................................................................................................1329 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1329 ECM Terminals and Reference Value.....................................................................................1329 On Board Diagnosis Logic..............................................................................................1330 DTC Confirmation Procedure............................................................................................1331 Wiring Diagram........................................................................................................1332 Diagnostic Procedure..................................................................................................1333 Component Inspection..................................................................................................1335 DTC P2127, P2128 APP SENSOR...............................................................................................1336 Component Description.................................................................................................1336 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1336 ECM Terminals and Reference Value.....................................................................................1336 On Board Diagnosis Logic..............................................................................................1337 DTC Confirmation Procedure............................................................................................1338 Wiring Diagram........................................................................................................1339 Diagnostic Procedure..................................................................................................1340 Component Inspection..................................................................................................1343 DTC P2135 TP SENSOR.......................................................................................................1344 Component Description.................................................................................................1344 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1344 ECM Terminals and Reference Value.....................................................................................1344 On Board Diagnosis Logic..............................................................................................1345 DTC Confirmation Procedure............................................................................................1345 Wiring Diagram........................................................................................................1347 Diagnostic Procedure..................................................................................................1348 Component Inspection..................................................................................................1350 DTC P2138 APP SENSOR......................................................................................................1352 Component Description.................................................................................................1352 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1352 ECM Terminals and Reference Value.....................................................................................1352 On Board Diagnosis Logic..............................................................................................1353 DTC Confirmation Procedure............................................................................................1354 Wiring Diagram........................................................................................................1355 Diagnostic Procedure..................................................................................................1356 Component Inspection..................................................................................................1358 VARIABLE INDUCTION AIR CONTROL SYSTEM (VIAS)..............................................................................1360 Description...........................................................................................................1360 ECM Terminals and Reference Value.....................................................................................1361 Wiring Diagram........................................................................................................1362 Diagnostic Procedure..................................................................................................1363 IGNITION SIGNAL...........................................................................................................1369 Component Description.................................................................................................1369 ECM Terminals and Reference Value.....................................................................................1369 Wiring Diagram........................................................................................................1370 Diagnostic Procedure..................................................................................................1373 INJECTOR..................................................................................................................1379 Component Description.................................................................................................1379 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1379 ECM Terminals and Reference Value.....................................................................................1379 Wiring Diagram........................................................................................................1380 Diagnostic Procedure..................................................................................................1381 FUEL PUMP.................................................................................................................1384 System Description....................................................................................................1384 Component Description.................................................................................................1384 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1384 ECM Terminals and Reference Value.....................................................................................1385 Wiring Diagram........................................................................................................1386 Diagnostic Procedure..................................................................................................1387 REFRIGERANT PRESSURE SENSOR...............................................................................................1391 Description...........................................................................................................1391 ECM Terminals and Reference Value.....................................................................................1391 Wiring Diagram........................................................................................................1392 Diagnostic Procedure..................................................................................................1393 ASCD BRAKE SWITCH.........................................................................................................1396 Component Description.................................................................................................1396 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1396 ECM Terminals and Reference Value.....................................................................................1396 Wiring Diagram........................................................................................................1397 Diagnostic Procedure..................................................................................................1398 ASCD INDICATOR LAMP.......................................................................................................1404 Component Description.................................................................................................1404 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1404 Wiring Diagram........................................................................................................1405 Diagnostic Procedure..................................................................................................1406 ELECTRICAL LOAD SIGNAL....................................................................................................1407 ECM Terminals and Reference Value.....................................................................................1407 Wiring Diagram........................................................................................................1408 Diagnostic Procedure..................................................................................................1409 MIL & DATA LINK CONNECTORS................................................................................................1412 Wiring Diagram........................................................................................................1412 SERVICE DATA AND SPECIFICATIONS (SDS).....................................................................................1413 Fuel Pressure Regulator...............................................................................................1413 Idle Speed and Ignition Timing........................................................................................1413 Mass Air Flow Sensor (Type I).........................................................................................1413 Mass Air Flow Sensor (Type II)........................................................................................1413 Engine Coolant Temperature Sensor.....................................................................................1413 Heated Oxygen Sensor 1 Heater.........................................................................................1413 Heated Oxygen Sensor 2 Heater.........................................................................................1413 Fuel Pump.............................................................................................................1413 Injector..............................................................................................................1413 Calculated Load Value.................................................................................................1414 Intake Air Temperature Sensor.........................................................................................1414 Fuel Tank Temperature Sensor..........................................................................................1414 Crankshaft Position Sensor (POS)......................................................................................1414 Camshaft Position Sensor (PHASE)......................................................................................1414 SUPER MULTIPLE JUNCTION (SMJ)............................................................................................. 0 FUSE BLOCK - JUNCTION BOX (J/B)........................................................................................... 2 FUSE AND FUSIBLE LINK BOX................................................................................................. 3 ELECTRICAL UNITS.......................................................................................................... 4 JOINT CONNECTOR (J/C)..................................................................................................... 5 el............................................................................................................................1416 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents.........................................................................................................1416 PRECAUTIONS...............................................................................................................1420 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"...........................................1420 Precautions for SRS "AIR BAG" and "SEAT BELT PRE-TENSIONER" Service...................................................1420 Precautions for Trouble Diagnosis.....................................................................................1420 Precautions for Harness Repair........................................................................................1421 Wiring Diagrams and Trouble Diagnosis.................................................................................1421 HARNESS CONNECTOR.........................................................................................................1422 Description...........................................................................................................1422 STANDARDIZED RELAY........................................................................................................1424 Description...........................................................................................................1424 POWER SUPPLY ROUTING......................................................................................................1426 Schematic.............................................................................................................1426 Wiring Diagram - POWER -..............................................................................................1427 Inspection............................................................................................................1433 GROUND....................................................................................................................1434 Ground Distribution...................................................................................................1434 COMBINATION SWITCH........................................................................................................1447 Check.................................................................................................................1447 Replacement...........................................................................................................1448 STEERING SWITCH...........................................................................................................1449 Check.................................................................................................................1449 HEADLAMP (FOR USA)........................................................................................................1450 Component Parts and Harness Connector Location........................................................................1450 System Description....................................................................................................1450 Schematic.............................................................................................................1453 Wiring Diagram - H/LAMP -.............................................................................................1454 CONSULT-II Inspection Procedure.......................................................................................1458 CONSULT-II Application Items..........................................................................................1459 Trouble Diagnoses.....................................................................................................1459 Bulb Replacement......................................................................................................1462 Aiming Adjustment.....................................................................................................1462 HEADLAMP (FOR CANADA) - DAYTIME LIGHT SYSTEM -............................................................................1465 Component Parts and Harness Connector Location........................................................................1465 System Description....................................................................................................1465 Schematic.............................................................................................................1469 Wiring Diagram - DTRL -...............................................................................................1470 CONSULT-II Inspection Procedure.......................................................................................1475 CONSULT-II Application Items..........................................................................................1475 Trouble Diagnoses.....................................................................................................1475 Bulb Replacement......................................................................................................1480 Aiming Adjustment.....................................................................................................1480 PARKING, LICENSE AND TAIL LAMPS...........................................................................................1481 System Description....................................................................................................1481 Schematic.............................................................................................................1483 Wiring Diagram - TAIL/L -.............................................................................................1484 CONSULT-II Inspection Procedure.......................................................................................1488 CONSULT-II Application Items..........................................................................................1489 Trouble Diagnoses.....................................................................................................1489 STOP LAMP.................................................................................................................1491 Wiring Diagram - STOP/L -.............................................................................................1491 BACK-UP LAMP..............................................................................................................1493 Wiring Diagram - BACK/L -.............................................................................................1493 FRONT FOG LAMP............................................................................................................1494 System Description....................................................................................................1494 Wiring Diagram - F/FOG -..............................................................................................1495 Aiming Adjustment.....................................................................................................1497 TURN SIGNAL AND HAZARD WARNING LAMPS......................................................................................1498 System Description....................................................................................................1498 Wiring Diagram - TURN -...............................................................................................1500 Trouble Diagnoses.....................................................................................................1502 Electrical Components Inspection......................................................................................1502 ILLUMINATION..............................................................................................................1503 System Description....................................................................................................1503 Schematic.............................................................................................................1505 Wiring Diagram - ILL -................................................................................................1506 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS......................................................................1512 System Description....................................................................................................1512 Schematic.............................................................................................................1514 Wiring Diagram - INT/L -..............................................................................................1515 CONSULT-II Inspection Procedure.......................................................................................1520 CONSULT-II Application Items..........................................................................................1521 Trouble Diagnoses for Interior Lamp Timer.............................................................................1523 METERS AND GAUGES.........................................................................................................1538 Component Parts and Harness Connector Location........................................................................1538 System Description....................................................................................................1538 Combination Meter.....................................................................................................1540 Schematic.............................................................................................................1542 Wiring Diagram - METER -..............................................................................................1543 Meter/Gauge Operation and Odo/Trip Meter Segment Check in Diagnosis Mode..............................................1544 Trouble Diagnoses.....................................................................................................1545 Electrical Components Inspection......................................................................................1549 COMPASS AND THERMOMETER...................................................................................................1550 System Description....................................................................................................1550 Wiring Diagram - COMPAS -.............................................................................................1551 Trouble Diagnoses.....................................................................................................1552 Calibration Procedure for Compass.....................................................................................1553 WARNING LAMPS.............................................................................................................1554 Schematic.............................................................................................................1554 Wiring Diagram - WARN -...............................................................................................1555 Fuel Warning Lamp Sensor Check........................................................................................1563 Electrical Components Inspection......................................................................................1563 WARNING CHIME.............................................................................................................1564 Component Parts and Harness Connector Location........................................................................1564 System Description....................................................................................................1564 Wiring Diagram - CHIME -..............................................................................................1566 