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2004 NISSAN PATHFINDER R50 Series Service Manual PDF DOWNLOAD
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2004 NISSAN PATHFINDER R50 Series Service Manual PDF DOWNLOAD
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2004 NISSAN PATHFINDER R50 Series Service Manual PDF DOWNLOAD
Language : English
Pages : 2810
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
2004 NISSAN PATHFINDER R50 Series Service Manual PDF DOWNLOAD
fwd........................................................................................................................... 1 Model Selection........................................................................................................... 1 QUICK REFERENCE INDEX..................................................................................................... 1 FOREWORD.................................................................................................................. 2 GI - General Information.................................................................................................. 0 MA - Maintenance.......................................................................................................... 0 EM - Engine Mechanical.................................................................................................... 0 LC - Engine Lubrication & Cooling Systems................................................................................. 0 EC - Engine Control System................................................................................................ 0 FE - Accelerator Control, Fuel & Exhaust Systems.......................................................................... 0 CL - Clutch............................................................................................................... 0 MT - Manual Transmission.................................................................................................. 0 AT - Automatic Transmission............................................................................................... 0 TF - Transfer............................................................................................................. 0 PD - Propeller Shaft & Differential Carrier............................................................................... 0 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 at............................................................................................................................ 5 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents......................................................................................................... 5 TROUBLE DIAGNOSIS - INDEX................................................................................................. 8 Alphabetical & P No. Index for DTC.................................................................................... 8 PRECAUTIONS............................................................................................................... 10 Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................... 10 Precautions for On Board Diagnostic (OBD) System of A/T and Engine.................................................... 10 Precautions........................................................................................................... 10 Service Notice or Precautions......................................................................................... 12 Wiring Diagrams and Trouble Diagnosis................................................................................. 13 PREPARATION............................................................................................................... 14 Special Service Tools................................................................................................. 14 OVERALL SYSTEM............................................................................................................ 16 A/T Electrical Parts Location......................................................................................... 16 Circuit Diagram....................................................................................................... 17 Cross-sectional View.................................................................................................. 18 Hydraulic Control Circuit............................................................................................. 19 Shift Mechanism....................................................................................................... 20 Control System........................................................................................................ 29 Control Mechanism..................................................................................................... 30 Control Valve......................................................................................................... 35 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION.................................................................................... 37 Introduction.......................................................................................................... 37 OBD-II Function for A/T System........................................................................................ 37 One or Two Trip Detection Logic of OBD-II............................................................................. 37 OBD-II Diagnostic Trouble Code (DTC).................................................................................. 37 Malfunction Indicator Lamp (MIL)...................................................................................... 41 CONSULT-II............................................................................................................ 41 Diagnostic Procedure Without CONSULT-II............................................................................... 52 TROUBLE DIAGNOSIS - INTRODUCTION.......................................................................................... 59 Introduction.......................................................................................................... 59 Work Flow............................................................................................................. 63 TROUBLE DIAGNOSIS - BASIC INSPECTION...................................................................................... 65 A/T Fluid Check....................................................................................................... 65 Stall Test............................................................................................................ 65 Line Pressure Test.................................................................................................... 68 Road Test............................................................................................................. 69 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION................................................................................... 87 Symptom Chart......................................................................................................... 87 TCM Terminals and Reference Value..................................................................................... 99 CAN COMMUNICATION......................................................................................................... 102 System Description.................................................................................................... 102 TROUBLE DIAGNOSIS FOR POWER SUPPLY........................................................................................ 103 Wiring Diagram - AT - MAIN............................................................................................ 103 Diagnostic Procedure.................................................................................................. 104 DTC P0705 PARK/NEUTRAL POSITION SWITCH.................................................................................... 106 Description........................................................................................................... 106 Wiring Diagram - AT - PNP/SW.......................................................................................... 108 Diagnostic Procedure.................................................................................................. 109 Component Inspection.................................................................................................. 110 DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT............................................................................ 112 Description........................................................................................................... 112 Wiring Diagram - AT - FTS............................................................................................. 114 Diagnostic Procedure.................................................................................................. 115 Component Inspection.................................................................................................. 117 DTC P0720 VEHICLE SPEED SENSOR.A/T (REVOLUTION SENSOR).................................................................... 118 Description........................................................................................................... 118 Wiring Diagram - AT - VSSA/T.......................................................................................... 120 Diagnostic Procedure.................................................................................................. 121 Component Inspection.................................................................................................. 122 DTC P0725 ENGINE SPEED SIGNAL............................................................................................. 123 Description........................................................................................................... 123 Wiring Diagram - AT - ENGSS........................................................................................... 124 Diagnostic Procedure.................................................................................................. 125 DTC P0731 IMPROPER SHIFTING TO 1ST GEAR POSITION.......................................................................... 127 Description........................................................................................................... 127 Wiring Diagram - AT - 1ST............................................................................................. 130 Diagnostic Procedure.................................................................................................. 131 Component Inspection.................................................................................................. 132 DTC P0732 IMPROPER SHIFTING TO 2ND GEAR POSITION.......................................................................... 133 Description........................................................................................................... 133 Wiring Diagram - AT - 2ND............................................................................................. 136 Diagnostic Procedure.................................................................................................. 137 Component Inspection.................................................................................................. 138 DTC P0733 IMPROPER SHIFTING TO 3RD GEAR POSITION.......................................................................... 139 Description........................................................................................................... 139 Wiring Diagram - AT - 3RD............................................................................................. 142 Diagnostic Procedure.................................................................................................. 143 Component Inspection.................................................................................................. 144 DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION.......................................................................... 145 Description........................................................................................................... 145 Wiring Diagram - AT - 4TH............................................................................................. 149 Diagnostic Procedure.................................................................................................. 150 Component Inspection.................................................................................................. 154 DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE.......................................................................... 155 Description........................................................................................................... 155 Wiring Diagram - AT - TCV............................................................................................. 157 Diagnostic Procedure.................................................................................................. 158 Component Inspection.................................................................................................. 159 DTC P0744 IMPROPER LOCK-UP OPERATION...................................................................................... 160 Description........................................................................................................... 160 Wiring Diagram - AT - TCCSIG.......................................................................................... 163 Diagnostic Procedure.................................................................................................. 164 Component Inspection.................................................................................................. 168 DTC P0745 LINE PRESSURE SOLENOID VALVE.................................................................................... 169 Description........................................................................................................... 169 Wiring Diagram - AT - LPSV............................................................................................ 171 Diagnostic Procedure.................................................................................................. 172 Component Inspection.................................................................................................. 174 DTC P0750 SHIFT SOLENOID VALVE A.......................................................................................... 175 Description........................................................................................................... 175 Wiring Diagram - AT - SSV/A........................................................................................... 176 Diagnostic Procedure.................................................................................................. 177 Component Inspection.................................................................................................. 178 DTC P0755 SHIFT SOLENOID VALVE B.......................................................................................... 179 Description........................................................................................................... 179 Wiring Diagram - AT - SSV/B........................................................................................... 180 Diagnostic Procedure.................................................................................................. 181 Component Inspection.................................................................................................. 182 DTC P1705 ACCELERATOR PEDAL POSITION SENSOR (THROTTLE POSITION SENSOR).................................................... 183 Description........................................................................................................... 183 On Board Diagnosis Logic.............................................................................................. 184 Possible Cause........................................................................................................ 184 Diagnostic Trouble Code (DTC) Confirmation Procedure.................................................................. 185 Wiring Diagram - AT - TPS............................................................................................. 186 Diagnostic Procedure.................................................................................................. 187 DTC P1760 OVERRUN CLUTCH SOLENOID VALVE................................................................................... 189 Description........................................................................................................... 189 Wiring Diagram - AT - OVRCSV.......................................................................................... 191 Diagnostic Procedure.................................................................................................. 192 Component Inspection.................................................................................................. 193 DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE).............................................. 194 Description........................................................................................................... 194 Wiring Diagram - AT - BA/FTS.......................................................................................... 196 Diagnostic Procedure.................................................................................................. 197 Component Inspection.................................................................................................. 200 DTC VEHICLE SPEED SENSOR.MTR.............................................................................................. 201 Description........................................................................................................... 201 Wiring Diagram - AT - VSSMTR.......................................................................................... 203 Diagnostic Procedure.................................................................................................. 204 DTC U1000 CAN COMMUNICATION LINE.......................................................................................... 206 Description........................................................................................................... 206 On Board Diagnosis Logic.............................................................................................. 206 Possible Cause........................................................................................................ 206 Diagnostic Trouble Code (DTC) Confirmation Procedure.................................................................. 207 Wiring Diagram - AT - CAN............................................................................................. 208 Diagnostic Procedure.................................................................................................. 209 DTC TURBINE REVOLUTION SENSOR............................................................................................. 210 Description........................................................................................................... 210 Wiring Diagram - AT - TRSA/T.......................................................................................... 212 Diagnostic Procedure.................................................................................................. 213 Component Inspection.................................................................................................. 214 DTC CONTROL UNIT (RAM), CONTROL UNIT (ROM)................................................................................ 215 Description........................................................................................................... 215 Diagnostic Procedure.................................................................................................. 216 DTC CONTROL UNIT (EEP ROM)................................................................................................ 217 Description........................................................................................................... 217 Diagnostic Procedure.................................................................................................. 218 TROUBLE DIAGNOSES FOR SYMPTOMS............................................................................................ 219 Wiring Diagram - AT - NONDTC.......................................................................................... 219 O/D OFF Indicator Lamp Does Not Come On............................................................................... 222 Engine Cannot Be Started In "P" and "N" Position...................................................................... 224 In "P" Position, Vehicle Moves Forward Or Backward When Pushed........................................................ 225 In "N" Position, Vehicle Moves........................................................................................ 226 Large Shock. "N" -> "R" Position...................................................................................... 228 Vehicle Does Not Creep Backward In "R" Position....................................................................... 230 Vehicle Does Not Creep Forward In "D", "2" Or "1" Position............................................................ 233 Vehicle Cannot Be Started From D1..................................................................................... 236 A/T Does Not Shift: D1 -> D2 Or Does Not Kickdown: D4 -> D2........................................................... 239 A/T Does Not Shift: D2 -> D3.......................................................................................... 242 A/T Does Not Shift: D3 -> D4.......................................................................................... 245 A/T Does Not Perform Lock-up.......................................................................................... 248 A/T Does Not Hold Lock-up Condition................................................................................... 250 Lock-up Is Not Released............................................................................................... 252 Engine Speed Does Not Return To Idle (Light Braking D4 -> D3)......................................................... 253 Vehicle Does Not Start From D1........................................................................................ 255 A/T Does Not Shift: D4 -> D3, When Overdrive Control Switch "ON" -> "OFF"............................................. 256 A/T Does Not Shift: D3 -> 22, When Selector Lever "D" -> "2" Position................................................. 257 A/T Does Not Shift: 22 -> 11, When Selector Lever "2" -> "1" Position................................................. 258 Vehicle Does Not Decelerate By Engine Brake........................................................................... 259 TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control and Accelerator Pedal Position Sensor Circuit Checks).... 259 A/T SHIFT LOCK SYSTEM..................................................................................................... 266 Description........................................................................................................... 266 Wiring Diagram - SHIFT -.............................................................................................. 267 Diagnostic Procedure.................................................................................................. 268 KEY INTERLOCK CABLE....................................................................................................... 271 Components............................................................................................................ 271 Removal............................................................................................................... 271 Installation.......................................................................................................... 272 ON-VEHICLE SERVICE........................................................................................................ 273 Control Valve Assembly and Accumulators............................................................................... 273 Revolution Sensor Replacement......................................................................................... 274 Turbine Revolution Sensor Replacement................................................................................. 274 Rear Oil Seal Replacement............................................................................................. 274 Rear Oil Seal and Companion Flange Oil Seal Replacement............................................................... 275 Parking Components Inspection......................................................................................... 275 Park/Neutral Position Switch Adjustment............................................................................... 276 Manual Control Linkage Adjustment..................................................................................... 276 REMOVAL AND INSTALLATION.................................................................................................. 277 Removal............................................................................................................... 277 Installation.......................................................................................................... 278 OVERHAUL.................................................................................................................. 282 Components............................................................................................................ 282 Oil Channel........................................................................................................... 285 Locations of Needle Bearings, Thrust Washers and Snap Rings........................................................... 286 DISASSEMBLY............................................................................................................... 287 REPAIR FOR COMPONENT PARTS................................................................................................ 298 Oil Pump.............................................................................................................. 298 Control Valve Assembly................................................................................................ 302 Control Valve Upper Body.............................................................................................. 308 Control Valve Lower Body.............................................................................................. 313 Reverse Clutch........................................................................................................ 315 High Clutch........................................................................................................... 318 Forward and Overrun Clutches.......................................................................................... 321 Low & Reverse Brake................................................................................................... 325 Forward Clutch Drum Assembly.......................................................................................... 329 Rear Internal Gear and Forward Clutch Hub............................................................................. 331 Band Servo Piston Assembly............................................................................................ 334 Parking Pawl Components............................................................................................... 338 ASSEMBLY.................................................................................................................. 340 Assembly (1).......................................................................................................... 340 Adjustment............................................................................................................ 348 Assembly (2).......................................................................................................... 350 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................... 357 General Specifications................................................................................................ 357 Shift Schedule........................................................................................................ 357 Stall Revolution...................................................................................................... 357 Line Pressure......................................................................................................... 357 Return Springs........................................................................................................ 358 Accumulator O-ring.................................................................................................... 359 Clutches and Brakes................................................................................................... 359 Oil Pump and Low One-way Clutch....................................................................................... 361 Total End Play........................................................................................................ 361 Reverse Clutch Drum End Play.......................................................................................... 362 Removal and Installation.............................................................................................. 362 Shift Solenoid Valves................................................................................................. 362 Solenoid Valves....................................................................................................... 362 A/T Fluid Temperature Sensor.......................................................................................... 362 Turbine Revolution Sensor............................................................................................. 362 Revolution Sensor..................................................................................................... 363 Dropping Resistor..................................................................................................... 363 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............................................................................................................................ 365 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents......................................................................................................... 365 FRONT AXLE................................................................................................................ 366 Precautions........................................................................................................... 366 PRECAUTIONS....................................................................................................... 366 Preparation........................................................................................................... 366 SPECIAL SERVICE TOOLS............................................................................................. 366 COMMERCIAL SERVICE TOOLS.......................................................................................... 366 Noise, Vibration and Harshness (NVH) Troubleshooting.................................................................. 367 NVH TROUBLESHOOTING CHART......................................................................................... 367 On-vehicle Service.................................................................................................... 367 FRONT AXLE PARTS.................................................................................................. 367 FRONT WHEEL BEARING............................................................................................... 368 DRIVE SHAFT (4WD)................................................................................................. 369 Wheel Hub and Rotor Disc.............................................................................................. 370 COMPONENTS........................................................................................................ 370 REMOVAL........................................................................................................... 371 INSTALLATION...................................................................................................... 373 DISASSEMBLY....................................................................................................... 373 INSPECTION........................................................................................................ 373 ASSEMBLY.......................................................................................................... 374 Knuckle Spindle....................................................................................................... 374 REMOVAL........................................................................................................... 374 INSPECTION........................................................................................................ 375 INSTALLATION...................................................................................................... 375 Drive Shaft (4WD)..................................................................................................... 376 COMPONENTS........................................................................................................ 376 REMOVAL........................................................................................................... 376 DISASSEMBLY....................................................................................................... 377 INSPECTION........................................................................................................ 378 ASSEMBLY.......................................................................................................... 378 INSTALLATION...................................................................................................... 379 Service Data and Specifications (SDS)................................................................................. 380 WHEEL BEARING (FRONT)............................................................................................. 380 DRIVE SHAFT (4WD)................................................................................................. 380 REAR AXLE................................................................................................................. 382 Precautions........................................................................................................... 382 PRECAUTIONS....................................................................................................... 382 Preparation........................................................................................................... 382 SPECIAL SERVICE TOOLS............................................................................................. 382 COMMERCIAL SERVICE TOOLS.......................................................................................... 383 Noise, Vibration and Harshness (NVH) Troubleshooting.................................................................. 383 On-vehicle Service.................................................................................................... 383 REAR AXLE PARTS................................................................................................... 383 REAR WHEEL BEARING................................................................................................ 383 Components............................................................................................................ 384 Removal............................................................................................................... 384 Inspection............................................................................................................ 386 AXLE SHAFT........................................................................................................ 386 BEARING CAGE...................................................................................................... 386 REAR AXLE HOUSING................................................................................................. 386 Installation.......................................................................................................... 386 Service Data and Specifications (SDS)................................................................................. 387 WHEEL BEARING (REAR).............................................................................................. 387 br............................................................................................................................ 389 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents......................................................................................................... 389 PRECAUTIONS............................................................................................................... 392 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................... 392 Precautions for SRS "Air Bag" and "SEAT BELT PRE-TENSIONER" Service................................................... 392 Precautions for Brake System.......................................................................................... 392 Wiring Diagrams and Trouble Diagnoses................................................................................. 393 PREPARATION............................................................................................................... 394 Special Service Tools................................................................................................. 394 Commercial Service Tools.............................................................................................. 394 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................... 395 NVH Troubleshooting Chart............................................................................................. 395 ON-VEHICLE SERVICE........................................................................................................ 396 Checking Brake Fluid Level............................................................................................ 396 Checking Brake Line................................................................................................... 396 Changing Brake Fluid.................................................................................................. 396 Bleeding Brake System................................................................................................. 397 BRAKE HYDRAULIC LINE...................................................................................................... 398 Hydraulic Circuit..................................................................................................... 398 Removal............................................................................................................... 399 Inspection............................................................................................................ 399 Installation.......................................................................................................... 399 PROPORTIONING VALVE....................................................................................................... 400 Inspection............................................................................................................ 400 Removal and Installation.............................................................................................. 400 BRAKE PEDAL AND BRACKET................................................................................................... 401 Removal and Installation.............................................................................................. 401 Inspection............................................................................................................ 401 Adjustment............................................................................................................ 401 MASTER CYLINDER........................................................................................................... 403 Removal............................................................................................................... 403 Disassembly........................................................................................................... 404 MODELS WITHOUT VDC................................................................................................ 404 MODELS WITH VDC................................................................................................... 404 Inspection............................................................................................................ 404 Assembly.............................................................................................................. 