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2005 NISSAN X-TRAIL T30 Series Service Manual PDF DOWNLOAD
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2005 NISSAN X-TRAIL T30 Series Service Manual PDF DOWNLOAD
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2005 NISSAN X-TRAIL T30 Series Service Manual PDF DOWNLOAD
Language : English
Pages : 2678
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
2005 NISSAN X-TRAIL T30 Series Service Manual PDF DOWNLOAD
fwd......................................................................................................................... 1 Exit.................................................................................................................... 0 QUICK REFERENCE INDEX................................................................................................... 1 FOREWORD................................................................................................................ 2 A: GENERAL INFORMATION.................................................................................................. 0 GI - General Information............................................................................................ 0 B: ENGINE............................................................................................................... 0 EM - Engine Mechanical.............................................................................................. 0 LU - Engine Lubrication System...................................................................................... 0 CO - Engine Cooling System.......................................................................................... 0 EC - Engine Control System.......................................................................................... 0 FL - Fuel System.................................................................................................... 0 EX - Exhaust System................................................................................................. 0 ACC - Accelerator Control System.................................................................................... 0 C: TRANSMISSION/TRANSAXLE............................................................................................... 0 CL - Clutch......................................................................................................... 0 MT - Manual Transaxle............................................................................................... 0 AT - Automatic Transaxle............................................................................................ 0 D: DRIVELINE/AXLE....................................................................................................... 0 TF - Transfer....................................................................................................... 0 PR - Propeller Shaft................................................................................................ 0 RFD - Rear Final Drive.............................................................................................. 0 FAX - Front Axle.................................................................................................... 0 RAX - Rear Axle..................................................................................................... 0 E: SUSPENSION........................................................................................................... 0 FSU - Front Suspension.............................................................................................. 0 RSU - Rear Suspension............................................................................................... 0 WT - Road Wheels & Tires............................................................................................ 0 F: BRAKES............................................................................................................... 0 BR - Brake System................................................................................................... 0 PB - Parking Brake System........................................................................................... 0 BRC - Brake Control System.......................................................................................... 0 G: STEERING............................................................................................................. 0 PS - Power Steering System.......................................................................................... 0 H: RESTRAINTS........................................................................................................... 0 SB - Seat Belts..................................................................................................... 0 SRS - Supplemental Restraint System (SRS)........................................................................... 0 I: BODY................................................................................................................. 0 BL - Body, Lock & Security System................................................................................... 0 GW - Glasses, Window System & Mirrors............................................................................... 0 RF - Roof........................................................................................................... 0 EI - Exterior & Interior............................................................................................ 0 IP - Instrument Panel............................................................................................... 0 SE - Seat........................................................................................................... 0 J: AIR CONDITIONER...................................................................................................... 0 ATC - Automatic Air Conditioner..................................................................................... 0 MTC - Manual Air Conditioner........................................................................................ 0 K: ELECTRICAL........................................................................................................... 0 SC - Starting & Charging System..................................................................................... 0 LT - Lighting System................................................................................................ 0 DI - Driver Information System...................................................................................... 0 WW - Wiper, Washer & Horn........................................................................................... 0 BCS - Body Control System........................................................................................... 0 LAN - LAN system.................................................................................................... 0 AV - Audio, Visual & Telephone System............................................................................... 0 ACS - Auto Cruise Control System.................................................................................... 0 PG - Power Supply, Ground & Circuit Elements........................................................................ 0 L: MAINTENANCE.......................................................................................................... 0 MA - Maintenance.................................................................................................... 0 M: INDEX................................................................................................................ 1 IDX - Alphabetical Index............................................................................................ 1 ELECTRICAL UNITS........................................................................................................ 45 FUSE BLOCK - JUNCTION BOX (J/B)......................................................................................... 48 FUSE AND FUSIBLE LINK BOX............................................................................................... 49 Comment Sheet........................................................................................................... 3 Inch to Metric Conversion Table......................................................................................... 4 Quick Reference Chart................................................................................................... 5 acc......................................................................................................................... 8 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents....................................................................................................... 8 PRECAUTIONS......................................................................................................... 9 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”..................... 9 ACCELERATOR CONTROL SYSTEM.......................................................................................... 10 Removal and Installation........................................................................................ 10 REMOVAL..................................................................................................... 10 INSTALLATION................................................................................................ 10 INSPECTION AFTER INSTALLATION............................................................................... 10 acs......................................................................................................................... 12 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents....................................................................................................... 12 AUTOMATIC SPEED CONTROL DEVICE (ASCD)............................................................................... 13 Description..................................................................................................... 13 at.......................................................................................................................... 14 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents....................................................................................................... 14 INDEX FOR DTC....................................................................................................... 18 Alphabetical Index.............................................................................................. 18 DTC No. Index................................................................................................... 19 PRECAUTIONS......................................................................................................... 20 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”..................... 20 Precautions for On Board Diagnostic (OBD) System of A/T and Engine.............................................. 20 Precautions..................................................................................................... 20 Service Notice or Precautions................................................................................... 22 ATF COOLER SERVICE.......................................................................................... 22 TORQUE CONVERTER SERVICE.................................................................................... 22 OBD-II SELF-DIAGNOSIS....................................................................................... 22 Wiring Diagrams and Trouble Diagnosis........................................................................... 23 PREPARATION......................................................................................................... 24 Special Service Tools........................................................................................... 24 Commercial Service Tools........................................................................................ 28 A/T FLUID........................................................................................................... 30 Checking A/T Fluid.............................................................................................. 30 Changing A/T Fluid.............................................................................................. 31 A/T Fluid Cooler Cleaning....................................................................................... 31 A/T FLUID COOLER CLEANING PROCEDURE......................................................................... 31 A/T FLUID COOLER DIAGNOSIS PROCEDURE........................................................................ 32 A/T FLUID COOLER INSPECTION PROCEDURE....................................................................... 33 A/T FLUID COOLER FINAL INSPECTION........................................................................... 33 A/T CONTROL SYSTEM.................................................................................................. 34 Cross-Sectional View............................................................................................ 34 Shift Mechanism................................................................................................. 35 CONSTRUCTION................................................................................................ 35 FUNCTION OF CLUTCH AND BRAKE................................................................................ 35 CLUTCH AND BAND CHART....................................................................................... 36 POWER TRANSMISSION.......................................................................................... 37 “N” and “P” Positions................................................................................... 37 "11"Position............................................................................................ 38 "D1" and "21" Positions................................................................................. 39 "D2", "22" and "12" Positions........................................................................... 40 "D3", "23" and "13" Positions........................................................................... 41 "D4" (OD) Position...................................................................................... 42 “R” Position............................................................................................ 43 TCM Function.................................................................................................... 44 CONTROL SYSTEM OUTLINE...................................................................................... 44 CONTROL SYSTEM DIAGRAM...................................................................................... 44 CAN Communication............................................................................................... 45 SYSTEM DESCRIPTION.......................................................................................... 45 Input/Output Signal of TCM...................................................................................... 45 Line Pressure Control........................................................................................... 46 NORMAL CONTROL.............................................................................................. 46 BACK-UP CONTROL (ENGINE BRAKE).............................................................................. 46 DURING SHIFT CHANGE......................................................................................... 46 AT LOW FLUID TEMPERATURE.................................................................................... 47 Shift Control................................................................................................... 47 CONTROL OF SHIFT SOLENOID VALVES A AND B.................................................................... 47 RELATION BETWEEN SHIFT SOLENOID VALVES A AND B AND GEAR POSITIONS........................................... 47 CONTROL OF SHIFT VALVES A AND B............................................................................. 48 Lock-Up Control................................................................................................. 48 CONDITIONS FOR LOCK-UP OPERATION............................................................................ 48 TORQUE CONVERTER CLUTCH SOLENOID VALVE CONTROL.............................................................. 48 Lock-Up Control System Diagram.......................................................................... 48 Lock-Up Released........................................................................................ 49 Lock-Up Applied......................................................................................... 49 SMOOTH LOCK-UP CONTROL...................................................................................... 49 Half-Clutched State..................................................................................... 49 Engine Brake Control (Overrun Clutch Control)................................................................... 49 OVERRUN CLUTCH OPERATING CONDITIONS......................................................................... 49 OVERRUN CLUTCH SOLENOID VALVE CONTROL....................................................................... 50 OVERRUN CLUTCH CONTROL VALVE OPERATION...................................................................... 50 Control Valve................................................................................................... 51 FUNCTION OF CONTROL VALVES.................................................................................. 51 ON BOARD DIAGNOSTIC (OBD) SYSTEM.................................................................................... 52 Introduction.................................................................................................... 52 OBD-II Function for A/T System.................................................................................. 52 One or Two Trip Detection Logic of OBD-II....................................................................... 52 ONE TRIP DETECTION LOGIC.................................................................................... 52 TWO TRIP DETECTION LOGIC.................................................................................... 52 OBD-II Diagnostic Trouble Code (DTC)............................................................................ 52 HOW TO READ DTC AND 1ST TRIP DTC............................................................................ 52 Freeze Frame Data and 1st Trip Freeze Frame Data........................................................ 53 HOW TO ERASE DTC............................................................................................ 53 HOW TO ERASE DTC (WITH CONSULT-II).......................................................................... 54 HOW TO ERASE DTC (WITH GST)................................................................................. 54 HOW TO ERASE DTC (NO TOOLS)................................................................................. 55 Malfunction Indicator Lamp (MIL)................................................................................ 55 DESCRIPTION................................................................................................. 55 TROUBLE DIAGNOSIS................................................................................................... 56 DTC Inspection Priority Chart................................................................................... 56 Fail-Safe....................................................................................................... 56 FAIL-SAFE FUNCTION.......................................................................................... 56 Vehicle Speed Sensor 1 (Revolution Sensor).............................................................. 56 Accelerator Pedal Position Sensor Signal................................................................ 56 Park/Neutral Position (PNP) Switch...................................................................... 57 Shift Solenoid Valve A and B............................................................................ 57 Line Pressure Solenoid Valve............................................................................ 57 Torque Converter Clutch Solenoid Valve.................................................................. 57 Overrun Clutch Solenoid Valve........................................................................... 57 How to Perform Trouble Diagnoses for Quick and Accurate Repair.................................................. 58 INTRODUCTION................................................................................................ 58 WORK FLOW................................................................................................... 58 Work Flow Chart......................................................................................... 59 DIAGNOSTIC WORKSHEET........................................................................................ 60 Information from Customer............................................................................... 60 Diagnostic Worksheet.................................................................................... 61 A/T Electrical Parts Location................................................................................... 63 Circuit Diagram................................................................................................. 64 Inspections before Trouble Diagnosis............................................................................ 65 A/T FLUID CHECK............................................................................................. 65 Fluid Leakage and Fluid Level Check..................................................................... 65 Fluid Condition Check................................................................................... 65 STALL TEST.................................................................................................. 65 Stall Test Procedure.................................................................................... 65 Judgement of Stall Test................................................................................. 66 LINE PRESSURE TEST.......................................................................................... 68 Line Pressure Test Ports................................................................................ 68 Line Pressure Test Procedure............................................................................ 68 Line Pressure........................................................................................... 69 Judgement of Line Pressure Test......................................................................... 69 Road Test....................................................................................................... 70 DESCRIPTION................................................................................................. 70 Check before Engine Is Started.................................................................................. 70 Check at Idle................................................................................................... 71 Cruise Test — Part 1............................................................................................ 73 Cruise Test — Part 2............................................................................................ 76 Cruise Test — Part 3............................................................................................ 77 Vehicle Speed When Shifting Gears............................................................................... 79 Vehicle Speed When Performing and Releasing Lock-Up............................................................. 79 Symptom Chart................................................................................................... 80 TCM Terminals and Reference Value............................................................................... 90 TCM CONNECTOR TERMINAL LAYOUT............................................................................... 90 TCM INSPECTION TABLE........................................................................................ 90 CONSULT-II Function (A/T)....................................................................................... 93 FUNCTION.................................................................................................... 93 CONSULT-II REFERENCE VALUE.................................................................................. 93 CONSULT-II SETTING PROCEDURE................................................................................ 95 SELF-DIAGNOSTIC RESULT MODE................................................................................. 95 Operation Procedure..................................................................................... 95 Display Items List...................................................................................... 96 How to Erase Self-Diagnostic Results.................................................................... 97 DATA MONITOR MODE........................................................................................... 97 Operation Procedure..................................................................................... 97 Display Items List...................................................................................... 97 CAN DIAGNOSTIC SUPPORT MONITOR MODE......................................................................... 100 Operation Procedure..................................................................................... 100 DTC WORK SUPPORT MODE....................................................................................... 100 Operation Procedure..................................................................................... 100 Display Items List...................................................................................... 103 Diagnostic Procedure Without CONSULT-II......................................................................... 104 TCM SELF-DIAGNOSTIC PROCEDURE............................................................................... 104 Diagnostic Procedure.................................................................................... 104 JUDGEMENT OF SELF-DIAGNOSIS CODE............................................................................ 105 HOW TO ERASE SELF-DIAGNOSTIC RESULTS........................................................................ 107 DTC U1000 CAN COMMUNICATION LINE.................................................................................... 108 Description..................................................................................................... 108 On Board Diagnosis Logic........................................................................................ 108 Possible Cause.................................................................................................. 108 DTC Confirmation Procedure...................................................................................... 108 WITH CONSULT-II............................................................................................. 108 WITH GST.................................................................................................... 108 WITHOUT CONSULT-II.......................................................................................... 108 Wiring Diagram — AT — CAN....................................................................................... 109 Diagnostic Procedure............................................................................................ 110 DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH........................................................................ 111 Description..................................................................................................... 111 CONSULT-II Reference Value...................................................................................... 111 On Board Diagnosis Logic........................................................................................ 111 Possible Cause.................................................................................................. 111 DTC Confirmation Procedure...................................................................................... 111 WITH CONSULT-II............................................................................................. 111 WITH GST.................................................................................................... 111 Wiring Diagram — AT — PNP/SW.................................................................................... 112 Diagnostic Procedure............................................................................................ 114 DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT...................................................................... 117 Description..................................................................................................... 117 CONSULT-II Reference Value...................................................................................... 117 On Board Diagnosis Logic........................................................................................ 117 Possible Cause.................................................................................................. 117 DTC Confirmation Procedure...................................................................................... 117 WITH CONSULT-II............................................................................................. 117 WITH GST.................................................................................................... 117 WITHOUT CONSULT-II.......................................................................................... 117 Wiring Diagram — AT — FTS....................................................................................... 118 Diagnostic Procedure............................................................................................ 119 Component Inspection............................................................................................ 121 A/T FLUID TEMPERATURE SENSOR................................................................................ 121 DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR).............................................................. 122 Description..................................................................................................... 122 CONSULT-II Reference Value...................................................................................... 122 On Board Diagnosis Logic........................................................................................ 122 Possible Cause.................................................................................................. 122 DTC Confirmation Procedure...................................................................................... 122 WITH CONSULT-II............................................................................................. 122 WITH GST.................................................................................................... 123 WITHOUT CONSULT-II.......................................................................................... 123 Wiring Diagram — AT — VSSA/T.................................................................................... 124 Diagnostic Procedure............................................................................................ 125 DTC P0725 ENGINE SPEED SIGNAL....................................................................................... 128 Description..................................................................................................... 128 CONSULT-II Reference Value...................................................................................... 128 On Board Diagnosis Logic........................................................................................ 128 Possible Cause.................................................................................................. 128 DTC Confirmation Procedure...................................................................................... 128 WITH CONSULT-II............................................................................................. 128 WITH GST.................................................................................................... 128 WITHOUT CONSULT-II.......................................................................................... 129 Wiring Diagram — AT — ENGSS..................................................................................... 130 Diagnostic Procedure............................................................................................ 131 DTC P0731 A/T 1ST GEAR FUNCTION..................................................................................... 133 Description..................................................................................................... 133 On Board Diagnosis Logic........................................................................................ 133 Possible Cause.................................................................................................. 133 DTC Confirmation Procedure...................................................................................... 133 WITH CONSULT-II............................................................................................. 134 WITH GST.................................................................................................... 134 Wiring Diagram — AT — 1STSIG.................................................................................... 