CONSULT-II Inspection Procedure.......................................................................................1568 CONSULT-II Application Items..........................................................................................1569 Trouble Diagnoses.....................................................................................................1570 FRONT WIPER AND WASHER....................................................................................................1578 System Description....................................................................................................1578 Wiring Diagram - WIPER -..............................................................................................1580 Removal and Installation..............................................................................................1581 Washer Nozzle Adjustment..............................................................................................1582 Washer Tube Layout....................................................................................................1582 REAR WIPER AND WASHER.....................................................................................................1583 System Description....................................................................................................1583 Wiring Diagram - WIP/R -..............................................................................................1585 Trouble Diagnoses.....................................................................................................1587 Removal and Installation..............................................................................................1587 Washer Nozzle Adjustment..............................................................................................1588 Washer Tube Layout....................................................................................................1588 Check Valve...........................................................................................................1588 HORN......................................................................................................................1589 Wiring Diagram - HORN -...............................................................................................1589 CIGARETTE LIGHTER.........................................................................................................1590 Wiring Diagram - CIGAR -..............................................................................................1590 CLOCK.....................................................................................................................1591 Wiring Diagram - CLOCK -..............................................................................................1591 REAR WINDOW DEFOGGER......................................................................................................1592 Component Parts and Harness Connector Location........................................................................1592 System Description....................................................................................................1592 Wiring Diagram - DEF -................................................................................................1594 CONSULT-II Inspection Procedure.......................................................................................1598 CONSULT-II Application Items..........................................................................................1599 Trouble Diagnoses.....................................................................................................1600 Electrical Components Inspection......................................................................................1603 Filament Check........................................................................................................1604 Filament Repair.......................................................................................................1605 AUDIO.....................................................................................................................1606 System Description....................................................................................................1606 Wiring Diagram - AUDIO -/Base System..................................................................................1607 Schematic/BOSE System.................................................................................................1609 Wiring Diagram - AUDIO -/BOSE System..................................................................................1610 Trouble Diagnoses.....................................................................................................1615 Inspection............................................................................................................1616 Audio Unit Removal and Installation...................................................................................1616 Wiring Diagram - REMOTE -.............................................................................................1617 AUDIO ANTENNA.............................................................................................................1618 System Description....................................................................................................1618 Wiring Diagram - P/ANT -..............................................................................................1619 Trouble Diagnoses.....................................................................................................1620 Location of Antenna...................................................................................................1620 Antenna Rod Replacement...............................................................................................1620 POWER SUNROOF.............................................................................................................1622 System Description....................................................................................................1622 Wiring Diagram - SROOF -..............................................................................................1623 CONSULT-II Inspection Procedure.......................................................................................1625 CONSULT-II Application Items..........................................................................................1626 Trouble Diagnoses.....................................................................................................1626 DOOR MIRROR...............................................................................................................1628 Wiring Diagram - MIRROR -.............................................................................................1628 GLASS HATCH OPENER........................................................................................................1629 Wiring Diagram - T&FLID -.............................................................................................1629 POWER SEAT................................................................................................................1630 Wiring Diagram - SEAT -...............................................................................................1630 HEATED SEAT...............................................................................................................1632 Wiring Diagram - HSEAT -..............................................................................................1632 Seatback Heating Unit.................................................................................................1635 AUTOMATIC DRIVE POSITIONER................................................................................................1636 Component Parts and Harness Connector Location........................................................................1636 System Description....................................................................................................1637 Schematic.............................................................................................................1640 Wiring Diagram - AUT/DP -.............................................................................................1641 On Board Diagnosis....................................................................................................1646 Trouble Diagnoses.....................................................................................................1648 AUTOMATIC SPEED CONTROL DEVICE (ASCD).....................................................................................1671 System Description....................................................................................................1671 POWER WINDOW..............................................................................................................1672 System Description....................................................................................................1672 Schematic.............................................................................................................1675 Wiring Diagram - WINDOW -.............................................................................................1676 CONSULT-II Inspection Procedure.......................................................................................1681 CONSULT-II Application Items..........................................................................................1682 Trouble Diagnoses.....................................................................................................1682 POWER DOOR LOCK...........................................................................................................1691 Component Parts and Harness Connector Location........................................................................1691 System Description....................................................................................................1691 Schematic.............................................................................................................1692 Wiring Diagram - D/LOCK -.............................................................................................1693 CONSULT-II Inspection Procedure.......................................................................................1699 CONSULT-II Application Items..........................................................................................1700 Trouble Diagnoses.....................................................................................................1701 REMOTE KEYLESS ENTRY SYSTEM...............................................................................................1714 Component Parts and Harness Connector Location........................................................................1714 System Description....................................................................................................1714 Schematic.............................................................................................................1718 Wiring Diagram - KEYLESS -............................................................................................1719 CONSULT-II Inspection Procedure.......................................................................................1723 CONSULT-II Application Items..........................................................................................1724 Trouble Diagnoses.....................................................................................................1725 ID Code Entry Procedure...............................................................................................1738 Keyfob Battery Replacement............................................................................................1742 VEHICLE SECURITY (THEFT WARNING) SYSTEM...................................................................................1743 Component Parts and Harness Connector Location........................................................................1743 System Description....................................................................................................1744 Schematic.............................................................................................................1749 Wiring Diagram - VEHSEC -.............................................................................................1751 CONSULT-II Inspection Procedure.......................................................................................1757 CONSULT-II Application Item...........................................................................................1758 Trouble Diagnoses.....................................................................................................1759 SMART ENTRANCE CONTROL UNIT...............................................................................................1777 Description...........................................................................................................1777 CONSULT-II............................................................................................................1779 Schematic.............................................................................................................1781 Smart Entrance Control Unit Inspection Table..........................................................................1783 HOMELINK UNIVERSAL TRANSCEIVER............................................................................................1786 Wiring Diagram - TRNSCV -.............................................................................................1786 Trouble Diagnoses.....................................................................................................1787 NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM - NATS)...........................................................................1790 Component Parts and Harness Connetor Location.........................................................................1790 System Description....................................................................................................1791 System Composition....................................................................................................1791 Wiring Diagram - NATS -...............................................................................................1792 CONSULT-II............................................................................................................1793 Trouble Diagnoses.....................................................................................................1796 How to Replace NVIS (NATS) IMMU.......................................................................................1809 NAVIGATION SYSTEM.........................................................................................................1810 Component Parts Location..............................................................................................1810 System Description....................................................................................................1811 Schematic.............................................................................................................1818 Wiring Diagram - NAVI -...............................................................................................1819 Self-diagnosis Mode...................................................................................................1822 Confirmation/Adjustment Mode..........................................................................................1825 Setting Mode..........................................................................................................1835 Trouble diagnoses.....................................................................................................1843 This Condition is Not Abnormal........................................................................................1849 Program Loading.......................................................................................................1858 Initialization........................................................................................................1859 CAN COMMUNICATION.........................................................................................................1862 System Description....................................................................................................1862 CAN Communication Unit................................................................................................1862 CAN SYSTEM (TYPE 1).......................................................................................................1867 Component Parts and Harness Connector Location........................................................................1867 System Description....................................................................................................1867 Wiring Diagram - CAN -................................................................................................1868 Trouble Diagnoses.....................................................................................................1870 Component Inspection..................................................................................................1890 CAN SYSTEM (TYPE 2).......................................................................................................1891 Component Parts and Harness Connector Location........................................................................1891 System Description....................................................................................................1891 Wiring Diagram - CAN -................................................................................................1892 Trouble Diagnoses.....................................................................................................1894 Component Inspection..................................................................................................1912 CAN SYSTEM (TYPE 3).......................................................................................................1913 Component Parts and Harness Connector Location........................................................................1913 System Description....................................................................................................1913 Wiring Diagram - CAN -................................................................................................1914 Trouble Diagnoses.....................................................................................................1915 Component Inspection..................................................................................................1925 CAN SYSTEM (TYPE 4).......................................................................................................1926 Component Parts and Harness Connector Location........................................................................1926 System Description....................................................................................................1926 Wiring Diagram - CAN -................................................................................................1927 Trouble Diagnoses.....................................................................................................1928 Component Inspection..................................................................................................1931 ELECTRICAL UNITS LOCATION.................................................................................................1932 Engine Compartment....................................................................................................1932 Passenger Compartment.................................................................................................1933 HARNESS LAYOUT............................................................................................................1935 How to Read Harness Layout............................................................................................1935 Outline...............................................................................................................1936 Main Harness..........................................................................................................1937 Engine Room Harness...................................................................................................1939 Engine Control Harness................................................................................................1941 Body Harness LH.......................................................................................................1943 Body Harness RH.......................................................................................................1944 Back Door Harness.....................................................................................................1945 Engine and Transmission Harness.......................................................................................1946 Room Lamp Harness.....................................................................................................1947 Air Bag Harness.......................................................................................................1948 Front Door Harness....................................................................................................1949 Rear Door Harness.....................................................................................................1950 BULB SPECIFICATIONS.......................................................................................................1951 Headlamp..............................................................................................................1951 Exterior Lamp.........................................................................................................1951 Interior Lamp.........................................................................................................1951 WIRING DIAGRAM CODES (CELL CODES).........................................................................................1952 SUPER MULTIPLE JUNCTION (SMJ)............................................................................................. 0 FUSE BLOCK - JUNCTION BOX (J/B)........................................................................................... 2 FUSE AND FUSIBLE LINK BOX................................................................................................. 3 ELECTRICAL UNITS.......................................................................................................... 4 JOINT CONNECTOR (J/C)..................................................................................................... 