405 MODELS WITHOUT VDC................................................................................................ 405 MODELS WITH VDC................................................................................................... 405 Installation.......................................................................................................... 406 BRAKE BOOSTER............................................................................................................. 407 On-vehicle Service.................................................................................................... 407 OPERATING CHECK................................................................................................... 407 AIRTIGHT CHECK.................................................................................................... 407 Removal............................................................................................................... 407 Inspection............................................................................................................ 407 OUTPUT ROD LENGTH CHECK........................................................................................... 407 Installation.......................................................................................................... 408 VACUUM PIPING............................................................................................................. 409 Vacuum Hose........................................................................................................... 409 Removal and Installation.............................................................................................. 409 Inspection............................................................................................................ 409 HOSES AND CONNECTORS.............................................................................................. 409 CHECK VALVE....................................................................................................... 409 FRONT DISC BRAKE.......................................................................................................... 410 Components............................................................................................................ 410 Pad Replacement....................................................................................................... 410 Removal............................................................................................................... 411 Disassembly........................................................................................................... 412 Inspection............................................................................................................ 412 CALIPER........................................................................................................... 412 ROTOR............................................................................................................. 412 Assembly.............................................................................................................. 413 Installation.......................................................................................................... 413 Brake Burnishing Procedure............................................................................................ 413 REAR DRUM BRAKE........................................................................................................... 414 Components............................................................................................................ 414 Removal............................................................................................................... 414 Inspection............................................................................................................ 415 WHEEL CYLINDER.................................................................................................... 415 Wheel Cylinder Overhaul............................................................................................... 416 Inspection............................................................................................................ 416 DRUM.............................................................................................................. 416 LINING............................................................................................................ 416 Installation.......................................................................................................... 416 PARKING BRAKE CONTROL..................................................................................................... 418 Components............................................................................................................ 418 Removal and Installation.............................................................................................. 418 Inspection............................................................................................................ 418 Adjustment............................................................................................................ 419 ABS....................................................................................................................... 420 DESCRIPTION........................................................................................................... 420 Purpose........................................................................................................... 420 Operation......................................................................................................... 420 ABS Hydraulic Circuit............................................................................................. 420 System Components................................................................................................. 421 System Description................................................................................................ 421 SENSOR........................................................................................................ 421 BUILT-IN ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)........................................................ 421 ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)................................................................. 421 G SENSOR (4WD MODELS ONLY).................................................................................... 422 Component Parts and Harness Connector Location.................................................................... 423 Schematic......................................................................................................... 424 Wiring Diagram - ABS -............................................................................................ 425 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION................................................................................ 429 Self-diagnosis.................................................................................................... 429 FUNCTION...................................................................................................... 429 SELF-DIAGNOSIS PROCEDURE...................................................................................... 429 HOW TO READ SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES)....................................................... 430 HOW TO ERASE SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES)...................................................... 430 CONSULT-II........................................................................................................ 431 CONSULT-II APPLICATION TO ABS................................................................................. 431 ECU [ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)] PART NUMBER MODE.......................................... 431 CONSULT-II Inspection Procedure................................................................................... 432 SELF-DIAGNOSIS PROCEDURE...................................................................................... 432 SELF-DIAGNOSTIC RESULTS MODE.................................................................................. 433 DATA MONITOR PROCEDURE........................................................................................ 434 ACTIVE TEST PROCEDURE......................................................................................... 435 DATA MONITOR MODE............................................................................................. 436 ACTIVE TEST MODE.............................................................................................. 436 TROUBLE DIAGNOSIS - INTRODUCTION...................................................................................... 437 How to Perform Trouble Diagnoses for Quick and Accurate Repair.................................................... 437 INTRODUCTION.................................................................................................. 437 TROUBLE DIAGNOSIS - BASIC INSPECTION.................................................................................. 438 Preliminary Check................................................................................................. 438 Ground Circuit Check.............................................................................................. 441 ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) GROUND.......................................................... 441 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION............................................................................... 442 Malfunction Code/Symptom Chart.................................................................................... 442 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS........................................................................... 444 Wheel Sensor or Rotor............................................................................................. 444 DIAGNOSTIC PROCEDURE.......................................................................................... 444 ABS Actuator Solenoid Valve or Solenoid Valve Relay............................................................... 447 DIAGNOSTIC PROCEDURE.......................................................................................... 447 Motor Relay or Motor.............................................................................................. 449 DIAGNOSTIC PROCEDURE.......................................................................................... 449 Low Voltage....................................................................................................... 451 DIAGNOSTIC PROCEDURE.......................................................................................... 451 G Sensor and Circuit.............................................................................................. 453 DIAGNOSTIC PROCEDURE.......................................................................................... 453 Control Unit...................................................................................................... 455 DIAGNOSTIC PROCEDURE.......................................................................................... 455 TROUBLE DIAGNOSES FOR SYMPTOMS........................................................................................ 456 1. ABS Works Frequently........................................................................................... 456 2. Unexpected Pedal Action........................................................................................ 456 3. Long Stopping Distance......................................................................................... 458 4. ABS Does Not Work.............................................................................................. 458 5. Pedal Vibration and Noise...................................................................................... 459 6. Warning Lamp Does Not Come On When Ignition Switch Is Turned On................................................ 460 7. Warning Lamp Stays On When Ignition Switch Is Turned On........................................................ 462 8. Vehicle Vibrates Excessively When ABS Is Operating............................................................. 465 REMOVAL AND INSTALLATION.............................................................................................. 468 Front Wheel Sensor................................................................................................ 468 Rear Wheel Sensor................................................................................................. 468 Front Sensor Rotor................................................................................................ 469 REMOVAL....................................................................................................... 469 INSTALLATION.................................................................................................. 469 Rear Sensor Rotor................................................................................................. 469 REMOVAL....................................................................................................... 469 INSTALLATION.................................................................................................. 469 G Sensor.......................................................................................................... 469 ABS Actuator and Electric Unit (Control Unit)..................................................................... 470 REMOVAL....................................................................................................... 470 INSTALLATION.................................................................................................. 470 VDC/TCS/ABS............................................................................................................... 471 PRECAUTIONS........................................................................................................... 471 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"....................................... 471 Precautions for SRS "Air Bag" and "SEAT BELT PRE-TENSIONER" Service............................................... 471 Precautions for Brake System...................................................................................... 471 Precautions for Brake Control..................................................................................... 472 PREPARATION........................................................................................................... 473 Commercial Service Tools.......................................................................................... 473 ON-VEHICLE SERVICE.................................................................................................... 474 Adjustment of Steering Angle Sensor Neutral Position.............................................................. 474 Calibration of Decel G Sensor..................................................................................... 474 GENERAL INFORMATION................................................................................................... 476 Fail-Safe......................................................................................................... 476 ABS SYSTEM.................................................................................................... 476 VDC/TCS SYSTEM................................................................................................ 476 Hydraulic Circuit Diagram......................................................................................... 476 ABS Function...................................................................................................... 476 TCS Function...................................................................................................... 477 VDC Function...................................................................................................... 477 System Diagram.................................................................................................... 477 CAN COMMUNICATION..................................................................................................... 478 System Description................................................................................................ 478 TROUBLE DIAGNOSES..................................................................................................... 479 How to Proceed with Diagnosis..................................................................................... 479 BASIC CONCEPT................................................................................................. 479 DIAGNOSIS FLOWCHART........................................................................................... 480 ASKING COMPLAINTS............................................................................................. 481 EXAMPLE OF DIAGNOSIS SHEET.................................................................................... 481 Component Installation Location................................................................................... 482 Schematic......................................................................................................... 483 Wiring Diagram - VDC -............................................................................................ 484 Control Unit Input/Output Signal Standard......................................................................... 489 STANDARDS BY CONSULT-II....................................................................................... 489 CONSULT-II Functions.............................................................................................. 491 CONSULT-II MAIN FUNCTION...................................................................................... 491 SELF-DIAGNOSIS................................................................................................ 493 DATA MONITOR.................................................................................................. 496 ACTIVE TEST................................................................................................... 499 For Fast and Accurate Diagnosis................................................................................... 501 PRECAUTIONS FOR DIAGNOSIS..................................................................................... 501 Basic Inspection.................................................................................................. 503 BASIC INSPECTION 1: BRAKE FLUID LEVEL AND LEAK INSPECTION..................................................... 503 BASIC INSPECTION 2: INSPECTION FOR LOOSENESS OF POWER SYSTEM TERMINALS........................................ 503 BASIC INSPECTION 3: INSPECTION OF ABS WARNING LAMP, VDC OFF INDICATOR LAMP AND SLIP INDICATOR LAMP............ 503 Inspection 1 Wheel Sensor System.................................................................................. 504 INSPECTION PROCEDURE.......................................................................................... 504 Inspection 2 Engine System........................................................................................ 506 Inspection 3 VDC/TCS/ABS Control Unit System...................................................................... 506 Inspection 4 VDC Pressure Sensor System........................................................................... 507 Inspection 5 Steering Angle Sensor System......................................................................... 508 Inspection 6 Yaw Rate/Side/Decel G Sensor System.................................................................. 509 Inspection 7 Solenoid Valve, VDC Switch-over Solenoid Valve and Circuit........................................... 511 Inspection 8 ABS Actuator Relay or ABS Motor Relay Power System................................................... 513 Inspection 9 Stop Lamp Switch and Circuit......................................................................... 514 Inspection 10 ABS Actuator and Electric Unit (Control Unit) Power Circuit......................................... 515 Inspection 11 When "SHIFT POSITION ERROR" Appears in Self-Diagnosis Results Display............................... 517 Inspection 12 When "ST ANG SEN COM CIR" Appears on Self-Diagnosis Results Display................................. 518 Inspection 13 Brake Fluid Level of Reservoir Tank................................................................. 518 Inspection 14 CAN Communications System........................................................................... 519 Inspecting Components............................................................................................. 519 VDC OFF SWITCH................................................................................................ 519 Symptom 1 ABS Works Frequently.................................................................................... 520 Symptom 2 Unexpected Pedal Reaction............................................................................... 520 Symptom 3 Long Stopping Distance.................................................................................. 521 Symptom 4 ABS Does Not Work....................................................................................... 522 Symptom 5 Pedal Vibration and Noise............................................................................... 522 Symptom 6 VDC OFF Indicator Lamp Does Not Illuminate.............................................................. 523 Symptom 7 SLIP Indicator Lamp Does Not Illuminate................................................................. 524 Symptom 8 Vehicle Behaves Jerkily During VDC/TCS/ABS Operation.................................................... 525 WHEEL SENSORS......................................................................................................... 527 Removal and Installation.......................................................................................... 527 REMOVAL....................................................................................................... 527 INSTALLATION.................................................................................................. 527 SENSOR ROTOR.......................................................................................................... 529 Removal and Installation.......................................................................................... 529 REMOVAL....................................................................................................... 529 INSTALLATION.................................................................................................. 529 VDC/TCS/ABS ACTUATOR.................................................................................................. 530 Removal and Installation.......................................................................................... 530 G SENSOR.............................................................................................................. 531 Removal and Installation.......................................................................................... 531 REMOVAL....................................................................................................... 531 INSTALLATION.................................................................................................. 531 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................... 532 General Specifications................................................................................................ 532 Disc Brake............................................................................................................ 532 Drum Brake............................................................................................................ 532 Brake Pedal........................................................................................................... 532 Parking Brake Control................................................................................................. 533 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............................................................................................................................ 535 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents......................................................................................................... 535 PRECAUTIONS............................................................................................................... 537 Service Notice........................................................................................................ 537 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................... 537 PREPARATION............................................................................................................... 538 Special Service Tools................................................................................................. 538 Commercial Service Tool............................................................................................... 538 SQUEAK AND RATTLE TROUBLE DIAGNOSES....................................................................................... 539 Work Flow............................................................................................................. 539 CUSTOMER INTERVIEW................................................................................................ 539 DUPLICATE THE NOISE AND TEST DRIVE................................................................................ 540 CHECK RELATED SERVICE BULLETINS................................................................................... 540 LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE...................................................................... 540 REPAIR THE CAUSE.................................................................................................. 540 CONFIRM THE REPAIR................................................................................................ 541 Generic Squeak and Rattle Troubleshooting............................................................................. 541 INSTRUMENT PANEL.................................................................................................. 541 CENTER CONSOLE.................................................................................................... 541 DOORS............................................................................................................. 541 TRUNK............................................................................................................. 542 SUNROOF/HEADLINER................................................................................................. 542 SEATS............................................................................................................. 542 UNDERHOOD......................................................................................................... 542 Diagnostic Worksheet.................................................................................................. 543 CLIP AND FASTENER......................................................................................................... 545 Description........................................................................................................... 545 BODY FRONT END............................................................................................................ 547 Removal and Installation.............................................................................................. 547 REMOVAL........................................................................................................... 548 INSTALLATION...................................................................................................... 550 BODY REAR END AND OPENER.................................................................................................. 551 Removal and Installation.............................................................................................. 551 REMOVAL........................................................................................................... 551 INSTALLATION...................................................................................................... 554 FRONT DOOR................................................................................................................ 555 Overhaul.............................................................................................................. 555 Front Door Limit Switch Reset......................................................................................... 556 RESET CONDITIONS.................................................................................................. 556 RESET PROCEDURES.................................................................................................. 556 REAR DOOR................................................................................................................. 557 Overhaul.............................................................................................................. 557 INSTRUMENT PANEL ASSEMBLY................................................................................................. 558 Removal and Installation.............................................................................................. 558 SIDE AND FLOOR TRIM....................................................................................................... 565 Removal and Installation.............................................................................................. 565 DOOR TRIM................................................................................................................. 567 Removal and Installation.............................................................................................. 567 TYPE A............................................................................................................ 567 TYPE B............................................................................................................ 568 ROOF TRIM................................................................................................................. 570 Removal and Installation.............................................................................................. 570 BACK DOOR TRIM............................................................................................................ 571 Removal and Installation.............................................................................................. 571 EXTERIOR.................................................................................................................. 572 Removal and Installation.............................................................................................. 572 FRONT SEAT................................................................................................................ 579 Removal and Installation.............................................................................................. 579 POWER SEAT........................................................................................................ 580 MANUAL SEAT....................................................................................................... 581 HEATED SEAT....................................................................................................... 582 REAR SEAT................................................................................................................. 583 Removal and Installation.............................................................................................. 583 SUNROOF................................................................................................................... 584 Adjustment............................................................................................................ 584 Contents of Working................................................................................................... 585 Contents of Switch Working............................................................................................ 586 JAM PROTECTION.................................................................................................... 586 Removal and Installation.............................................................................................. 586 Trouble Diagnoses..................................................................................................... 590 DIAGNOSTIC TABLE.................................................................................................. 590 WIND DEFLECTOR.................................................................................................... 590 ADJUSTMENT........................................................................................................ 591 DRAIN HOSES....................................................................................................... 592 WEATHERSTRIP...................................................................................................... 593 LINK AND WIRE ASSEMBLY............................................................................................ 593 WINDSHIELD AND WINDOWS.................................................................................................... 594 Removal and Installation.............................................................................................. 594 REMOVAL........................................................................................................... 594 INSTALLATION...................................................................................................... 594 WINDSHIELD........................................................................................................ 595 REAR SIDE WINDOW.................................................................................................. 596 DOOR MIRROR............................................................................................................... 597 Removal and Installation.............................................................................................. 597 BODY (ALIGNMENT).......................................................................................................... 598 Alignment............................................................................................................. 598 ENGINE COMPARTMENT................................................................................................ 599 UNDERBODY......................................................................................................... 601 cl............................................................................................................................ 603 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents......................................................................................................... 603 PRECAUTIONS............................................................................................................... 604 Precautions........................................................................................................... 604 PREPARATION............................................................................................................... 605 Special Service Tools................................................................................................. 605 Commercial Service Tools.............................................................................................. 605 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................... 606 NVH Troubleshooting Chart............................................................................................. 606 CLUTCH............................................................................................................ 606 CLUTCH SYSTEM - HYDRAULIC TYPE............................................................................................ 607 Components............................................................................................................ 607 On-Vehicle Inspection and Adjustment.................................................................................. 608 Air Bleeding Procedure................................................................................................ 609 CLUTCH MASTER CYLINDER.................................................................................................... 610 Components............................................................................................................ 610 Disassembly and Assembly.............................................................................................. 610 Inspection............................................................................................................ 610 OPERATING CYLINDER........................................................................................................ 611 Components............................................................................................................ 611 Inspection............................................................................................................ 611 CLUTCH RELEASE MECHANISM.................................................................................................. 612 Components............................................................................................................ 612 Removal............................................................................................................... 612 Inspection............................................................................................................ 613 Installation.......................................................................................................... 613 Lubrication........................................................................................................... 613 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL.................................................................................... 614 Components............................................................................................................ 614 Removal............................................................................................................... 614 Inspection and Adjustment............................................................................................. 614 CLUTCH DISC....................................................................................................... 614 CLUTCH COVER...................................................................................................... 615 FLYWHEEL INSPECTION............................................................................................... 615 Installation.......................................................................................................... 615 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................... 617 Clutch Control System................................................................................................. 617 Clutch Master Cylinder (With damper).................................................................................. 617 Clutch Operating Cylinder............................................................................................. 617 Clutch Disc........................................................................................................... 617 Clutch Cover.......................................................................................................... 617 Clutch Pedal.......................................................................................................... 617 ec............................................................................................................................ 619 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents......................................................................................................... 619 TROUBLE DIAGNOSIS - INDEX................................................................................................. 627 Alphabetical Index.................................................................................................... 627 DTC No. Index......................................................................................................... 631 PRECAUTIONS............................................................................................................... 636 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................... 636 Precautions for On Board Diagnostic (OBD) System of Engine and A/T.................................................... 636 Engine Fuel & Emission Control System................................................................................. 637 Precautions........................................................................................................... 638 Wiring Diagrams and Trouble Diagnosis................................................................................. 639 PREPARATION............................................................................................................... 