135 Diagnostic Procedure............................................................................................ 136 DTC P0732 A/T 2ND GEAR FUNCTION..................................................................................... 138 Description..................................................................................................... 138 On Board Diagnosis Logic........................................................................................ 138 Possible Cause.................................................................................................. 138 DTC Confirmation Procedure...................................................................................... 138 WITH CONSULT-II............................................................................................. 139 WITH GST.................................................................................................... 139 Wiring Diagram — AT — 2NDSIG.................................................................................... 140 Diagnostic Procedure............................................................................................ 141 DTC P0733 A/T 3RD GEAR FUNCTION..................................................................................... 143 Description..................................................................................................... 143 On Board Diagnosis Logic........................................................................................ 143 Possible Cause.................................................................................................. 143 DTC Confirmation Procedure...................................................................................... 143 WITH CONSULT-II............................................................................................. 144 WITH GST.................................................................................................... 144 Wiring Diagram — AT — 3RDSIG.................................................................................... 145 Diagnostic Procedure............................................................................................ 146 DTC P0734 A/T 4TH GEAR FUNCTION..................................................................................... 148 Description..................................................................................................... 148 CONSULT-II Reference Value...................................................................................... 148 On Board Diagnosis Logic........................................................................................ 148 Possible Cause.................................................................................................. 148 DTC Confirmation Procedure...................................................................................... 148 WITH CONSULT-II............................................................................................. 149 WITH GST.................................................................................................... 149 Wiring Diagram — AT — 4THSIG.................................................................................... 150 Diagnostic Procedure............................................................................................ 151 DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE.................................................................... 155 Description..................................................................................................... 155 CONSULT-II Reference Value...................................................................................... 155 On Board Diagnosis Logic........................................................................................ 155 Possible Cause.................................................................................................. 155 DTC Confirmation Procedure...................................................................................... 155 WITH CONSULT-II............................................................................................. 155 WITH GST.................................................................................................... 155 WITHOUT CONSULT-II.......................................................................................... 155 Wiring Diagram — AT — TCV....................................................................................... 156 Diagnostic Procedure............................................................................................ 157 Component Inspection............................................................................................ 159 TORQUE CONVERTER CLUTCH SOLENOID VALVE...................................................................... 159 Resistance.............................................................................................. 159 Operation............................................................................................... 159 DTC P0744 A/T TCC S/V FUNCTION (LOCK-UP)............................................................................ 160 Description..................................................................................................... 160 CONSULT-II Reference Value...................................................................................... 160 On Board Diagnosis Logic........................................................................................ 160 Possible Cause.................................................................................................. 160 DTC Confirmation Procedure...................................................................................... 161 WITH CONSULT-II............................................................................................. 161 Wiring Diagram — AT — TCCSIG.................................................................................... 162 Diagnostic Procedure............................................................................................ 163 DTC P0745 LINE PRESSURE SOLENOID VALVE.............................................................................. 168 Description..................................................................................................... 168 CONSULT-II Reference Value...................................................................................... 168 On Board Diagnosis Logic........................................................................................ 168 Possible Cause.................................................................................................. 168 DTC Confirmation Procedure...................................................................................... 168 WITH CONSULT-II............................................................................................. 168 WITH GST.................................................................................................... 169 WITHOUT CONSULT-II.......................................................................................... 169 Wiring Diagram — AT — LPSV...................................................................................... 170 Diagnostic Procedure............................................................................................ 171 Component Inspection............................................................................................ 174 LINE PRESSURE SOLENOID VALVE................................................................................ 174 Resistance.............................................................................................. 174 Operation............................................................................................... 174 DROPPING RESISTOR........................................................................................... 174 DTC P0750 SHIFT SOLENOID VALVE A.................................................................................... 175 Description..................................................................................................... 175 CONSULT-II Reference Value...................................................................................... 175 On Board Diagnosis Logic........................................................................................ 175 Possible Cause.................................................................................................. 175 DTC Confirmation Procedure...................................................................................... 175 WITH CONSULT-II............................................................................................. 175 WITH GST.................................................................................................... 175 WITHOUT CONSULT-II.......................................................................................... 175 Wiring Diagram — AT — SSV/A..................................................................................... 176 Diagnostic Procedure............................................................................................ 177 Component Inspection............................................................................................ 179 SHIFT SOLENOID VALVE A...................................................................................... 179 Resistance.............................................................................................. 179 Operation............................................................................................... 179 DTC P0755 SHIFT SOLENOID VALVE B.................................................................................... 180 Description..................................................................................................... 180 CONSULT-II Reference Value...................................................................................... 180 On Board Diagnosis Logic........................................................................................ 180 Possible Cause.................................................................................................. 180 DTC Confirmation Procedure...................................................................................... 180 WITH CONSULT-II............................................................................................. 180 WITH GST.................................................................................................... 180 WITHOUT CONSULT-II.......................................................................................... 180 Wiring Diagram — AT — SSV/B..................................................................................... 181 Diagnostic Procedure............................................................................................ 182 Component Inspection............................................................................................ 184 SHIFT SOLENOID VALVE B...................................................................................... 184 Resistance.............................................................................................. 184 Operation............................................................................................... 184 DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR................................................................... 185 Description..................................................................................................... 185 CONSULT-II Reference Value...................................................................................... 185 On Board Diagnosis Logic........................................................................................ 185 Possible Cause.................................................................................................. 185 DTC Confirmation Procedure...................................................................................... 185 WITH CONSULT-II............................................................................................. 185 WITH GST.................................................................................................... 186 WITHOUT CONSULT-II.......................................................................................... 186 Wiring Diagram — AT — TPS....................................................................................... 187 Diagnostic Procedure............................................................................................ 188 DTC P1760 OVERRUN CLUTCH SOLENOID VALVE............................................................................. 190 Description..................................................................................................... 190 CONSULT-II Reference Value...................................................................................... 190 On Board Diagnosis Logic........................................................................................ 190 Possible Cause.................................................................................................. 190 DTC Confirmation Procedure...................................................................................... 190 WITH CONSULT-II............................................................................................. 190 WITH GST.................................................................................................... 190 WITHOUT CONSULT-II.......................................................................................... 190 Wiring Diagram — AT — OVRCSV.................................................................................... 191 Diagnostic Procedure............................................................................................ 192 Component Inspection............................................................................................ 194 OVERRUN CLUTCH SOLENOID VALVE............................................................................... 194 Resistance.............................................................................................. 194 Operation............................................................................................... 194 DTC VEHICLE SPEED SENSOR MTR........................................................................................ 195 Description..................................................................................................... 195 CONSULT-II Reference Value...................................................................................... 195 On Board Diagnosis Logic........................................................................................ 195 Possible Cause.................................................................................................. 195 DTC Confirmation Procedure...................................................................................... 195 WITH CONSULT-II............................................................................................. 195 WITH GST.................................................................................................... 195 WITHOUT CONSULT-II.......................................................................................... 196 Wiring Diagram — AT — VSSMTR.................................................................................... 197 Diagnostic Procedure............................................................................................ 198 DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE)........................................ 200 Description..................................................................................................... 200 CONSULT-II Reference Value...................................................................................... 200 On Board Diagnosis Logic........................................................................................ 200 Possible Cause.................................................................................................. 200 DTC Confirmation Procedure...................................................................................... 200 WITH CONSULT-II............................................................................................. 200 WITH GST.................................................................................................... 200 WITHOUT CONSULT-II.......................................................................................... 201 Wiring Diagram — AT — BA/FTS.................................................................................... 202 Diagnostic Procedure............................................................................................ 203 Component Inspection............................................................................................ 206 A/T FLUID TEMPERATURE SENSOR................................................................................ 206 MAIN POWER SUPPLY AND GROUND CIRCUIT................................................................................ 207 Description..................................................................................................... 207 On Board Diagnosis Logic........................................................................................ 207 Possible Cause.................................................................................................. 207 DTC Confirmation Procedure...................................................................................... 207 WITH CONSULT-II............................................................................................. 207 Wiring Diagram — AT — MAIN...................................................................................... 208 Diagnostic Procedure............................................................................................ 209 DTC CONTROL UNIT (RAM), CONTROL UNIT (ROM).......................................................................... 211 Description..................................................................................................... 211 On Board Diagnosis Logic........................................................................................ 211 Possible Cause.................................................................................................. 211 DTC Confirmation Procedure...................................................................................... 211 WITH CONSULT-II............................................................................................. 211 Diagnostic Procedure............................................................................................ 212 DTC CONTROL UNIT(EEPROM)............................................................................................ 213 Description..................................................................................................... 213 On Board Diagnosis Logic........................................................................................ 213 Possible Cause.................................................................................................. 213 DTC Confirmation Procedure...................................................................................... 213 WITH CONSULT-II............................................................................................. 213 Diagnostic Procedure............................................................................................ 214 TROUBLE DIAGNOSES FOR SYMPTOMS...................................................................................... 215 Wiring Diagram — AT — NONDTC.................................................................................... 215 O/D OFF Indicator Lamp Does Not Come On......................................................................... 218 Engine Cannot Be Started in “P” and “N” Position................................................................ 220 In “P” Position, Vehicle Moves Forward or Backward When Pushed.................................................. 221 In “N” Position, Vehicle Moves.................................................................................. 222 Large Shock. “N -> “R” Position................................................................................. 224 Vehicle Does Not Creep Backward in “R” Position................................................................. 225 Vehicle Does Not Creep Forward in “D”, “2” or “1” Position...................................................... 228 Vehicle Cannot Be Started From D1............................................................................... 230 A/T Does Not Shift: D1 -> D2 or Does Not Kickdown: D4 -> D2..................................................... 233 A/T Does Not Shift: D2 -> D3.................................................................................... 236 A/T Does Not Shift: D3 -> D4.................................................................................... 239 A/T Does Not Perform Lock-Up.................................................................................... 241 A/T Does Not Hold Lock-Up Condition............................................................................. 242 Lock-Up Is Not Released......................................................................................... 244 Engine Speed Does Not Return to Idle (Light Braking D4 -> D3)................................................... 245 A/T Does Not Shift: D4 -> D3, When Overdrive Control Switch "ON" -> "OFF"....................................... 247 A/T Does Not Shift: D3 -> 22, When Selector Lever "D" -> "2" Position........................................... 248 A/T Does Not Shift: 22 -> 11, When Selector Lever "2" -> "1" on Position........................................ 250 Vehicle Does Not Decelerate by Engine Brake..................................................................... 253 TCM Self-Diagnosis Does Not Activate............................................................................ 257 DESCRIPTION................................................................................................. 257 DIAGNOSTIC PROCEDURE........................................................................................ 258 COMPONENT INSPECTION........................................................................................ 262 Overdrive Control Switch................................................................................ 262 PNP Switch.............................................................................................. 262 SHIFT CONTROL SYSTEM................................................................................................ 264 Control Device Removal and Installation......................................................................... 264 CONTROL DEVICE COMPONENTS................................................................................... 264 CONTROL CABLE COMPONENTS.................................................................................... 265 REMOVAL..................................................................................................... 265 INSTALLATION................................................................................................ 265 Adjustment of A/T Position...................................................................................... 265 Checking of A/T Position........................................................................................ 266 A/T SHIFT LOCK SYSTEM............................................................................................... 267 Description..................................................................................................... 267 Shift Lock System Electrical Parts Location..................................................................... 267 Wiring Diagram — AT — SHIFT..................................................................................... 268 Diagnostic Procedure............................................................................................ 269 KEY INTERLOCK CABLE................................................................................................. 271 Components...................................................................................................... 271 Removal......................................................................................................... 271 Installation.................................................................................................... 272 ON-VEHICLE SERVICE.................................................................................................. 273 Control Valve Assembly and Accumulators......................................................................... 273 COMPONENTS.................................................................................................. 273 REMOVAL AND INSTALLATION.................................................................................... 273 Removal................................................................................................. 273 Installation............................................................................................ 276 Park/Neutral Position (PNP) Switch.............................................................................. 276 COMPONENTS.................................................................................................. 276 REMOVAL AND INSTALLATION.................................................................................... 276 Removal................................................................................................. 276 Installation............................................................................................ 277 PARK/NEUTRAL POSITION (PNP) SWITCH ADJUSTMENT............................................................... 277 Differential Side Oil Seal Replacement.......................................................................... 278 COMPONENTS.................................................................................................. 278 REMOVAL AND INSTALLATION.................................................................................... 278 Removal................................................................................................. 278 Installation............................................................................................ 279 Revolution Sensor Replacement................................................................................... 280 COMPONENTS.................................................................................................. 280 REMOVAL AND INSTALLATION.................................................................................... 280 Removal................................................................................................. 280 Installation............................................................................................ 280 AIR BREATHER HOSE................................................................................................... 281 Removal and Installation........................................................................................ 281 TRANSAXLE ASSEMBLY.................................................................................................. 282 Removal and Installation........................................................................................ 282 COMPONENTS.................................................................................................. 282 REMOVAL..................................................................................................... 282 INSPECTION.................................................................................................. 283 Installation and Inspection of Torque Converter......................................................... 283 INSTALLATION................................................................................................ 284 OVERHAUL............................................................................................................ 285 Components...................................................................................................... 285 Oil Channel..................................................................................................... 291 Locations of Adjusting Shims, Needle Bearings, Thrust Washers and Snap Rings.................................... 292 DISASSEMBLY......................................................................................................... 293 Disassembly..................................................................................................... 293 REPAIR FOR COMPONENT PARTS.......................................................................................... 309 Manual Shaft.................................................................................................... 309 COMPONENTS.................................................................................................. 309 REMOVAL..................................................................................................... 309 INSPECTION.................................................................................................. 310 INSTALLATION................................................................................................ 310 Oil Pump........................................................................................................ 312 COMPONENTS.................................................................................................. 312 DISASSEMBLY................................................................................................. 312 INSPECTION.................................................................................................. 314 Oil Pump Housing, Oil Pump Cover, Inner Gear and Outer Gear............................................. 314 Side Clearances......................................................................................... 314 Seal Ring Clearance..................................................................................... 314 ASSEMBLY.................................................................................................... 315 Control Valve Assembly.......................................................................................... 317 COMPONENTS.................................................................................................. 317 DISASSEMBLY................................................................................................. 318 INSPECTION.................................................................................................. 320 Control Valve Lower Body and Upper Body................................................................. 320 Oil Strainer............................................................................................ 321 Shift Solenoid Valves “A” and “B”, Line Pressure Solenoid Valve, Torque Converter Clutch Solenoid....... 321 Oil Cooler Relief Valve Springs......................................................................... 321 ASSEMBLY.................................................................................................... 322 Control Valve Upper Body........................................................................................ 326 COMPONENTS.................................................................................................. 326 DISASSEMBLY................................................................................................. 327 INSPECTION.................................................................................................. 328 Valve Springs........................................................................................... 328 Control Valves.......................................................................................... 328 ASSEMBLY.................................................................................................... 328 1-2 Accumulator Valve................................................................................... 329 Retainer Plates (Control Valve Upper Body).............................................................. 329 Control Valve Lower Body........................................................................................ 330 COMPONENTS.................................................................................................. 330 DISASSEMBLY................................................................................................. 331 INSPECTION.................................................................................................. 331 Valve Springs........................................................................................... 331 Control Valves.......................................................................................... 331 ASSEMBLY.................................................................................................... 331 Retainer Plates (Control Valve Lower Body).............................................................. 332 Reverse Clutch.................................................................................................. 333 COMPONENTS.................................................................................................. 333 DISASSEMBLY................................................................................................. 333 INSPECTION.................................................................................................. 334 Reverse Clutch Snap Rings, Spring Retainer and Return Spring............................................ 