5 em............................................................................................................................1956 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents.........................................................................................................1956 PRECAUTIONS...............................................................................................................1958 Parts Requiring Angular Tightening....................................................................................1958 Liquid Gasket Application Procedure...................................................................................1958 PREPARATION...............................................................................................................1959 Special Service Tools.................................................................................................1959 Commercial Service Tools..............................................................................................1961 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING......................................................................1963 NVH Troubleshooting - Engine Noise....................................................................................1964 OUTER COMPONENT PARTS.....................................................................................................1965 Removal and Installation..............................................................................................1965 TIGHTENING PROCEDURES.............................................................................................1967 MEASUREMENT OF COMPRESSION PRESSURE.......................................................................................1969 OIL PAN...................................................................................................................1971 Components............................................................................................................1971 Removal...............................................................................................................1971 Installation..........................................................................................................1974 TIMING CHAIN..............................................................................................................1976 Components............................................................................................................1976 POSITION FOR APPLYING LIQUID GASKET...............................................................................1977 Removal...............................................................................................................1979 Inspection............................................................................................................1986 Installation..........................................................................................................1986 OIL SEAL..................................................................................................................1994 Replacement...........................................................................................................1994 VALVE OIL SEAL....................................................................................................1994 OIL SEAL INSTALLATION DIRECTION...................................................................................1995 FRONT OIL SEAL....................................................................................................1995 REAR OIL SEAL.....................................................................................................1995 CYLINDER HEAD.............................................................................................................1996 Components............................................................................................................1996 Removal...............................................................................................................1997 Disassembly...........................................................................................................1999 Inspection............................................................................................................1999 CYLINDER HEAD DISTORTION..........................................................................................1999 CAMSHAFT VISUAL CHECK.............................................................................................2000 CAMSHAFT RUNOUT...................................................................................................2000 CAMSHAFT CAM HEIGHT...............................................................................................2000 CAMSHAFT JOURNAL CLEARANCE........................................................................................2000 CAMSHAFT END PLAY.................................................................................................2001 CAMSHAFT SPROCKET RUNOUT..........................................................................................2001 VALVE GUIDE CLEARANCE.............................................................................................2001 VALVE GUIDE REPLACEMENT...........................................................................................2002 VALVE SEATS.......................................................................................................2002 REPLACING VALVE SEAT FOR SERVICE PARTS............................................................................2003 VALVE DIMENSIONS..................................................................................................2003 VALVE SPRING......................................................................................................2004 VALVE LIFTER......................................................................................................2004 Assembly..............................................................................................................2005 Installation..........................................................................................................2005 Valve Clearance.......................................................................................................2009 CHECKING..........................................................................................................2009 ADJUSTING.........................................................................................................2012 ENGINE ASSEMBLY...........................................................................................................2014 Removal and Installation..............................................................................................2014 REMOVAL...........................................................................................................2015 INSTALLATION......................................................................................................2017 CYLINDER BLOCK............................................................................................................2018 Components............................................................................................................2018 CYLINDER BLOCK HEATER.............................................................................................2019 Removal and Installation..............................................................................................2019 Disassembly...........................................................................................................2019 PISTON, CRANKSHAFT AND OIL JET....................................................................................2019 Inspection............................................................................................................2020 PISTON AND PISTON PIN CLEARANCE...................................................................................2020 PISTON RING SIDE CLEARANCE........................................................................................2021 PISTON RING END GAP...............................................................................................2021 CONNECTING ROD BEND AND TORSION...................................................................................2022 CYLINDER BLOCK DISTORTION AND WEAR................................................................................2022 PISTON-TO-BORE CLEARANCE..........................................................................................2023 CRANKSHAFT........................................................................................................2024 BEARING CLEARANCE.................................................................................................2024 CONNECTING ROD BUSHING CLEARANCE (SMALL END)......................................................................2027 FLYWHEEL/DRIVE PLATE RUNOUT.......................................................................................2028 Assembly..............................................................................................................2028 PISTON............................................................................................................2028 OIL JET...........................................................................................................2029 CRANKSHAFT........................................................................................................2029 KNOCK SENSOR......................................................................................................2031 REPLACEMENT OF PILOT BUSHING (M/T) OR PILOT CONVERTER (A/T).......................................................2032 FLYWHEEL/DRIVE PLATE..............................................................................................2032 SERVICE DATA AND SPECIFICATIONS (SDS).....................................................................................2033 General Specifications................................................................................................2033 Compression Pressure..................................................................................................2033 Cylinder Head.........................................................................................................2033 Valve.................................................................................................................2034 VALVE.............................................................................................................2034 VALVE CLEARANCE...................................................................................................2034 VALVE SPRING......................................................................................................2034 VALVE LIFTER......................................................................................................2034 AVAILABLE LIFTERS (SHIMLESS TYPE).................................................................................2035 VALVE GUIDE.......................................................................................................2036 Valve Seat............................................................................................................2036 Camshaft and Camshaft Bearing.........................................................................................2037 Cylinder Block........................................................................................................2038 Piston, Piston Ring and Piston Pin....................................................................................2039 AVAILABLE PISTON..................................................................................................2039 PISTON RING.......................................................................................................2040 PISTON PIN........................................................................................................2040 Connecting Rod........................................................................................................2040 Crankshaft............................................................................................................2041 Available Main Bearing................................................................................................2042 UNDERSIZE.........................................................................................................2042 Available Connecting Rod Bearing......................................................................................2043 CONNECTING ROD BEARING............................................................................................2043 UNDERSIZE.........................................................................................................2043 Miscellaneous Components..............................................................................................2043 BEARING CLEARANCE.................................................................................................2043 fe............................................................................................................................2044 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents.........................................................................................................2044 PREPARATION...............................................................................................................2045 Special Service Tool..................................................................................................2045 Commercial Service Tools..............................................................................................2045 ACCELERATOR CONTROL SYSTEM................................................................................................2046 Removal and Installation..............................................................................................2046 REMOVAL...........................................................................................................2046 INSTALLATION......................................................................................................2046 INSPECTION AFTER INSTALLATION.....................................................................................2046 FUEL SYSTEM...............................................................................................................2047 Removal and Installation..............................................................................................2047 FUEL TANK.........................................................................................................2048 FUEL PUMP AND FUEL LEVEL SENSOR UNIT..............................................................................2049 EXHAUST SYSTEM............................................................................................................2052 Removal and Installation..............................................................................................2052 foldout.......................................................................................................................2056 QUICK REFERENCE INDEX..................................................................................................... 0 SUPER MULTIPLE JUNCTION (SMJ).............................................................................................2056 FUSE BLOCK - JUNCTION BOX (J/B)...........................................................................................2058 FUSE AND FUSIBLE LINK BOX.................................................................................................2059 ELECTRICAL UNITS..........................................................................................................2060 JOINT CONNECTOR (J/C).....................................................................................................2061 QUICK REFERENCE CHART.....................................................................................................2062 gi............................................................................................................................2064 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents.........................................................................................................2064 PRECAUTIONS...............................................................................................................2066 Precautions...........................................................................................................2066 PRECAUTIONS FOR SUPPLEMENTAL RESTRAINT SYSTEM (SRS) "AIR BAG" AND "SEAT BELT PRE-TENSIONER".......................2066 PRECAUTIONS FOR NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM - NATS)...................................................2066 GENERAL PRECAUTIONS...............................................................................................2067 PRECAUTIONS FOR MULTIPORT FUEL INJECTION SYSTEM OR ENGINE CONTROL SYSTEM..........................................2069 PRECAUTIONS FOR THREE WAY CATALYST................................................................................2069 PRECAUTIONS FOR HOSES.............................................................................................2069 PRECAUTIONS FOR ENGINE OILS.......................................................................................2070 PRECAUTIONS FOR FUEL..............................................................................................2071 PRECAUTIONS FOR AIR CONDITIONING..................................................................................2071 HOW TO USE THIS MANUAL....................................................................................................2072 HOW TO READ WIRING DIAGRAMS...............................................................................................2074 Sample/Wiring Diagram - EXAMPL -......................................................................................2074 OPTIONAL SPLICE...................................................................................................2075 Description...........................................................................................................2076 CONNECTOR SYMBOLS.................................................................................................2078 HARNESS INDICATION................................................................................................2079 COMPONENT INDICATION..............................................................................................2079 SWITCH POSITIONS..................................................................................................2079 DETECTABLE LINES AND NON-DETECTABLE LINES.........................................................................2080 MULTIPLE SWITCH...................................................................................................2081 REFERENCE AREA....................................................................................................2082 HOW TO CHECK TERMINAL.....................................................................................................2084 Connector and Terminal Pin Kit........................................................................................2084 How to Probe Connectors...............................................................................................2084 PROBING FROM HARNESS SIDE.........................................................................................2084 PROBING FROM TERMINAL SIDE........................................................................................2084 How to Check Enlarged Contact Spring of Terminal......................................................................2085 Waterproof Connector Inspection.......................................................................................2086 RUBBER SEAL INSPECTION............................................................................................2086 WIRE SEAL INSPECTION..............................................................................................2086 Terminal Lock Inspection..............................................................................................2086 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT.............................................................2087 Work Flow.............................................................................................................2087 Incident Simulation Tests.............................................................................................2088 INTRODUCTION......................................................................................................2088 VEHICLE VIBRATION.................................................................................................2088 HEAT SENSITIVE....................................................................................................2089 FREEZING..........................................................................................................2089 WATER INTRUSION...................................................................................................2090 ELECTRICAL LOAD...................................................................................................2090 COLD OR HOT START UP..............................................................................................2090 Circuit Inspection....................................................................................................2090 INTRODUCTION......................................................................................................2090 TESTING FOR "OPENS" IN THE CIRCUIT................................................................................2091 TESTING FOR "SHORTS" IN THE CIRCUIT...............................................................................2092 GROUND INSPECTION.................................................................................................2093 VOLTAGE DROP TESTS................................................................................................2093 CONTROL UNIT CIRCUIT TEST.........................................................................................2095 HOW TO FOLLOW TROUBLE DIAGNOSES...........................................................................................2097 How to Follow Test Groups in Trouble Diagnoses........................................................................2098 Harness Wire Color and Connector Number Indication....................................................................2099 TYPE 1: HARNESS WIRE COLOR AND CONNECTOR NUMBER ARE SHOWN IN ILLUSTRATION.........................................2099 TYPE 2: HARNESS WIRE COLOR AND CONNECTOR NUMBER ARE SHOWN IN TEXT.................................................2099 Key to Symbols Signifying Measurements or Procedures..................................................................2100 CONSULT-II CHECKING SYSTEM................................................................................................2102 Function and System Application.......................................................................................2102 Nickel Metal Hydride Battery Replacement..............................................................................2103 Checking Equipment....................................................................................................2103 CONSULT-II Start Procedure............................................................................................2104 CONSULT-II Data Link Connector (DLC) Circuit..........................................................................2104 INSPECTION PROCEDURE..............................................................................................2104 IDENTIFICATION INFORMATION................................................................................................2106 Model