640 Special Service Tools................................................................................................. 640 Commercial Service Tools.............................................................................................. 641 ENGINE AND EMISSION CONTROL OVERALL SYSTEM................................................................................ 643 Engine Control Component Parts Location............................................................................... 643 Circuit Diagram....................................................................................................... 648 System Diagram........................................................................................................ 649 Vacuum Hose Drawing................................................................................................... 650 System Chart.......................................................................................................... 651 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION...................................................................... 652 Multiport Fuel Injection (MFI) System................................................................................. 652 Electronic Ignition (EI) System....................................................................................... 654 Air Conditioning Cut Control.......................................................................................... 655 Fuel Cut Control (at no load & high engine speed)..................................................................... 656 Evaporative Emission System........................................................................................... 656 On Board Refueling Vapor Recovery (ORVR).............................................................................. 662 Positive Crankcase Ventilation........................................................................................ 671 CAN Communication..................................................................................................... 672 Automatic Speed Control Device (ASCD) System.......................................................................... 672 BASIC SERVICE PROCEDURE................................................................................................... 674 Fuel Pressure Release................................................................................................. 674 Fuel Pressure Check................................................................................................... 674 Fuel Pressure Regulator Check......................................................................................... 675 Injector.............................................................................................................. 676 How to Check Idle Speed and Ignition Timing........................................................................... 677 Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment.............................................................. 679 Accelerator Pedal Released Position Learning.......................................................................... 691 Throttle Valve Closed Position Learning............................................................................... 691 Idle Air Volume Learning.............................................................................................. 691 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION.................................................................................... 695 Introduction.......................................................................................................... 695 Two Trip Detection Logic.............................................................................................. 695 Emission-related Diagnostic Information............................................................................... 696 Malfunction Indicator Lamp (MIL)...................................................................................... 712 OBD System Operation Chart............................................................................................ 716 CONSULT-II Function (ENGINE).......................................................................................... 721 Generic Scan Tool (GST)............................................................................................... 735 TROUBLE DIAGNOSIS - INTRODUCTION.......................................................................................... 737 Introduction.......................................................................................................... 737 Work Flow............................................................................................................. 739 TROUBLE DIAGNOSIS - BASIC INSPECTION...................................................................................... 741 Basic Inspection...................................................................................................... 741 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION................................................................................... 747 DTC Inspection Priority Chart......................................................................................... 747 Fail-safe Chart....................................................................................................... 748 Symptom Matrix Chart.................................................................................................. 749 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 753 Major Sensor Reference Graph in Data Monitor Mode..................................................................... 757 ECM Terminals and Reference Value..................................................................................... 759 TROUBLE DIAGNOSIS - SPECIFICATION VALUE................................................................................... 769 Description........................................................................................................... 769 Testing Condition..................................................................................................... 769 Inspection Procedure.................................................................................................. 769 Diagnostic Procedure.................................................................................................. 770 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT............................................................................... 773 Description........................................................................................................... 773 Diagnostic Procedure.................................................................................................. 773 POWER SUPPLY AND GROUND CIRCUIT........................................................................................... 774 ECM Terminals and Reference Value..................................................................................... 774 Wiring Diagram........................................................................................................ 775 Diagnostic Procedure.................................................................................................. 777 Ground Inspection..................................................................................................... 783 DTC U1000, U1001 CAN COMMUNICATION LINE................................................................................... 784 Description........................................................................................................... 784 On Board Diagnosis Logic.............................................................................................. 784 DTC Confirmation Procedure............................................................................................ 784 Wiring Diagram........................................................................................................ 785 Diagnostic Procedure.................................................................................................. 786 DTC P0011, P0021 IVT CONTROL.............................................................................................. 787 Description........................................................................................................... 787 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 788 On Board Diagnosis Logic.............................................................................................. 788 DTC Confirmation Procedure............................................................................................ 788 Diagnostic Procedure.................................................................................................. 789 Component Inspection.................................................................................................. 790 DTC P0031, P0032, P0051, P0052 HO2S1 HEATER............................................................................... 791 Description........................................................................................................... 791 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 791 ECM Terminals and Reference Value..................................................................................... 791 On Board Diagnosis Logic.............................................................................................. 792 DTC Confirmation Procedure............................................................................................ 792 Wiring Diagram........................................................................................................ 794 Diagnostic Procedure.................................................................................................. 796 DTC P0037, P0038, P0057, P0058 HO2S2 HEATER............................................................................... 799 Description........................................................................................................... 799 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 799 ECM Terminals and Reference Value..................................................................................... 799 On Board Diagnosis Logic.............................................................................................. 800 DTC Confirmation Procedure............................................................................................ 800 Wiring Diagram........................................................................................................ 801 Diagnostic Procedure.................................................................................................. 803 DTC P0101 MAF SENSOR...................................................................................................... 805 Component Description................................................................................................. 805 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 805 ECM Terminals and Reference Value..................................................................................... 805 On Board Diagnosis Logic.............................................................................................. 806 DTC Confirmation Procedure............................................................................................ 806 Overall Function Check................................................................................................ 807 Wiring Diagram........................................................................................................ 808 Diagnostic Procedure.................................................................................................. 809 DTC P0102, P0103 MAF SENSOR............................................................................................... 812 Component Description................................................................................................. 812 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 812 ECM Terminals and Reference Value..................................................................................... 812 On Board Diagnosis Logic.............................................................................................. 813 DTC Confirmation Procedure............................................................................................ 813 Wiring Diagram........................................................................................................ 814 Diagnostic Procedure.................................................................................................. 815 DTC P0112, P0113 IAT SENSOR............................................................................................... 818 Component Description................................................................................................. 818 On Board Diagnosis Logic.............................................................................................. 818 DTC Confirmation Procedure............................................................................................ 818 Wiring Diagram........................................................................................................ 819 Diagnostic Procedure.................................................................................................. 820 Component Inspection.................................................................................................. 821 DTC P0117, P0118 ECT SENSOR............................................................................................... 822 Component Description................................................................................................. 822 On Board Diagnosis Logic.............................................................................................. 822 DTC Confirmation Procedure............................................................................................ 823 Wiring Diagram........................................................................................................ 824 Diagnostic Procedure.................................................................................................. 825 DTC P0122, P0123 TP SENSOR................................................................................................ 828 Component Description................................................................................................. 828 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 828 ECM Terminals and Reference Value..................................................................................... 828 On Board Diagnosis Logic.............................................................................................. 829 DTC Confirmation Procedure............................................................................................ 829 Wiring Diagram........................................................................................................ 831 Diagnostic Procedure.................................................................................................. 832 Component Inspection.................................................................................................. 834 DTC P0125 ECT SENSOR...................................................................................................... 835 Description........................................................................................................... 835 On Board Diagnosis Logic.............................................................................................. 835 DTC Confirmation Procedure............................................................................................ 836 Diagnostic Procedure.................................................................................................. 836 DTC P0127 IAT SENSOR...................................................................................................... 838 Component Description................................................................................................. 838 On Board Diagnosis Logic.............................................................................................. 838 DTC Confirmation Procedure............................................................................................ 838 Diagnostic Procedure.................................................................................................. 839 DTC P0128 THERMOSTAT FUNCTION............................................................................................. 840 On Board Diagnosis Logic.............................................................................................. 840 DTC Confirmation Procedure............................................................................................ 840 Diagnostic Procedure.................................................................................................. 841 DTC P0132, P0152 HO2S1.................................................................................................... 842 Component Description................................................................................................. 842 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 842 ECM Terminals and Reference Value..................................................................................... 842 On Board Diagnosis Logic.............................................................................................. 843 DTC Confirmation Procedure............................................................................................ 843 Wiring Diagram........................................................................................................ 844 Diagnostic Procedure.................................................................................................. 846 DTC P0133, P0153 HO2S1.................................................................................................... 851 Component Description................................................................................................. 851 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 851 ECM Terminals and Reference Value..................................................................................... 851 On Board Diagnosis Logic.............................................................................................. 852 DTC Confirmation Procedure............................................................................................ 852 Overall Function Check................................................................................................ 853 Wiring Diagram........................................................................................................ 854 Diagnostic Procedure.................................................................................................. 856 DTC P0134, P0154 HO2S1.................................................................................................... 864 Component Description................................................................................................. 864 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 864 ECM Terminals and Reference Value..................................................................................... 864 On Board Diagnosis Logic.............................................................................................. 865 DTC Confirmation Procedure............................................................................................ 865 Overall Function Check................................................................................................ 866 Wiring Diagram........................................................................................................ 867 Diagnostic Procedure.................................................................................................. 869 DTC P0138, P0158 HO2S2.................................................................................................... 873 Component Description................................................................................................. 873 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 873 ECM Terminals and Reference Value..................................................................................... 873 On Board Diagnosis Logic.............................................................................................. 873 DTC Confirmation Procedure............................................................................................ 874 Wiring Diagram........................................................................................................ 875 Diagnostic Procedure.................................................................................................. 877 DTC P0139, P0159 HO2S2.................................................................................................... 881 Component Description................................................................................................. 881 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 881 ECM Terminals and Reference Value..................................................................................... 881 On Board Diagnosis Logic.............................................................................................. 881 DTC Confirmation Procedure............................................................................................ 882 Overall Function Check................................................................................................ 882 Wiring Diagram........................................................................................................ 884 Diagnostic Procedure.................................................................................................. 886 DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION........................................................................... 891 On Board Diagnosis Logic.............................................................................................. 891 DTC Confirmation Procedure............................................................................................ 891 Wiring Diagram........................................................................................................ 893 Diagnostic Procedure.................................................................................................. 895 DTC P0172, P0175 FUEL INJECTION SYSTEM FUNCTION........................................................................... 900 On Board Diagnosis Logic.............................................................................................. 900 DTC Confirmation Procedure............................................................................................ 900 Wiring Diagram........................................................................................................ 902 Diagnostic Procedure.................................................................................................. 904 DTC P0181 FTT SENSOR...................................................................................................... 908 Component Description................................................................................................. 908 On Board Diagnosis Logic.............................................................................................. 908 DTC Confirmation Procedure............................................................................................ 908 Diagnostic Procedure.................................................................................................. 909 DTC P0182, P0183 FTT SENSOR............................................................................................... 911 Component Description................................................................................................. 911 On Board Diagnosis Logic.............................................................................................. 911 DTC Confirmation Procedure............................................................................................ 911 Wiring Diagram........................................................................................................ 913 Diagnostic Procedure.................................................................................................. 914 DTC P0222, P0223 TP SENSOR................................................................................................ 916 Component Description................................................................................................. 916 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 916 ECM Terminals and Reference Value..................................................................................... 916 On Board Diagnosis Logic.............................................................................................. 917 DTC Confirmation Procedure............................................................................................ 917 Wiring Diagram........................................................................................................ 919 Diagnostic Procedure.................................................................................................. 920 Component Inspection.................................................................................................. 922 DTC P0300 - P0306 MULTIPLE CYLINDER MISFIRE, NO. 1 - 6 CYLINDER MISFIRE................................................... 923 On Board Diagnosis Logic.............................................................................................. 923 DTC Confirmation Procedure............................................................................................ 924 Diagnostic Procedure.................................................................................................. 925 DTC P0327, P0328 KS....................................................................................................... 932 Component Description................................................................................................. 932 ECM Terminals and Reference Value..................................................................................... 932 On Board Diagnosis Logic.............................................................................................. 932 DTC Confirmation Procedure............................................................................................ 932 Wiring Diagram........................................................................................................ 933 Diagnostic Procedure.................................................................................................. 934 DTC P0335 CKP SENSOR (POS)................................................................................................ 937 Component Description................................................................................................. 937 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 937 On Board Diagnosis Logic.............................................................................................. 937 DTC Confirmation Procedure............................................................................................ 938 Wiring Diagram........................................................................................................ 939 Diagnostic Procedure.................................................................................................. 940 Component Inspection.................................................................................................. 943 DTC P0340, P0345 CMP SENSOR (PHASE)....................................................................................... 944 Component Description................................................................................................. 944 On Board Diagnosis Logic.............................................................................................. 944 DTC Confirmation Procedure............................................................................................ 944 Wiring Diagram........................................................................................................ 946 Diagnostic Procedure.................................................................................................. 948 Component Inspection.................................................................................................. 951 DTC P0420, P0430 THREE WAY CATALYST FUNCTION.............................................................................. 952 On Board Diagnosis Logic.............................................................................................. 952 DTC Confirmation Procedure............................................................................................ 952 Overall Function Check................................................................................................ 953 Diagnostic Procedure.................................................................................................. 953 DTC P0441 EVAP CONTROL SYSTEM............................................................................................. 957 System Description.................................................................................................... 957 On Board Diagnosis Logic.............................................................................................. 957 DTC Confirmation Procedure............................................................................................ 958 Overall Function Check................................................................................................ 958 Diagnostic Procedure.................................................................................................. 960 DTC P0442 EVAP CONTROL SYSTEM............................................................................................. 967 On Board Diagnosis Logic.............................................................................................. 967 DTC Confirmation Procedure............................................................................................ 968 Diagnostic Procedure.................................................................................................. 969 DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE........................................................ 982 Description........................................................................................................... 982 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 982 ECM Terminals and Reference Value..................................................................................... 983 On Board Diagnosis Logic.............................................................................................. 983 DTC Confirmation Procedure............................................................................................ 984 Wiring Diagram........................................................................................................ 985 Diagnostic Procedure.................................................................................................. 986 DTC P0447 EVAP CANISTER VENT CONTROL VALVE................................................................................ 989 Component Description................................................................................................. 989 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 989 ECM Terminals and Reference Value..................................................................................... 989 On Board Diagnosis Logic.............................................................................................. 989 DTC Confirmation Procedure............................................................................................ 990 Wiring Diagram........................................................................................................ 991 Diagnostic Procedure.................................................................................................. 992 DTC P0452 EVAP SYSTEM PRESSURE SENSOR..................................................................................... 996 Component Description................................................................................................. 996 CONSULT-II Reference Value in Data Monitor Mode....................................................................... 996 ECM Terminals and Reference Value..................................................................................... 996 On Board Diagnosis Logic.............................................................................................. 996 DTC Confirmation Procedure............................................................................................ 997 Wiring Diagram........................................................................................................ 998 Diagnostic Procedure.................................................................................................. 999 DTC P0453 EVAP SYSTEM PRESSURE SENSOR.....................................................................................1002 Component Description.................................................................................................1002 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1002 ECM Terminals and Reference Value.....................................................................................1002 On Board Diagnosis Logic..............................................................................................1003 DTC Confirmation Procedure............................................................................................1003 Wiring Diagram........................................................................................................1004 Diagnostic Procedure..................................................................................................1005 DTC P0455 EVAP CONTROL SYSTEM.............................................................................................1012 On Board Diagnosis Logic..............................................................................................1012 DTC Confirmation Procedure............................................................................................1013 Diagnostic Procedure..................................................................................................1014 DTC P0456 EVAP CONTROL SYSTEM.............................................................................................1025 On Board Diagnosis Logic..............................................................................................1025 DTC Confirmation Procedure............................................................................................1026 Overall Function Check................................................................................................1027 Diagnostic Procedure..................................................................................................1028 DTC P0460 FUEL LEVEL SENSOR...............................................................................................1041 Component Description.................................................................................................1041 On Board Diagnostic Logic.............................................................................................1041 DTC Confirmation Procedure............................................................................................1041 Diagnostic Procedure..................................................................................................1042 DTC P0461 FUEL LEVEL SENSOR...............................................................................................1043 Component Description.................................................................................................1043 On Board Diagnostic Logic.............................................................................................1043 Overall Function Check................................................................................................1043 Diagnostic Procedure..................................................................................................1044 DTC P0462, P0463 FUEL LEVEL SENSOR........................................................................................1046 Component Description.................................................................................................1046 On Board Diagnostic Logic.............................................................................................1046 DTC Confirmation Procedure............................................................................................1046 Diagnostic Procedure..................................................................................................1047 DTC P0500 VSS.............................................................................................................1048 Description...........................................................................................................1048 On Board Diagnosis Logic..............................................................................................1048 DTC Confirmation Procedure............................................................................................1048 Overall Function Check................................................................................................1049 Diagnostic Procedure..................................................................................................1049 DTC P0506 ISC SYSTEM......................................................................................................1050 Description...........................................................................................................1050 On Board Diagnosis Logic..............................................................................................1050 DTC Confirmation Procedure............................................................................................1050 Diagnostic Procedure..................................................................................................1051 DTC P0507 ISC SYSTEM......................................................................................................1052 Description...........................................................................................................1052 On Board Diagnosis Logic..............................................................................................1052 DTC Confirmation Procedure............................................................................................1052 Diagnostic Procedure..................................................................................................1053 DTC P0550 PSP SENSOR......................................................................................................1054 Component Description.................................................................................................1054 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1054 On Board Diagnosis Logic..............................................................................................1054 DTC Confirmation Procedure............................................................................................1054 Wiring Diagram........................................................................................................1055 Diagnostic Procedure..................................................................................................1056 Component Inspection..................................................................................................1058 DTC P0605 ECM.............................................................................................................1059 Component Description.................................................................................................1059 On Board Diagnosis Logic..............................................................................................1059 DTC Confirmation Procedure............................................................................................1059 Diagnostic Procedure..................................................................................................1060 DTC P1065 ECM POWER SUPPLY (BACK UP)......................................................................................1061 Component Description.................................................................................................1061 ECM Terminals and Reference Value.....................................................................................1061 On Board Diagnosis Logic..............................................................................................1061 DTC Confirmation Procedure............................................................................................1061 Wiring Diagram........................................................................................................1063 Diagnostic