334 Reverse Clutch Drive Plates............................................................................. 334 Reverse Clutch Dish Plates.............................................................................. 334 Reverse Clutch Piston................................................................................... 334 ASSEMBLY.................................................................................................... 335 High Clutch..................................................................................................... 338 COMPONENTS.................................................................................................. 338 DISASSEMBLY................................................................................................. 338 INSPECTION.................................................................................................. 339 High Clutch Snap Rings, Spring Retainer and Return Springs.............................................. 339 High Clutch Drive Plates................................................................................ 340 High Clutch Piston...................................................................................... 340 Seal Ring Clearance..................................................................................... 340 ASSEMBLY.................................................................................................... 340 Forward and Overrun Clutches.................................................................................... 344 COMPONENTS.................................................................................................. 344 DISASSEMBLY................................................................................................. 344 INSPECTION.................................................................................................. 346 Snap Rings, Spring Retainer and Return Springs.......................................................... 346 Forward Clutch and Overrun Clutch Drive Plates.......................................................... 346 Forward Clutch and Overrun Clutch Dish Plates........................................................... 346 Forward Clutch Drum..................................................................................... 346 Overrun Clutch Piston................................................................................... 347 ASSEMBLY.................................................................................................... 347 Low & Reverse Brake............................................................................................. 351 COMPONENTS.................................................................................................. 351 DISASSEMBLY................................................................................................. 351 INSPECTION.................................................................................................. 352 Low & Reverse Brake Snap Rings, Spring Retainer and Return Springs...................................... 352 Low & Reverse Brake Drive Plate......................................................................... 352 ASSEMBLY.................................................................................................... 352 Rear Internal Gear, Forward Clutch Hub and Overrun Clutch Hub................................................... 355 COMPONENTS.................................................................................................. 355 DISASSEMBLY................................................................................................. 355 INSPECTION.................................................................................................. 357 Rear Internal Gear, Forward Clutch Hub and Overrun Clutch Hub........................................... 357 Bearing Races and Forward One-Way Clutch................................................................ 357 ASSEMBLY.................................................................................................... 357 Output Shaft, Idler Gear, Reduction Pinion Gear and Bearing Retainer............................................ 359 COMPONENTS.................................................................................................. 359 DISASSEMBLY................................................................................................. 359 INSPECTION.................................................................................................. 361 Output Shaft, Idler Gear and Reduction Pinion Gear...................................................... 361 Bearings................................................................................................ 361 Seal Ring Clearance..................................................................................... 361 ASSEMBLY.................................................................................................... 362 Band Servo Piston Assembly...................................................................................... 365 COMPONENTS.................................................................................................. 365 DISASSEMBLY................................................................................................. 365 INSPECTION.................................................................................................. 367 Pistons, Retainers and Piston Stem...................................................................... 367 Return Springs.......................................................................................... 367 ASSEMBLY.................................................................................................... 368 Final Drive..................................................................................................... 371 COMPONENTS.................................................................................................. 371 DISASSEMBLY................................................................................................. 371 INSPECTION.................................................................................................. 372 Gears, Washers, Pinion Mate Shaft and Differential Case................................................. 372 Bearings................................................................................................ 373 ASSEMBLY.................................................................................................... 373 ASSEMBLY............................................................................................................ 375 Assembly (1).................................................................................................... 375 Adjustment (1).................................................................................................. 376 DIFFERENTIAL SIDE BEARING PRELOAD........................................................................... 376 REDUCTION PINION GEAR BEARING PRELOAD....................................................................... 377 OUTPUT SHAFT END PLAY....................................................................................... 380 Assembly (2).................................................................................................... 381 Adjustment (2).................................................................................................. 388 TOTAL END PLAY.............................................................................................. 388 REVERSE CLUTCH END PLAY..................................................................................... 390 Assembly (3).................................................................................................... 391 SERVICE DATA AND SPECIFICATIONS (SDS)............................................................................... 398 General Specifications.......................................................................................... 398 Vehicle Speed When Shifting Gears............................................................................... 398 Vehicle Speed When Performing and Releasing Look-Up............................................................. 398 Stall Revolution................................................................................................ 398 Line Pressure................................................................................................... 398 Control Valves.................................................................................................. 399 CONTROL VALVE AND PLUG RETURN SPRINGS....................................................................... 399 Accumulator..................................................................................................... 399 O-RING...................................................................................................... 399 RETURN SPRING............................................................................................... 400 Clutch and Brakes............................................................................................... 400 REVERSE CLUTCH.............................................................................................. 400 HIGH CLUTCH................................................................................................. 400 FORWARD CLUTCH.............................................................................................. 401 OVERRUN CLUTCH.............................................................................................. 401 LOW & REVERSE BRAKE......................................................................................... 402 CLUTCH AND BRAKE RETURN SPRINGS............................................................................. 402 BRAKE BAND.................................................................................................. 402 Final Drive..................................................................................................... 402 DIFFERENTIAL SIDE GEAR CLEARANCE............................................................................ 402 DIFFERENTIAL SIDE GEAR THRUST WASHERS....................................................................... 402 DIFFERENTIAL SIDE BEARING PRELOAD ADJUSTING SHIMS........................................................... 403 BEARING PRELOAD............................................................................................. 403 TURNING TORQUE.............................................................................................. 403 Planetary Carrier and Oil Pump.................................................................................. 403 PLANETARY CARRIER........................................................................................... 403 OIL PUMP.................................................................................................... 403 Input Shaft..................................................................................................... 403 SEAL RING CLEARANCE......................................................................................... 403 SEAL RING................................................................................................... 403 Reduction Pinion Gear........................................................................................... 404 TURNING TORQUE.............................................................................................. 404 REDUCTION PINION GEAR ADJUSTING SHIMS....................................................................... 404 Band Servo...................................................................................................... 404 RETURN SPRING............................................................................................... 404 Output Shaft.................................................................................................... 405 SEAL RING CLEARANCE......................................................................................... 405 SEAL RING................................................................................................... 405 END PLAY.................................................................................................... 405 OUTPUT SHAFT ADJUSTING SHIMS................................................................................ 405 Bearing Retainer................................................................................................ 405 SEAL RING CLEARANCE......................................................................................... 405 Total End Play.................................................................................................. 405 BEARING RACE FOR ADJUSTING TOTAL END PLAY................................................................... 405 Reverse Clutch End Play......................................................................................... 405 THRUST WASHERS FOR ADJUSTING REVERSE CLUTCH DRUM END PLAY................................................... 406 Removal and Installation........................................................................................ 406 Shift Solenoid Valves........................................................................................... 406 Solenoid Valves................................................................................................. 406 A/T Fluid Temperature Sensor.................................................................................... 406 Revolution Sensor............................................................................................... 406 Dropping Resistor............................................................................................... 406 ELECTRICAL UNITS.................................................................................................... 45 FUSE BLOCK - JUNCTION BOX (J/B)..................................................................................... 48 FUSE AND FUSIBLE LINK BOX........................................................................................... 49 atc......................................................................................................................... 408 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents....................................................................................................... 408 PRECAUTIONS......................................................................................................... 411 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”..................... 411 Precautions for Working with HFC-134a (R-134a).................................................................. 411 CONTAMINATED REFRIGERANT.................................................................................... 412 General Refrigerant Precautions................................................................................. 412 Lubricant Precautions........................................................................................... 412 Precautions for Refrigerant Connection.......................................................................... 413 FEATURES OF NEW TYPE REFRIGERANT CONNECTION................................................................. 413 O-RING AND REFRIGERANT CONNECTION........................................................................... 414 O-Ring Part Numbers and Specifications.................................................................. 414 Precautions for Servicing Compressor............................................................................ 416 Precautions for Service Equipment............................................................................... 416 RECOVERY/RECYCLING EQUIPMENT................................................................................ 416 ELECTRONIC LEAK DETECTOR.................................................................................... 416 VACUUM PUMP................................................................................................. 416 MANIFOLD GAUGE SET.......................................................................................... 416 SERVICE HOSES............................................................................................... 417 SERVICE COUPLERS............................................................................................ 417 REFRIGERANT WEIGHT SCALE.................................................................................... 417 CHARGING CYLINDER........................................................................................... 417 Precautions for Leak Detection Dye.............................................................................. 417 IDENTIFICATION.............................................................................................. 418 IDENTIFICATION LABEL FOR VEHICLE............................................................................ 418 Wiring Diagrams and Trouble Diagnosis........................................................................... 418 PREPARATION......................................................................................................... 419 Special Service Tools........................................................................................... 419 HFC-134a (R-134a) Service Tools and Equipment................................................................... 419 Commercial Service Tools........................................................................................ 422 REFRIGERATION SYSTEM................................................................................................ 423 Refrigerant Cycle............................................................................................... 423 REFRIGERANT FLOW............................................................................................ 423 FREEZE PROTECTION........................................................................................... 423 Refrigerant System Protection................................................................................... 423 REFRIGERANT PRESSURE SENSOR................................................................................. 423 PRESSURE RELIEF VALVE....................................................................................... 423 V-6 Variable Displacement Compressor............................................................................ 424 GENERAL INFORMATION......................................................................................... 424 DESCRIPTION................................................................................................. 425 General................................................................................................. 425 Operation............................................................................................... 426 Component Layout................................................................................................ 428 LUBRICANT........................................................................................................... 429 Maintenance of Lubricant Quantity in Compressor................................................................. 429 LUBRICANT................................................................................................... 429 LUBRICANT RETURN OPERATION.................................................................................. 429 LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COMPRESSOR.................................. 430 LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT.................................................... 430 AIR CONDITIONER CONTROL............................................................................................. 432 Description of Air Conditioner LAN Control System............................................................... 432 System Construction............................................................................................. 432 OPERATION................................................................................................... 432 TRANSMISSION DATA AND TRANSMISSION ORDER.................................................................... 433 Start:.................................................................................................. 433 Address:................................................................................................ 433 Opening Angle:.......................................................................................... 433 Error Check:............................................................................................ 433 Stop Signal:............................................................................................ 434 AIR MIX DOOR CONTROL (AUTOMATIC TEMPERATURE CONTROL)........................................................ 434 FAN SPEED CONTROL........................................................................................... 434 INTAKE DOOR CONTROL......................................................................................... 434 OUTLET DOOR CONTROL......................................................................................... 434 MAGNET CLUTCH CONTROL....................................................................................... 434 SELF-DIAGNOSTIC SYSTEM...................................................................................... 434 Description of Control System................................................................................... 435 Control Operation............................................................................................... 436 MODE CONTROL DIAL........................................................................................... 436 TEMPERATURE CONTROL DIAL (POTENTIO TEMPERATURE CONTROL)..................................................... 436 FAN CONTROL DIAL............................................................................................ 436 REAR WINDOW DEFOGGER SWITCH................................................................................. 436 INTAKE SWITCH............................................................................................... 436 A/C SWITCH.................................................................................................. 436 Discharge Air Flow.............................................................................................. 437 System Description.............................................................................................. 438 SWITCHES AND THEIR CONTROL FUNCTION......................................................................... 438 TROUBLE DIAGNOSIS................................................................................................... 439 How to Perform Trouble Diagnoses for Quick and Accurate Repair.................................................. 439 WORK FLOW................................................................................................... 439 SYMPTOM TABLE............................................................................................... 439 Component Parts and Harness Connector Location.................................................................. 440 ENGINE COMPARTMENT.......................................................................................... 440 PASSENGER COMPARTMENT....................................................................................... 441 Schematic — A/C, A —............................................................................................ 442 Wiring Diagram — A/C, A —....................................................................................... 443 Auto Amp. Terminals and Reference Value......................................................................... 447 PIN CONNECTOR TERMINAL LAYOUT............................................................................... 447 TERMINALS AND REFERENCE VALUE FOR AUTO AMP.................................................................. 447 Self-diagnosis Function......................................................................................... 449 DESCRIPTION................................................................................................. 449 FUNCTION CONFIRMATION PROCEDURE............................................................................. 451 AUXILIARY MECHANISM: TEMPERATURE SETTING TRIMMER............................................................ 455 AUXILIARY MECHANISM: FOOT POSITION SETTING TRIMMER.......................................................... 456 AUXILIARY MECHANISM: INLET PORT MEMORY FUNCTION............................................................. 456 Operational Check............................................................................................... 457 CHECKING BLOWER............................................................................................. 457 CHECKING DISCHARGE AIR...................................................................................... 457 CHECKING INTAKE DOOR........................................................................................ 457 CHECKING TEMPERATURE DECREASE............................................................................... 458 CHECKING TEMPERATURE INCREASE............................................................................... 458 CHECKING A/C SWITCH......................................................................................... 458 Power Supply and Ground Circuit for Auto Amp.................................................................... 459 INSPECTION FLOW............................................................................................. 459 COMPONENT DESCRIPTION....................................................................................... 459 Auto Amp. (Automatic Amplifier)......................................................................... 459 Potentio Temperature Control (PTC)...................................................................... 459 DIAGNOSTIC PROCEDURE FOR A/C SYSTEM......................................................................... 460 LAN System Circuit.............................................................................................. 461 DIAGNOSTIC PROCEDURE FOR LAN CIRCUIT........................................................................ 461 Mode Door Motor Circuit......................................................................................... 464 INSPECTION FLOW............................................................................................. 464 SYSTEM DESCRIPTION.......................................................................................... 465 Component Parts......................................................................................... 465 System Operation........................................................................................ 465 Mode Door Control Specification......................................................................... 465 COMPONENT DESCRIPTION....................................................................................... 466 Mode Door Motor......................................................................................... 466 DIAGNOSTIC PROCEDURE FOR MODE DOOR MOTOR.................................................................... 466 Air Mix Door Motor Circuit...................................................................................... 467 INSPECTION FLOW............................................................................................. 467 SYSTEM DESCRIPTION.......................................................................................... 468 Component Parts......................................................................................... 468 System Operation........................................................................................ 468 Air Mix Door Control Specification...................................................................... 468 COMPONENT DESCRIPTION....................................................................................... 469 Air Mix Door Motor...................................................................................... 469 DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR................................................................. 469 Intake Door Motor Circuit....................................................................................... 470 INSPECTION FLOW............................................................................................. 470 SYSTEM DESCRIPTION.......................................................................................... 471 Component Parts......................................................................................... 471 System Operation........................................................................................ 471 Intake Door Control Specification....................................................................... 471 COMPONENT DESCRIPTION....................................................................................... 472 Intake Door Motor....................................................................................... 472 DIAGNOSTIC PROCEDURE FOR INTAKE DOOR MOTOR.................................................................. 472 Blower Motor Circuit............................................................................................ 473 INSPECTION FLOW............................................................................................. 473 SYSTEM DESCRIPTION.......................................................................................... 474 Component Parts......................................................................................... 474 System Operation........................................................................................ 474 Automatic Mode.......................................................................................... 474 Starting Fan Speed Control.............................................................................. 475 Blower Speed Compensation............................................................................... 475 Fan Speed Control Specification......................................................................... 475 COMPONENT DESCRIPTION....................................................................................... 475 Fan Control Amp......................................................................................... 475 DIAGNOSTIC PROCEDURE FOR BLOWER MOTOR....................................................................... 475 COMPONENT INSPECTION........................................................................................ 478 Blower Motor............................................................................................ 478 Magnet Clutch Circuit........................................................................................... 479 INSPECTION FLOW............................................................................................. 479 SYSTEM DESCRIPTION.......................................................................................... 480 Low Temperature Protection Control...................................................................... 480 DIAGNOSTIC PROCEDURE FOR MAGNET CLUTCH...................................................................... 480 COMPONENT INSPECTION........................................................................................ 484 A/C Relay............................................................................................... 484 Refrigerant Pressure Sensor............................................................................. 484 Insufficient Cooling............................................................................................ 485 INSPECTION FLOW............................................................................................. 485 PERFORMANCE TEST DIAGNOSIS.................................................................................. 487 PERFORMANCE CHART........................................................................................... 489 Test Condition.......................................................................................... 489 Test Reading............................................................................................ 489 TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE...................................................................... 490 Both High- and Low-pressure Sides are Too High.......................................................... 490 High-pressure Side is Too High and Low-pressure Side is Too Low......................................... 490 High-pressure Side Is Too Low and Low-pressure Side is Too High......................................... 491 Both High- and Low-pressure Sides are Too Low........................................................... 491 Low-pressure Side Sometimes Becomes Negative............................................................ 492 Low-pressure Side Becomes Negative...................................................................... 492 Insufficient Heating............................................................................................ 493 INSPECTION FLOW............................................................................................. 493 Noise........................................................................................................... 494 INSPECTION FLOW............................................................................................. 494 Self-diagnosis.................................................................................................. 