Variation.......................................................................................................2106 2WD...............................................................................................................2106 4WD...............................................................................................................2106 PREFIX AND SUFFIX DESIGNATIONS....................................................................................2106 Identification Number.................................................................................................2107 VEHICLE IDENTIFICATION NUMBER ARRANGEMENT.........................................................................2107 IDENTIFICATION PLATE..............................................................................................2108 ENGINE SERIAL NUMBER..............................................................................................2108 MANUAL TRANSMISSION NUMBER........................................................................................2108 AUTOMATIC TRANSMISSION NUMBER.....................................................................................2108 TRANSFER SERIAL NUMBER............................................................................................2109 Dimensions............................................................................................................2109 Wheels & Tires........................................................................................................2109 LIFTING POINTS AND TOW TRUCK TOWING.......................................................................................2110 Screw Jack............................................................................................................2110 Garage Jack and Safety Stand..........................................................................................2111 2-pole Lift...........................................................................................................2112 Tow Truck Towing......................................................................................................2112 2WD MODELS........................................................................................................2113 PART TIME 4WD MODELS..............................................................................................2113 ALL-MODE 4WD MODELS...............................................................................................2114 VEHICLE RECOVERY..................................................................................................2114 TIGHTENING TORQUE OF STANDARD BOLTS.......................................................................................2115 RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS................................................................................2116 SAE J1930 TERMINOLOGY LIST................................................................................................2117 SAE J1930 Terminology List............................................................................................2117 ha............................................................................................................................2122 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents.........................................................................................................2122 AUTO......................................................................................................................2124 PRECAUTIONS...........................................................................................................2124 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER".......................................2124 Precautions for Working with HFC-134a (R-134a)....................................................................2124 General Refrigerant Precautions...................................................................................2125 Precautions for Leak Detection Dye................................................................................2125 Precaution for Identification Label on Vehicle....................................................................2126 Precautions for Refrigerant Connection............................................................................2126 Precautions for Servicing Compressor..............................................................................2128 Precautions for Service Equipment.................................................................................2129 Wiring Diagrams and Trouble Diagnoses.............................................................................2131 PREPARATION...........................................................................................................2132 Special Service Tools.............................................................................................2132 HFC-134a (R-134a) Service Tools and Equipment.....................................................................2133 DESCRIPTION...........................................................................................................2137 Refrigeration System..............................................................................................2137 V-6 Variable Displacement Compressor..............................................................................2138 Component Layout..................................................................................................2142 Introduction......................................................................................................2143 Features..........................................................................................................2143 Overview of Control System........................................................................................2146 Control Operation.................................................................................................2147 Discharge Air Flow................................................................................................2150 System Description................................................................................................2151 TROUBLE DIAGNOSES.....................................................................................................2152 Component Location................................................................................................2152 Circuit Diagram (Without Navigation System).......................................................................2155 Wiring Diagram - A/C, A - (Without Navigation System).............................................................2156 Circuit Diagram (With Navigation System)..........................................................................2160 Wiring Diagram - A/C, A - (With Navigation System)................................................................2161 Auto Amp. Terminals and Reference Value...........................................................................2165 Self-diagnosis....................................................................................................2169 How to Perform Trouble Diagnoses for Quick and Accurate Repair....................................................2200 Operational Check.................................................................................................2201 A/C System........................................................................................................2209 Mode Door Motor...................................................................................................2213 Air Mix Door Motor................................................................................................2221 Intake Door Motor.................................................................................................2226 Blower Motor......................................................................................................2235 Magnet Clutch.....................................................................................................2246 Insufficient Cooling..............................................................................................2254 Insufficient Heating..............................................................................................2264 Noise.............................................................................................................2267 Self-diagnosis....................................................................................................2268 Memory Function...................................................................................................2271 ECON (ECONOMY) Mode...............................................................................................2274 Ambient Sensor Circuit............................................................................................2276 In-vehicle Sensor Circuit.........................................................................................2279 Sunload Sensor Circuit............................................................................................2283 Intake Sensor Circuit.............................................................................................2286 Air Mix Door Motor PBR Circuit....................................................................................2288 Multiplex Communication Circuit...................................................................................2289 SERVICE PROCEDURE.....................................................................................................2291 HFC-134a (R-134a) Service Procedure...............................................................................2291 Maintenance of Lubricant Quantity in Compressor...................................................................2293 Compressor........................................................................................................2296 Compressor Clutch.................................................................................................2296 Refrigerant Lines.................................................................................................2300 Checking for Refrigerant Leaks....................................................................................2301 Electronic Refrigerant Leak Detector..............................................................................2301 Fluorescent Dye Leak Detector.....................................................................................2304 Belt..............................................................................................................2305 In-cabin Microfilter..............................................................................................2305 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................2307 Auto..............................................................................................................2307 MANUAL....................................................................................................................2308 PRECAUTIONS...........................................................................................................2308 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER".......................................2308 Precautions for Working with HFC-134a (R-134a)....................................................................2308 General Refrigerant Precautions...................................................................................2309 Precautions for Leak Detection Dye................................................................................2309 Precaution for Identification Label on Vehicle....................................................................2310 Precautions for Refrigerant Connection............................................................................2310 Precautions for Servicing Compressor..............................................................................2312 Precautions for Service Equipment.................................................................................2313 Wiring Diagrams and Trouble Diagnoses.............................................................................2315 PREPARATION...........................................................................................................2316 Special Service Tools.............................................................................................2316 HFC-134a (R-134a) Service Tools and Equipment.....................................................................2317 DESCRIPTION...........................................................................................................2321 Refrigeration System..............................................................................................2321 V-6 Variable Displacement Compressor..............................................................................2322 Component Layout..................................................................................................2326 Control Operation.................................................................................................2327 Discharge Air Flow................................................................................................2328 System Description................................................................................................2329 TROUBLE DIAGNOSES.....................................................................................................2330 Component Location................................................................................................2330 Wiring Diagram - HEATER -.........................................................................................2332 Circuit Diagram - Air Conditioner.................................................................................2333 Wiring Diagram - A/C, M -.........................................................................................2334 How to Perform Trouble Diagnoses for Quick and Accurate Repair....................................................2337 Operational Check.................................................................................................2338 Intake Door.......................................................................................................2340 Blower Motor......................................................................................................2347 Insufficient Cooling..............................................................................................2354 Insufficient Heating..............................................................................................2362 Air Outlet........................................................................................................2364 Magnet Clutch.....................................................................................................2366 Noise.............................................................................................................2373 SERVICE PROCEDURE.....................................................................................................2374 HFC-134a (R-134a) Service Procedure...............................................................................2374 Maintenance of Lubricant Quantity in Compressor...................................................................2376 Compressor........................................................................................................2379 Compressor Clutch.................................................................................................2379 Refrigerant Lines.................................................................................................2383 Checking for Refrigerant Leaks....................................................................................2384 Electronic Refrigerant Leak Detector..............................................................................2384 Fluorescent Dye Leak Detector.....................................................................................2387 Belt..............................................................................................................2388 In-cabin Microfilter..............................................................................................2388 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................2390 Manual............................................................................................................2390 SUPER MULTIPLE JUNCTION (SMJ)............................................................................................. 0 FUSE BLOCK - JUNCTION BOX (J/B)........................................................................................... 2 FUSE AND FUSIBLE LINK BOX................................................................................................. 3 ELECTRICAL UNITS.......................................................................................................... 4 JOINT CONNECTOR (J/C)..................................................................................................... 5 idx...........................................................................................................................2392 QUICK REFERENCE INDEX..................................................................................................... 0 GI - General Information.................................................................................................. 0 MA - Maintenance.......................................................................................................... 0 EM - Engine Mechanical.................................................................................................... 0 LC - Engine Lubrication & Cooling Systems................................................................................. 0 EC - Engine Control System................................................................................................ 0 FE - Accelerator Control, Fuel & Exhaust Systems.......................................................................... 0 CL - Clutch............................................................................................................... 0 MT - Manual Transmission.................................................................................................. 0 AT - Automatic Transmission............................................................................................... 0 TF - Transfer............................................................................................................. 0 PD - Propeller Shaft & Differential Carrier............................................................................... 0 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............................................................................................................................2402 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents.........................................................................................................2402 ENGINE LUBRICATION SYSTEM.................................................................................................2403 Precautions...........................................................................................................2403 LIQUID GASKET APPLICATION PROCEDURE...............................................................................2403 Preparation...........................................................................................................2403 SPECIAL SERVICE TOOLS.............................................................................................2403 COMMERCIAL SERVICE TOOL...........................................................................................2404 Lubrication Circuit...................................................................................................2404 Oil Pressure Check....................................................................................................2406 Oil Pump..............................................................................................................2407 REMOVAL AND INSTALLATION..........................................................................................2407 DISASSEMBLY AND ASSEMBLY..........................................................................................2407 OIL PUMP INSPECTION...............................................................................................2408 REGULATOR VALVE INSPECTION........................................................................................2408 OIL FILTER........................................................................................................2409 Oil Cooler............................................................................................................2409 REMOVAL AND INSTALLATION..........................................................................................2409 INSPECTION........................................................................................................2410 Service Data and Specifications (SDS).................................................................................2410 OIL PRESSURE......................................................................................................2410 REGULATOR VALVE...................................................................................................2410 OIL PUMP..........................................................................................................2410 ENGINE COOLING SYSTEM.....................................................................................................2411 Precautions...........................................................................................................2411 LIQUID GASKET APPLICATION PROCEDURE...............................................................................2411 Preparation...........................................................................................................2411 SPECIAL SERVICE TOOLS.............................................................................................2411 Cooling Circuit.......................................................................................................2412 System Check..........................................................................................................2413 CHECKING COOLING SYSTEM HOSES.....................................................................................2413 CHECKING RADIATOR.................................................................................................2413 CHECKING RADIATOR CAP.............................................................................................2413 CHECKING COOLING SYSTEM FOR LEAKS.................................................................................2414 Water Pump............................................................................................................2414 REMOVAL AND INSTALLATION..........................................................................................2414 REMOVAL...........................................................................................................2415 INSPECTION........................................................................................................2416 INSTALLATION......................................................................................................2417 