Procedure..................................................................................................1064 DTC P1110, P1135 IVT CONTROL..............................................................................................1066 Description...........................................................................................................1066 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1066 On Board Diagnosis Logic..............................................................................................1067 DTC Confirmation Procedure............................................................................................1067 Diagnostic Procedure..................................................................................................1068 DTC P1111, P1136 IVT CONTROL SOLENOID VALVE...............................................................................1069 Component Description.................................................................................................1069 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1069 ECM Terminals and Reference Value.....................................................................................1069 On Board Diagnosis Logic..............................................................................................1070 DTC Confirmation Procedure............................................................................................1070 Wiring Diagram........................................................................................................1071 Diagnostic Procedure..................................................................................................1073 DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR..............................................................................1075 Component Description.................................................................................................1075 On Board Diagnosis Logic..............................................................................................1075 DTC Confirmation Procedure............................................................................................1075 Diagnostic Procedure..................................................................................................1076 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION..............................................................................1077 Description...........................................................................................................1077 ECM Terminals and Reference Value.....................................................................................1077 On Board Diagnosis Logic..............................................................................................1078 DTC Confirmation Procedure............................................................................................1078 Wiring Diagram........................................................................................................1079 Diagnostic Procedure..................................................................................................1080 Component Inspection..................................................................................................1084 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY.............................................................................1085 Component Description.................................................................................................1085 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1085 ECM Terminals and Reference Value.....................................................................................1085 On Board Diagnosis Logic..............................................................................................1085 DTC Confirmation Procedure............................................................................................1086 Wiring Diagram........................................................................................................1087 Diagnostic Procedure..................................................................................................1088 Component Inspection..................................................................................................1089 DTC P1128 THROTTLE CONTROL MOTOR..........................................................................................1090 Component Description.................................................................................................1090 ECM Terminals and Reference Value.....................................................................................1090 On Board Diagnosis Logic..............................................................................................1090 DTC Confirmation Procedure............................................................................................1090 Wiring Diagram........................................................................................................1092 Diagnostic Procedure..................................................................................................1093 Component Inspection..................................................................................................1094 DTC P1130 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE......................................................................1095 Description...........................................................................................................1095 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1096 ECM Terminals and Reference Value.....................................................................................1096 On Board Diagnosis Logic..............................................................................................1097 DTC Confirmation Procedure............................................................................................1097 Wiring Diagram........................................................................................................1099 Diagnostic Procedure..................................................................................................1100 DTC P1131 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE......................................................................1116 Component Description.................................................................................................1116 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1116 ECM Terminals and Reference Value.....................................................................................1116 On Board Diagnosis Logic..............................................................................................1116 DTC Confirmation Procedure............................................................................................1117 Wiring Diagram........................................................................................................1118 Diagnostic Procedure..................................................................................................1119 DTC P1143, P1163 HO2S1....................................................................................................1122 Component Description.................................................................................................1122 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1122 ECM Terminals and Reference Value.....................................................................................1122 On Board Diagnosis Logic..............................................................................................1123 DTC Confirmation Procedure............................................................................................1123 Overall Function Check................................................................................................1124 Diagnostic Procedure..................................................................................................1125 DTC P1144, P1164 HO2S1....................................................................................................1130 Component Description.................................................................................................1130 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1130 ECM Terminals and Reference Value.....................................................................................1130 On Board Diagnosis Logic..............................................................................................1131 DTC Confirmation Procedure............................................................................................1131 Overall Function Check................................................................................................1132 Diagnostic Procedure..................................................................................................1133 DTC P1146, P1166 HO2S2....................................................................................................1139 Component Description.................................................................................................1139 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1139 ECM Terminals and Reference Value.....................................................................................1139 On Board Diagnosis Logic..............................................................................................1139 DTC Confirmation Procedure............................................................................................1140 Overall Function Check................................................................................................1140 Wiring Diagram........................................................................................................1142 Diagnostic Procedure..................................................................................................1144 DTC P1147, P1167 HO2S2....................................................................................................1149 Component Description.................................................................................................1149 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1149 ECM Terminals and Reference Value.....................................................................................1149 On Board Diagnosis Logic..............................................................................................1149 DTC Confirmation Procedure............................................................................................1150 Overall Function Check................................................................................................1150 Wiring Diagram........................................................................................................1152 Diagnostic Procedure..................................................................................................1154 DTC P1148, P1168 CLOSED LOOP CONTROL......................................................................................1159 On Board Diagnosis Logic..............................................................................................1159 DTC Confirmation Procedure............................................................................................1159 Overall Function Check................................................................................................1160 Diagnostic Procedure..................................................................................................1160 DTC P1165 SWIRL CONTROL VALVE CONTROL VACUUM CHECK SWITCH.................................................................1161 Component Description.................................................................................................1161 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1161 ECM Terminals and Reference Value.....................................................................................1161 On Board Diagnosis Logic..............................................................................................1162 DTC Confirmation Procedure............................................................................................1162 Wiring Diagram........................................................................................................1163 Diagnostic Procedure..................................................................................................1164 DTC P1211 ABS/TCS CONTROL UNIT............................................................................................1167 Description...........................................................................................................1167 On Board Diagnosis Logic..............................................................................................1167 DTC Confirmation Procedure............................................................................................1167 Diagnostic Procedure..................................................................................................1168 DTC P1212 ABS/TCS COMMUNICATION LINE......................................................................................1169 Description...........................................................................................................1169 On Board Diagnosis Logic..............................................................................................1169 DTC Confirmation Procedure............................................................................................1169 Diagnostic Procedure..................................................................................................1170 DTC P1217 ENGINE OVER TEMPERATURE.........................................................................................1171 On Board Diagnosis Logic..............................................................................................1171 Overall Function Check................................................................................................1171 Diagnostic Procedure..................................................................................................1172 Main 12 Causes of Overheating.........................................................................................1175 DTC P1225 TP SENSOR.......................................................................................................1176 Component Description.................................................................................................1176 On Board Diagnosis Logic..............................................................................................1176 DTC Confirmation Procedure............................................................................................1176 Diagnostic Procedure..................................................................................................1177 DTC P1226 TP SENSOR.......................................................................................................1178 Component Description.................................................................................................1178 On Board Diagnosis Logic..............................................................................................1178 DTC Confirmation Procedure............................................................................................1178 Diagnostic Procedure..................................................................................................1179 DTC P1229 SENSOR POWER SUPPLY.............................................................................................1180 ECM Terminals and Reference Value.....................................................................................1180 On Board Diagnosis Logic..............................................................................................1180 DTC Confirmation Procedure............................................................................................1180 Wiring Diagram........................................................................................................1182 Diagnostic Procedure..................................................................................................1183 DTC P1442 EVAP CONTROL SYSTEM.............................................................................................1185 On Board Diagnosis Logic..............................................................................................1185 DTC Confirmation Procedure............................................................................................1186 Diagnostic Procedure..................................................................................................1187 DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE...............................................................1200 Description...........................................................................................................1200 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1200 ECM Terminals and Reference Value.....................................................................................1201 On Board Diagnosis Logic..............................................................................................1201 DTC Confirmation Procedure............................................................................................1201 Wiring Diagram........................................................................................................1203 Diagnostic Procedure..................................................................................................1204 DTC P1446 EVAP CANISTER VENT CONTROL VALVE................................................................................1212 Component Description.................................................................................................1212 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1212 ECM Terminals and Reference Value.....................................................................................1212 On Board Diagnosis Logic..............................................................................................1212 DTC Confirmation Procedure............................................................................................1213 Wiring Diagram........................................................................................................1214 Diagnostic Procedure..................................................................................................1215 DTC P1448 EVAP CANISTER VENT CONTROL VALVE................................................................................1220 Component Description.................................................................................................1220 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1220 ECM Terminals and Reference Value.....................................................................................1220 On Board Diagnosis Logic..............................................................................................1220 DTC Confirmation Procedure............................................................................................1221 Overall Function Check................................................................................................1222 Wiring Diagram........................................................................................................1223 Diagnostic Procedure..................................................................................................1224 DTC P1456 EVAP CONTROL SYSTEM.............................................................................................1229 On Board Diagnosis Logic..............................................................................................1229 DTC Confirmation Procedure............................................................................................1230 Overall Function Check................................................................................................1231 Diagnostic Procedure..................................................................................................1232 DTC P1490 VACUUM CUT VALVE BYPASS VALVE...................................................................................1245 Description...........................................................................................................1245 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1245 ECM Terminals and Reference Value.....................................................................................1245 On Board Diagnosis Logic..............................................................................................1246 DTC Confirmation Procedure............................................................................................1246 Wiring Diagram........................................................................................................1247 Diagnostic Procedure..................................................................................................1248 DTC P1491 VACUUM CUT VALVE BYPASS VALVE...................................................................................1251 Description...........................................................................................................1251 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1251 ECM Terminals and Reference Value.....................................................................................1251 On Board Diagnosis Logic..............................................................................................1252 DTC Confirmation Procedure............................................................................................1252 Overall Function Check................................................................................................1253 Wiring Diagram........................................................................................................1254 Diagnostic Procedure..................................................................................................1255 DTC P1564 ASCD STEERING SWITCH............................................................................................1263 Component Description.................................................................................................1263 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1263 ECM Terminals and Reference Value.....................................................................................1263 On Board Diagnosis Procedure..........................................................................................1264 DTC Confirmation Procedure............................................................................................1264 Wiring Diagram........................................................................................................1265 Diagnostic Procedure..................................................................................................1266 Component Inspection..................................................................................................1269 DTC P1572 ASCD BRAKE SWITCH...............................................................................................1270 Component Description.................................................................................................1270 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1270 ECM Terminals and Reference Value.....................................................................................1270 On Board Diagnosis Procedure..........................................................................................1271 DTC Confirmation Procedure............................................................................................1271 Wiring Diagram........................................................................................................1273 Diagnostic Procedure..................................................................................................1274 Component Inspection..................................................................................................1279 DTC P1706 PNP SWITCH......................................................................................................1281 Component Description.................................................................................................1281 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1281 ECM Terminals and Reference Value.....................................................................................1281 On Board Diagnosis Logic..............................................................................................1281 DTC Confirmation Procedure............................................................................................1281 Overall Function Check................................................................................................1282 Wiring Diagram........................................................................................................1283 Diagnostic Procedure..................................................................................................1284 DTC P1805 BRAKE SWITCH....................................................................................................1287 Description...........................................................................................................1287 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1287 ECM Terminals and Reference Value.....................................................................................1287 On Board Diagnosis Logic..............................................................................................1287 DTC Confirmation Procedure............................................................................................1288 Wiring Diagram........................................................................................................1289 Diagnostic Procedure..................................................................................................1290 Component Inspection..................................................................................................1292 DTC P2122, P2123 APP SENSOR...............................................................................................1293 Component Description.................................................................................................1293 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1293 ECM Terminals and Reference Value.....................................................................................1293 On Board Diagnosis Logic..............................................................................................1294 DTC Confirmation Procedure............................................................................................1295 Wiring Diagram........................................................................................................1296 Diagnostic Procedure..................................................................................................1297 Component Inspection..................................................................................................1299 DTC P2127, P2128 APP SENSOR...............................................................................................1300 Component Description.................................................................................................1300 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1300 ECM Terminals and Reference Value.....................................................................................1300 On Board Diagnosis Logic..............................................................................................1301 DTC Confirmation Procedure............................................................................................1302 Wiring Diagram........................................................................................................1303 Diagnostic Procedure..................................................................................................1304 Component Inspection..................................................................................................1307 DTC P2135 TP SENSOR.......................................................................................................1308 Component Description.................................................................................................1308 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1308 ECM Terminals and Reference Value.....................................................................................1308 On Board Diagnosis Logic..............................................................................................1309 DTC Confirmation Procedure............................................................................................1309 Wiring Diagram........................................................................................................1311 Diagnostic Procedure..................................................................................................1312 Component Inspection..................................................................................................1314 DTC P2138 APP SENSOR......................................................................................................1315 Component Description.................................................................................................1315 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1315 ECM Terminals and Reference Value.....................................................................................1315 On Board Diagnosis Logic..............................................................................................1316 DTC Confirmation Procedure............................................................................................1317 Wiring Diagram........................................................................................................1318 Diagnostic Procedure..................................................................................................1319 Component Inspection..................................................................................................1322 VARIABLE INDUCTION AIR CONTROL SYSTEM (VIAS)..............................................................................1323 Description...........................................................................................................1323 ECM Terminals and Reference Value.....................................................................................1324 Wiring Diagram........................................................................................................1325 Diagnostic Procedure..................................................................................................1326 IGNITION SIGNAL...........................................................................................................1332 Component Description.................................................................................................1332 ECM Terminals and Reference Value.....................................................................................1332 Wiring Diagram........................................................................................................1333 Diagnostic Procedure..................................................................................................1336 INJECTOR..................................................................................................................1342 Component Description.................................................................................................1342 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1342 ECM Terminals and Reference Value.....................................................................................1342 Wiring Diagram........................................................................................................1343 Diagnostic Procedure..................................................................................................1344 FUEL PUMP.................................................................................................................1347 System Description....................................................................................................1347 Component Description.................................................................................................1347 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1347 ECM Terminals and Reference Value.....................................................................................1348 Wiring Diagram........................................................................................................1349 Diagnostic Procedure..................................................................................................1350 REFRIGERANT PRESSURE SENSOR...............................................................................................1354 Description...........................................................................................................1354 ECM Terminals and Reference Value.....................................................................................1354 Wiring Diagram........................................................................................................1355 Diagnostic Procedure..................................................................................................1356 ASCD BRAKE SWITCH.........................................................................................................1359 Component Description.................................................................................................1359 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1359 ECM Terminals and Reference Value.....................................................................................1359 Wiring Diagram........................................................................................................1360 Diagnostic Procedure..................................................................................................1361 ASCD INDICATOR LAMP.......................................................................................................1367 Component Description.................................................................................................1367 CONSULT-II Reference Value in Data Monitor Mode.......................................................................1367 Wiring Diagram........................................................................................................1368 Diagnostic Procedure..................................................................................................1369 ELECTRICAL LOAD SIGNAL....................................................................................................1370 ECM Terminals and Reference Value.....................................................................................1370 Wiring Diagram........................................................................................................1371 Diagnostic Procedure..................................................................................................1372 MIL & DATA LINK CONNECTORS................................................................................................1375 Wiring Diagram........................................................................................................1375 SERVICE DATA AND SPECIFICATIONS (SDS).....................................................................................1376 Fuel Pressure Regulator...............................................................................................1376 Idle Speed and Ignition Timing........................................................................................1376 Mass Air Flow Sensor..................................................................................................1376 Engine Coolant Temperature Sensor.....................................................................................1376 Heated Oxygen Sensor 1 Heater.........................................................................................1376 Heated Oxygen Sensor 2 Heater.........................................................................................1376 Fuel Pump.............................................................................................................1376 Injector..............................................................................................................1376 Calculated Load Value.................................................................................................1376 Intake Air Temperature Sensor.........................................................................................1377 Fuel Tank Temperature Sensor..........................................................................................1377 Crankshaft Position Sensor (POS)......................................................................................1377 Camshaft Position Sensor (PHASE)......................................................................................1377 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............................................................................................................................1379 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents.........................................................................................................1379 PRECAUTIONS...............................................................................................................1383 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"...........................................1383 Precautions for SRS "AIR BAG" and "SEAT BELT PRE-TENSIONER" Service...................................................1383 Precautions for Trouble Diagnosis.....................................................................................1383 Precautions for Harness Repair........................................................................................1384 Wiring Diagrams and Trouble Diagnosis.................................................................................1384 HARNESS CONNECTOR.........................................................................................................1385 Description...........................................................................................................1385 STANDARDIZED RELAY........................................................................................................1387 Description...........................................................................................................1387 POWER SUPPLY ROUTING......................................................................................................1389 Schematic.............................................................................................................1389 Wiring Diagram - POWER -..............................................................................................1390 Inspection............................................................................................................1396 GROUND....................................................................................................................1397 Ground Distribution...................................................................................................1397 COMBINATION SWITCH........................................................................................................1410 Check.................................................................................................................1410 Replacement...........................................................................................................1411 STEERING SWITCH...........................................................................................................1412 Check.................................................................................................................1412 HEADLAMP (FOR USA)........................................................................................................1413 Component Parts and Harness Connector Location........................................................................1413 System Description....................................................................................................1413 Schematic.............................................................................................................1416 Wiring Diagram - H/LAMP -.............................................................................................1417 CONSULT-II Inspection Procedure.......................................................................................1421 CONSULT-II Application Items..........................................................................................1422 Trouble Diagnoses.....................................................................................................1422 Bulb Replacement......................................................................................................1425 