495 INSPECTION FLOW............................................................................................. 495 Ambient Sensor Circuit.......................................................................................... 496 COMPONENT DESCRIPTION....................................................................................... 496 Ambient Sensor.......................................................................................... 496 AMBIENT TEMPERATURE INPUT PROCESS........................................................................... 496 DIAGNOSTIC PROCEDURE FOR AMBIENT SENSOR..................................................................... 496 COMPONENT INSPECTION........................................................................................ 498 Ambient Sensor.......................................................................................... 498 In-vehicle Sensor Circuit....................................................................................... 498 COMPONENT DESCRIPTION....................................................................................... 498 In-vehicle Sensor....................................................................................... 498 Aspirator............................................................................................... 498 DIAGNOSTIC PROCEDURE FOR IN-VEHICLE SENSOR.................................................................. 499 COMPONENT INSPECTION........................................................................................ 500 In-vehicle Sensor....................................................................................... 500 Sunload Sensor Circuit.......................................................................................... 501 COMPONENT DESCRIPTION....................................................................................... 501 SUNLOAD INPUT PROCESS....................................................................................... 501 DIAGNOSTIC PROCEDURE FOR SUNLOAD SENSOR..................................................................... 501 COMPONENT INSPECTION........................................................................................ 503 Sunload Sensor.......................................................................................... 503 Intake Sensor Circuit........................................................................................... 504 COMPONENT DESCRIPTION....................................................................................... 504 Intake Sensor........................................................................................... 504 DIAGNOSTIC PROCEDURE FOR INTAKE SENSOR...................................................................... 504 COMPONENT INSPECTION........................................................................................ 505 Intake Sensor........................................................................................... 505 CONTROLLER.......................................................................................................... 506 Removal and Installation........................................................................................ 506 REMOVAL..................................................................................................... 506 INSTALLATION................................................................................................ 506 AMBIENT SENSOR...................................................................................................... 507 Removal and Installation........................................................................................ 507 REMOVAL..................................................................................................... 507 INSTALLATION................................................................................................ 507 IN-VEHICLE SENSOR................................................................................................... 508 Removal and Installation........................................................................................ 508 REMOVAL..................................................................................................... 508 INSTALLATION................................................................................................ 508 SUNLOAD SENSOR...................................................................................................... 509 Removal and Installation........................................................................................ 509 REMOVAL..................................................................................................... 509 INSTALLATION................................................................................................ 509 INTAKE SENSOR....................................................................................................... 510 Removal and Installation........................................................................................ 510 REMOVAL..................................................................................................... 510 INSTALLATION................................................................................................ 510 BLOWER UNIT......................................................................................................... 511 Removal and Installation........................................................................................ 511 REMOVAL..................................................................................................... 511 INSTALLATION................................................................................................ 511 Disassembly and Assembly........................................................................................ 512 BLOWER MOTOR........................................................................................................ 513 Removal and Installation........................................................................................ 513 REMOVAL..................................................................................................... 513 INSTALLATION................................................................................................ 513 INTAKE DOOR MOTOR................................................................................................... 514 Removal and Installation........................................................................................ 514 REMOVAL..................................................................................................... 514 INSTALLATION................................................................................................ 514 FAN CONTROL AMPLIFIER............................................................................................... 515 Removal and Installation........................................................................................ 515 REMOVAL..................................................................................................... 515 INSTALLATION................................................................................................ 515 IN-CABIN MICROFILTER................................................................................................ 516 Removal and Installation........................................................................................ 516 FUNCTION.................................................................................................... 516 REPLACEMENT TIMING.......................................................................................... 516 REPLACEMENT PROCEDURES...................................................................................... 516 HEATER & COOLING UNIT ASSEMBLY...................................................................................... 517 Removal and Installation........................................................................................ 517 REMOVAL..................................................................................................... 517 INSTALLATION................................................................................................ 518 Disassembly and Assembly........................................................................................ 519 MODE DOOR MOTOR..................................................................................................... 520 Removal and Installation........................................................................................ 520 REMOVAL..................................................................................................... 520 INSTALLATION................................................................................................ 520 AIR MIX DOOR MOTOR.................................................................................................. 521 Removal and Installation........................................................................................ 521 REMOVAL..................................................................................................... 521 INSTALLATION................................................................................................ 521 HEATER CORE......................................................................................................... 522 Removal and Installation........................................................................................ 522 REMOVAL..................................................................................................... 522 INSTALLATION................................................................................................ 522 DUCTS AND GRILLES................................................................................................... 523 Removal and Installation........................................................................................ 523 REMOVAL..................................................................................................... 523 Removal of Center Ventilator Grille..................................................................... 524 Removal of Side Ventilator Grille....................................................................... 524 Removal of Driver Ventilator Grille..................................................................... 524 Removal of Defroster Nozzle, Duct and Side Ventilator Duct.............................................. 525 Removal of Adaptor...................................................................................... 525 Removal of Multi-Box Duct............................................................................... 525 Removal of Foot Duct.................................................................................... 526 Removal of Floor Duct................................................................................... 526 INSTALLATION................................................................................................ 526 REFRIGERANT LINES................................................................................................... 527 HFC-134a (R-134a) Service Procedure............................................................................. 527 SETTING OF SERVICE TOOLS AND EQUIPMENT...................................................................... 527 Discharging Refrigerant................................................................................. 527 Evacuating System and Charging Refrigerant.............................................................. 527 Components...................................................................................................... 529 Removal and Installation of Compressor.......................................................................... 529 REMOVAL..................................................................................................... 529 INSTALLATION................................................................................................ 530 Removal and Installation of Compressor Clutch................................................................... 531 REMOVAL..................................................................................................... 531 Overhaul................................................................................................ 531 Inspection.............................................................................................. 532 INSTALLATION................................................................................................ 533 Break-In Operation...................................................................................... 534 Removal and Installation of Low-Pressure Flexible Hose.......................................................... 534 REMOVAL..................................................................................................... 534 INSTALLATION................................................................................................ 534 Removal and Installation of High-Pressure Flexible Hose......................................................... 535 REMOVAL..................................................................................................... 535 INSTALLATION................................................................................................ 535 Removal and Installation of High-Pressure Pipe.................................................................. 535 REMOVAL..................................................................................................... 535 INSTALLATION................................................................................................ 536 Removal and Installation of Condenser........................................................................... 536 REMOVAL..................................................................................................... 536 INSTALLATION................................................................................................ 537 Removal and Installation of Liquid Tank......................................................................... 537 REMOVAL..................................................................................................... 537 INSTALLATION................................................................................................ 537 Removal and Installation of Refrigerant Pressure Sensor......................................................... 538 REMOVAL..................................................................................................... 538 INSTALLATION................................................................................................ 538 Removal and Installation of Evaporator.......................................................................... 538 REMOVAL..................................................................................................... 538 INSTALLATION................................................................................................ 539 Removal and Installation of Expansion Valve..................................................................... 539 REMOVAL..................................................................................................... 539 INSTALLATION................................................................................................ 539 Checking for Refrigerant Leaks.................................................................................. 540 Checking System for Leaks Using the Fluorescent Leak Detector................................................... 540 Dye Injection................................................................................................... 540 Electronic Refrigerant Leak Detector............................................................................ 541 PRECAUTIONS FOR HANDLING LEAK DETECTOR...................................................................... 541 CHECKING PROCEDURE.......................................................................................... 542 SERVICE DATA AND SPECIFICATIONS (SDS)............................................................................... 544 Compressor...................................................................................................... 544 Lubricant....................................................................................................... 544 Refrigerant..................................................................................................... 544 Engine Idling Speed............................................................................................. 544 Belt Tension.................................................................................................... 544 ELECTRICAL UNITS.................................................................................................... 45 FUSE BLOCK - JUNCTION BOX (J/B)..................................................................................... 48 FUSE AND FUSIBLE LINK BOX........................................................................................... 49 av.......................................................................................................................... 546 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents....................................................................................................... 546 PRECAUTIONS......................................................................................................... 547 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”..................... 547 Wiring Diagrams and Trouble Diagnosis........................................................................... 547 PREPARATION......................................................................................................... 548 Commercial Service Tools........................................................................................ 548 AUDIO............................................................................................................... 549 System Description.............................................................................................. 549 Wiring Diagram —AUDIO—.......................................................................................... 550 Terminals and Reference Value for Audio Unit.................................................................... 552 Trouble Diagnoses............................................................................................... 553 AUDIO UNIT.................................................................................................. 553 Inspection...................................................................................................... 554 AUDIO UNIT.................................................................................................. 554 ANTENNA..................................................................................................... 554 Removal and Installation of Audio Unit.......................................................................... 555 REMOVAL..................................................................................................... 555 INSTALLATION................................................................................................ 555 Removal and Installation of Speakers............................................................................ 555 REMOVAL..................................................................................................... 555 INSTALLATION................................................................................................ 555 Removal and Installation of Tweeters............................................................................ 556 REMOVAL..................................................................................................... 556 INSTALLATION................................................................................................ 556 AUDIO ANTENNA....................................................................................................... 557 Antenna Route................................................................................................... 557 Removal and Installation of Roof Antenna........................................................................ 557 ELECTRICAL UNITS.................................................................................................... 45 FUSE BLOCK - JUNCTION BOX (J/B)..................................................................................... 48 FUSE AND FUSIBLE LINK BOX........................................................................................... 49 bcs......................................................................................................................... 558 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents....................................................................................................... 558 PRECAUTIONS......................................................................................................... 559 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”..................... 559 Wiring Diagrams and Trouble Diagnosis........................................................................... 559 SMART ENTRANCE CONTROL UNIT......................................................................................... 560 Description..................................................................................................... 560 OUTLINE..................................................................................................... 560 INPUT/OUTPUT................................................................................................ 560 Schematic....................................................................................................... 561 Terminals and Reference Value for Smart Entrance Control Unit................................................... 563 Removal and Installation of Smart Entrance Control Unit......................................................... 564 REMOVAL..................................................................................................... 564 INSTALLATION................................................................................................ 565 bl.......................................................................................................................... 566 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents....................................................................................................... 566 PRECAUTIONS......................................................................................................... 569 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”..................... 569 Precautions for Work............................................................................................ 569 Wiring Diagrams and Trouble Diagnosis........................................................................... 569 PREPARATION......................................................................................................... 570 Special Service Tools........................................................................................... 570 Commercial Service Tools........................................................................................ 570 SQUEAK AND RATTLE TROUBLE DIAGNOSES................................................................................. 571 Work Flow....................................................................................................... 571 CUSTOMER INTERVIEW.......................................................................................... 571 DUPLICATE THE NOISE AND TEST DRIVE.......................................................................... 572 CHECK RELATED SERVICE BULLETINS............................................................................. 572 LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE................................................................ 572 REPAIR THE CAUSE............................................................................................ 572 CONFIRM THE REPAIR.......................................................................................... 573 Generic Squeak and Rattle Troubleshooting....................................................................... 573 INSTRUMENT PANEL............................................................................................ 573 CENTER CONSOLE.............................................................................................. 573 DOORS....................................................................................................... 573 TRUNK....................................................................................................... 574 SUNROOF/HEADLINING.......................................................................................... 574 SEATS....................................................................................................... 574 UNDERHOOD................................................................................................... 574 Diagnostic Worksheet............................................................................................ 575 HOOD................................................................................................................ 577 Fitting Adjustment.............................................................................................. 577 LONGITUDINAL AND LATERAL CLEARANCE ADJUSTMENT............................................................... 577 FRONT END HEIGHT ADJUSTMENT................................................................................. 578 SURFACE HEIGHT ADJUSTMENT................................................................................... 579 Removal and Installation of Hood Assembly....................................................................... 580 REMOVAL..................................................................................................... 580 INSTALLATION................................................................................................ 580 Removal and Installation of Hood Lock Control................................................................... 581 REMOVAL..................................................................................................... 581 INSTALLATION................................................................................................ 582 Hood Lock Control Inspection.................................................................................... 582 FRONT FENDER........................................................................................................ 583 Removal and Installation........................................................................................ 583 REMOVAL..................................................................................................... 583 INSTALLATION................................................................................................ 583 DOOR................................................................................................................ 584 Fitting Adjustment.............................................................................................. 584 FRONT DOOR.................................................................................................. 584 Longitudinal Clearance and Surface Height Adjustment at Front End....................................... 584 REAR DOOR................................................................................................... 584 Longitudinal Clearance and Surface Height Adjustment at Front End....................................... 584 STRIKER ADJUSTMENT.......................................................................................... 584 Removal and Installation of Front Door.......................................................................... 585 REMOVAL..................................................................................................... 585 INSTALLATION................................................................................................ 585 Removal and Installation of Rear Door........................................................................... 585 REMOVAL..................................................................................................... 586 INSTALLATION................................................................................................ 586 Door Weatherstrip............................................................................................... 587 REMOVAL..................................................................................................... 587 INSTALLATION................................................................................................ 587 POWER DOOR LOCK SYSTEM.............................................................................................. 588 Component Parts and Harness Connector Location.................................................................. 588 System Description.............................................................................................. 588 OPERATION................................................................................................... 588 DOOR LOCK/UNLOCK SWITCH (POWER WINDOW MAIN SWITCH) OPERATION................................................ 589 DOOR LOCK/UNLOCK SWITCH (PASSENGER SIDE) OPERATION.......................................................... 589 DOOR KEY CYLINDER SWITCH OPERATION.......................................................................... 589 Driver Side............................................................................................. 589 Passenger Side.......................................................................................... 590 KEY REMINDER SYSTEM......................................................................................... 590 Schematic....................................................................................................... 591 Wiring Diagram — D/LOCK —....................................................................................... 592 Terminal and Reference Value for Smart Entrance Control Unit.................................................... 597 Symptom Chart................................................................................................... 598 Smart Entrance Control Unit Power Supply and Ground Circuit Check............................................... 598 Power Window Main Switch (Door Lock/Unlock Switch) Check........................................................ 599 Door Lock/Unlock Switch (Passenger Side) Check.................................................................. 600 Door Key Cylinder Switch (Driver Side) Check.................................................................... 601 Door Key Cylinder Switch (Passenger Side) Circuit Check......................................................... 602 Front Door Lock Actuator (Driver Side) Check.................................................................... 603 Front Door Lock Actuator (Passenger Side) Check................................................................. 604 Rear Door Lock Actuator LH Check................................................................................ 605 Rear Door Lock Actuator RH Check................................................................................ 605 Back Door Lock Actuator Check................................................................................... 606 Front Door Switch (Driver Side) Check........................................................................... 607 All Door Switch Check........................................................................................... 607 Key Switch Check................................................................................................ 609 MULTI-REMOTE CONTROL SYSTEM......................................................................................... 610 Component Parts and Harness Connector Location.................................................................. 610 System Description.............................................................................................. 610 INPUTS...................................................................................................... 610 OPERATED PROCEDURE.......................................................................................... 611 Power Door Lock Operation............................................................................... 611 Hazard and Horn Reminder................................................................................ 611 Interior Room Lamp Operation............................................................................ 612 Panic Alarm Operation................................................................................... 612 Schematic....................................................................................................... 613 Wiring Diagram — MULTI —........................................................................................ 614 Terminal and Reference Value for Smart Entrance Control Unit.................................................... 620 Symptom Chart................................................................................................... 621 Remote Controller Battery Check................................................................................. 