Thermostat............................................................................................................2419 REMOVAL AND INSTALLATION..........................................................................................2419 INSPECTION........................................................................................................2419 Water Control Valve...................................................................................................2420 REMOVAL AND INSTALLATION..........................................................................................2420 INSPECTION........................................................................................................2421 Radiator..............................................................................................................2422 REMOVAL AND INSTALLATION..........................................................................................2422 Cooling Fan (Crankshaft driven).......................................................................................2423 REMOVAL AND INSTALLATION..........................................................................................2423 INSPECTION........................................................................................................2423 Refilling Engine Coolant..............................................................................................2423 Radiator (Aluminum type)..............................................................................................2424 PREPARATION.......................................................................................................2424 DISASSEMBLY.......................................................................................................2424 ASSEMBLY..........................................................................................................2425 INSPECTION........................................................................................................2426 Overheating Cause Analysis............................................................................................2427 Service Data and Specifications (SDS).................................................................................2428 THERMOSTAT........................................................................................................2428 WATER CONTROL VALVE...............................................................................................2428 RADIATOR..........................................................................................................2428 ma............................................................................................................................2430 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents.........................................................................................................2430 PRECAUTIONS...............................................................................................................2432 Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"...........................2432 PREPARATION...............................................................................................................2433 Special Service Tool..................................................................................................2433 Commercial Service Tool...............................................................................................2433 GENERAL MAINTENANCE.......................................................................................................2434 PERIODIC MAINTENANCE......................................................................................................2436 Schedule 1............................................................................................................2437 EMISSION CONTROL SYSTEM MAINTENANCE...............................................................................2437 CHASSIS AND BODY MAINTENANCE......................................................................................2438 Schedule 2............................................................................................................2439 EMISSION CONTROL SYSTEM MAINTENANCE...............................................................................2439 CHASSIS AND BODY MAINTENANCE......................................................................................2440 RECOMMENDED FLUIDS AND LUBRICANTS.........................................................................................2441 Fluids and Lubricants.................................................................................................2441 SAE Viscosity Number..................................................................................................2442 GASOLINE ENGINE OIL...............................................................................................2442 Anti-freeze Coolant Mixture Ratio.....................................................................................2442 ENGINE MAINTENANCE........................................................................................................2443 Checking Drive Belts..................................................................................................2443 Changing Engine Coolant...............................................................................................2444 -DRAINING ENGINE COOLANT-.........................................................................................2444 -REFILLING ENGINE COOLANT-........................................................................................2445 -FLUSHING COOLING SYSTEM-.........................................................................................2445 Checking Fuel Lines...................................................................................................2446 Changing Fuel Filter..................................................................................................2446 WITH CONSULT-II..................................................................................................2446 WITHOUT CONSULT-II...............................................................................................2447 Changing Air Cleaner Filter...........................................................................................2447 VISCOUS PAPER TYPE................................................................................................2447 Changing Engine Oil...................................................................................................2447 Changing Oil Filter...................................................................................................2448 Changing Spark Plugs..................................................................................................2449 Checking EVAP Vapor Lines.............................................................................................2450 CHASSIS AND BODY MAINTENANCE..............................................................................................2451 Checking Exhaust System...............................................................................................2451 Checking Clutch Fluid Level and Leaks.................................................................................2451 Checking M/T Oil......................................................................................................2451 Changing M/T Oil......................................................................................................2451 Checking A/T Fluid....................................................................................................2452 Changing A/T Fluid....................................................................................................2452 Checking Part Time 4WD Transfer Fluid.................................................................................2453 Changing Part Time 4WD Transfer Fluid.................................................................................2453 Checking All-mode 4WD Transfer Fluid..................................................................................2453 Changing All-mode 4WD Transfer Fluid..................................................................................2453 Checking Propeller Shaft..............................................................................................2454 Greasing Propeller Shaft..............................................................................................2454 Checking Differential Gear Oil........................................................................................2454 Changing Differential Gear Oil........................................................................................2455 LIMITED-SLIP DIFFERENTIAL GEAR....................................................................................2455 Balancing Wheels......................................................................................................2455 Tire Rotation.........................................................................................................2455 Checking Brake Fluid Level and Leaks..................................................................................2456 Checking Brake Lines and Cables.......................................................................................2456 Checking Disc Brake...................................................................................................2456 ROTOR.............................................................................................................2456 CALIPER...........................................................................................................2456 PAD...............................................................................................................2456 Checking Drum Brake...................................................................................................2457 WHEEL CYLINDER....................................................................................................2457 DRUM..............................................................................................................2457 LINING............................................................................................................2457 TEMPORARY METHOD FOR CHECKING LINING WEAR.........................................................................2457 Checking Steering Gear, Linkage and Transfer Gear.....................................................................2457 STEERING GEAR.....................................................................................................2457 STEERING LINKAGE..................................................................................................2457 STEERING TRANSFER GEAR............................................................................................2457 Checking Power Steering Fluid and Lines...............................................................................2458 CHECKING FLUID LEVEL..............................................................................................2458 CHECKING LINES....................................................................................................2458 Axle and Suspension Parts.............................................................................................2458 FRONT WHEEL BEARING...............................................................................................2459 Drive Shaft...........................................................................................................2459 Lubricating Locks, Hinges and Hood Latches............................................................................2459 Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters.......................................................2460 SERVICE DATA AND SPECIFICATIONS (SDS).....................................................................................2461 Engine Maintenance....................................................................................................2461 DRIVE BELT DEFLECTION.............................................................................................2461 DRIVE BELT TENSION................................................................................................2461 SPARK PLUG (PLATINUM-TIPPED TYPE).................................................................................2461 Chassis and Body Maintenance..........................................................................................2461 WHEEL BALANCE.....................................................................................................2461 mt............................................................................................................................2462 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents.........................................................................................................2462 PREPARATION...............................................................................................................2463 Special Service Tools.................................................................................................2463 Commercial Service Tool...............................................................................................2464 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING......................................................................2465 NVH Troubleshooting Chart.............................................................................................2465 MANUAL TRANSMISSION...............................................................................................2465 ON-VEHICLE SERVICE........................................................................................................2466 Position Switch Check.................................................................................................2466 DESCRIPTION...............................................................................................................2467 Cross-sectional View..................................................................................................2467 REMOVAL AND INSTALLATION..................................................................................................2468 Removal...............................................................................................................2468 Installation..........................................................................................................2469 OVERHAUL..................................................................................................................2471 Case Components.......................................................................................................2471 Gear Components.......................................................................................................2472 Shift Control Components..............................................................................................2474 DISASSEMBLY...............................................................................................................2475 Case Components.......................................................................................................2475 DISASSEMBLY.......................................................................................................2475 Shift Control Components..............................................................................................2476 DISASSEMBLY.......................................................................................................2476 Gear Components.......................................................................................................2477 DISASSEMBLY.......................................................................................................2477 INSPECTION................................................................................................................2481 Shift Control Components..............................................................................................2481 INSPECTION........................................................................................................2481 Gear Components.......................................................................................................2481 INSPECTION........................................................................................................2481 ASSEMBLY..................................................................................................................2483 Gear Components.......................................................................................................2483 ASSEMBLY..........................................................................................................2483 Shift Control Components..............................................................................................2491 ASSEMBLY..........................................................................................................2491 Case Components.......................................................................................................2491 ASSEMBLY..........................................................................................................2491 SERVICE DATA AND SPECIFICATIONS (SDS).....................................................................................2494 General Specifications................................................................................................2494 Gear End Play.........................................................................................................2494 Clearance Between Baulk Ring and Gear.................................................................................2494 2ND AND 3RD BAULK RING............................................................................................2495 Distance Between Rear Surface of Reverse Cone and Reverse Baulk Ring..................................................2495 Available Snap Ring...................................................................................................2495 MAIN DRIVE GEAR SNAP RING.........................................................................................2495 MAINSHAFT FRONT SNAP RING.........................................................................................2495 COUNTER GEAR REAR SNAP RING.......................................................................................2496 Available C-ring......................................................................................................2496 MAINSHAFT C-RING..................................................................................................2496 Available Shim and Washer.............................................................................................2497 TABLE FOR SELECTING PROPER COUNTER GEAR FRONT BEARING THRUST WASHER...............................................2497 REVERSE IDLER REAR THRUST WASHER..................................................................................2497 pd............................................................................................................................2498 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents.........................................................................................................2498 PROPELLER SHAFT...........................................................................................................2500 Preparation...........................................................................................................2500 SPECIAL SERVICE TOOLS.............................................................................................2500 Noise, Vibration and Harshness (NVH) Troubleshooting..................................................................2501 NVH TROUBLESHOOTING CHART.........................................................................................2501 Components............................................................................................................2502 FRONT PROPELLER SHAFT.............................................................................................2502 REAR PROPELLER SHAFT..............................................................................................2503 On-vehicle Service....................................................................................................2505 PROPELLER SHAFT VIBRATION.........................................................................................2505 APPEARANCE CHECKING...............................................................................................2505 Removal and Installation..............................................................................................2505 Inspection............................................................................................................2506 Disassembly...........................................................................................................2506 CENTER BEARING - 2WD -............................................................................................2506 JOURNAL (71H AND 80B).............................................................................................2507 Assembly..............................................................................................................2508 CENTER BEARING - 2WD -............................................................................................2508 JOURNAL (71H AND 80B).............................................................................................2508 Service Data and Specifications (SDS).................................................................................2509 GENERAL SPECIFICATIONS............................................................................................2509 SERVICE DATA......................................................................................................2510 SNAP RING (80B)...................................................................................................2510 SNAP RING (71H)...................................................................................................2510 SNAP RING (1310)..................................................................................................2510 R200A.....................................................................................................................2511 FRONT FINAL DRIVE.....................................................................................................2511 Preparation.......................................................................................................2511 SPECIAL SERVICE TOOLS.........................................................................................2511 Noise, Vibration and Harshness (NVH) Troubleshooting..............................................................2513 On-vehicle Service................................................................................................2513 FRONT OIL SEAL REPLACEMENT....................................................................................2513 REAR COVER GASKET REPLACEMENT.................................................................................2514 