Aiming Adjustment.....................................................................................................1425 HEADLAMP (FOR CANADA) - DAYTIME LIGHT SYSTEM -............................................................................1428 Component Parts and Harness Connector Location........................................................................1428 System Description....................................................................................................1428 Schematic.............................................................................................................1432 Wiring Diagram - DTRL -...............................................................................................1433 CONSULT-II Inspection Procedure.......................................................................................1438 CONSULT-II Application Items..........................................................................................1438 Trouble Diagnoses.....................................................................................................1438 Bulb Replacement......................................................................................................1443 Aiming Adjustment.....................................................................................................1443 PARKING, LICENSE AND TAIL LAMPS...........................................................................................1444 System Description....................................................................................................1444 Schematic.............................................................................................................1446 Wiring Diagram - TAIL/L -.............................................................................................1447 CONSULT-II Inspection Procedure.......................................................................................1451 CONSULT-II Application Items..........................................................................................1452 Trouble Diagnoses.....................................................................................................1452 STOP LAMP.................................................................................................................1454 Wiring Diagram - STOP/L -.............................................................................................1454 BACK-UP LAMP..............................................................................................................1456 Wiring Diagram - BACK/L -.............................................................................................1456 FRONT FOG LAMP............................................................................................................1457 System Description....................................................................................................1457 Wiring Diagram - F/FOG -..............................................................................................1458 Aiming Adjustment.....................................................................................................1460 TURN SIGNAL AND HAZARD WARNING LAMPS......................................................................................1461 System Description....................................................................................................1461 Wiring Diagram - TURN -...............................................................................................1463 Trouble Diagnoses.....................................................................................................1465 Electrical Components Inspection......................................................................................1465 ILLUMINATION..............................................................................................................1466 System Description....................................................................................................1466 Schematic.............................................................................................................1468 Wiring Diagram - ILL -................................................................................................1469 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS......................................................................1476 System Description....................................................................................................1476 Schematic.............................................................................................................1478 Wiring Diagram - INT/L -..............................................................................................1479 CONSULT-II Inspection Procedure.......................................................................................1484 CONSULT-II Application Items..........................................................................................1485 Trouble Diagnoses for Interior Lamp Timer.............................................................................1487 METERS AND GAUGES.........................................................................................................1502 Component Parts and Harness Connector Location........................................................................1502 System Description....................................................................................................1502 Combination Meter/With Normal Meter...................................................................................1504 Combination Meter/With Fine Vision Meter..............................................................................1506 Schematic/With Normal Meter...........................................................................................1508 Schematic/With Fine Vision Meter......................................................................................1509 Wiring Diagram - METER -..............................................................................................1510 Meter/Gauge Operation and Odo/Trip Meter Segment Check in Diagnosis Mode..............................................1511 Trouble Diagnoses.....................................................................................................1512 Electrical Components Inspection......................................................................................1518 COMPASS AND THERMOMETER...................................................................................................1519 System Description....................................................................................................1519 Wiring Diagram - COMPAS -.............................................................................................1520 Trouble Diagnoses.....................................................................................................1521 Calibration Procedure for Compass.....................................................................................1522 WARNING LAMPS.............................................................................................................1523 Schematic/With Normal Meter...........................................................................................1523 Wiring Diagram - WARN -/With Normal Meter.............................................................................1524 Schematic/With Fine Vision Meter......................................................................................1532 Wiring Diagram - WARN -/With Fine Vision Meter........................................................................1533 Fuel Warning Lamp Sensor Check........................................................................................1541 Electrical Components Inspection......................................................................................1541 WARNING CHIME.............................................................................................................1542 Component Parts and Harness Connector Location........................................................................1542 System Description....................................................................................................1542 Wiring Diagram - CHIME -..............................................................................................1544 CONSULT-II Inspection Procedure.......................................................................................1546 CONSULT-II Application Items..........................................................................................1547 Trouble Diagnoses.....................................................................................................1548 FRONT WIPER AND WASHER....................................................................................................1556 System Description....................................................................................................1556 Wiring Diagram - WIPER -..............................................................................................1558 Removal and Installation..............................................................................................1559 Washer Nozzle Adjustment..............................................................................................1560 Washer Tube Layout....................................................................................................1560 REAR WIPER AND WASHER.....................................................................................................1561 System Description....................................................................................................1561 Wiring Diagram - WIP/R -..............................................................................................1563 Trouble Diagnoses.....................................................................................................1565 Removal and Installation..............................................................................................1565 Washer Nozzle Adjustment..............................................................................................1566 Washer Tube Layout....................................................................................................1566 Check Valve...........................................................................................................1566 HORN......................................................................................................................1567 Wiring Diagram - HORN -...............................................................................................1567 CIGARETTE LIGHTER.........................................................................................................1568 Wiring Diagram - CIGAR -..............................................................................................1568 CLOCK.....................................................................................................................1569 Wiring Diagram - CLOCK -..............................................................................................1569 REAR WINDOW DEFOGGER......................................................................................................1570 Component Parts and Harness Connector Location........................................................................1570 System Description....................................................................................................1570 Wiring Diagram - DEF -................................................................................................1572 CONSULT-II Inspection Procedure.......................................................................................1576 CONSULT-II Application Items..........................................................................................1577 Trouble Diagnoses.....................................................................................................1578 Electrical Components Inspection......................................................................................1581 Filament Check........................................................................................................1582 Filament Repair.......................................................................................................1583 AUDIO.....................................................................................................................1584 System Description....................................................................................................1584 Wiring Diagram - AUDIO -/Base System..................................................................................1585 Schematic/BOSE System.................................................................................................1587 Wiring Diagram - AUDIO -/BOSE System..................................................................................1588 Trouble Diagnoses.....................................................................................................1593 Inspection............................................................................................................1594 Audio Unit Removal and Installation...................................................................................1594 Wiring Diagram - REMOTE -.............................................................................................1595 AUDIO ANTENNA.............................................................................................................1596 System Description....................................................................................................1596 Wiring Diagram - P/ANT -..............................................................................................1597 Trouble Diagnoses.....................................................................................................1598 Location of Antenna...................................................................................................1598 Antenna Rod Replacement...............................................................................................1598 POWER SUNROOF.............................................................................................................1600 System Description....................................................................................................1600 Wiring Diagram - SROOF -..............................................................................................1601 CONSULT-II Inspection Procedure.......................................................................................1603 CONSULT-II Application Items..........................................................................................1604 Trouble Diagnoses.....................................................................................................1604 DOOR MIRROR...............................................................................................................1606 Wiring Diagram - MIRROR -.............................................................................................1606 GLASS HATCH OPENER........................................................................................................1607 Wiring Diagram - T&FLID -.............................................................................................1607 POWER SEAT................................................................................................................1608 Wiring Diagram - SEAT -...............................................................................................1608 HEATED SEAT...............................................................................................................1610 Wiring Diagram - HSEAT -..............................................................................................1610 Seatback Heating Unit.................................................................................................1613 AUTOMATIC DRIVE POSITIONER................................................................................................1614 Component Parts and Harness Connector Location........................................................................1614 System Description....................................................................................................1615 Schematic.............................................................................................................1618 Wiring Diagram - AUT/DP -.............................................................................................1619 On Board Diagnosis....................................................................................................1624 Trouble Diagnoses.....................................................................................................1626 AUTOMATIC SPEED CONTROL DEVICE (ASCD).....................................................................................1649 System Description....................................................................................................1649 POWER WINDOW..............................................................................................................1650 System Description....................................................................................................1650 Schematic.............................................................................................................1653 Wiring Diagram - WINDOW -.............................................................................................1654 CONSULT-II Inspection Procedure.......................................................................................1659 CONSULT-II Application Items..........................................................................................1660 Trouble Diagnoses.....................................................................................................1660 POWER DOOR LOCK...........................................................................................................1669 Component Parts and Harness Connector Location........................................................................1669 System Description....................................................................................................1669 Schematic.............................................................................................................1670 Wiring Diagram - D/LOCK -.............................................................................................1671 CONSULT-II Inspection Procedure.......................................................................................1677 CONSULT-II Application Items..........................................................................................1678 Trouble Diagnoses.....................................................................................................1679 REMOTE KEYLESS ENTRY SYSTEM...............................................................................................1692 Component Parts and Harness Connector Location........................................................................1692 System Description....................................................................................................1692 Schematic.............................................................................................................1696 Wiring Diagram - KEYLESS -............................................................................................1697 CONSULT-II Inspection Procedure.......................................................................................1701 CONSULT-II Application Items..........................................................................................1702 Trouble Diagnoses.....................................................................................................1703 ID Code Entry Procedure...............................................................................................1716 Keyfob Battery Replacement............................................................................................1720 VEHICLE SECURITY (THEFT WARNING) SYSTEM...................................................................................1721 Component Parts and Harness Connector Location........................................................................1721 System Description....................................................................................................1722 Schematic.............................................................................................................1726 Wiring Diagram - VEHSEC -.............................................................................................1728 CONSULT-II Inspection Procedure.......................................................................................1734 CONSULT-II Application Item...........................................................................................1735 Trouble Diagnoses.....................................................................................................1736 SMART ENTRANCE CONTROL UNIT...............................................................................................1754 Description...........................................................................................................1754 CONSULT-II............................................................................................................1756 Schematic.............................................................................................................1758 Smart Entrance Control Unit Inspection Table..........................................................................1760 HOMELINK UNIVERSAL TRANSCEIVER............................................................................................1763 Wiring Diagram - TRNSCV -.............................................................................................1763 Trouble Diagnoses.....................................................................................................1764 NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM - NATS)...........................................................................1767 Component Parts and Harness Connetor Location.........................................................................1767 System Description....................................................................................................1768 System Composition....................................................................................................1768 Wiring Diagram - NATS -...............................................................................................1769 CONSULT-II............................................................................................................1770 Trouble Diagnoses.....................................................................................................1773 How to Replace NVIS (NATS) IMMU.......................................................................................1786 CAN COMMUNICATION.........................................................................................................1787 System Description....................................................................................................1787 CAN Communication Unit................................................................................................1787 CAN SYSTEM (TYPE 1).......................................................................................................1792 Component Parts and Harness Connector Location........................................................................1792 System Description....................................................................................................1792 Wiring Diagram - CAN -................................................................................................1793 Trouble Diagnoses.....................................................................................................1795 Component Inspection..................................................................................................1815 CAN SYSTEM (TYPE 2).......................................................................................................1816 Component Parts and Harness Connector Location........................................................................1816 System Description....................................................................................................1816 Wiring Diagram - CAN -................................................................................................1817 Trouble Diagnoses.....................................................................................................1819 Component Inspection..................................................................................................1837 CAN SYSTEM (TYPE 3).......................................................................................................1838 Component Parts and Harness Connector Location........................................................................1838 System Description....................................................................................................1838 Wiring Diagram - CAN -................................................................................................1839 Trouble Diagnoses.....................................................................................................1840 Component Inspection..................................................................................................1850 CAN SYSTEM (TYPE 4).......................................................................................................1851 Component Parts and Harness Connector Location........................................................................1851 System Description....................................................................................................1851 Wiring Diagram - CAN -................................................................................................1852 Trouble Diagnoses.....................................................................................................1853 Component Inspection..................................................................................................1856 ELECTRICAL UNITS LOCATION.................................................................................................1857 Engine Compartment....................................................................................................1857 Passenger Compartment.................................................................................................1858 HARNESS LAYOUT............................................................................................................1860 How to Read Harness Layout............................................................................................1860 Outline...............................................................................................................1861 Main Harness..........................................................................................................1862 Engine Room Harness...................................................................................................1864 Engine Control Harness................................................................................................1866 Body Harness LH.......................................................................................................1868 Body Harness RH.......................................................................................................1869 Back Door Harness.....................................................................................................1870 Engine and Transmission Harness.......................................................................................1871 Room Lamp Harness.....................................................................................................1872 Air Bag Harness.......................................................................................................1873 Front Door Harness....................................................................................................1874 Rear Door Harness.....................................................................................................1875 BULB SPECIFICATIONS.......................................................................................................1876 Headlamp..............................................................................................................1876 Exterior Lamp.........................................................................................................1876 Interior Lamp.........................................................................................................1876 WIRING DIAGRAM CODES (CELL CODES).........................................................................................1877 SUPER MULTIPLE JUNCTION (SMJ)............................................................................................. 0 FUSE BLOCK - JUNCTION BOX (J/B)........................................................................................... 2 FUSE AND FUSIBLE LINK BOX................................................................................................. 3 ELECTRICAL UNITS.......................................................................................................... 4 JOINT CONNECTOR (J/C)..................................................................................................... 5 em............................................................................................................................1879 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents.........................................................................................................1879 PRECAUTIONS...............................................................................................................1881 Parts Requiring Angular Tightening....................................................................................1881 Liquid Gasket Application Procedure...................................................................................1881 PREPARATION...............................................................................................................1882 Special Service Tools.................................................................................................1882 Commercial Service Tools..............................................................................................1884 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING......................................................................1886 NVH Troubleshooting - Engine Noise....................................................................................1887 OUTER COMPONENT PARTS.....................................................................................................1888 Removal and Installation..............................................................................................1888 TIGHTENING PROCEDURES.............................................................................................1890 Disassembly and Assembly of Power Valve (A/T).........................................................................1892 DISASSEMBLY.......................................................................................................1892 ASSEMBLY..........................................................................................................1893 INSPECTION AFTER ASSEMBLY.........................................................................................1894 MEASUREMENT OF COMPRESSION PRESSURE.......................................................................................1895 OIL PAN...................................................................................................................1897 Components............................................................................................................1897 Removal...............................................................................................................1897 Installation..........................................................................................................1900 TIMING CHAIN..............................................................................................................1902 Components............................................................................................................1902 POSITION FOR APPLYING LIQUID GASKET...............................................................................1903 Removal...............................................................................................................1905 Inspection............................................................................................................1912 Installation..........................................................................................................1912 OIL SEAL..................................................................................................................1920 Replacement...........................................................................................................1920 VALVE OIL SEAL....................................................................................................1920 OIL SEAL INSTALLATION DIRECTION...................................................................................1921 FRONT OIL SEAL....................................................................................................1921 REAR OIL SEAL.....................................................................................................1921 CYLINDER HEAD.............................................................................................................1922 Components............................................................................................................1922 Removal...............................................................................................................1923 Disassembly...........................................................................................................1925 Inspection............................................................................................................1926 CYLINDER HEAD DISTORTION..........................................................................................1926 CAMSHAFT VISUAL CHECK.............................................................................................1926 CAMSHAFT RUNOUT...................................................................................................1926 CAMSHAFT CAM HEIGHT...............................................................................................1926 CAMSHAFT JOURNAL CLEARANCE........................................................................................1927 CAMSHAFT END PLAY.................................................................................................1927 CAMSHAFT SPROCKET RUNOUT..........................................................................................1928 VALVE GUIDE CLEARANCE.............................................................................................1928 VALVE GUIDE REPLACEMENT...........................................................................................1928 VALVE SEATS.......................................................................................................1929 REPLACING VALVE SEAT FOR SERVICE PARTS............................................................................1929 VALVE DIMENSIONS..................................................................................................1930 VALVE SPRING......................................................................................................1930 VALVE LIFTER......................................................................................................1931 Assembly..............................................................................................................1931 Installation..........................................................................................................1932 Valve Clearance.......................................................................................................1936 CHECKING..........................................................................................................1936 ADJUSTING.........................................................................................................1938 ENGINE ASSEMBLY...........................................................................................................1940 Removal and Installation..............................................................................................1940 REMOVAL...........................................................................................................1941 INSTALLATION......................................................................................................1943 CYLINDER BLOCK............................................................................................................1944 Components............................................................................................................1944 CYLINDER BLOCK HEATER.............................................................................................1945 Removal and Installation..............................................................................................1945 Disassembly...........................................................................................................1945 PISTON, CRANKSHAFT AND OIL JET....................................................................................1945 Inspection............................................................................................................1947 PISTON AND PISTON PIN CLEARANCE...................................................................................1947 PISTON RING SIDE CLEARANCE........................................................................................1947 PISTON RING END GAP...............................................................................................1947 CONNECTING ROD BEND AND TORSION...................................................................................1948 CYLINDER BLOCK DISTORTION AND WEAR................................................................................1948 PISTON-TO-BORE CLEARANCE..........................................................................................1949 CRANKSHAFT........................................................................................................1950 BEARING CLEARANCE.................................................................................................1950 CONNECTING ROD BUSHING CLEARANCE (SMALL END)......................................................................1953 FLYWHEEL/DRIVE PLATE RUNOUT.......................................................................................1954 Assembly..............................................................................................................1954 PISTON............................................................................................................1954 PLUG..............................................................................................................1955 OIL JET...........................................................................................................1955 CRANKSHAFT........................................................................................................1956 KNOCK SENSOR......................................................................................................1958 REPLACEMENT OF PILOT BUSHING (M/T) OR PILOT CONVERTER (A/T).......................................................1958 FLYWHEEL/DRIVE PLATE..............................................................................................1959 SERVICE DATA AND SPECIFICATIONS (SDS).....................................................................................1960 General Specifications................................................................................................1960 Compression Pressure..................................................................................................1960 Cylinder Head.........................................................................................................1960 Valve.................................................................................................................1961 VALVE.............................................................................................................1961 VALVE CLEARANCE...................................................................................................1961 VALVE SPRING......................................................................................................1961 VALVE LIFTER......................................................................................................1961 AVAILABLE LIFTERS (SHIMLESS TYPE).................................................................................1962 VALVE GUIDE.......................................................................................................1963 Valve Seat............................................................................................................1963 Camshaft and Camshaft Bearing.........................................................................................1964 Cylinder Block........................................................................................................1965 Piston, Piston Ring and Piston Pin....................................................................................1966 AVAILABLE PISTON..................................................................................................1966 PISTON RING.......................................................................................................1967 PISTON PIN........................................................................................................1967 Connecting Rod........................................................................................................1967 Crankshaft............................................................................................................1968 Available Main Bearing................................................................................................1969 UNDERSIZE.........................................................................................................1969 Available Connecting Rod Bearing......................................................................................1970 CONNECTING ROD BEARING............................................................................................1970 UNDERSIZE.........................................................................................................1970 Miscellaneous Components..............................................................................................1970 BEARING CLEARANCE.................................................................................................1970 fe............................................................................................................................1971 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents.........................................................................................................1971 PREPARATION...............................................................................................................1972 Special Service Tool..................................................................................................1972 Commercial Service Tools..............................................................................................1972 ACCELERATOR CONTROL SYSTEM................................................................................................1973 Removal and Installation..............................................................................................1973 REMOVAL...........................................................................................................1973 INSTALLATION......................................................................................................1973 INSPECTION AFTER INSTALLATION.....................................................................................1973 FUEL SYSTEM...............................................................................................................1974 Removal and Installation..............................................................................................1974 FUEL TANK.........................................................................................................1975 FUEL PUMP AND FUEL LEVEL SENSOR UNIT..............................................................................1976 EXHAUST SYSTEM............................................................................................................1979 Removal and Installation..............................................................................................1979 foldout.......................................................................................................................1983 QUICK REFERENCE INDEX..................................................................................................... 