622 ACC Switch Circuit Check........................................................................................ 622 Power Supply and Ground Circuit Check........................................................................... 622 Front Door Switch (Driver Side) Circuit Check................................................................... 624 All Door Switch Circuit Check................................................................................... 624 Key Switch Circuit Check........................................................................................ 625 Hazard Reminder Check........................................................................................... 626 Horn Reminder Check............................................................................................. 627 Interior Room Lamp Operation Check.............................................................................. 627 ID Code Entry Procedure......................................................................................... 628 KEY FOB ID SET UP........................................................................................... 628 Key Fob Battery Replacement..................................................................................... 629 FRONT DOOR LOCK..................................................................................................... 630 Component Parts Location........................................................................................ 630 Inspection and Adjustment....................................................................................... 630 OUT SIDE HANDLE ROD ADJUSTMENT.............................................................................. 630 Removal and Installation........................................................................................ 630 REMOVAL..................................................................................................... 630 INSTALLATION................................................................................................ 631 Disassembly and Assembly........................................................................................ 632 DISASSEMBLY................................................................................................. 632 ASSEMBLY.................................................................................................... 632 REAR DOOR LOCK...................................................................................................... 633 Component Parts Location........................................................................................ 633 Inspection and Adjustment....................................................................................... 633 OUT SIDE HANDLE ROD ADJUSTMENT.............................................................................. 633 Removal and Installation........................................................................................ 633 REMOVAL..................................................................................................... 633 INSTALLATION................................................................................................ 634 Disassembly and Assembly........................................................................................ 635 DISASSEMBLY................................................................................................. 635 ASSEMBLY.................................................................................................... 635 BACK DOOR........................................................................................................... 636 Fitting Adjustment.............................................................................................. 636 VERTICAL/LATERAL CLEARANCE ADJUSTMENT....................................................................... 636 Back Door Assembly.............................................................................................. 637 REMOVAL AND INSTALLATION.................................................................................... 637 Removal................................................................................................. 637 Installation............................................................................................ 637 INSPECTION.................................................................................................. 638 Removal and Installation of Back Door Handle.................................................................... 638 REMOVAL..................................................................................................... 638 INSTALLATION................................................................................................ 638 Removal and Installation of Back Door Lock and Actuator......................................................... 638 REMOVAL..................................................................................................... 638 INSTALLATION................................................................................................ 638 Disassembly and Assembly of Back Door Lock & Back Door Lock Actuator............................................ 638 DISASSEMBLY................................................................................................. 638 ASSEMBLY.................................................................................................... 639 Removal and Installation of Back Door Weatherstrip.............................................................. 639 REMOVAL..................................................................................................... 639 INSTALLATION................................................................................................ 639 FUEL FILLER LID OPENER.............................................................................................. 640 Component Parts Location........................................................................................ 640 Removal and Installation of Fuel Filler Lid Opener Cable........................................................ 640 REMOVAL..................................................................................................... 640 INSTALLATION................................................................................................ 640 VEHICLE SECURITY (THEFT WARNING) SYSTEM............................................................................. 641 Component Parts and Harness Connector Location.................................................................. 641 System Description.............................................................................................. 642 DESCRIPTION................................................................................................. 642 Operation Flow.......................................................................................... 642 Setting the Theft Warning System........................................................................ 642 Canceling the Set Theft Warning System.................................................................. 642 Activating the Alarm Operation of the Theft Warning System.............................................. 642 POWER SUPPLY AND GROUND..................................................................................... 643 INITIAL CONDITION TO ACTIVATE THE SYSTEM.................................................................... 643 THEFT WARNING SYSTEM ACTIVATION............................................................................. 643 THEFT WARNING SYSTEM ALARM OPERATION........................................................................ 643 THEFT WARNING SYSTEM DEACTIVATION........................................................................... 644 PANIC ALARM OPERATION....................................................................................... 644 Schematic....................................................................................................... 645 Wiring Diagram — VEHSEC —....................................................................................... 646 Terminals and Reference Value for Smart Entrance Control Unit................................................... 651 Preliminary Check............................................................................................... 652 Symptom Chart................................................................................................... 653 Diagnostic Procedure 1.......................................................................................... 654 Diagnostic Procedure 2.......................................................................................... 655 Diagnostic Procedure 3.......................................................................................... 655 Diagnostic Procedure 4.......................................................................................... 656 Diagnostic Procedure 5.......................................................................................... 657 Diagnostic Procedure 6.......................................................................................... 659 Diagnostic Procedure 7.......................................................................................... 659 Diagnostic Procedure 8.......................................................................................... 661 NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM-NATS)....................................................................... 662 Component Parts and Harness Connector Location.................................................................. 662 System Description.............................................................................................. 663 System Composition.............................................................................................. 663 ECM Re-communicating Function................................................................................... 664 Wiring Diagram — NATS —......................................................................................... 665 CONSULT-II...................................................................................................... 666 CONSULT-II INSPECTION PROCEDURE............................................................................. 666 CONSULT-II DIAGNOSTIC TEST MODE FUNCTION.................................................................... 667 HOW TO READ SELF-DIAGNOSTIC RESULTS......................................................................... 667 NVIS (NATS) SELF-DIAGNOSTIC RESULTS ITEM CHART.............................................................. 668 Work Flow....................................................................................................... 669 Trouble Diagnoses............................................................................................... 670 SYMPTOM MATRIX CHART 1...................................................................................... 670 SYMPTOM MATRIX CHART 2...................................................................................... 671 DIAGNOSTIC SYSTEM DIAGRAM................................................................................... 671 Diagnostic Procedure 1.......................................................................................... 672 Diagnostic Procedure 2.......................................................................................... 672 Diagnostic Procedure 3.......................................................................................... 675 Diagnostic Procedure 4.......................................................................................... 676 Diagnostic Procedure 5.......................................................................................... 677 Diagnostic Procedure 6.......................................................................................... 678 Diagnostic Procedure 7.......................................................................................... 679 How to Replace NATS IMMU........................................................................................ 680 BODY REPAIR......................................................................................................... 681 Body Exterior Paint Color....................................................................................... 681 Body Component Parts............................................................................................ 682 UNDERBODY COMPONENT PARTS................................................................................... 682 BODY COMPONENT PARTS........................................................................................ 684 Corrosion Protection............................................................................................ 686 DESCRIPTION................................................................................................. 686 Anti-Corrosive Precoated Steel (Galvannealed Steel)..................................................... 686 Phosphate Coating Treatment and Cationic Electrodeposition Primer....................................... 686 ANTI-CORROSIVE WAX.......................................................................................... 687 UNDERCOATING................................................................................................ 688 Precautions in Undercoating............................................................................. 688 STONE GUARD COAT............................................................................................ 689 Body Sealing.................................................................................................... 690 DESCRIPTION................................................................................................. 690 Body Construction............................................................................................... 693 BODY CONSTRUCTION........................................................................................... 693 Body Alignment.................................................................................................. 694 BODY CENTER MARKS........................................................................................... 694 PANEL PARTS MATCHING MARKS.................................................................................. 695 DESCRIPTION................................................................................................. 696 ENGINE COMPARTMENT.......................................................................................... 697 Measurement............................................................................................. 697 Measurement Points...................................................................................... 698 UNDERBODY................................................................................................... 699 Measurement............................................................................................. 699 Measurement Points...................................................................................... 700 PASSENGER COMPARTMENT....................................................................................... 701 Measurement............................................................................................. 701 Measurement Points...................................................................................... 702 REAR BODY................................................................................................... 703 Measurement............................................................................................. 703 Measurement Points...................................................................................... 704 Handling Precautions for Plastics............................................................................... 705 HANDLING PRECAUTIONS for PLASTICS........................................................................... 705 LOCATION OF PLASTIC PARTS.................................................................................. 706 Precautions in Repairing High Strength Steel.................................................................... 708 HIGH STRENGTH STEEL (HSS) USED IN NISSAN VEHICLES........................................................... 708 Read the Following Precautions When Repairing HSS:...................................................... 709 Replacement Operations.......................................................................................... 711 DESCRIPTION................................................................................................. 711 RADIATOR CORE SUPPORT....................................................................................... 714 RADIATOR CORE SUPPORT (PARTIAL REPLACEMENT)................................................................. 715 HOODLEDGE................................................................................................... 716 HOODLEDGE (PARTIAL REPLACEMENT)............................................................................. 718 FRONT SIDE MEMBER........................................................................................... 720 FRONT SIDE MEMBER (PARTIAL REPLACEMENT)..................................................................... 722 FRONT PILLAR................................................................................................ 724 CENTER PILLAR............................................................................................... 726 OUTER SILL.................................................................................................. 727 REAR FENDER................................................................................................. 728 REAR PANEL.................................................................................................. 729 REAR FLOOR REAR............................................................................................. 730 REAR SIDE MEMBER EXTENSION.................................................................................. 732 ELECTRICAL UNITS.................................................................................................... 45 FUSE BLOCK - JUNCTION BOX (J/B)..................................................................................... 48 FUSE AND FUSIBLE LINK BOX........................................................................................... 49 br.......................................................................................................................... 734 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents....................................................................................................... 734 PRECAUTIONS......................................................................................................... 736 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”..................... 736 Precautions for Brake System.................................................................................... 736 PREPARATION......................................................................................................... 737 Commercial Service Tools........................................................................................ 737 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING................................................................ 738 NVH Troubleshooting Chart....................................................................................... 738 BRAKE PEDAL......................................................................................................... 739 Inspection and Adjustment....................................................................................... 739 ADJUSTMENT.................................................................................................. 740 Removal and Installation........................................................................................ 740 COMPONENTS.................................................................................................. 740 REMOVAL..................................................................................................... 741 INSPECTION AFTER REMOVAL.................................................................................... 741 INSTALLATION................................................................................................ 741 BRAKE FLUID......................................................................................................... 742 On-Board Inspection............................................................................................. 742 CHECKING BRAKE FLUID LEVEL.................................................................................. 742 Drain and Refill................................................................................................ 742 Bleeding Brake System........................................................................................... 743 BRAKE PIPING AND HOSE............................................................................................... 744 Hydraulic Circuit............................................................................................... 744 Removal and Installation of Front Brake Piping and Hose......................................................... 745 REMOVAL..................................................................................................... 745 INSTALLATION................................................................................................ 745 Removal and Installation of Rear Brake Piping and Hose.......................................................... 745 REMOVAL..................................................................................................... 745 INSTALLATION................................................................................................ 745 Inspection after Installation................................................................................... 746 BRAKE MASTER CYLINDER............................................................................................... 747 On-Board Inspection............................................................................................. 747 LEAK INSPECTION............................................................................................. 747 Removal and Installation........................................................................................ 747 REMOVAL..................................................................................................... 747 INSTALLATION................................................................................................ 747 Disassembly and Assembly........................................................................................ 748 COMPONENTS.................................................................................................. 748 MODEL WITHOUT VDC........................................................................................... 748 Disassembly (Piston Assembly)........................................................................... 748 Inspection After Disassembly (Piston Assembly).......................................................... 749 Assembly (Piston Assembly).............................................................................. 749 Disassembly (Reservoir Tank)............................................................................ 749 Assembly (Reservoir Tank)............................................................................... 750 MODEL WITH VDC.............................................................................................. 750 Disassembly............................................................................................. 750 Inspection After Disassembly............................................................................ 751 Assembly................................................................................................ 751 BRAKE BOOSTER....................................................................................................... 754 On-Board Inspection and Service................................................................................. 754 OPERATION CHECK............................................................................................. 754 AIR TIGHT CHECK............................................................................................. 754 Removal and Installation........................................................................................ 755 COMPONENTS.................................................................................................. 755 REMOVAL..................................................................................................... 755 INSPECTION AFTER REMOVAL.................................................................................... 755 Output Rod Length Inspection............................................................................ 755 INSTALLATION................................................................................................ 756 VACUUM LINES........................................................................................................ 757 Components...................................................................................................... 757 Removal and Installation........................................................................................ 757 Inspection...................................................................................................... 757 VISUAL INSPECTION........................................................................................... 757 CHECK VALVE INSPECTION...................................................................................... 757 Airtightness Inspection................................................................................. 757 FRONT DISC BRAKE.................................................................................................... 758 On-Board Inspection............................................................................................. 758 PAD WEAR INSPECTION......................................................................................... 758 Components...................................................................................................... 758 Removal and Installation of Brake Pad........................................................................... 759 REMOVAL..................................................................................................... 759 INSTALLATION................................................................................................ 759 Removal and Installation of Brake Caliper Assembly.............................................................. 759 REMOVAL..................................................................................................... 759 INSTALLATION................................................................................................ 760 Disassembly and Assembly of Brake Caliper Assembly.............................................................. 760 DISASSEMBLY................................................................................................. 760 INSPECTION AFTER DISASSEMBLY................................................................................ 761 Cylinder Body........................................................................................... 761 Torque Member........................................................................................... 761 Piston.................................................................................................. 761 Sliding Pin, Sliding Pin Bolt, and Sliding Pin Boot..................................................... 761 ASSEMBLY.................................................................................................... 762 DISC ROTOR INSPECTION....................................................................................... 763 Visual Inspection....................................................................................... 763 Runout Inspection....................................................................................... 763 Thickness Inspection.................................................................................... 763 BRAKE BURNISHING PROCEDURE.................................................................................. 763 REAR DISC BRAKE..................................................................................................... 764 On-Board Inspection............................................................................................. 764 PAD WEAR INSPECTION......................................................................................... 764 Components...................................................................................................... 764 Removal and Installation of Brake Pad........................................................................... 765 REMOVAL..................................................................................................... 765 INSTALLATION................................................................................................ 765 Removal and Installation of Brake Caliper Assembly.............................................................. 765 REMOVAL..................................................................................................... 765 INSTALLATION................................................................................................ 765 Disassembly and Assembly of Brake Caliper Assembly.............................................................. 766 DISASSEMBLY................................................................................................. 766 INSPECTION AFTER DISASSEMBLY................................................................................ 767 Cylinder Body........................................................................................... 767 Torque Member........................................................................................... 767 Piston.................................................................................................. 767 Sliding pin,Sliding Pin Bolt, Sliding Pin Boot.......................................................... 767 ASSEMBLY.................................................................................................... 767 DISC ROTOR INSPECTION....................................................................................... 768 Visual Inspection....................................................................................... 768 Runout Inspection....................................................................................... 768 Thickness Inspection.................................................................................... 768 BRAKE BURNISHING PROCEDURE.................................................................................. 769 SERVICE DATA AND SPECIFICATIONS (SDS)............................................................................... 770 General Specifications.......................................................................................... 770 Brake Pedal..................................................................................................... 770 Brake Booster................................................................................................... 770 Check Valve..................................................................................................... 770 Front Disc Brake................................................................................................ 770 Rear Disc Brake................................................................................................. 771 cl.......................................................................................................................... 772 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents....................................................................................................... 772 PRECAUTIONS......................................................................................................... 773 Service Notice or Precautions................................................................................... 773 PREPARATION......................................................................................................... 774 Special Service Tools........................................................................................... 774 Commercial Service Tools........................................................................................ 774 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING................................................................ 775 NVH Troubleshooting Chart....................................................................................... 775 CLUTCH PEDAL........................................................................................................ 776 On-Vehicle Inspection and Adjustment............................................................................ 776 Removal and Installation........................................................................................ 777 COMPONENTS.................................................................................................. 777 REMOVAL..................................................................................................... 777 INSPECTION AFTER REMOVAL.................................................................................... 