Components........................................................................................................2515 Removal and Installation..........................................................................................2516 REMOVAL.......................................................................................................2516 INSTALLATION..................................................................................................2516 Disassembly.......................................................................................................2516 PRE-INSPECTION................................................................................................2516 FINAL DRIVE HOUSING...........................................................................................2517 DIFFERENTIAL CASE.............................................................................................2519 DIFFERENTIAL SIDE SHAFT.......................................................................................2520 Inspection........................................................................................................2521 RING GEAR AND DRIVE PINION....................................................................................2521 DIFFERENTIAL CASE ASSEMBLY....................................................................................2521 BEARING.......................................................................................................2521 Adjustment........................................................................................................2522 SIDE BEARING PRELOAD..........................................................................................2522 PINION GEAR HEIGHT AND PINION BEARING PRELOAD.................................................................2523 TOOTH CONTACT.................................................................................................2527 Assembly..........................................................................................................2528 DIFFERENTIAL SIDE SHAFT.......................................................................................2528 DIFFERENTIAL CASE.............................................................................................2529 FINAL DRIVE HOUSING...........................................................................................2530 Service Data and Specifications (SDS).............................................................................2534 R200A.........................................................................................................2534 H233B.....................................................................................................................2536 REAR FINAL DRIVE......................................................................................................2536 Preparation.......................................................................................................2536 SPECIAL SERVICE TOOLS.........................................................................................2536 Noise, Vibration and Harshness (NVH) Troubleshooting..............................................................2538 On-vehicle Service................................................................................................2538 FRONT OIL SEAL REPLACEMENT....................................................................................2538 Components........................................................................................................2540 Removal and Installation..........................................................................................2541 REMOVAL.......................................................................................................2541 INSTALLATION..................................................................................................2541 Disassembly.......................................................................................................2541 PRE-INSPECTION................................................................................................2541 DIFFERENTIAL CARRIER..........................................................................................2542 DIFFERENTIAL CASE.............................................................................................2544 Inspection........................................................................................................2545 RING GEAR AND DRIVE PINION....................................................................................2545 DIFFERENTIAL CASE ASSEMBLY....................................................................................2545 BEARING.......................................................................................................2545 Limited Slip Differential.........................................................................................2545 PREPARATION FOR DISASSEMBLY...................................................................................2545 DISASSEMBLY...................................................................................................2546 INSPECTION....................................................................................................2547 ADJUSTMENT....................................................................................................2548 ASSEMBLY......................................................................................................2549 Adjustment........................................................................................................2551 PINION GEAR HEIGHT............................................................................................2551 TOOTH CONTACT.................................................................................................2554 Assembly..........................................................................................................2555 DIFFERENTIAL CASE.............................................................................................2555 DIFFERENTIAL CARRIER..........................................................................................2556 Service Data and Specifications (SDS).............................................................................2559 H233B.........................................................................................................2559 rs............................................................................................................................2564 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents.........................................................................................................2564 SEAT BELTS................................................................................................................2566 Precautions...........................................................................................................2566 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) "AIR BAG" AND "SEAT BELT PRE-TENSIONER".......................................2566 PRECAUTION FOR SEAT BELT SERVICE..................................................................................2566 Front Seat Belt.......................................................................................................2568 REMOVAL AND INSTALLATION..........................................................................................2568 Rear Seat Belt........................................................................................................2569 REMOVAL AND INSTALLATION..........................................................................................2569 Seat Belt Inspection..................................................................................................2571 AFTER A COLLISION.................................................................................................2571 PRELIMINARY CHECKS................................................................................................2571 SEAT BELT RETRACTOR ON-VEHICLE CHECK..............................................................................2572 SEAT BELT RETRACTOR OFF-VEHICLE CHECK.............................................................................2572 Tether Anchor Plate...................................................................................................2573 REMOVAL AND INSTALLATION..........................................................................................2573 SUPPLEMENTAL RESTRAINT SYSTEM (SRS).......................................................................................2574 Precautions...........................................................................................................2574 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) "AIR BAG" AND "SEAT BELT PRE-TENSIONER".......................................2574 PRECAUTIONS FOR SRS "AIR BAG" AND "SEAT BELT PRE-TENSIONER" SERVICE...............................................2574 WIRING DIAGRAMS AND TROUBLE DIAGNOSIS.............................................................................2574 Preparation...........................................................................................................2575 SPECIAL SERVICE TOOLS.............................................................................................2575 COMMERCIAL SERVICE TOOL...........................................................................................2576 Description...........................................................................................................2577 Seat Belt Pre-tensioner with Load Limiter.............................................................................2578 Side Air Bag..........................................................................................................2578 Side Curtain Air Bag..................................................................................................2578 SRS Component Parts Location..........................................................................................2579 Diagnosis Sensor Unit.................................................................................................2579 REMOVAL AND INSTALLATION..........................................................................................2579 Seat Belt Pre-tensioner...............................................................................................2580 REMOVAL AND INSTALLATION..........................................................................................2580 Satellite Sensor......................................................................................................2580 REMOVAL AND INSTALLATION..........................................................................................2580 Driver Air Bag Module and Spiral Cable................................................................................2581 REMOVAL AND INSTALLATION..........................................................................................2581 REMOVAL...........................................................................................................2581 INSTALLATION......................................................................................................2583 Front Passenger Air Bag Module........................................................................................2583 REMOVAL...........................................................................................................2583 INSTALLATION......................................................................................................2585 Side Air Bag Module...................................................................................................2585 REMOVAL...........................................................................................................2585 INSTALLATION......................................................................................................2586 Side Curtain Air Bag Module...........................................................................................2587 REMOVAL AND INSTALLATION..........................................................................................2587 Disposal of Air Bag Module and Seat Belt Pre-tensioner................................................................2588 CHECKING DEPLOYMENT TOOL..........................................................................................2589 DEPLOYMENT PROCEDURES FOR AIR BAG MODULE (OUTSIDE OF VEHICLE).....................................................2589 DEPLOYMENT PROCEDURES FOR SIDE CURTAIN AIR BAG MODULE (OUTSIDE OF VEHICLE)........................................2592 DEPLOYMENT PROCEDURES FOR SEAT BELT PRE-TENSIONER (OUTSIDE OF VEHICLE)............................................2593 DEPLOYMENT OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER WHILE MOUNTED IN VEHICLE.................................2594 DISPOSING OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER...........................................................2594 Trouble Diagnoses Introduction........................................................................................2595 DIAGNOSIS FUNCTION................................................................................................2595 DIAGNOSIS MODE FOR CONSULT-II.....................................................................................2595 HOW TO CHANGE SELF-DIAGNOSIS MODE WITH CONSULT-II.................................................................2596 HOW TO CHANGE SELF-DIAGNOSIS MODE WITHOUT CONSULT-II..............................................................2596 HOW TO ERASE SELF-DIAGNOSIS RESULTS...............................................................................2596 How to Perform Trouble Diagnoses for Quick and Accurate Repair........................................................2598 INFORMATION FROM CUSTOMER.........................................................................................2598 PRELIMINARY CHECK.................................................................................................2598 WORK FLOW.........................................................................................................2599 Schematic.............................................................................................................2600 Wiring Diagram - SRS -................................................................................................2601 SRS Operation Check...................................................................................................2604 DIAGNOSTIC PROCEDURE 1............................................................................................2604 Trouble Diagnoses with CONSULT-II.....................................................................................2605 DIAGNOSTIC PROCEDURE 2............................................................................................2605 DIAGNOSTIC PROCEDURE 3............................................................................................2609 DIAGNOSTIC PROCEDURE 4 (CONTINUED FROM DIAGNOSTIC PROCEDURE 2)....................................................2610 DIAGNOSTIC PROCEDURE 5............................................................................................2611 Trouble Diagnoses without CONSULT-II..................................................................................2615 DIAGNOSTIC PROCEDURE 6............................................................................................2615 DIAGNOSTIC PROCEDURE 7............................................................................................2621 DIAGNOSTIC PROCEDURE 8 (CONTINUED FROM DIAGNOSTIC PROCEDURE 6)....................................................2622 Trouble Diagnoses: "AIR BAG" Warning Lamp Does Not Turn Off...........................................................2623 DIAGNOSTIC PROCEDURE 9............................................................................................2623 Trouble Diagnoses: "AIR BAG" Warning Lamp Does Not Turn On............................................................2625 DIAGNOSTIC PROCEDURE 10...........................................................................................2625 Collision Diagnosis...................................................................................................2626 FOR FRONTAL COLLISION.............................................................................................2626 FOR SIDE COLLISION................................................................................................2628 SUPER MULTIPLE JUNCTION (SMJ)............................................................................................. 0 FUSE BLOCK - JUNCTION BOX (J/B)........................................................................................... 2 FUSE AND FUSIBLE LINK BOX................................................................................................. 3 ELECTRICAL UNITS.......................................................................................................... 4 JOINT CONNECTOR (J/C)..................................................................................................... 5 sc............................................................................................................................2630 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents.........................................................................................................2630 PRECAUTIONS...............................................................................................................2631 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"...........................................2631 Precautions for SRS "AIR BAG" and "SEAT BELT PRE-TENSIONER" Service...................................................2631 Wiring Diagrams and Trouble Diagnosis.................................................................................2631 PREPARATION...............................................................................................................2632 Special Service Tool..................................................................................................2632 BATTERY...................................................................................................................2633 How to Handle Battery.................................................................................................2633 METHODS OF PREVENTING OVER-DISCHARGE..............................................................................2633 CHECKING ELECTROLYTE LEVEL........................................................................................2633 SPECIFIC GRAVITY CHECK............................................................................................2634 CHARGING THE BATTERY..............................................................................................2635 Trouble Diagnoses with Battery/Starting/Charging System Tester........................................................2636 DIAGNOSTIC RESULT ITEM CHART......................................................................................2638 STARTING SYSTEM...........................................................................................................2639 System Description....................................................................................................2639 WITH M/T..........................................................................................................2639 WITH A/T..........................................................................................................2639 Wiring Diagram - START -/With M/T.....................................................................................2640 Wiring Diagram - START -/With A/T.....................................................................................2641 Trouble Diagnoses with Battery/Starting/Charging System Tester........................................................2642 DIAGNOSTIC RESULT ITEM CHART......................................................................................2643 WORK FLOW.........................................................................................................2644 DIAGNOSTIC PROCEDURE 1............................................................................................2645 DIAGNOSTIC PROCEDURE 2............................................................................................2647 MINIMUM SPECIFICATION OF CRANKING VOLTAGE REFERENCING COOLANT TEMPERATURE.........................................2648 Construction..........................................................................................................2648 Removal and Installation..............................................................................................2648 Pinion/Clutch Check...................................................................................................2649 CHARGING SYSTEM...........................................................................................................2650 System Description....................................................................................................2650 Wiring Diagram - CHARGE -.............................................................................................2651 Trouble Diagnoses with Battery/Starting/Charging System Tester........................................................2652 DIAGNOSTIC RESULT ITEM CHART......................................................................................2654 WORK FLOW.........................................................................................................2655 DIAGNOSTIC PROCEDURE 1............................................................................................2656 DIAGNOSTIC PROCEDURE 2............................................................................................2657 DIAGNOSTIC PROCEDURE 3............................................................................................2658 MALFUNCTION INDICATOR.............................................................................................2659 Construction..........................................................................................................2659 Removal and Installation..............................................................................................2659 SERVICE DATA AND SPECIFICATIONS (SDS).....................................................................................2660 Battery...............................................................................................................2660 Starter...............................................................................................................2660 Alternator............................................................................................................2660 SUPER MULTIPLE JUNCTION (SMJ)............................................................................................. 0 FUSE BLOCK - JUNCTION BOX (J/B)........................................................................................... 2 FUSE AND FUSIBLE LINK BOX................................................................................................. 3 ELECTRICAL UNITS.......................................................................................................... 4 JOINT CONNECTOR (J/C)..................................................................................................... 