0 SUPER MULTIPLE JUNCTION (SMJ).............................................................................................1983 FUSE BLOCK - JUNCTION BOX (J/B)...........................................................................................1985 FUSE AND FUSIBLE LINK BOX.................................................................................................1986 ELECTRICAL UNITS..........................................................................................................1987 JOINT CONNECTOR (J/C).....................................................................................................1988 QUICK REFERENCE CHART.....................................................................................................1989 gi............................................................................................................................1991 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents.........................................................................................................1991 PRECAUTIONS...............................................................................................................1993 Precautions...........................................................................................................1993 PRECAUTIONS FOR SUPPLEMENTAL RESTRAINT SYSTEM (SRS) "AIR BAG" AND "SEAT BELT PRE-TENSIONER".......................1993 PRECAUTIONS FOR NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM - NATS)...................................................1993 GENERAL PRECAUTIONS...............................................................................................1994 PRECAUTIONS FOR MULTIPORT FUEL INJECTION SYSTEM OR ENGINE CONTROL SYSTEM..........................................1996 PRECAUTIONS FOR THREE WAY CATALYST................................................................................1996 PRECAUTIONS FOR HOSES.............................................................................................1996 PRECAUTIONS FOR ENGINE OILS.......................................................................................1997 PRECAUTIONS FOR FUEL (UNLEADED PREMIUM GASOLINE RECOMMENDED)......................................................1998 PRECAUTIONS FOR AIR CONDITIONING..................................................................................1998 HOW TO USE THIS MANUAL....................................................................................................1999 HOW TO READ WIRING DIAGRAMS...............................................................................................2001 Sample/Wiring Diagram - EXAMPL -......................................................................................2001 OPTIONAL SPLICE...................................................................................................2002 Description...........................................................................................................2003 CONNECTOR SYMBOLS.................................................................................................2005 HARNESS INDICATION................................................................................................2006 COMPONENT INDICATION..............................................................................................2006 SWITCH POSITIONS..................................................................................................2006 DETECTABLE LINES AND NON-DETECTABLE LINES.........................................................................2007 MULTIPLE SWITCH...................................................................................................2008 REFERENCE AREA....................................................................................................2009 HOW TO CHECK TERMINAL.....................................................................................................2011 Connector and Terminal Pin Kit........................................................................................2011 How to Probe Connectors...............................................................................................2011 PROBING FROM HARNESS SIDE.........................................................................................2011 PROBING FROM TERMINAL SIDE........................................................................................2011 How to Check Enlarged Contact Spring of Terminal......................................................................2012 Waterproof Connector Inspection.......................................................................................2013 RUBBER SEAL INSPECTION............................................................................................2013 WIRE SEAL INSPECTION..............................................................................................2013 Terminal Lock Inspection..............................................................................................2013 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT.............................................................2014 Work Flow.............................................................................................................2014 Incident Simulation Tests.............................................................................................2015 INTRODUCTION......................................................................................................2015 VEHICLE VIBRATION.................................................................................................2015 HEAT SENSITIVE....................................................................................................2016 FREEZING..........................................................................................................2016 WATER INTRUSION...................................................................................................2017 ELECTRICAL LOAD...................................................................................................2017 COLD OR HOT START UP..............................................................................................2017 Circuit Inspection....................................................................................................2017 INTRODUCTION......................................................................................................2017 TESTING FOR "OPENS" IN THE CIRCUIT................................................................................2018 TESTING FOR "SHORTS" IN THE CIRCUIT...............................................................................2019 GROUND INSPECTION.................................................................................................2020 VOLTAGE DROP TESTS................................................................................................2020 CONTROL UNIT CIRCUIT TEST.........................................................................................2022 HOW TO FOLLOW TROUBLE DIAGNOSES...........................................................................................2024 How to Follow Test Groups in Trouble Diagnoses........................................................................2025 Harness Wire Color and Connector Number Indication....................................................................2026 TYPE 1: HARNESS WIRE COLOR AND CONNECTOR NUMBER ARE SHOWN IN ILLUSTRATION.........................................2026 TYPE 2: HARNESS WIRE COLOR AND CONNECTOR NUMBER ARE SHOWN IN TEXT.................................................2026 Key to Symbols Signifying Measurements or Procedures..................................................................2027 CONSULT-II CHECKING SYSTEM................................................................................................2029 Description...........................................................................................................2029 Function and System Application.......................................................................................2029 Nickel Metal Hydride Battery Replacement..............................................................................2030 Checking Equipment....................................................................................................2031 CONSULT-II Start Procedure............................................................................................2031 CONSULT-II Data Link Connector (DLC) Circuit..........................................................................2032 INSPECTION PROCEDURE..............................................................................................2032 IDENTIFICATION INFORMATION................................................................................................2033 Model Variation.......................................................................................................2033 2WD...............................................................................................................2033 4WD...............................................................................................................2033 PREFIX AND SUFFIX DESIGNATIONS....................................................................................2033 Identification Number.................................................................................................2034 VEHICLE IDENTIFICATION NUMBER ARRANGEMENT.........................................................................2034 IDENTIFICATION PLATE..............................................................................................2035 ENGINE SERIAL NUMBER..............................................................................................2035 MANUAL TRANSMISSION NUMBER........................................................................................2035 AUTOMATIC TRANSMISSION NUMBER.....................................................................................2035 TRANSFER SERIAL NUMBER............................................................................................2036 Dimensions............................................................................................................2036 Wheels & Tires........................................................................................................2036 LIFTING POINTS AND TOW TRUCK TOWING.......................................................................................2037 Screw Jack............................................................................................................2037 Garage Jack and Safety Stand..........................................................................................2038 2-pole Lift...........................................................................................................2039 Tow Truck Towing......................................................................................................2039 2WD MODELS........................................................................................................2040 PART TIME 4WD MODELS..............................................................................................2040 ALL-MODE 4WD MODELS...............................................................................................2041 VEHICLE RECOVERY..................................................................................................2041 TIGHTENING TORQUE OF STANDARD BOLTS.......................................................................................2042 RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS................................................................................2043 SAE J1930 TERMINOLOGY LIST................................................................................................2044 SAE J1930 Terminology List............................................................................................2044 ha............................................................................................................................2049 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents.........................................................................................................2049 AUTO......................................................................................................................2051 PRECAUTIONS...........................................................................................................2051 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER".......................................2051 Precautions for Working with HFC-134a (R-134a)....................................................................2051 General Refrigerant Precautions...................................................................................2052 Precautions for Leak Detection Dye................................................................................2052 Precaution for Identification Label on Vehicle....................................................................2053 Precautions for Refrigerant Connection............................................................................2053 Precautions for Servicing Compressor..............................................................................2055 Precautions for Service Equipment.................................................................................2056 Wiring Diagrams and Trouble Diagnoses.............................................................................2057 PREPARATION...........................................................................................................2058 Special Service Tools.............................................................................................2058 HFC-134a (R-134a) Service Tools and Equipment.....................................................................2059 DESCRIPTION...........................................................................................................2063 Refrigeration System..............................................................................................2063 V-6 Variable Displacement Compressor..............................................................................2064 Component Layout..................................................................................................2068 Introduction......................................................................................................2069 Features..........................................................................................................2069 Overview of Control System........................................................................................2072 Control Operation.................................................................................................2073 Discharge Air Flow................................................................................................2075 System Description................................................................................................2076 TROUBLE DIAGNOSES.....................................................................................................2077 Component Location................................................................................................2077 Circuit Diagram...................................................................................................2079 Wiring Diagram - A/C, A -.........................................................................................2080 Auto Amp. Terminals and Reference Value...........................................................................2084 Self-diagnosis....................................................................................................2087 How to Perform Trouble Diagnoses for Quick and Accurate Repair....................................................2107 Operational Check.................................................................................................2108 A/C System........................................................................................................2113 Mode Door Motor...................................................................................................2116 Air Mix Door Motor................................................................................................2123 Intake Door Motor.................................................................................................2127 Blower Motor......................................................................................................2135 Magnet Clutch.....................................................................................................2145 Insufficient Cooling..............................................................................................2152 Insufficient Heating..............................................................................................2161 Noise.............................................................................................................2163 Self-diagnosis....................................................................................................2164 Memory Function...................................................................................................2166 ECON (ECONOMY) Mode...............................................................................................2168 Ambient Sensor Circuit............................................................................................2169 In-vehicle Sensor Circuit.........................................................................................2172 Sunload Sensor Circuit............................................................................................2176 Intake Sensor Circuit.............................................................................................2179 Air Mix Door Motor PBR Circuit....................................................................................2181 SERVICE PROCEDURE.....................................................................................................2182 HFC-134a (R-134a) Service Procedure...............................................................................2182 Maintenance of Lubricant Quantity in Compressor...................................................................2184 Compressor........................................................................................................2187 Compressor Clutch.................................................................................................2187 Refrigerant Lines.................................................................................................2191 Checking for Refrigerant Leaks....................................................................................2192 Electronic Refrigerant Leak Detector..............................................................................2192 Fluorescent Dye Leak Detector.....................................................................................2195 Belt..............................................................................................................2196 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................2197 Auto..............................................................................................................2197 MANUAL....................................................................................................................2198 PRECAUTIONS...........................................................................................................2198 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER".......................................2198 Precautions for Working with HFC-134a (R-134a)....................................................................2198 General Refrigerant Precautions...................................................................................2199 Precautions for Leak Detection Dye................................................................................2199 Precaution for Identification Label on Vehicle....................................................................2200 Precautions for Refrigerant Connection............................................................................2200 Precautions for Servicing Compressor..............................................................................2202 Precautions for Service Equipment.................................................................................2203 Wiring Diagrams and Trouble Diagnoses.............................................................................2204 PREPARATION...........................................................................................................2205 Special Service Tools.............................................................................................2205 HFC-134a (R-134a) Service Tools and Equipment.....................................................................2206 DESCRIPTION...........................................................................................................2210 Refrigeration System..............................................................................................2210 V-6 Variable Displacement Compressor..............................................................................2211 Component Layout..................................................................................................2215 Control Operation.................................................................................................2216 Discharge Air Flow................................................................................................2217 System Description................................................................................................2218 TROUBLE DIAGNOSES.....................................................................................................2219 Component Location................................................................................................2219 Wiring Diagram - HEATER -.........................................................................................2221 Circuit Diagram - Air Conditioner.................................................................................2222 Wiring Diagram - A/C, M -.........................................................................................2223 How to Perform Trouble Diagnoses for Quick and Accurate Repair....................................................2226 Operational Check.................................................................................................2227 Intake Door.......................................................................................................2229 Blower Motor......................................................................................................2236 Insufficient Cooling..............................................................................................2243 Insufficient Heating..............................................................................................2251 Air Outlet........................................................................................................2253 Magnet Clutch.....................................................................................................2255 Noise.............................................................................................................2262 SERVICE PROCEDURE.....................................................................................................2263 HFC-134a (R-134a) Service Procedure...............................................................................2263 Maintenance of Lubricant Quantity in Compressor...................................................................2265 Compressor........................................................................................................2268 Compressor Clutch.................................................................................................2268 Refrigerant Lines.................................................................................................2272 Checking for Refrigerant Leaks....................................................................................2273 Electronic Refrigerant Leak Detector..............................................................................2273 Fluorescent Dye Leak Detector.....................................................................................2276 Belt..............................................................................................................2277 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................2278 Manual............................................................................................................2278 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...........................................................................................................................2279 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............................................................................................................................2289 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents.........................................................................................................2289 ENGINE LUBRICATION SYSTEM.................................................................................................2290 Precautions...........................................................................................................2290 LIQUID GASKET APPLICATION PROCEDURE...............................................................................2290 Preparation...........................................................................................................2290 SPECIAL SERVICE TOOLS.............................................................................................2290 COMMERCIAL SERVICE TOOL...........................................................................................2291 Lubrication Circuit...................................................................................................2291 Oil Pressure Check....................................................................................................2293 Oil Pump..............................................................................................................2294 REMOVAL AND INSTALLATION..........................................................................................2294 DISASSEMBLY AND ASSEMBLY..........................................................................................2294 OIL PUMP INSPECTION...............................................................................................2295 REGULATOR VALVE INSPECTION........................................................................................2295 OIL FILTER........................................................................................................2296 Oil Cooler............................................................................................................2296 REMOVAL AND INSTALLATION..........................................................................................2296 INSPECTION........................................................................................................2297 Service Data and Specifications (SDS).................................................................................2297 OIL PRESSURE......................................................................................................2297 REGULATOR VALVE...................................................................................................2297 OIL PUMP..........................................................................................................2297 ENGINE COOLING SYSTEM.....................................................................................................2298 Precautions...........................................................................................................2298 LIQUID GASKET APPLICATION PROCEDURE...............................................................................2298 Preparation...........................................................................................................2298 SPECIAL SERVICE TOOLS.............................................................................................2298 COMMERCIAL SERVICE TOOL...........................................................................................2299 Cooling Circuit.......................................................................................................2299 System Check..........................................................................................................2300 CHECKING COOLING SYSTEM HOSES.....................................................................................2300 CHECKING RADIATOR.................................................................................................2300 CHECKING RADIATOR CAP.............................................................................................2301 CHECKING COOLING SYSTEM FOR LEAKS.................................................................................2301 Water Pump............................................................................................................2302 REMOVAL AND INSTALLATION..........................................................................................2302 REMOVAL...........................................................................................................2303 INSPECTION........................................................................................................2304 INSTALLATION......................................................................................................2305 Thermostat............................................................................................................2307 REMOVAL AND INSTALLATION..........................................................................................2307 INSPECTION........................................................................................................2307 Water Control Valve...................................................................................................2308 REMOVAL AND INSTALLATION..........................................................................................2308 INSPECTION........................................................................................................2309 Radiator..............................................................................................................2310 REMOVAL AND INSTALLATION..........................................................................................2310 Cooling Fan (Crankshaft driven).......................................................................................2311 REMOVAL AND INSTALLATION..........................................................................................2311 INSPECTION........................................................................................................2311 Refilling Engine Coolant..............................................................................................2311 Radiator (Aluminum type)..............................................................................................2312 PREPARATION.......................................................................................................2312 DISASSEMBLY.......................................................................................................2312 ASSEMBLY..........................................................................................................2313 INSPECTION........................................................................................................2314 Overheating Cause Analysis............................................................................................2315 Service Data and Specifications (SDS).................................................................................2316 THERMOSTAT........................................................................................................2316 WATER CONTROL VALVE...............................................................................................2316 RADIATOR..........................................................................................................2316 ma............................................................................................................................2317 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents.........................................................................................................2317 PRECAUTIONS...............................................................................................................2319 Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"...........................2319 PREPARATION...............................................................................................................2320 Special Service Tool..................................................................................................2320 Commercial Service Tool...............................................................................................2320 GENERAL MAINTENANCE.......................................................................................................2321 PERIODIC MAINTENANCE......................................................................................................2323 Schedule 1............................................................................................................2324 EMISSION CONTROL SYSTEM MAINTENANCE...............................................................................2324 CHASSIS AND BODY MAINTENANCE......................................................................................2325 Schedule 2............................................................................................................2326 EMISSION CONTROL SYSTEM MAINTENANCE...............................................................................2326 CHASSIS AND BODY MAINTENANCE......................................................................................2327 RECOMMENDED FLUIDS AND LUBRICANTS.........................................................................................2328 Fluids and Lubricants.................................................................................................2328 SAE Viscosity Number..................................................................................................2329 GASOLINE ENGINE OIL...............................................................................................2329 Anti-freeze Coolant Mixture Ratio.....................................................................................2329 ENGINE MAINTENANCE........................................................................................................2330 Checking Drive Belts..................................................................................................2330 Changing Engine Coolant...............................................................................................2331 -DRAINING ENGINE COOLANT-.........................................................................................2331 -REFILLING ENGINE COOLANT-........................................................................................2332 -FLUSHING COOLING SYSTEM-.........................................................................................2332 Checking Fuel Lines...................................................................................................2333 Changing Fuel Filter..................................................................................................2333 WITH CONSULT-II...................................................................................................2333 WITHOUT CONSULT-II................................................................................................2334 Changing Air Cleaner Filter...........................................................................................2334 VISCOUS PAPER TYPE................................................................................................2334 Changing Engine Oil...................................................................................................2334 Changing Oil Filter...................................................................................................2335 Changing Spark Plugs..................................................................................................2336 Checking EVAP Vapor Lines.............................................................................................2337 CHASSIS AND BODY MAINTENANCE..............................................................................................2338 Checking Exhaust System...............................................................................................2338 