777 INSTALLATION................................................................................................ 777 CLUTCH FLUID........................................................................................................ 778 Air Bleeding Procedure.......................................................................................... 778 CLUTCH MASTER CYLINDER.............................................................................................. 779 Components...................................................................................................... 779 Removal and Installation........................................................................................ 779 REMOVAL..................................................................................................... 779 INSTALLATION................................................................................................ 779 Disassembly and Assembly........................................................................................ 780 DISASSEMBLY................................................................................................. 780 INSPECTION AFTER DISASSEMBLY................................................................................ 780 ASSEMBLY.................................................................................................... 780 OPERATING CYLINDER.................................................................................................. 781 Components...................................................................................................... 781 Removal and Installation........................................................................................ 781 REMOVAL..................................................................................................... 781 INSTALLATION................................................................................................ 781 Disassembly and Assembly........................................................................................ 781 DISASSEMBLY................................................................................................. 781 INSPECTION AFTER DISASSEMBLY................................................................................ 781 ASSEMBLY.................................................................................................... 781 CLUTCH PIPING....................................................................................................... 782 Removal and Installation........................................................................................ 782 CLUTCH RELEASE MECHANISM............................................................................................ 783 Removal and Installation........................................................................................ 783 COMPONENTS.................................................................................................. 783 REMOVAL..................................................................................................... 783 INSPECTION AFTER REMOVAL.................................................................................... 783 INSTALLATION................................................................................................ 783 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL.............................................................................. 785 Removal and Installation........................................................................................ 785 COMPONENTS.................................................................................................. 785 REMOVAL..................................................................................................... 785 INSPECTION AND ADJUSTMENT AFTER REMOVAL..................................................................... 785 Clutch Disc............................................................................................. 785 Clutch Cover............................................................................................ 786 Flywheel Runout......................................................................................... 786 INSTALLATION................................................................................................ 786 SERVICE DATA AND SPECIFICATIONS (SDS)............................................................................... 787 Clutch Control System........................................................................................... 787 Clutch Master Cylinder.......................................................................................... 787 Clutch Operating Cylinder....................................................................................... 787 Clutch Disc..................................................................................................... 787 Clutch Cover.................................................................................................... 787 Clutch Pedal.................................................................................................... 787 co.......................................................................................................................... 788 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents....................................................................................................... 788 PRECAUTIONS......................................................................................................... 789 Precautions for Liquid Gasket................................................................................... 789 LIQUID GASKET APPLICATION PROCEDURE......................................................................... 789 PREPARATION......................................................................................................... 790 Special Service Tools........................................................................................... 790 Commercial Service Tools........................................................................................ 790 OVERHEATING CAUSE ANALYSIS.......................................................................................... 791 Troubleshooting Chart........................................................................................... 791 COOLING SYSTEM...................................................................................................... 793 Cooling Circuit................................................................................................. 793 System Chart.................................................................................................... 794 ENGINE COOLANT...................................................................................................... 795 Inspection...................................................................................................... 795 CHECKING ENGINE COOLANT LEVEL............................................................................... 795 CHECKING LEAKAGE............................................................................................ 795 Changing Engine Coolant......................................................................................... 795 DRAINING ENGINE COOLANT..................................................................................... 795 REFILLING ENGINE COOLANT.................................................................................... 796 FLUSHING COOLING SYSTEM..................................................................................... 797 RADIATOR............................................................................................................ 798 Removal and Installation........................................................................................ 798 REMOVAL..................................................................................................... 798 INSTALLATION................................................................................................ 799 INSPECTION AFTER INSTALLATION............................................................................... 799 Checking Radiator Cap........................................................................................... 799 Checking Radiator............................................................................................... 799 RADIATOR (ALUMINUM TYPE)............................................................................................ 801 Disassembly and Assembly........................................................................................ 801 PREPARATION................................................................................................. 801 DISASSEMBLY................................................................................................. 801 ASSEMBLY.................................................................................................... 802 INSPECTION.................................................................................................. 804 COOLING FAN......................................................................................................... 805 Removal and Installation........................................................................................ 805 REMOVAL..................................................................................................... 805 INSTALLATION................................................................................................ 805 INSPECTION AFTER INSTALLATION............................................................................... 805 Disassembly and Assembly........................................................................................ 806 DISASSEMBLY................................................................................................. 806 INSPECTION AFTER DISASSEMBLY................................................................................ 806 Cooling Fan............................................................................................. 806 ASSEMBLY.................................................................................................... 806 WATER PUMP.......................................................................................................... 807 Removal and Installation........................................................................................ 807 REMOVAL..................................................................................................... 807 INSPECTION AFTER REMOVAL.................................................................................... 808 INSTALLATION................................................................................................ 808 INSPECTION AFTER INSTALLATION............................................................................... 808 THERMOSTAT AND WATER CONTROL VALVE.................................................................................. 809 Removal and Installation........................................................................................ 809 REMOVAL..................................................................................................... 809 INSPECTION AFTER REMOVAL.................................................................................... 810 INSTALLATION................................................................................................ 810 Thermostat and Water Control Valve...................................................................... 810 Heater Pipe Installation................................................................................ 810 INSPECTION AFTER INSTALLATION............................................................................... 810 SERVICE DATA AND SPECIFICATIONS (SDS)............................................................................... 811 Standard and Limit.............................................................................................. 811 ENGINE COOLANT CAPACITY (APPROXIMATE)....................................................................... 811 RADIATOR.................................................................................................... 811 THERMOSTAT.................................................................................................. 811 WATER CONTROL VALVE......................................................................................... 811 di.......................................................................................................................... 812 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents....................................................................................................... 812 PRECAUTIONS......................................................................................................... 814 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”..................... 814 Wiring Diagrams and Trouble Diagnosis........................................................................... 814 COMBINATION METERS.................................................................................................. 815 System Description.............................................................................................. 815 UNIFIED METER CONTROL UNIT.................................................................................. 815 POWER SUPPLY AND GROUND CIRCUIT............................................................................. 815 ODO/TRIP METER, CLOCK AND AMBIENT TEMPERATURE INDICATOR..................................................... 815 How to Change The Display............................................................................... 815 SPEEDOMETER................................................................................................. 815 TACHOMETER.................................................................................................. 816 WATER TEMPERATURE GAUGE..................................................................................... 816 FUEL GAUGE.................................................................................................. 816 AMBIENT TEMPERATURE INDICATOR............................................................................... 816 Without Auto A/C........................................................................................ 816 With Auto A/C........................................................................................... 816 Indication When Turning Ignition Switch OFF............................................................. 816 Indication During Running............................................................................... 817 CAN Communication............................................................................................... 817 SYSTEM DESCRIPTION.......................................................................................... 817 CAN COMMUNICATION UNIT...................................................................................... 817 Arrangement of Combination Meter................................................................................ 818 Component Parts and Harness Connector Location.................................................................. 819 Schematic....................................................................................................... 820 Wiring Diagram — METER —........................................................................................ 821 AWD MODELS.................................................................................................. 821 2WD MODELS.................................................................................................. 823 Terminals and Reference Value for Combination Meter............................................................. 825 Self-Diagnosis Mode of Combination Meter........................................................................ 825 SELF-DIAGNOSIS FUNCTION..................................................................................... 825 OPERATION PROCEDURE......................................................................................... 825 Trouble Diagnosis............................................................................................... 826 HOW TO PROCEED WITH TROUBLE DIAGNOSIS....................................................................... 826 PRELIMINARY CHECK........................................................................................... 826 SYMPTOM CHART............................................................................................... 827 Power Supply and Ground Circuit Inspection...................................................................... 827 Vehicle Speed Signal Inspection (With VDC)...................................................................... 828 Vehicle Speed Signal Inspection (Without VDC)................................................................... 828 Engine Speed Signal Inspection.................................................................................. 828 Engine Coolant Temperature Signal Inspection.................................................................... 829 Fuel Level Sensor Inspection.................................................................................... 829 The Fuel Gauge Pointer Fluctuates, Indicator Wrong Value or Varies.............................................. 830 The Fuel Gauge Does Not Move to FULL Position................................................................... 831 Ambient Temperature Signal Inspection [Without Auto A/C]........................................................ 831 Ambient Temperature Signal Inspection [With Auto A/C]........................................................... 833 Electrical Components Inspection................................................................................ 834 FUEL LEVEL SENSOR UNIT CHECK................................................................................ 834 Fuel Level Sensor Unit.................................................................................. 834 Sub Fuel Level Sensor Unit.............................................................................. 834 AMBIENT SENSOR CHECK........................................................................................ 834 Removal and Installation for Combination Meter.................................................................. 835 REMOVAL..................................................................................................... 835 INSTALLATION................................................................................................ 835 Disassembly and Assembly for Combination Meter.................................................................. 835 DISASSEMBLY................................................................................................. 835 ASSEMBLY.................................................................................................... 835 WARNING LAMPS....................................................................................................... 836 Schematic....................................................................................................... 836 Wiring Diagram — WARN —......................................................................................... 837 AWD MODELS.................................................................................................. 837 2WD MODELS.................................................................................................. 843 Electrical Components Inspection................................................................................ 849 OIL PRESSURE SWITCH CHECK................................................................................... 849 DIODE CHECK................................................................................................. 849 A/T INDICATOR....................................................................................................... 850 Wiring Diagram — AT/IND —....................................................................................... 850 AWD MODELS.................................................................................................. 850 2WD MODELS.................................................................................................. 851 A/T Indicator Does Not Illuminate............................................................................... 852 WARNING CHIME....................................................................................................... 853 System Description.............................................................................................. 853 POWER SUPPLY AND GROUND CIRCUIT............................................................................. 853 IGNITION KEY WARNING CHIME.................................................................................. 853 LIGHT WARNING CHIME......................................................................................... 853 SEAT BELT WARNING CHIME..................................................................................... 853 Without Power Seat...................................................................................... 853 With Power Seat......................................................................................... 854 Component Parts and Harness Connector Location.................................................................. 854 Schematic....................................................................................................... 855 Wiring Diagram — CHIME —........................................................................................ 856 Terminals and Reference Value for Smart Entrance Control Unit................................................... 859 Trouble Diagnosis............................................................................................... 859 HOW TO PROCEED WITH TROUBLE DIAGNOSIS....................................................................... 859 SYMPTOM CHART............................................................................................... 859 Power Supply and Ground Circuit Inspection...................................................................... 859 Front Door Switch (Driver Side) Inspection...................................................................... 860 Lighting Switch Input Signal Inspection......................................................................... 862 Key Switch Insert Signal Inspection............................................................................. 862 Seat Belt Buckle Switch Input Signal Inspection [Without Power Seat]............................................ 863 Seat Belt Buckle Switch Input Signal Inspection [With Power Seat]............................................... 865 CLOCK............................................................................................................... 867 Wiring Diagram — CLOCK —........................................................................................ 867 ELECTRICAL UNITS.................................................................................................... 45 FUSE BLOCK - JUNCTION BOX (J/B)..................................................................................... 48 FUSE AND FUSIBLE LINK BOX........................................................................................... 49 ec.......................................................................................................................... 868 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents....................................................................................................... 868 INDEX FOR DTC....................................................................................................... 875 DTC No. Index................................................................................................... 875 Alphabetical Index.............................................................................................. 878 PRECAUTIONS......................................................................................................... 881 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”..................... 881 On Board Diagnostic (OBD) System of Engine and A/T.............................................................. 881 Precaution...................................................................................................... 881 Wiring Diagrams and Trouble Diagnosis........................................................................... 884 PREPARATION......................................................................................................... 885 Special Service Tools........................................................................................... 885 Commercial Service Tools........................................................................................ 886 ENGINE CONTROL SYSTEM............................................................................................... 888 System Diagram.................................................................................................. 888 Multiport Fuel Injection (MFI) System........................................................................... 889 INPUT/OUTPUT SIGNAL CHART................................................................................... 889 SYSTEM DESCRIPTION.......................................................................................... 889 VARIOUS FUEL INJECTION INCREASE/DECREASE COMPENSATION....................................................... 889 MIXTURE RATIO FEEDBACK CONTROL (CLOSED LOOP CONTROL)........................................................ 890 Open Loop Control....................................................................................... 890 MIXTURE RATIO SELF-LEARNING CONTROL......................................................................... 890 FUEL INJECTION TIMING....................................................................................... 891 Sequential Multiport Fuel Injection System.............................................................. 891 Simultaneous Multiport Fuel Injection System............................................................ 891 FUEL SHUT-OFF............................................................................................... 891 Electronic Ignition (EI) System................................................................................. 891 INPUT/OUTPUT SIGNAL CHART................................................................................... 891 SYSTEM DESCRIPTION.......................................................................................... 891 Fuel Cut Control (at No Load and High Engine Speed)............................................................. 892 INPUT/OUTPUT SIGNAL CHART................................................................................... 892 SYSTEM DESCRIPTION.......................................................................................... 892 AIR CONDITIONING CUT CONTROL........................................................................................ 893 Input/Output Signal Chart....................................................................................... 893 SYSTEM DESCRIPTION.......................................................................................... 893 AUTOMATIC SPEED CONTROL DEVICE (ASCD)............................................................................... 894 System Description.............................................................................................. 894 INPUT/OUTPUT SIGNAL CHART................................................................................... 894 BASIC ASCD SYSTEM........................................................................................... 894 SET OPERATION............................................................................................... 894 ACCEL OPERATION............................................................................................. 894 CANCEL OPERATION............................................................................................ 894 COAST OPERATION............................................................................................. 895 RESUME OPERATION............................................................................................ 895 Component Description........................................................................................... 895 ASCD STEERING SWITCH........................................................................................ 895 ASCD BRAKE SWITCH........................................................................................... 895 ASCD CLUTCH SWITCH.......................................................................................... 895 STOP LAMP SWITCH............................................................................................ 895 ELECTRIC THROTTLE CONTROL ACTUATOR.......................................................................... 895 ASCD INDICATOR.............................................................................................. 895 CAN COMMUNICATION................................................................................................... 896 System Description.............................................................................................. 896 EVAPORATIVE EMISSION SYSTEM......................................................................................... 897 Description..................................................................................................... 897 SYSTEM DESCRIPTION.......................................................................................... 897 EVAPORATIVE EMISSION LINE DRAWING........................................................................... 898 Component Inspection............................................................................................ 900 EVAP CANISTER............................................................................................... 900 FUEL TANK VACUUM RELIEF VALVE (BUILT INTO FUEL FULLER CAP).................................................. 900 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE........................................................... 900 FUEL TANK TEMPERATURE SENSOR................................................................................ 900 EVAP CANISTER VENT CONTROL VALVE............................................................................ 900 EVAP CONTROL SYSTEM PRESSURE SENSOR......................................................................... 900 EVAP SERVICE PORT........................................................................................... 901 Removal and Installation........................................................................................ 901 EVAP CANISTER............................................................................................... 901 EVAP CANISTER VENT CONTROL VALVE............................................................................ 901 How to Detect Fuel Vapor Leakage................................................................................ 901 WITH CONSULT-II............................................................................................. 902 WITHOUT CONSULT-II.......................................................................................... 902 ON BOARD REFUELING VAPOR RECOVERY (ORVR)............................................................................ 904 System Description.............................................................................................. 904 Diagnostic Procedure............................................................................................ 905 SYMPTOM: FUEL ODOR FROM EVAP CANISTER IS STRONG............................................................. 905 SYMPTOM: CANNOT REFUEL/FUEL ODOR FROM THE FUEL FILLER OPENING IS STRONG WHILE REFUELING..................... 906 Component Inspection............................................................................................ 908 REFUELING EVAP VAPOR CUT VALVE.............................................................................. 908 With CONSULT-II......................................................................................... 908 Without CONSULT-II...................................................................................... 908 REFUELING CONTROL VALVE..................................................................................... 909 WATER SEPARATOR............................................................................................. 909 POSITIVE CRANKCASE VENTILATION...................................................................................... 911 Description..................................................................................................... 911 SYSTEM DESCRIPTION.......................................................................................... 911 Component Inspection............................................................................................ 911 PCV (POSITIVE CRANKCASE VENTILATION) VALVE.................................................................. 911 PCV VALVE VENTILATION HOSE.................................................................................. 912 NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM-NATS)....................................................................... 913 Description..................................................................................................... 