5 st............................................................................................................................2662 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents.........................................................................................................2662 PRECAUTIONS...............................................................................................................2663 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"...........................................2663 Precautions for SRS "AIR BAG" and "SEAT BELT PRE-TENSIONER" Service...................................................2663 Precautions for Steering System.......................................................................................2663 PREPARATION...............................................................................................................2664 Special Service Tools.................................................................................................2664 Commercial Service Tools..............................................................................................2665 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING......................................................................2667 NVH Troubleshooting Chart.............................................................................................2667 ON-VEHICLE SERVICE........................................................................................................2668 Checking Steering Wheel Play..........................................................................................2668 Checking Neutral Position on Steering Wheel...........................................................................2668 PRE-CHECKING......................................................................................................2668 CHECKING..........................................................................................................2668 Front Wheel Turning Angle.............................................................................................2668 Checking Gear Housing Movement........................................................................................2669 Adjusting Rack Retainer...............................................................................................2669 Checking and Adjusting Drive Belts....................................................................................2669 Checking Fluid Level..................................................................................................2669 Checking Fluid Leakage................................................................................................2669 Bleeding Hydraulic System.............................................................................................2670 Checking Steering Wheel Turning Force.................................................................................2670 Checking Hydraulic System.............................................................................................2671 STEERING WHEEL AND STEERING COLUMN........................................................................................2672 Components............................................................................................................2672 Removal and Installation..............................................................................................2672 STEERING WHEEL....................................................................................................2672 STEERING COLUMN...................................................................................................2673 Disassembly and Assembly..............................................................................................2674 Inspection............................................................................................................2675 TILT MECHANISM....................................................................................................2675 STEERING TRANSFER GEAR....................................................................................................2676 Removal...............................................................................................................2676 Installation..........................................................................................................2677 Inspection............................................................................................................2677 POWER STEERING GEAR AND LINKAGE...........................................................................................2678 Components............................................................................................................2678 Removal and Installation..............................................................................................2679 Disassembly...........................................................................................................2680 Inspection............................................................................................................2681 BOOT..............................................................................................................2681 RACK..............................................................................................................2681 PINION ASSEMBLY...................................................................................................2681 GEAR HOUSING CYLINDER.............................................................................................2681 TIE-ROD OUTER AND INNER SOCKETS...................................................................................2682 Assembly..............................................................................................................2682 Adjustment............................................................................................................2685 POWER STEERING OIL PUMP...................................................................................................2688 Components............................................................................................................2688 Pre-disassembly Inspection............................................................................................2688 Disassembly...........................................................................................................2689 Inspection............................................................................................................2690 Assembly..............................................................................................................2690 SERVICE DATA AND SPECIFICATIONS (SDS).....................................................................................2693 General Specifications................................................................................................2693 Steering Wheel........................................................................................................2693 Steering Column.......................................................................................................2693 Steering Transfer Gear................................................................................................2693 Steering Gear and Linkage.............................................................................................2694 Power Steering........................................................................................................2694 su............................................................................................................................2696 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents.........................................................................................................2696 FRONT SUSPENSION..........................................................................................................2698 Precautions...........................................................................................................2698 PRECAUTIONS.......................................................................................................2698 Preparation...........................................................................................................2698 SPECIAL SERVICE TOOLS.............................................................................................2698 COMMERCIAL SERVICE TOOLS..........................................................................................2698 Noise, Vibration and Harshness (NVH) Troubleshooting..................................................................2699 NVH TROUBLESHOOTING CHART.........................................................................................2699 Components............................................................................................................2700 2WD...............................................................................................................2700 4WD...............................................................................................................2701 On-vehicle Service....................................................................................................2702 FRONT SUSPENSION PARTS............................................................................................2702 FRONT WHEEL ALIGNMENT.............................................................................................2703 Coil Spring and Strut Assembly........................................................................................2705 COMPONENTS........................................................................................................2705 REMOVAL...........................................................................................................2707 DISASSEMBLY.......................................................................................................2707 INSPECTION........................................................................................................2707 ASSEMBLY..........................................................................................................2708 Stabilizer Bar........................................................................................................2708 REMOVAL AND INSTALLATION..........................................................................................2708 INSPECTION........................................................................................................2709 Transverse Link and Lower Ball Joint..................................................................................2709 REMOVAL AND INSTALLATION..........................................................................................2709 INSPECTION........................................................................................................2710 Low Tire Pressure Warning System......................................................................................2711 SYSTEM COMPONENTS.................................................................................................2711 SYSTEM DESCRIPTION................................................................................................2711 Trouble Diagnoses.....................................................................................................2713 WIRING DIAGRAM....................................................................................................2713 LOW TIRE PRESSURE WARNING CONTROL UNIT INPUT/OUTPUT SIGNAL STANDARD...............................................2715 ID REGISTRATION PROCEDURE.........................................................................................2715 SELF-DIAGNOSIS....................................................................................................2718 HOW TO PERFORM TROUBLE DIAGNOSIS FOR QUICK AND ACCURATE REPAIR....................................................2720 PRELIMINARY CHECK.................................................................................................2721 MALFUNCTION CODE/SYMPTOM CHART....................................................................................2722 Trouble Diagnoses for Self-diagnostic Items...........................................................................2722 INSPECTION 1: TRANSMITTER OR TIRE PRESSURE WARNING CONTROL UNIT...................................................2722 INSPECTION 2: TRANSMITTER-1.......................................................................................2723 INSPECTION 3: TRANSMITTER-2.......................................................................................2724 INSPECTION 4: LOW TIRE PRESSURE WARNING CONTROL UNIT..............................................................2724 Trouble Diagnoses for Symptoms........................................................................................2725 INSPECTION 1: WARNING LAMP DOES NOT COME ON WHEN IGNITION SWITCH IS TURNED ON.....................................2725 INSPECTION 2: WARNING LAMP STAYS ON WHEN IGNITION SWITCH IS TURNED ON.............................................2726 INSPECTION 3: WARNING LAMP BLINKS WHEN IGNITION SWITCH IS TURNED ON...............................................2728 INSPECTION 4: TAIL LAMP BLINKS WHEN IGNITION SWITCH IS TURNED ON..................................................2729 INSPECTION 5: ID REGISTRATION CANNOT BE COMPLETED.................................................................2729 Service Data and Specifications (SDS).................................................................................2729 GENERAL SPECIFICATIONS (FRONT)....................................................................................2729 WHEEL ALIGNMENT (UNLADEN*1).......................................................................................2729 LOWER BALL JOINT..................................................................................................2730 WHEELARCH HEIGHT (UNLADEN*).......................................................................................2730 WHEEL RUNOUT AVERAGE*.............................................................................................2731 REAR SUSPENSION...........................................................................................................2732 Precautions...........................................................................................................2732 PRECAUTIONS.......................................................................................................2732 Preparation...........................................................................................................2732 COMMERCIAL SERVICE TOOLS..........................................................................................2732 Noise, Vibration and Harshness (NVH) Troubleshooting..................................................................2732 Components............................................................................................................2733 On-vehicle Service....................................................................................................2733 REAR SUSPENSION PARTS.............................................................................................2733 Removal and Installation..............................................................................................2734 Coil Spring and Shock Absorber........................................................................................2735 COMPONENTS........................................................................................................2735 REMOVAL AND INSTALLATION..........................................................................................2736 INSPECTION........................................................................................................2736 Upper Link, Lower Link and Panhard Rod................................................................................2736 INSPECTION........................................................................................................2736 BUSHING REPLACEMENT...............................................................................................2736 INSTALLATION......................................................................................................2737 Stabilizer Bar........................................................................................................2737 REMOVAL AND INSTALLATION..........................................................................................2737 Low Tire Pressure Warning System......................................................................................2737 Service Data and Specifications (SDS).................................................................................2738 GENERAL SPECIFICATIONS (REAR).....................................................................................2738 tf............................................................................................................................2740 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents.........................................................................................................2740 PREPARATION...............................................................................................................2743 Special Service Tools.................................................................................................2743 Commercial Service Tools..............................................................................................2748 TX10A.....................................................................................................................2749 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING..................................................................2749 NVH Troubleshooting Chart.........................................................................................2749 TRANSFER......................................................................................................2749 DESCRIPTION...........................................................................................................2750 Cross-sectional View..............................................................................................2750 ON-VEHICLE SERVICE....................................................................................................2751 Replacing Oil Seal................................................................................................2751 CENTER CASE OIL SEAL..........................................................................................2751 SHIFT SHAFT OIL SEAL..........................................................................................2752 REAR OIL SEAL.................................................................................................2752 Position Switch Check.............................................................................................2753 REMOVAL AND INSTALLATION..............................................................................................2754 Removal...........................................................................................................2754 Installation......................................................................................................2754 M/T MODEL.....................................................................................................2754 A/T MODEL.....................................................................................................2754 OVERHAUL..............................................................................................................2755 Transfer Gear Control.............................................................................................2755 Case Components...................................................................................................2756 Gear Components...................................................................................................2757 Shift Control Components..........................................................................................2758 DISASSEMBLY...........................................................................................................2759 REPAIR FOR COMPONENT PARTS............................................................................................2763 Mainshaft.........................................................................................................2763 DISASSEMBLY...................................................................................................2763 INSPECTION....................................................................................................2764 ASSEMBLY......................................................................................................2764 Front Drive Shaft.................................................................................................2765 DISASSEMBLY...................................................................................................2765 INSPECTION....................................................................................................2765 ASSEMBLY......................................................................................................2765 Counter Gear......................................................................................................2765 DISASSEMBLY...................................................................................................2765 INSPECTION....................................................................................................2766 ASSEMBLY......................................................................................................2766 Main Gear.........................................................................................................2766 DISASSEMBLY...................................................................................................2766 INSPECTION....................................................................................................2767 ASSEMBLY......................................................................................................2767 Front Case........................................................................................................2767 REMOVAL.......................................................................................................2767 INSTALLATION..................................................................................................2768 Front Case Cover..................................................................................................2768 REMOVAL.......................................................................................................2768 INSTALLATION..................................................................................................2768 Bearing Retainer..................................................................................................2768 REMOVAL.......................................................................................................2768 INSTALLATION..................................................................................................2768 Center Case.......................................................................................................2769 