Checking Clutch Fluid Level and Leaks.................................................................................2338 Checking M/T Oil......................................................................................................2338 Changing M/T Oil......................................................................................................2338 Checking A/T Fluid....................................................................................................2339 Changing A/T Fluid....................................................................................................2339 Checking Part Time 4WD Transfer Fluid.................................................................................2340 Changing Part Time 4WD Transfer Fluid.................................................................................2340 Checking All-mode 4WD Transfer Fluid..................................................................................2340 Changing All-mode 4WD Transfer Fluid..................................................................................2340 Checking Propeller Shaft..............................................................................................2341 Greasing Propeller Shaft..............................................................................................2341 Checking Differential Gear Oil........................................................................................2341 Changing Differential Gear Oil........................................................................................2342 LIMITED-SLIP DIFFERENTIAL GEAR....................................................................................2342 Balancing Wheels......................................................................................................2342 Tire Rotation.........................................................................................................2342 Checking Brake Fluid Level and Leaks..................................................................................2343 Checking Brake Lines and Cables.......................................................................................2343 Checking Disc Brake...................................................................................................2343 ROTOR.............................................................................................................2343 CALIPER...........................................................................................................2343 PAD...............................................................................................................2343 Checking Drum Brake...................................................................................................2344 WHEEL CYLINDER....................................................................................................2344 DRUM..............................................................................................................2344 LINING............................................................................................................2344 TEMPORARY METHOD FOR CHECKING LINING WEAR.........................................................................2344 Checking Steering Gear, Linkage and Transfer Gear.....................................................................2344 STEERING GEAR.....................................................................................................2344 STEERING LINKAGE..................................................................................................2344 STEERING TRANSFER GEAR............................................................................................2344 Checking Power Steering Fluid and Lines...............................................................................2345 CHECKING FLUID LEVEL..............................................................................................2345 CHECKING LINES....................................................................................................2345 Axle and Suspension Parts.............................................................................................2345 FRONT WHEEL BEARING...............................................................................................2346 Drive Shaft...........................................................................................................2346 Lubricating Locks, Hinges and Hood Latches............................................................................2346 Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters.......................................................2347 SERVICE DATA AND SPECIFICATIONS (SDS).....................................................................................2348 Engine Maintenance....................................................................................................2348 DRIVE BELT DEFLECTION.............................................................................................2348 DRIVE BELT TENSION................................................................................................2348 SPARK PLUG (PLATINUM-TIPPED TYPE).................................................................................2348 Chassis and Body Maintenance..........................................................................................2348 WHEEL BALANCE.....................................................................................................2348 mt............................................................................................................................2349 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents.........................................................................................................2349 PREPARATION...............................................................................................................2350 Special Service Tools.................................................................................................2350 Commercial Service Tool...............................................................................................2351 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING......................................................................2352 NVH Troubleshooting Chart.............................................................................................2352 MANUAL TRANSMISSION...............................................................................................2352 ON-VEHICLE SERVICE........................................................................................................2353 Position Switch Check.................................................................................................2353 DESCRIPTION...............................................................................................................2354 Cross-sectional View..................................................................................................2354 REMOVAL AND INSTALLATION..................................................................................................2355 Removal...............................................................................................................2355 Installation..........................................................................................................2356 OVERHAUL..................................................................................................................2358 Case Components.......................................................................................................2358 Gear Components.......................................................................................................2359 Shift Control Components..............................................................................................2361 DISASSEMBLY...............................................................................................................2362 Case Components.......................................................................................................2362 DISASSEMBLY.......................................................................................................2362 Shift Control Components..............................................................................................2363 DISASSEMBLY.......................................................................................................2363 Gear Components.......................................................................................................2364 DISASSEMBLY.......................................................................................................2364 INSPECTION................................................................................................................2368 Shift Control Components..............................................................................................2368 INSPECTION........................................................................................................2368 Gear Components.......................................................................................................2368 INSPECTION........................................................................................................2368 ASSEMBLY..................................................................................................................2370 Gear Components.......................................................................................................2370 ASSEMBLY..........................................................................................................2370 Shift Control Components..............................................................................................2378 ASSEMBLY..........................................................................................................2378 Case Components.......................................................................................................2378 ASSEMBLY..........................................................................................................2378 SERVICE DATA AND SPECIFICATIONS (SDS).....................................................................................2381 General Specifications................................................................................................2381 Gear End Play.........................................................................................................2381 Clearance Between Baulk Ring and Gear.................................................................................2381 2ND AND 3RD BAULK RING............................................................................................2382 Distance Between Rear Surface of Reverse Cone and Reverse Baulk Ring..................................................2382 Available Snap Ring...................................................................................................2382 MAIN DRIVE GEAR SNAP RING.........................................................................................2382 MAINSHAFT FRONT SNAP RING.........................................................................................2382 COUNTER GEAR REAR SNAP RING.......................................................................................2383 Available C-ring......................................................................................................2383 MAINSHAFT C-RING..................................................................................................2383 Available Shim and Washer.............................................................................................2384 TABLE FOR SELECTING PROPER COUNTER GEAR FRONT BEARING THRUST WASHER...............................................2384 REVERSE IDLER REAR THRUST WASHER..................................................................................2384 pd............................................................................................................................2385 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents.........................................................................................................2385 PROPELLER SHAFT...........................................................................................................2387 Preparation...........................................................................................................2387 SPECIAL SERVICE TOOLS.............................................................................................2387 Noise, Vibration and Harshness (NVH) Troubleshooting..................................................................2388 NVH TROUBLESHOOTING CHART.........................................................................................2388 Components............................................................................................................2389 FRONT PROPELLER SHAFT.............................................................................................2389 REAR PROPELLER SHAFT..............................................................................................2390 On-vehicle Service....................................................................................................2392 PROPELLER SHAFT VIBRATION.........................................................................................2392 APPEARANCE CHECKING...............................................................................................2392 Removal and Installation..............................................................................................2392 Inspection............................................................................................................2393 Disassembly...........................................................................................................2393 CENTER BEARING - 2WD -............................................................................................2393 JOURNAL (71H AND 80B).............................................................................................2394 Assembly..............................................................................................................2395 CENTER BEARING - 2WD -............................................................................................2395 JOURNAL (71H AND 80B).............................................................................................2395 Service Data and Specifications (SDS).................................................................................2396 GENERAL SPECIFICATIONS............................................................................................2396 SERVICE DATA......................................................................................................2397 SNAP RING (80B)...................................................................................................2397 SNAP RING (71H)...................................................................................................2397 SNAP RING (1310)..................................................................................................2397 R200A.....................................................................................................................2398 FRONT FINAL DRIVE.....................................................................................................2398 Preparation.......................................................................................................2398 SPECIAL SERVICE TOOLS.........................................................................................2398 Noise, Vibration and Harshness (NVH) Troubleshooting..............................................................2400 On-vehicle Service................................................................................................2400 FRONT OIL SEAL REPLACEMENT....................................................................................2400 REAR COVER GASKET REPLACEMENT.................................................................................2401 Components........................................................................................................2402 Removal and Installation..........................................................................................2403 REMOVAL.......................................................................................................2403 INSTALLATION..................................................................................................2403 Disassembly.......................................................................................................2403 PRE-INSPECTION................................................................................................2403 FINAL DRIVE HOUSING...........................................................................................2404 DIFFERENTIAL CASE.............................................................................................2406 DIFFERENTIAL SIDE SHAFT.......................................................................................2407 Inspection........................................................................................................2408 DRIVE GEAR AND DRIVE PINION...................................................................................2408 DIFFERENTIAL CASE ASSEMBLY....................................................................................2408 BEARING.......................................................................................................2408 Adjustment........................................................................................................2409 SIDE BEARING PRELOAD..........................................................................................2409 PINION GEAR HEIGHT AND PINION BEARING PRELOAD.................................................................2410 TOOTH CONTACT.................................................................................................2414 Assembly..........................................................................................................2415 DIFFERENTIAL SIDE SHAFT.......................................................................................2415 DIFFERENTIAL CASE.............................................................................................2416 FINAL DRIVE HOUSING...........................................................................................2417 Service Data and Specifications (SDS).............................................................................2421 R200A.........................................................................................................2421 H233B.....................................................................................................................2423 REAR FINAL DRIVE......................................................................................................2423 Preparation.......................................................................................................2423 SPECIAL SERVICE TOOLS.........................................................................................2423 Noise, Vibration and Harshness (NVH) Troubleshooting..............................................................2425 On-vehicle Service................................................................................................2425 FRONT OIL SEAL REPLACEMENT....................................................................................2425 Components........................................................................................................2427 Removal and Installation..........................................................................................2428 REMOVAL.......................................................................................................2428 INSTALLATION..................................................................................................2428 Disassembly.......................................................................................................2428 PRE-INSPECTION................................................................................................2428 DIFFERENTIAL CARRIER..........................................................................................2429 DIFFERENTIAL CASE.............................................................................................2431 Inspection........................................................................................................2432 DRIVE GEAR AND DRIVE PINION...................................................................................2432 DIFFERENTIAL CASE ASSEMBLY....................................................................................2432 BEARING.......................................................................................................2432 Limited Slip Differential.........................................................................................2432 PREPARATION FOR DISASSEMBLY...................................................................................2432 DISASSEMBLY...................................................................................................2433 INSPECTION....................................................................................................2434 ADJUSTMENT....................................................................................................2435 ASSEMBLY......................................................................................................2436 Adjustment........................................................................................................2438 PINION GEAR HEIGHT............................................................................................2438 TOOTH CONTACT.................................................................................................2441 Assembly..........................................................................................................2442 DIFFERENTIAL CASE.............................................................................................2442 DIFFERENTIAL CARRIER..........................................................................................2443 Service Data and Specifications (SDS).............................................................................2446 H233B.........................................................................................................2446 rs............................................................................................................................2451 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents.........................................................................................................2451 SEAT BELTS................................................................................................................2453 Precautions...........................................................................................................2453 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) "AIR BAG" AND "SEAT BELT PRE-TENSIONER".......................................2453 PRECAUTION FOR SEAT BELT SERVICE..................................................................................2453 Front Seat Belt.......................................................................................................2455 REMOVAL AND INSTALLATION..........................................................................................2455 Rear Seat Belt........................................................................................................2456 REMOVAL AND INSTALLATION..........................................................................................2456 Seat Belt Inspection..................................................................................................2458 AFTER A COLLISION.................................................................................................2458 PRELIMINARY CHECKS................................................................................................2458 SEAT BELT RETRACTOR ON-VEHICLE CHECK..............................................................................2459 SEAT BELT RETRACTOR OFF-VEHICLE CHECK.............................................................................2459 Tether Anchor Plate...................................................................................................2460 REMOVAL AND INSTALLATION..........................................................................................2460 SUPPLEMENTAL RESTRAINT SYSTEM (SRS).......................................................................................2461 Precautions...........................................................................................................2461 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) "AIR BAG" AND "SEAT BELT PRE-TENSIONER".......................................2461 PRECAUTIONS FOR SRS "AIR BAG" AND "SEAT BELT PRE-TENSIONER" SERVICE...............................................2461 WIRING DIAGRAMS AND TROUBLE DIAGNOSIS.............................................................................2461 Preparation...........................................................................................................2462 COMMERCIAL SERVICE TOOL...........................................................................................2462 Description...........................................................................................................2463 Seat Belt Pre-tensioner with Load Limiter.............................................................................2464 Side Air Bag..........................................................................................................2464 Side Curtain Air Bag..................................................................................................2464 SRS Component Parts Location..........................................................................................2465 Diagnosis Sensor Unit.................................................................................................2465 REMOVAL AND INSTALLATION..........................................................................................2465 Seat Belt Pre-tensioner...............................................................................................2466 REMOVAL AND INSTALLATION..........................................................................................2466 Satellite Sensor......................................................................................................2466 REMOVAL AND INSTALLATION..........................................................................................2466 Driver Air Bag Module and Spiral Cable................................................................................2467 REMOVAL AND INSTALLATION..........................................................................................2467 REMOVAL...........................................................................................................2467 INSTALLATION......................................................................................................2469 Front Passenger Air Bag Module........................................................................................2469 REMOVAL...........................................................................................................2469 INSTALLATION......................................................................................................2471 Side Curtain Air Bag Module...........................................................................................2472 REMOVAL AND INSTALLATION..........................................................................................2472 Trouble Diagnoses Introduction........................................................................................2473 DIAGNOSIS FUNCTION................................................................................................2473 DIAGNOSIS MODE FOR CONSULT-II.....................................................................................2473 HOW TO CHANGE SELF-DIAGNOSIS MODE WITH CONSULT-II.................................................................2474 HOW TO CHANGE SELF-DIAGNOSIS MODE WITHOUT CONSULT-II..............................................................2474 HOW TO ERASE SELF-DIAGNOSIS RESULTS...............................................................................2474 How to Perform Trouble Diagnoses for Quick and Accurate Repair........................................................2475 INFORMATION FROM CUSTOMER.........................................................................................2475 PRELIMINARY CHECK.................................................................................................2475 WORK FLOW.........................................................................................................2476 Schematic.............................................................................................................2477 Wiring Diagram - SRS -................................................................................................2478 SRS Operation Check...................................................................................................2481 DIAGNOSTIC PROCEDURE 1............................................................................................2481 Trouble Diagnoses with CONSULT-II.....................................................................................2482 DIAGNOSTIC PROCEDURE 2............................................................................................2482 DIAGNOSTIC PROCEDURE 3............................................................................................2486 DIAGNOSTIC PROCEDURE 4 (CONTINUED FROM DIAGNOSTIC PROCEDURE 2)....................................................2487 DIAGNOSTIC PROCEDURE 5............................................................................................2488 Trouble Diagnoses without CONSULT-II..................................................................................2492 DIAGNOSTIC PROCEDURE 6............................................................................................2492 DIAGNOSTIC PROCEDURE 7............................................................................................2498 DIAGNOSTIC PROCEDURE 8 (CONTINUED FROM DIAGNOSTIC PROCEDURE 6)....................................................2499 Trouble Diagnoses: "AIR BAG" Warning Lamp Does Not Turn Off...........................................................2500 DIAGNOSTIC PROCEDURE 9............................................................................................2500 Trouble Diagnoses: "AIR BAG" Warning Lamp Does Not Turn On............................................................2502 DIAGNOSTIC PROCEDURE 10...........................................................................................2502 Collision Diagnosis...................................................................................................2503 FOR FRONTAL COLLISION.............................................................................................2503 FOR SIDE COLLISION................................................................................................2505 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............................................................................................................................2507 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents.........................................................................................................2507 PRECAUTIONS...............................................................................................................2508 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"...........................................2508 Precautions for SRS "AIR BAG" and "SEAT BELT PRE-TENSIONER" Service...................................................2508 Wiring Diagrams and Trouble Diagnosis.................................................................................2508 PREPARATION...............................................................................................................2509 Special Service Tool..................................................................................................2509 BATTERY...................................................................................................................2510 How to Handle Battery.................................................................................................2510 METHODS OF PREVENTING OVER-DISCHARGE..............................................................................2510 CHECKING ELECTROLYTE LEVEL........................................................................................2510 SPECIFIC GRAVITY CHECK............................................................................................2511 CHARGING THE BATTERY..............................................................................................2512 Trouble Diagnoses with Battery/Starting/Charging System Tester........................................................2513 DIAGNOSTIC RESULT ITEM CHART......................................................................................2515 STARTING SYSTEM...........................................................................................................2516 System Description....................................................................................................2516 WITH M/T..........................................................................................................2516 WITH A/T..........................................................................................................2516 Wiring Diagram - START -/With M/T.....................................................................................2517 Wiring Diagram - START -/With A/T.....................................................................................2518 Trouble Diagnoses with Battery/Starting/Charging System Tester........................................................2519 DIAGNOSTIC RESULT ITEM CHART......................................................................................2520 WORK FLOW.........................................................................................................2521 DIAGNOSTIC PROCEDURE 1............................................................................................2522 DIAGNOSTIC PROCEDURE 2............................................................................................2524 MINIMUM SPECIFICATION OF CRANKING VOLTAGE REFERENCING COOLANT TEMPERATURE.........................................2525 Construction..........................................................................................................2525 Removal and Installation..............................................................................................2525 Pinion/Clutch Check...................................................................................................2526 CHARGING SYSTEM...........................................................................................................2527 System Description....................................................................................................2527 Wiring Diagram - CHARGE -.............................................................................................2528 Trouble Diagnoses with Battery/Starting/Charging System Tester........................................................2529 DIAGNOSTIC RESULT ITEM CHART......................................................................................2531 WORK FLOW.........................................................................................................2532 DIAGNOSTIC PROCEDURE 1............................................................................................2533 DIAGNOSTIC PROCEDURE 2............................................................................................2534 DIAGNOSTIC PROCEDURE 3............................................................................................2535 MALFUNCTION INDICATOR.............................................................................................2536 Construction..........................................................................................................2536 Removal and Installation..............................................................................................2536 SERVICE DATA AND SPECIFICATIONS (SDS).....................................................................................2537 Battery...............................................................................................................2537 Starter...............................................................................................................2537 Alternator............................................................................................................2537 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............................................................................................................................2539 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents.........................................................................................................2539 PRECAUTIONS...............................................................................................................2540 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"...........................................2540 Precautions for SRS "AIR BAG" and "SEAT BELT PRE-TENSIONER" Service...................................................2540 Precautions for Steering System.......................................................................................2540 PREPARATION...............................................................................................................2541 Special Service Tools.................................................................................................2541 Commercial Service Tools..............................................................................................2542 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING......................................................................2544 NVH Troubleshooting Chart.............................................................................................2544 ON-VEHICLE SERVICE........................................................................................................2545 Checking Steering Wheel Play..........................................................................................2545 Checking Neutral Position on Steering Wheel...........................................................................2545 PRE-CHECKING......................................................................................................2545 CHECKING..........................................................................................................2545 Front Wheel Turning Angle.............................................................................................2545 Checking Gear Housing Movement........................................................................................2546 Adjusting Rack Retainer...............................................................................................2546 Checking and Adjusting Drive Belts....................................................................................2546 Checking Fluid Level..................................................................................................2546 Checking Fluid Leakage................................................................................................2546 Bleeding Hydraulic System.............................................................................................2547 Checking Steering Wheel Turning Force.................................................................................2547 Checking Hydraulic System.............................................................................................2548 STEERING WHEEL AND STEERING COLUMN........................................................................................2549 Components............................................................................................................2549 Removal and Installation..............................................................................................2549 STEERING WHEEL....................................................................................................2549 STEERING COLUMN...................................................................................................2550 Disassembly and Assembly..............................................................................................2551 Inspection............................................................................................................2552 TILT MECHANISM....................................................................................................2552 STEERING TRANSFER