913 ON BOARD DIAGNOSTIC (OBD) SYSTEM.................................................................................... 914 Introduction.................................................................................................... 914 Two Trip Detection Logic........................................................................................ 914 Emission-Related Diagnostic Information......................................................................... 915 EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS............................................................... 915 DTC AND 1ST TRIP DTC........................................................................................ 918 How to Read DTC and 1st Trip DTC........................................................................ 918 FREEZE FRAME DATA AND 1ST TRIP FREEZE FRAME DATA............................................................ 919 SYSTEM READINESS TEST (SRT) CODE............................................................................ 919 SRT Item................................................................................................ 919 SRT Set Timing.......................................................................................... 921 SRT Service Procedure................................................................................... 922 How to Display SRT Status............................................................................... 923 How to Set SRT Code..................................................................................... 923 Driving Pattern......................................................................................... 924 TEST VALUE AND TEST LIMIT (GST ONLY — NOT APPLICABLE TO CONSULT-II)......................................... 926 HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION........................................................ 927 How to Erase DTC........................................................................................ 927 Malfunction Indicator Lamp (MIL)................................................................................ 928 DESCRIPTION................................................................................................. 928 ON BOARD DIAGNOSTIC SYSTEM FUNCTION......................................................................... 928 MIL Flashing Without DTC................................................................................ 929 HOW TO SWITCH DIAGNOSTIC TEST MODE.......................................................................... 930 How to Set Diagnostic Test Mode II (Self-Diagnostic Results)............................................ 930 How to Set Diagnostic Test Mode II (Heated Oxygen Sensor 1 Monitor)..................................... 930 How to Erase Diagnostic Test Mode II (Self-Diagnostic Results).......................................... 930 DIAGNOSTIC TEST MODE I — BULB CHECK......................................................................... 930 DIAGNOSTIC TEST MODE I — MALFUNCTION WARNING................................................................ 930 DIAGNOSTIC TEST MODE II — SELF-DIAGNOSTIC RESULTS........................................................... 931 How to Erase Diagnostic Test Mode II (Self-Diagnostic Results).......................................... 931 DIAGNOSTIC TEST MODE II — HEATED OXYGEN SENSOR 1 MONITOR.................................................... 931 OBD System Operation Chart...................................................................................... 932 RELATIONSHIP BETWEEN MIL, 1ST TRIP DTC, DTC, AND DETECTABLE ITEMS........................................... 932 SUMMARY CHART............................................................................................... 932 RELATIONSHIP BETWEEN MIL, DTC, 1ST TRIP DTC AND DRIVING PATTERNS FOR “MISFIRE <EXHAUST QUALITY DE........... 933 EXPLANATION FOR DRIVING PATTERNS FOR “MISFIRE <EXHAUST QUALITY DETERIORATION>”, “FUEL INJECTION S........... 934 <Driving Pattern B>..................................................................................... 934 <Driving Pattern C>..................................................................................... 934 RELATIONSHIP BETWEEN MIL, DTC, 1ST TRIP DTC AND DRIVING PATTERNS............................................ 935 EXPLANATION FOR DRIVING PATTERNS............................................................................ 936 <Driving Pattern A>..................................................................................... 936 <Driving Pattern B>..................................................................................... 936 BASIC SERVICE PROCEDURE............................................................................................. 937 Basic Inspection................................................................................................ 937 Idle Speed and Ignition Timing Check............................................................................ 942 IDLE SPEED.................................................................................................. 942 With CONSULT-II......................................................................................... 942 With GST................................................................................................ 942 IGNITION TIMING............................................................................................. 942 Method A................................................................................................ 942 Method B................................................................................................ 943 Idle Mixture Ratio Adjustment................................................................................... 944 PREPARATION................................................................................................. 944 OVERALL SEQUENCE............................................................................................ 945 DETAILED PROCEDURE.......................................................................................... 946 VIN Registration................................................................................................ 954 DESCRIPTION................................................................................................. 954 OPERATION PROCEDURE......................................................................................... 954 With CONSULT-II......................................................................................... 954 Accelerator Pedal Released Position Learning.................................................................... 955 DESCRIPTION................................................................................................. 955 OPERATION PROCEDURE......................................................................................... 955 Throttle Valve Closed Position Learning......................................................................... 955 DESCRIPTION................................................................................................. 955 OPERATION PROCEDURE......................................................................................... 955 Idle Air Volume Learning........................................................................................ 955 DESCRIPTION................................................................................................. 955 PREPARATION................................................................................................. 955 OPERATION PROCEDURE......................................................................................... 956 With CONSULT-II......................................................................................... 956 Without CONSULT-II...................................................................................... 956 DIAGNOSTIC PROCEDURE........................................................................................ 957 Fuel Pressure Check............................................................................................. 957 FUEL PRESSURE RELEASE....................................................................................... 957 With CONSULT-II......................................................................................... 957 Without CONSULT-II...................................................................................... 958 FUEL PRESSURE CHECK......................................................................................... 958 Method A................................................................................................ 958 Method B................................................................................................ 959 TROUBLE DIAGNOSIS................................................................................................... 961 Trouble Diagnosis Introduction.................................................................................. 961 INTRODUCTION................................................................................................ 961 WORK FLOW................................................................................................... 962 Overall Sequence........................................................................................ 962 Detailed Flow........................................................................................... 963 DIAGNOSTIC WORKSHEET........................................................................................ 965 Description............................................................................................. 965 Worksheet Sample........................................................................................ 966 DTC Inspection Priority Chart................................................................................... 967 Fail-Safe Chart................................................................................................. 969 Symptom Matrix Chart............................................................................................ 970 SYSTEM — BASIC ENGINE CONTROL SYSTEM........................................................................ 970 SYSTEM — ENGINE MECHANICAL & OTHER.......................................................................... 972 Engine Control Component Parts Location......................................................................... 974 Vacuum Hose Drawing............................................................................................. 979 Circuit Diagram................................................................................................. 980 ECM Harness Connector Terminal Layout........................................................................... 982 ECM Terminals and Reference Value............................................................................... 982 PREPARATION................................................................................................. 982 ECM INSPECTION TABLE........................................................................................ 982 CONSULT-II Function (ENGINE).................................................................................... 990 FUNCTION.................................................................................................... 990 ENGINE CONTROL COMPONENT PARTS/CONTROL SYSTEMS APPLICATION.................................................. 991 INSPECTION PROCEDURE........................................................................................ 992 WORK SUPPORT MODE........................................................................................... 993 Work Item............................................................................................... 993 SELF-DIAG RESULTS MODE...................................................................................... 994 Self Diagnostic Item.................................................................................... 994 Freeze Frame Data and 1st Trip Freeze Frame Data........................................................ 994 DATA MONITOR MODE........................................................................................... 995 Monitored Item.......................................................................................... 995 DATA MONITOR (SPEC) MODE.................................................................................... 999 Monitored Item.......................................................................................... 999 ACTIVE TEST MODE............................................................................................ 999 Test Item............................................................................................... 999 DTC & SRT CONFIRMATION MODE.................................................................................1000 SRT STATUS Mode.........................................................................................1000 SRT WORK SUPPORT Mode...................................................................................1000 DTC WORK SUPPORT Mode...................................................................................1001 REAL TIME DIAGNOSIS IN DATA MONITOR MODE (RECORDING VEHICLE DATA)...........................................1002 Description.............................................................................................1002 Operation...............................................................................................1002 Generic Scan Tool (GST) Function................................................................................1003 DESCRIPTION.................................................................................................1003 FUNCTION....................................................................................................1003 INSPECTION PROCEDURE........................................................................................1004 CONSULT-II Reference Value in Data Monitor......................................................................1005 Major Sensor Reference Graph in Data Monitor Mode...............................................................1009 CLSD THL POS, ACCEL SEN 1, THRTL SEN 1......................................................................1009 ENG SPEED, MAS A/F SE-B1, THRTL SEN 1, HO2S1 (B1), HO2S2 (B1), INJ PULSE-B1.................................1009 TROUBLE DIAGNOSIS - SPECIFICATION VALUE.............................................................................1011 Description.....................................................................................................1011 Testing Condition...............................................................................................1011 Inspection Procedure............................................................................................1011 Diagnostic Procedure............................................................................................1012 OVERALL SEQUENCE............................................................................................1012 DETAILED PROCEDURE..........................................................................................1014 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT.........................................................................1021 Description.....................................................................................................1021 Diagnostic Procedure............................................................................................1021 POWER SUPPLY AND GROUND CIRCUIT.....................................................................................1022 Wiring Diagram..................................................................................................1022 Diagnostic Procedure............................................................................................1023 Component Inspection............................................................................................1029 ECM RELAY...................................................................................................1029 Ground Inspection...............................................................................................1029 DTC U1000, U1001 CAN COMMUNICATION LINE.............................................................................1030 Description.....................................................................................................1030 On Board Diagnosis Logic........................................................................................1030 DTC Confirmation Procedure......................................................................................1030 Wiring Diagram..................................................................................................1031 Diagnostic Procedure............................................................................................1032 DTC P0011 IVT CONTROL...............................................................................................1033 Description.....................................................................................................1033 SYSTEM DESCRIPTION..........................................................................................1033 CONSULT-II Reference Value in Data Monitor Mode.................................................................1033 On Board Diagnosis Logic........................................................................................1034 FAIL-SAFE MODE..............................................................................................1034 DTC Confirmation Procedure......................................................................................1034 WITH CONSULT-II.............................................................................................1034 WITH GST....................................................................................................1035 Diagnostic Procedure............................................................................................1035 Component Inspection............................................................................................1036 INTAKE VALVE TIMING CONTROL SOLENOID VALVE..................................................................1036 Removal and Installation........................................................................................1036 INTAKE VALVE TIMING CONTROL SOLENOID VALVE..................................................................1036 DTC P0031, P0032 HO2S1 HEATER.......................................................................................1037 Description.....................................................................................................1037 SYSTEM DESCRIPTION..........................................................................................1037 OPERATION...................................................................................................1037 CONSULT-II Reference Value in Data Monitor Mode.................................................................1037 On Board Diagnosis Logic........................................................................................1037 DTC Confirmation Procedure......................................................................................1038 WITH CONSULT-II.............................................................................................1038 WITH GST....................................................................................................1038 Wiring Diagram..................................................................................................1039 Diagnostic Procedure............................................................................................1040 Component Inspection............................................................................................1042 HEATED OXYGEN SENSOR 1 HEATER...............................................................................1042 Removal and Installation........................................................................................1042 HEATED OXYGEN SENSOR 1......................................................................................1042 DTC P0037, P0038 HO2S2 HEATER.......................................................................................1043 Description.....................................................................................................1043 SYSTEM DESCRIPTION..........................................................................................1043 OPERATION...................................................................................................1043 CONSULT-II Reference Value in Data Monitor Mode.................................................................1043 On Board Diagnosis Logic........................................................................................1043 DTC Confirmation Procedure......................................................................................1044 WITH CONSULT-II.............................................................................................1044 WITH GST....................................................................................................1044 Wiring Diagram..................................................................................................1045 Diagnostic Procedure............................................................................................1046 Component Inspection............................................................................................1048 HEATED OXYGEN SENSOR 2 HEATER...............................................................................1048 Removal and Installation........................................................................................1048 HEATED OXYGEN SENSOR 2......................................................................................1048 DTC P0101 MAF SENSOR................................................................................................1049 Component Description...........................................................................................1049 CONSULT-II Reference Value in Data Monitor Mode.................................................................1049 On Board Diagnosis Logic........................................................................................1049 DTC Confirmation Procedure......................................................................................1049 PROCEDURE FOR MALFUNCTION A.................................................................................1050 With CONSULT-II.........................................................................................1050 With GST................................................................................................1050 PROCEDURE FOR MALFUNCTION B.................................................................................1050 With CONSULT-II.........................................................................................1050 Overall Function Check..........................................................................................1051 PROCEDURE FOR MALFUNCTION B.................................................................................1051 With GST................................................................................................1051 Wiring Diagram..................................................................................................1052 Diagnostic Procedure............................................................................................1053 Component Inspection............................................................................................1056 MASS AIR FLOW SENSOR........................................................................................1056 With CONSULT-II.........................................................................................1056 Without CONSULT-II......................................................................................1057 Removal and Installation........................................................................................1057 MASS AIR FLOW SENSOR........................................................................................1057 DTC P0102, P0103 MAF SENSOR.........................................................................................1058 Component Description...........................................................................................1058 CONSULT-II Reference Value in Data Monitor Mode.................................................................1058 On Board Diagnosis Logic........................................................................................1058 FAIL-SAFE MODE..............................................................................................1058 DTC Confirmation Procedure......................................................................................1058 PROCEDURE FOR DTC P0102.....................................................................................1059 With CONSULT-II.........................................................................................1059 With GST................................................................................................1059 PROCEDURE FOR DTC P0103.....................................................................................1059 With CONSULT-II.........................................................................................1059 With GST................................................................................................1059 Wiring Diagram..................................................................................................1060 Diagnostic Procedure............................................................................................1061 Component Inspection............................................................................................1064 MASS AIR FLOW SENSOR........................................................................................1064 With CONSULT-II.........................................................................................1064 Without CONSULT-II......................................................................................1065 Removal and Installation........................................................................................1065 MASS AIR FLOW SENSOR........................................................................................1065 DTC P0112, P0113 IAT SENSOR.........................................................................................1066 Component Description...........................................................................................1066 On Board Diagnosis Logic........................................................................................1066 DTC Confirmation Procedure......................................................................................1066 WITH CONSULT-II.............................................................................................1066 WITH GST....................................................................................................1067 Wiring Diagram..................................................................................................1068 Diagnostic Procedure............................................................................................1069 Component Inspection............................................................................................1071 INTAKE AIR TEMPERATURE SENSOR...............................................................................1071 Removal and Installation........................................................................................1071 MASS AIR FLOW SENSOR........................................................................................1071 DTC P0117, P0118 ECT SENSOR.........................................................................................1072 Component Description...........................................................................................1072 On Board Diagnosis Logic........................................................................................1072 FAIL-SAFE MODE..............................................................................................1072 DTC Confirmation Procedure......................................................................................1073 WITH CONSULT-II.............................................................................................1073 WITH GST....................................................................................................1073 Wiring Diagram..................................................................................................1074 Diagnostic Procedure............................................................................................1075 Component Inspection............................................................................................1077 ENGINE COOLANT TEMPERATURE SENSOR...........................................................................1077 Removal and Installation........................................................................................1077 ENGINE COOLANT TEMPERATURE SENSOR...........................................................................1077 DTC P0122, P0123 TP SENSOR..........................................................................................1078 Component Description...........................................................................................1078 CONSULT-II Reference Value in Data Monitor Mode.................................................................1078 On Board Diagnosis Logic........................................................................................1078 FAIL-SAFE MODE..............................................................................................1078 DTC Confirmation Procedure......................................................................................1079 WITH CONSULT-II.............................................................................................1079 WITH GST....................................................................................................1079 Wiring Diagram..................................................................................................1080 Diagnostic Procedure............................................................................................1082 Component Inspection............................................................................................1085 THROTTLE POSITION SENSOR....................................................................................1085 Remove and Installation.........................................................................................1085 ELECTRIC THROTTLE CONTROL ACTUATOR..........................................................................1085 DTC P0125 ECT SENSOR................................................................................................1086 Description.....................................................................................................1086 COMPONENT DESCRIPTION.......................................................................................1086 On Board Diagnosis Logic........................................................................................1086 DTC Confirmation Procedure......................................................................................1086 WITH CONSULT-II.............................................................................................1086 WITH GST....................................................................................................1087 Diagnostic Procedure............................................................................................1087 Component Inspection............................................................................................1088 ENGINE COOLANT TEMPERATURE SENSOR...........................................................................1088 Removal and Installation........................................................................................1088 ENGINE COOLANT TEMPERATURE SENSOR...........................................................................1088 DTC P0127 IAT SENSOR................................................................................................1089 Component Description...........................................................................................1089 On Board Diagnosis Logic........................................................................................1089 DTC Confirmation Procedure......................................................................................1089 WITH CONSULT-II.............................................................................................1089 WITH GST....................................................................................................1090 Diagnostic Procedure............................................................................................1090 Component Inspection............................................................................................1091 INTAKE AIR TEMPERATURE SENSOR...............................................................................1091 Removal and Installation........................................................................................1091 MASS AIR FLOW SENSOR........................................................................................1091 DTC P0128 THERMOSTAT