REMOVAL.......................................................................................................2769 INSTALLATION..................................................................................................2769 Rear Case.........................................................................................................2769 REMOVAL.......................................................................................................2769 INSTALLATION..................................................................................................2769 Shift Control Components..........................................................................................2770 INSPECTION....................................................................................................2770 ASSEMBLY..............................................................................................................2771 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................2778 General Specifications............................................................................................2778 Gear End Play.....................................................................................................2778 Available Snap Ring...............................................................................................2778 MAINSHAFT FRONT BEARING.......................................................................................2778 MAINSHAFT REAR BEARING........................................................................................2778 MAIN GEAR BEARING.............................................................................................2778 Available Shim....................................................................................................2779 COUNTER GEAR REAR BEARING.....................................................................................2779 ATX14A....................................................................................................................2780 PRECAUTIONS...........................................................................................................2780 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER".......................................2780 Precautions.......................................................................................................2780 Service Notice....................................................................................................2781 Wiring Diagrams and Trouble Diagnosis.............................................................................2781 ALL-MODE 4WD SYSTEM...................................................................................................2782 Cross-sectional View..............................................................................................2782 Control System....................................................................................................2783 ALL-MODE 4WD TRANSFER BASIC CONTROL...........................................................................2784 HYDRAULIC CONTROL CIRCUITS....................................................................................2784 OUTLINE.......................................................................................................2784 CONTROL SYSTEM DIAGRAM........................................................................................2785 INDICATIONS OF 4WD WARNING LAMP...............................................................................2785 CAN Communication (With VDC)......................................................................................2786 SYSTEM DESCRIPTION............................................................................................2786 INPUT/OUTPUT SIGNAL CHART.....................................................................................2786 Location of Electrical Parts......................................................................................2788 Description of Electrical Parts...................................................................................2789 TRANSFER MOTOR................................................................................................2789 WAIT DETECTION SWITCH.........................................................................................2789 2-4WD SHIFT SOLENOID VALVE....................................................................................2790 LINE PRESSURE SWITCH..........................................................................................2790 Circuit Diagram for Quick Pinpoint Check..........................................................................2791 Wiring Diagram - TF -.............................................................................................2792 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION................................................................................2801 Trouble Diagnosis without CONSULT-II..............................................................................2801 DESCRIPTION...................................................................................................2801 SELF-DIAGNOSTIC PROCEDURE.....................................................................................2802 INDICATIONS OF 4WD WARNING LAMP...............................................................................2803 Trouble Diagnosis with CONSULT-II.................................................................................2804 CONSULT-II FUNCTION...........................................................................................2804 SELF-DIAGNOSIS................................................................................................2804 SELF-DIAGNOSTIC ITEMS.........................................................................................2806 DATA MONITOR..................................................................................................2807 DATA MONITOR ITEMS............................................................................................2809 REFERENCE VALUE IN DATA MONITOR MODE..........................................................................2811 WORK SUPPORT..................................................................................................2814 CLUTCH FORCE RELEASE LIMIT ADJUSTMENT.........................................................................2815 TROUBLE DIAGNOSIS - INTRODUCTION......................................................................................2816 Introduction......................................................................................................2816 DESCRIPTION...................................................................................................2816 DIAGNOSTIC WORKSHEET..........................................................................................2816 Work Flow.........................................................................................................2818 HOW TO PERFORM TROUBLE DIAGNOSES FOR QUICK AND ACCURATE REPAIR................................................2818 TROUBLE DIAGNOSIS - BASIC INSPECTION..................................................................................2819 Listen to Customer Complaints.....................................................................................2819 Transfer Fluid Check..............................................................................................2819 Road Test.........................................................................................................2819 PREPARATION FOR ROAD TEST.....................................................................................2819 1. CHECK BEFORE ENGINE IS STARTED.............................................................................2820 2. CHECK AT IDLE..............................................................................................2821 3. CRUISE TEST................................................................................................2825 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION...............................................................................2828 Transfer Control Unit Terminals and Reference Value...............................................................2828 REMOVAL AND INSTALLATION OF TRANSFER CONTROL UNIT.............................................................2828 INSPECTION OF TRANSFER CONTROL UNIT...........................................................................2828 TRANSFER CONTROL UNIT INSPECTION TABLE........................................................................2829 DTC U1000 CAN COMMUNICATION LINE (WITH VDC)...........................................................................2835 Description.......................................................................................................2835 On Board Diagnosis Logic..........................................................................................2835 Possible Cause....................................................................................................2835 DTC Confirmation Procedure........................................................................................2835 WITH CONSULT-II...............................................................................................2835 WITH GST......................................................................................................2835 Diagnostic Procedure..............................................................................................2836 VEHICLE SPEED SENSOR (FRONT REVOLUTION SENSOR) (WITHOUT VDC)..........................................................2837 Diagnostic Procedure..............................................................................................2837 4WD SOLENOID VALVE....................................................................................................2840 Diagnostic Procedure..............................................................................................2840 2-4WD SHIFT SOLENOID VALVE AND 4WD SHIFT SWITCH.......................................................................2842 Diagnostic Procedure..............................................................................................2842 TRANSFER MOTOR AND TRANSFER MOTOR RELAY...............................................................................2846 Diagnostic Procedure..............................................................................................2846 TRANSFER FLUID TEMPERATURE SENSOR.....................................................................................2849 Diagnostic Procedure..............................................................................................2849 ATP SWITCH, WAIT DETECTION SWITCH AND NEUTRAL-4LO SWITCH..............................................................2852 Diagnostic Procedure..............................................................................................2852 CLUTCH PRESSURE SWITCH................................................................................................2856 Diagnostic Procedure..............................................................................................2856 LINE PRESSURE SWITCH..................................................................................................2859 Diagnostic Procedure..............................................................................................2859 ABS OPERATION SIGNAL (WITHOUT VDC)....................................................................................2862 Diagnostic Procedure..............................................................................................2862 DATA ERASE/DISPLAY....................................................................................................2864 Diagnostic Procedure..............................................................................................2864 SHIFT ACTUATOR........................................................................................................2865 Diagnostic Procedure..............................................................................................2865 SHIFT ACTUATOR POSITION SWITCH........................................................................................2868 Diagnostic Procedure..............................................................................................2868 SHIFT ACTUATOR CIRCUIT................................................................................................2870 Diagnostic Procedure..............................................................................................2870 TROUBLE DIAGNOSES FOR SYMPTOMS........................................................................................2874 Symptom 1. 4WD Shift Indicator Lamp Does Not Turn ON..............................................................2874 Symptom 2. 4WD Warning Lamp Does Not Turn ON......................................................................2876 Symptom 3. 4WD Shift Indicator Lamp Does Not Turn OFF.............................................................2878 Symptom 4. ATP Warning Lamp Does Not Turn ON......................................................................2878 Symptom 5. 4LO Indicator Lamp Does Not Turn ON....................................................................2880 Symptom 6. 4WD Shift Indicator Lamp Does Not Indicate "4H"........................................................2882 Symptom 7. 4WD Shift Indicator Lamp Repeats Flickering............................................................2883 Symptom 8. Tight Corner Braking Symptom...........................................................................2884 Symptom 9. 4WD System Does Not Operate............................................................................2885 COMPONENT INSPECTION..................................................................................................2887 4WD Shift Switch..................................................................................................2887 2-4WD Shift Solenoid Valve and Transfer Fluid Temperature Sensor..................................................2887 4WD Solenoid Valve, Clutch Pressure Switch and Line Pressure Switch...............................................2887 Front Revolution Sensor...........................................................................................2888 Transfer Dropping Resistor........................................................................................2888 ATP Switch, Neutral-4LO Switch and Wait Detection Switch..........................................................2888 Transfer Motor....................................................................................................2889 Transfer Motor Relay..............................................................................................2889 Transfer Sub-harness..............................................................................................2889 FRONT REVOLUTION SENSOR SUB-HARNESS CONNECTOR.................................................................2889 TRANSFER SWITCH ASSEMBLY SUB-HARNESS CONNECTOR................................................................2890 TRANSFER TERMINAL CORD ASSEMBLY SUB-HARNESS CONNECTOR.........................................................2890 Transfer Shift Relay (High & low).................................................................................2890 Actuator & Actuator Position Switch...............................................................................2891 ACTUATOR......................................................................................................2891 ACTUATOR POSITION SWITCH......................................................................................2891 ON-VEHICLE SERVICE....................................................................................................2892 Replacing Oil Seal................................................................................................2892 FRONT CASE OIL SEAL...........................................................................................2892 SHIFT SHAFT OIL SEAL..........................................................................................2893 REAR OIL SEAL.................................................................................................2893 Transfer Motor....................................................................................................2894 REMOVAL.......................................................................................................2894 INSTALLATION..................................................................................................2894 Transfer Oil Filter...............................................................................................2894 REMOVAL.......................................................................................................2894 INSTALLATION..................................................................................................2894 REMOVAL AND INSTALLATION..............................................................................................2895 Removal...........................................................................................................2895 Installation......................................................................................................2895 OVERHAUL..............................................................................................................2896 Transfer Gear Control.............................................................................................2896 Transfer Components...............................................................................................2897 DISASSEMBLY...........................................................................................................2899 Rear Case.........................................................................................................2899 DISASSEMBLY...................................................................................................2899 Center Case.......................................................................................................2899 DISASSEMBLY...................................................................................................2899 Front Case........................................................................................................2909 DISASSEMBLY...................................................................................................2909 REPAIR FOR COMPONENT PARTS............................................................................................2913 Front Case........................................................................................................2913 INSPECTION....................................................................................................2913 Center Case.......................................................................................................2914 INSPECTION....................................................................................................2914 ASSEMBLY..............................................................................................................2917 Front Case........................................................................................................2917 ASSEMBLY......................................................................................................2917 Center Case.......................................................................................................2921 ASSEMBLY......................................................................................................2921 Final Assembly....................................................................................................2929 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................2932 General Specifications............................................................................................2932 Inner Gear and Outer Gear.........................................................................................2932 SUB-OIL PUMP..................................................................................................2932 MAIN OIL PUMP.................................................................................................2932 Control Valve.....................................................................................................2932 VALVE.........................................................................................................2932 SPRING........................................................................................................2932 Clutch............................................................................................................2933 DRIVE PLATE...................................................................................................2933 DRIVEN PLATE..................................................................................................2933 RETURN SPRING.................................................................................................2933 RETAINING PLATE...............................................................................................2933 Seal Ring (Mainshaft side)........................................................................................2934 Bearing Race (Thrust needle bearing side).........................................................................2934 Snap Ring (Sun gear side).........................................................................................2934 SUPER MULTIPLE JUNCTION (SMJ)............................................................................................. 0 FUSE BLOCK - JUNCTION BOX (J/B)........................................................................................... 2 FUSE AND FUSIBLE LINK BOX................................................................................................. 3 ELECTRICAL UNITS.......................................................................................................... 4 JOINT CONNECTOR (J/C)..................................................................................................... 5
DESCRIPTION:
2003 NISSAN PATHFINDER R50 Series Service Manual PDF DOWNLOAD
FOREWORD:
- This manual contains maintenance and repair procedures for the 2003 Nissan PATHFINDER.
- In order to assure your safety and the efficient functioning of the vehicle, this manual should be read thoroughly.
- It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task.
- All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice.
Important safety notice
- The proper performance of service is essential for both the safety of the technician and the efficient functioning of the vehicle.
- The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately.
- Service varies with the procedures used, the skills of the technician and the tools and parts available.
- Accordingly, anyone using service procedures, tools or parts which are not specifically recommended by NISSAN must first be completely satisfied that neither parsonal safety nor the vehicle’s safety will be jeopardized by the service method selected.
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PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
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