GEAR....................................................................................................2553 Removal...............................................................................................................2553 Installation..........................................................................................................2554 Inspection............................................................................................................2554 POWER STEERING GEAR AND LINKAGE...........................................................................................2555 Components............................................................................................................2555 Removal and Installation..............................................................................................2556 Disassembly...........................................................................................................2557 Inspection............................................................................................................2558 BOOT..............................................................................................................2558 RACK..............................................................................................................2558 PINION ASSEMBLY...................................................................................................2558 GEAR HOUSING CYLINDER.............................................................................................2558 TIE-ROD OUTER AND INNER SOCKETS...................................................................................2559 Assembly..............................................................................................................2559 Adjustment............................................................................................................2562 POWER STEERING OIL PUMP...................................................................................................2565 Components............................................................................................................2565 Pre-disassembly Inspection............................................................................................2565 Disassembly...........................................................................................................2566 Inspection............................................................................................................2567 Assembly..............................................................................................................2567 SERVICE DATA AND SPECIFICATIONS (SDS).....................................................................................2570 General Specifications................................................................................................2570 Steering Wheel........................................................................................................2570 Steering Column.......................................................................................................2570 Steering Transfer Gear................................................................................................2570 Steering Gear and Linkage.............................................................................................2571 Power Steering........................................................................................................2571 su............................................................................................................................2573 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents.........................................................................................................2573 FRONT SUSPENSION..........................................................................................................2575 Precautions...........................................................................................................2575 PRECAUTIONS.......................................................................................................2575 Preparation...........................................................................................................2575 SPECIAL SERVICE TOOLS.............................................................................................2575 COMMERCIAL SERVICE TOOLS..........................................................................................2575 Noise, Vibration and Harshness (NVH) Troubleshooting..................................................................2576 NVH TROUBLESHOOTING CHART.........................................................................................2576 Components............................................................................................................2577 2WD...............................................................................................................2577 4WD...............................................................................................................2578 On-vehicle Service....................................................................................................2579 FRONT SUSPENSION PARTS............................................................................................2579 FRONT WHEEL ALIGNMENT.............................................................................................2580 Coil Spring and Strut Assembly........................................................................................2582 COMPONENTS........................................................................................................2582 REMOVAL...........................................................................................................2584 DISASSEMBLY.......................................................................................................2584 INSPECTION........................................................................................................2584 ASSEMBLY..........................................................................................................2585 Stabilizer Bar........................................................................................................2585 REMOVAL AND INSTALLATION..........................................................................................2585 INSPECTION........................................................................................................2586 Transverse Link and Lower Ball Joint..................................................................................2586 REMOVAL AND INSTALLATION..........................................................................................2586 INSPECTION........................................................................................................2587 Low Tire Pressure Warning System......................................................................................2588 SYSTEM COMPONENTS.................................................................................................2588 SYSTEM DESCRIPTION................................................................................................2588 Trouble Diagnoses.....................................................................................................2590 WIRING DIAGRAM....................................................................................................2590 LOW TIRE PRESSURE WARNING CONTROL UNIT INPUT/OUTPUT SIGNAL STANDARD...............................................2592 ID REGISTRATION PROCEDURE.........................................................................................2592 SELF-DIAGNOSIS....................................................................................................2595 HOW TO PERFORM TROUBLE DIAGNOSIS FOR QUICK AND ACCURATE REPAIR....................................................2597 PRELIMINARY CHECK.................................................................................................2598 MALFUNCTION CODE/SYMPTOM CHART....................................................................................2599 Trouble Diagnoses for Self-diagnostic Items...........................................................................2599 INSPECTION 1: TRANSMITTER OR TIRE PRESSURE WARNING CONTROL UNIT...................................................2599 INSPECTION 2: TRANSMITTER-1.......................................................................................2600 INSPECTION 3: TRANSMITTER-2.......................................................................................2601 INSPECTION 4: LOW TIRE PRESSURE WARNING CONTROL UNIT..............................................................2601 Trouble Diagnoses for Symptoms........................................................................................2602 INSPECTION 1: WARNING LAMP DOES NOT COME ON WHEN IGNITION SWITCH IS TURNED ON.....................................2602 INSPECTION 2: WARNING LAMP STAYS ON WHEN IGNITION SWITCH IS TURNED ON.............................................2603 INSPECTION 3: WARNING LAMP BLINKS WHEN IGNITION SWITCH IS TURNED ON...............................................2605 INSPECTION 4: TAIL LAMP BLINKS WHEN IGNITION SWITCH IS TURNED ON..................................................2606 INSPECTION 5: ID REGISTRATION CANNOT BE COMPLETED.................................................................2606 Service Data and Specifications (SDS).................................................................................2606 GENERAL SPECIFICATIONS (FRONT)....................................................................................2606 WHEEL ALIGNMENT (UNLADEN*1).......................................................................................2606 LOWER BALL JOINT..................................................................................................2607 WHEELARCH HEIGHT (UNLADEN*).......................................................................................2607 WHEEL RUNOUT AVERAGE*.............................................................................................2608 REAR SUSPENSION...........................................................................................................2609 Precautions...........................................................................................................2609 PRECAUTIONS.......................................................................................................2609 Preparation...........................................................................................................2609 COMMERCIAL SERVICE TOOLS..........................................................................................2609 Noise, Vibration and Harshness (NVH) Troubleshooting..................................................................2609 Components............................................................................................................2610 On-vehicle Service....................................................................................................2610 REAR SUSPENSION PARTS.............................................................................................2610 Removal and Installation..............................................................................................2611 Coil Spring and Shock Absorber........................................................................................2612 COMPONENTS........................................................................................................2612 REMOVAL AND INSTALLATION..........................................................................................2613 INSPECTION........................................................................................................2613 Upper Link, Lower Link and Panhard Rod................................................................................2613 INSPECTION........................................................................................................2613 BUSHING REPLACEMENT...............................................................................................2613 INSTALLATION......................................................................................................2614 Stabilizer Bar........................................................................................................2614 REMOVAL AND INSTALLATION..........................................................................................2614 Low Tire Pressure Warning System......................................................................................2614 Service Data and Specifications (SDS).................................................................................2615 GENERAL SPECIFICATIONS (REAR).....................................................................................2615 tf............................................................................................................................2617 QUICK REFERENCE INDEX..................................................................................................... 0 Table of Contents.........................................................................................................2617 PREPARATION...............................................................................................................2620 Special Service Tools.................................................................................................2620 Commercial Service Tools..............................................................................................2625 TX10A.....................................................................................................................2626 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING..................................................................2626 NVH Troubleshooting Chart.........................................................................................2626 TRANSFER......................................................................................................2626 DESCRIPTION...........................................................................................................2627 Cross-sectional View..............................................................................................2627 ON-VEHICLE SERVICE....................................................................................................2628 Replacing Oil Seal................................................................................................2628 CENTER CASE OIL SEAL..........................................................................................2628 SHIFT SHAFT OIL SEAL..........................................................................................2629 REAR OIL SEAL.................................................................................................2629 Position Switch Check.............................................................................................2630 REMOVAL AND INSTALLATION..............................................................................................2631 Removal...........................................................................................................2631 Installation......................................................................................................2631 M/T MODEL.....................................................................................................2631 A/T MODEL.....................................................................................................2631 OVERHAUL..............................................................................................................2632 Transfer Gear Control.............................................................................................2632 Case Components...................................................................................................2633 Gear Components...................................................................................................2634 Shift Control Components..........................................................................................2635 DISASSEMBLY...........................................................................................................2636 REPAIR FOR COMPONENT PARTS............................................................................................2640 Mainshaft.........................................................................................................2640 DISASSEMBLY...................................................................................................2640 INSPECTION....................................................................................................2641 ASSEMBLY......................................................................................................2641 Front Drive Shaft.................................................................................................2642 DISASSEMBLY...................................................................................................2642 INSPECTION....................................................................................................2642 ASSEMBLY......................................................................................................2642 Counter Gear......................................................................................................2642 DISASSEMBLY...................................................................................................2642 INSPECTION....................................................................................................2643 ASSEMBLY......................................................................................................2643 Main Gear.........................................................................................................2643 DISASSEMBLY...................................................................................................2643 INSPECTION....................................................................................................2644 ASSEMBLY......................................................................................................2644 Front Case........................................................................................................2644 REMOVAL.......................................................................................................2644 INSTALLATION..................................................................................................2645 Front Case Cover..................................................................................................2645 REMOVAL.......................................................................................................2645 INSTALLATION..................................................................................................2645 Bearing Retainer..................................................................................................2645 REMOVAL.......................................................................................................2645 INSTALLATION..................................................................................................2645 Center Case.......................................................................................................2646 REMOVAL.......................................................................................................2646 INSTALLATION..................................................................................................2646 Rear Case.........................................................................................................2646 REMOVAL.......................................................................................................2646 INSTALLATION..................................................................................................2646 Shift Control Components..........................................................................................2647 INSPECTION....................................................................................................2647 ASSEMBLY..............................................................................................................2648 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................2655 General Specifications............................................................................................2655 Gear End Play.....................................................................................................2655 Available Snap Ring...............................................................................................2655 MAINSHAFT FRONT BEARING.......................................................................................2655 MAINSHAFT REAR BEARING........................................................................................2655 MAIN GEAR BEARING.............................................................................................2655 Available Shim....................................................................................................2656 COUNTER GEAR REAR BEARING.....................................................................................2656 ATX14A....................................................................................................................2657 PRECAUTIONS...........................................................................................................2657 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER".......................................2657 Precautions.......................................................................................................2657 Service Notice....................................................................................................2658 Wiring Diagrams and Trouble Diagnosis.............................................................................2658 ALL-MODE 4WD SYSTEM...................................................................................................2659 Cross-sectional View..............................................................................................2659 Control System....................................................................................................2660 ALL-MODE 4WD TRANSFER BASIC CONTROL...........................................................................2661 HYDRAULIC CONTROL CIRCUITS....................................................................................2661 OUTLINE.......................................................................................................2661 CONTROL SYSTEM DIAGRAM........................................................................................2662 INDICATIONS OF 4WD WARNING LAMP...............................................................................2662 CAN Communication (With VDC)......................................................................................2663 SYSTEM DESCRIPTION............................................................................................2663 Location of Electrical Parts......................................................................................2664 Description of Electrical Parts...................................................................................2665 TRANSFER MOTOR................................................................................................2665 WAIT DETECTION SWITCH.........................................................................................2665 2-4WD SHIFT SOLENOID VALVE....................................................................................2666 LINE PRESSURE SWITCH..........................................................................................2666 Circuit Diagram for Quick Pinpoint Check..........................................................................2667 Wiring Diagram - TF -.............................................................................................2668 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION................................................................................2677 Trouble Diagnosis without CONSULT-II..............................................................................2677 DESCRIPTION...................................................................................................2677 SELF-DIAGNOSTIC PROCEDURE.....................................................................................2678 INDICATIONS OF 4WD WARNING LAMP...............................................................................2679 Trouble Diagnosis with CONSULT-II.................................................................................2680 CONSULT-II FUNCTION...........................................................................................2680 SELF-DIAGNOSIS................................................................................................2680 SELF-DIAGNOSTIC ITEMS.........................................................................................2682 DATA MONITOR..................................................................................................2683 DATA MONITOR ITEMS............................................................................................2685 REFERENCE VALUE IN DATA MONITOR MODE..........................................................................2687 WORK SUPPORT..................................................................................................2689 CLUTCH FORCE RELEASE LIMIT ADJUSTMENT.........................................................................2690 TROUBLE DIAGNOSIS - INTRODUCTION......................................................................................2692 Introduction......................................................................................................2692 DESCRIPTION...................................................................................................2692 DIAGNOSTIC WORKSHEET..........................................................................................2692 Work Flow.........................................................................................................2694 HOW TO PERFORM TROUBLE DIAGNOSES FOR QUICK AND ACCURATE REPAIR................................................2694 TROUBLE DIAGNOSIS - BASIC INSPECTION..................................................................................2695 Listen to Customer Complaints.....................................................................................2695 Transfer Fluid Check..............................................................................................2695 Road Test.........................................................................................................2695 PREPARATION FOR ROAD TEST.....................................................................................2695 1. CHECK BEFORE ENGINE IS STARTED.............................................................................2696 2. CHECK AT IDLE..............................................................................................2697 3. CRUISE TEST................................................................................................2701 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION...............................................................................2704 Transfer Control Unit Terminals and Reference Value...............................................................2704 REMOVAL AND INSTALLATION OF TRANSFER CONTROL UNIT.............................................................2704 INSPECTION OF TRANSFER CONTROL UNIT...........................................................................2704 TRANSFER CONTROL UNIT INSPECTION TABLE........................................................................2705 DTC U1000 CAN COMMUNICATION LINE (WITH VDC)...........................................................................2711 Description.......................................................................................................2711 On Board Diagnosis Logic..........................................................................................2711 Possible Cause....................................................................................................2711 DTC Confirmation Procedure........................................................................................2711 WITH CONSULT-II...............................................................................................2711 WITH GST......................................................................................................2711 Diagnostic Procedure..............................................................................................2712 VEHICLE SPEED SENSOR (FRONT REVOLUTION SENSOR) (WITHOUT VDC)..........................................................2713 Diagnostic Procedure..............................................................................................2713 4WD SOLENOID VALVE....................................................................................................2716 Diagnostic Procedure..............................................................................................2716 2-4WD SHIFT SOLENOID VALVE AND 4WD SHIFT SWITCH.......................................................................2718 Diagnostic Procedure..............................................................................................2718 TRANSFER MOTOR AND TRANSFER MOTOR RELAY...............................................................................2722 Diagnostic Procedure..............................................................................................2722 TRANSFER FLUID TEMPERATURE SENSOR.....................................................................................2725 Diagnostic Procedure..............................................................................................2725 ATP SWITCH, WAIT DETECTION SWITCH AND NEUTRAL-4LO SWITCH..............................................................2728 Diagnostic Procedure..............................................................................................2728 CLUTCH PRESSURE SWITCH................................................................................................2732 Diagnostic Procedure..............................................................................................2732 LINE PRESSURE SWITCH..................................................................................................2735 Diagnostic Procedure..............................................................................................2735 ABS OPERATION SIGNAL (WITHOUT VDC)....................................................................................2738 Diagnostic Procedure..............................................................................................2738 DATA ERASE/DISPLAY....................................................................................................2740 Diagnostic Procedure..............................................................................................2740 SHIFT ACTUATOR........................................................................................................2741 Diagnostic Procedure..............................................................................................2741 SHIFT ACTUATOR POSITION SWITCH........................................................................................2744 Diagnostic Procedure..............................................................................................2744 SHIFT ACTUATOR CIRCUIT................................................................................................2746 Diagnostic Procedure..............................................................................................2746 TROUBLE DIAGNOSES FOR SYMPTOMS........................................................................................2750 Symptom 1. 4WD Shift Indicator Lamp Does Not Turn ON..............................................................2750 Symptom 2. 4WD Warning Lamp Does Not Turn ON......................................................................2752 Symptom 3. 4WD Shift Indicator Lamp Does Not Turn OFF.............................................................2754 Symptom 4. ATP Warning Lamp Does Not Turn ON......................................................................2754 Symptom 5. 4LO Indicator Lamp Does Not Turn ON....................................................................2756 Symptom 6. 4WD Shift Indicator Lamp Does Not Indicate "4H"........................................................2758 Symptom 7. 4WD Shift Indicator Lamp Repeats Flickering............................................................2759 Symptom 8. Tight Corner Braking Symptom...........................................................................2760 Symptom 9. 4WD System Does Not Operate............................................................................2761 COMPONENT INSPECTION..................................................................................................2763 4WD Shift Switch..................................................................................................2763 2-4WD Shift Solenoid Valve and Transfer Fluid Temperature Sensor..................................................2763 4WD Solenoid Valve, Clutch Pressure Switch and Line Pressure Switch...............................................2763 Front Revolution Sensor...........................................................................................2764 Transfer Dropping Resistor........................................................................................2764 ATP Switch, Neutral-4LO Switch and Wait Detection Switch..........................................................2764 Transfer Motor....................................................................................................2765 Transfer Motor Relay..............................................................................................2765 Transfer Sub-harness..............................................................................................2765 FRONT REVOLUTION SENSOR SUB-HARNESS CONNECTOR.................................................................2765 TRANSFER SWITCH ASSEMBLY SUB-HARNESS CONNECTOR................................................................2766 TRANSFER TERMINAL CORD ASSEMBLY SUB-HARNESS CONNECTOR.........................................................2766 Transfer Shift Relay (High & low).................................................................................2766 Actuator & Actuator Position Switch...............................................................................2767 ACTUATOR......................................................................................................2767 ACTUATOR POSITION SWITCH......................................................................................2767 ON-VEHICLE SERVICE....................................................................................................2768 Replacing Oil Seal................................................................................................2768 FRONT CASE OIL SEAL...........................................................................................2768 SHIFT SHAFT OIL SEAL..........................................................................................2769 REAR OIL SEAL.................................................................................................2769 Transfer Motor....................................................................................................2770 REMOVAL.......................................................................................................2770 INSTALLATION..................................................................................................2770 Transfer Oil Filter...............................................................................................2770 REMOVAL.......................................................................................................2770 INSTALLATION..................................................................................................2770 REMOVAL AND INSTALLATION..............................................................................................2771 Removal...........................................................................................................2771 Installation......................................................................................................2771 OVERHAUL..............................................................................................................2772 Transfer Gear Control.............................................................................................2772 Transfer Components...............................................................................................2773 DISASSEMBLY...........................................................................................................2775 Rear Case.........................................................................................................2775 DISASSEMBLY...................................................................................................2775 Center Case.......................................................................................................2775 DISASSEMBLY...................................................................................................2775 Front Case........................................................................................................2785 DISASSEMBLY...................................................................................................2785 REPAIR FOR COMPONENT PARTS............................................................................................2789 Front Case........................................................................................................2789 INSPECTION....................................................................................................2789 Center Case.......................................................................................................2790 INSPECTION....................................................................................................2790 ASSEMBLY..............................................................................................................2793 Front Case........................................................................................................2793 ASSEMBLY......................................................................................................2793 Center Case.......................................................................................................2797 ASSEMBLY......................................................................................................2797 Final Assembly....................................................................................................2805 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................2808 General Specifications............................................................................................2808 Inner Gear and Outer Gear.........................................................................................2808 SUB-OIL PUMP..................................................................................................2808 MAIN OIL PUMP.................................................................................................2808 Control Valve.....................................................................................................2808 VALVE.........................................................................................................2808 SPRING........................................................................................................2808 Clutch............................................................................................................2809 DRIVE PLATE...................................................................................................2809 DRIVEN PLATE..................................................................................................2809 RETURN SPRING.................................................................................................2809 RETAINING PLATE...............................................................................................2809 Seal Ring (Mainshaft side)........................................................................................2810 Bearing Race (Thrust needle bearing side).........................................................................2810 Snap Ring (Sun gear side).........................................................................................2810 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:
2004 NISSAN PATHFINDER R50 Series Service Manual PDF DOWNLOAD
FOREWORD
- This manual contains maintenance and repair procedures for the 2004 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
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
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