FUNCTION.......................................................................................1092 On Board Diagnosis Logic........................................................................................1092 DTC Confirmation Procedure......................................................................................1092 WITH CONSULT-II.............................................................................................1092 WITH GST....................................................................................................1092 Diagnostic Procedure............................................................................................1092 Component Inspection............................................................................................1093 ENGINE COOLANT TEMPERATURE SENSOR...........................................................................1093 Removal and Installation........................................................................................1093 ENGINE COOLANT TEMPERATURE SENSOR...........................................................................1093 DTC P0132 HO2S1.....................................................................................................1094 Component Description...........................................................................................1094 CONSULT-II Reference Value in Data Monitor Mode.................................................................1094 On Board Diagnosis Logic........................................................................................1094 DTC Confirmation Procedure......................................................................................1095 WITH CONSULT-II.............................................................................................1095 WITH GST....................................................................................................1095 Wiring Diagram..................................................................................................1096 Diagnostic Procedure............................................................................................1097 Component Inspection............................................................................................1099 HEATED OXYGEN SENSOR 1......................................................................................1099 With CONSULT-II.........................................................................................1099 Without CONSULT-II......................................................................................1100 Removal and Installation........................................................................................1100 HEATED OXYGEN SENSOR 1......................................................................................1100 DTC P0133 HO2S1.....................................................................................................1101 Component Description...........................................................................................1101 CONSULT-II Reference Value in Data Monitor Mode.................................................................1101 On Board Diagnosis Logic........................................................................................1101 DTC Confirmation Procedure......................................................................................1102 WITH CONSULT-II.............................................................................................1102 Overall Function Check..........................................................................................1103 WITH GST....................................................................................................1103 Wiring Diagram..................................................................................................1104 Diagnostic Procedure............................................................................................1105 Component Inspection............................................................................................1109 HEATED OXYGEN SENSOR 1......................................................................................1109 With CONSULT-II.........................................................................................1109 Without CONSULT-II......................................................................................1109 Removal and Installation........................................................................................1110 HEATED OXYGEN SENSOR 1......................................................................................1110 DTC P0134 HO2S1.....................................................................................................1111 Component Description...........................................................................................1111 CONSULT-II Reference Value in Data Monitor Mode.................................................................1111 On Board Diagnosis Logic........................................................................................1111 DTC Confirmation Procedure......................................................................................1112 WITH CONSULT-II.............................................................................................1112 Overall Function Check..........................................................................................1113 WITH GST....................................................................................................1113 Wiring Diagram..................................................................................................1114 Diagnostic Procedure............................................................................................1115 Component Inspection............................................................................................1117 HEATED OXYGEN SENSOR 1......................................................................................1117 With CONSULT-II.........................................................................................1117 Without CONSULT-II......................................................................................1117 Removal and Installation........................................................................................1118 HEATED OXYGEN SENSOR 1......................................................................................1118 DTC P0138 HO2S2.....................................................................................................1119 Component Description...........................................................................................1119 CONSULT-II Reference Value in Data Monitor Mode.................................................................1119 On Board Diagnosis Logic........................................................................................1119 DTC Confirmation Procedure......................................................................................1119 WITH CONSULT-II.............................................................................................1119 WITH GST....................................................................................................1120 Wiring Diagram..................................................................................................1121 Diagnostic Procedure............................................................................................1122 Component Inspection............................................................................................1124 HEATED OXYGEN SENSOR 2......................................................................................1124 With CONSULT-II.........................................................................................1124 Without CONSULT-II......................................................................................1124 Removal and Installation........................................................................................1125 HEATED OXYGEN SENSOR 2......................................................................................1125 DTC P0139 HO2S2.....................................................................................................1126 Component Description...........................................................................................1126 CONSULT-II Reference Value in Data Monitor Mode.................................................................1126 On Board Diagnosis Logic........................................................................................1126 DTC Confirmation Procedure......................................................................................1127 WITH CONSULT-II.............................................................................................1127 Overall Function Check..........................................................................................1127 WITH GST....................................................................................................1127 Wiring Diagram..................................................................................................1129 Diagnostic Procedure............................................................................................1130 Component Inspection............................................................................................1132 HEATED OXYGEN SENSOR 2......................................................................................1132 With CONSULT-II.........................................................................................1132 Without CONSULT-II......................................................................................1133 Removal and Installation........................................................................................1133 HEATED OXYGEN SENSOR 2......................................................................................1133 DTC P0171 FUEL INJECTION SYSTEM FUNCTION............................................................................1134 On Board Diagnosis Logic........................................................................................1134 DTC Confirmation Procedure......................................................................................1134 WITH CONSULT-II.............................................................................................1134 WITH GST....................................................................................................1135 Wiring Diagram..................................................................................................1136 Diagnostic Procedure............................................................................................1137 DTC P0172 FUEL INJECTION SYSTEM FUNCTION............................................................................1141 On Board Diagnosis Logic........................................................................................1141 DTC Confirmation Procedure......................................................................................1141 WITH CONSULT-II.............................................................................................1141 WITH GST....................................................................................................1142 Wiring Diagram..................................................................................................1143 Diagnostic Procedure............................................................................................1144 DTC P0181 FTT SENSOR................................................................................................1147 Component Description...........................................................................................1147 On Board Diagnosis Logic........................................................................................1147 DTC Confirmation Procedure......................................................................................1147 WITH CONSULT-II.............................................................................................1147 WITH GST....................................................................................................1148 Wiring Diagram..................................................................................................1149 Diagnostic Procedure............................................................................................1150 Component Inspection............................................................................................1152 FUEL TANK TEMPERATURE SENSOR................................................................................1152 Removal and Installation........................................................................................1152 FUEL TANK TEMPERATURE SENSOR................................................................................1152 DTC P0182, P0183 FTT SENSOR.........................................................................................1153 Component Description...........................................................................................1153 On Board Diagnosis Logic........................................................................................1153 DTC Confirmation Procedure......................................................................................1153 WITH CONSULT-II.............................................................................................1153 WITH GST....................................................................................................1153 Wiring Diagram..................................................................................................1154 Diagnostic Procedure............................................................................................1155 Component Inspection............................................................................................1157 FUEL TANK TEMPERATURE SENSOR................................................................................1157 Removal and Installation........................................................................................1157 FUEL TANK TEMPERATURE SENSOR................................................................................1157 DTC P0222, P0223 TP SENSOR..........................................................................................1158 Component Description...........................................................................................1158 CONSULT-II Reference Value in Data Monitor Mode.................................................................1158 On Board Diagnosis Logic........................................................................................1158 FAIL-SAFE MODE..............................................................................................1158 DTC Confirmation Procedure......................................................................................1159 WITH CONSULT-II.............................................................................................1159 WITH GST....................................................................................................1159 Wiring Diagram..................................................................................................1160 Diagnostic Procedure............................................................................................1162 Component Inspection............................................................................................1165 THROTTLE POSITION SENSOR....................................................................................1165 Remove and Installation.........................................................................................1165 ELECTRIC THROTTLE CONTROL ACTUATOR..........................................................................1165 DTC P0300 - P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 - 4 CYLINDER MISFIRE.............................................1166 On Board Diagnosis Logic........................................................................................1166 DTC Confirmation Procedure......................................................................................1166 WITH CONSULT-II.............................................................................................1167 WITH GST....................................................................................................1167 Diagnostic Procedure............................................................................................1167 DTC P0327, P0328 KS.................................................................................................1173 Component Description...........................................................................................1173 On Board Diagnosis Logic........................................................................................1173 DTC Confirmation Procedure......................................................................................1173 WITH CONSULT-II.............................................................................................1173 WITH GST....................................................................................................1173 Wiring Diagram..................................................................................................1174 Diagnostic Procedure............................................................................................1175 Component Inspection............................................................................................1177 KNOCK SENSOR................................................................................................1177 Removal and Installation........................................................................................1177 KNOCK SENSOR................................................................................................1177 DTC P0335 CKP SENSOR (POS)..........................................................................................1178 Component Description...........................................................................................1178 CONSULT-II Reference Value in Data Monitor Mode.................................................................1178 On Board Diagnosis Logic........................................................................................1178 DTC Confirmation Procedure......................................................................................1179 WITH CONSULT-II.............................................................................................1179 WITH GST....................................................................................................1179 Wiring Diagram..................................................................................................1180 Diagnostic Procedure............................................................................................1182 Component Inspection............................................................................................1185 CRANKSHAFT POSITION SENSOR (POS)............................................................................1185 Removal and Installation........................................................................................1185 CRANKSHAFT POSITION SENSOR (POS)............................................................................1185 DTC P0340 CMP SENSOR (PHASE)........................................................................................1186 Component Description...........................................................................................1186 On Board Diagnosis Logic........................................................................................1186 DTC Confirmation Procedure......................................................................................1187 WITH CONSULT-II.............................................................................................1187 WITH GST....................................................................................................1187 Wiring Diagram..................................................................................................1188 Diagnostic Procedure............................................................................................1189 Component Inspection............................................................................................1192 CAMSHAFT POSITION SENSOR (PHASE)............................................................................1192 Removal and Installation........................................................................................1193 CAMSHAFT POSITION SENSOR (PHASE)............................................................................1193 DTC P0420 THREE WAY CATALYST FUNCTION...............................................................................1194 On Board Diagnosis Logic........................................................................................1194 DTC Confirmation Procedure......................................................................................1194 With CONSULT-II.............................................................................................1194 Overall Function Check..........................................................................................1195 WITH GST....................................................................................................1195 Diagnostic Procedure............................................................................................1196 DTC P0441 EVAP CONTROL SYSTEM.......................................................................................1199 System Description..............................................................................................1199 On Board Diagnosis Logic........................................................................................1199 DTC Confirmation Procedure......................................................................................1200 WITH CONSULT-II.............................................................................................1200 Overall Function Check..........................................................................................1200 WITH GST....................................................................................................1200 Diagnostic Procedure............................................................................................1201 DTC P0442 EVAP CONTROL SYSTEM.......................................................................................1205 On Board Diagnosis Logic........................................................................................1205 DTC Confirmation Procedure......................................................................................1206 WITH CONSULT-II.............................................................................................1206 WITH GST....................................................................................................1208 Diagnostic Procedure............................................................................................1208 Component Inspection............................................................................................1214 WATER SEPARATOR.............................................................................................1214 DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE..................................................1215 Description.....................................................................................................1215 SYSTEM DESCRIPTION..........................................................................................1215 COMPONENT DESCRIPTION.......................................................................................1215 CONSULT-II Reference Value in Data Monitor Mode.................................................................1215 On Board Diagnosis Logic........................................................................................1216 DTC Confirmation Procedure......................................................................................1216 WITH CONSULT-II.............................................................................................1216 WITH GST....................................................................................................1216 Wiring Diagram..................................................................................................1217 Diagnostic Procedure............................................................................................1219 Component Inspection............................................................................................1220 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE...........................................................1220 With CONSULT-II.........................................................................................1220 Without CONSULT-II......................................................................................1220 Removal and Installation........................................................................................1221 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE...........................................................1221 DTC P0447 EVAP CANISTER VENT CONTROL VALVE..........................................................................1222 Component Description...........................................................................................1222 CONSULT-II Reference Value in Data Monitor Mode.................................................................1222 On Board Diagnosis Logic........................................................................................1222 DTC Confirmation Procedure......................................................................................1223 WITH CONSULT-II.............................................................................................1223 WITH GST....................................................................................................1223 Wiring Diagram..................................................................................................1224 Diagnostic Procedure............................................................................................1225 Component Inspection............................................................................................1227 EVAP CANISTER VENT CONTROL VALVE............................................................................1227 With CONSULT-II.........................................................................................1227 Without CONSULT-II......................................................................................1228 DTC P0451 EVAP CONTROL SYSTEM PRESSURE SENSOR.......................................................................1229 Component Description...........................................................................................1229 CONSULT-II Reference Value in Data Monitor Mode.................................................................1229 On Board Diagnosis Logic........................................................................................1229 DTC Confirmation Procedure......................................................................................1230 WITH CONSULT-II.............................................................................................1230 WITH GST....................................................................................................1230 Diagnostic Procedure............................................................................................1230 Component Inspection............................................................................................1231 EVAP CONTROL SYSTEM PRESSURE SENSOR.........................................................................1231 DTC P0452 EVAP CONTROL SYSTEM PRESSURE SENSOR.......................................................................1232 Component Description...........................................................................................1232 CONSULT-II Reference Value in Data Monitor Mode.................................................................1232 On Board Diagnosis Logic........................................................................................1232 DTC Confirmation Procedure......................................................................................1233 WITH CONSULT-II.............................................................................................1233 WITH GST....................................................................................................1233 Wiring Diagram..................................................................................................1234 Diagnostic Procedure............................................................................................1235 Component Inspection............................................................................................1238 EVAP CONTROL SYSTEM PRESSURE SENSOR.........................................................................1238 DTC P0453 EVAP CONTROL SYSTEM PRESSURE SENSOR.......................................................................1239 Component Description...........................................................................................1239 CONSULT-II Reference Value in Data Monitor Mode.................................................................1239 On Board Diagnosis Logic........................................................................................1239 DTC Confirmation Procedure......................................................................................1240 WITH CONSULT-II.............................................................................................1240 WITH GST....................................................................................................1240 Wiring Diagram..................................................................................................1241 Diagnostic Procedure............................................................................................1242 Component Inspection............................................................................................1246 EVAP CONTROL PRESSURE SENSOR................................................................................1246 WATER SEPARATOR.............................................................................................1246 DTC P0455 EVAP CONTROL SYSTEM.......................................................................................1247 On Board Diagnosis Logic........................................................................................1247 DTC Confirmation Procedure......................................................................................1248 WITH CONSULT-II.............................................................................................1248 WITH GST....................................................................................................1249 Diagnostic Procedure............................................................................................1249 DTC P0456 EVAP CONTROL SYSTEM.......................................................................................1255 On Board Diagnosis Logic........................................................................................1255 DTC Confirmation Procedure......................................................................................1256 WITH CONSULT-II.............................................................................................1257 Overall Function Check..........................................................................................1257 WITH GST....................................................................................................1257 Diagnostic Procedure............................................................................................1258 Component Inspection............................................................................................1265 WATER SEPARATOR.............................................................................................1265 DTC P0460 FUEL LEVEL SENSOR.........................................................................................1266 Component Description...........................................................................................1266 On Board Diagnostic Logic.......................................................................................1266 DTC Confirmation Procedure......................................................................................1266 WITH CONSULT-II.............................................................................................1266 WITH GST....................................................................................................1266 Diagnostic Procedure............................................................................................1267 Removal and Installation........................................................................................1267 FUEL LEVEL SENSOR...........................................................................................1267 DTC P0461 FUEL LEVEL SENSOR.........................................................................................1268 Component Description...........................................................................................1268 On Board Diagnostic Logic.......................................................................................1268 Overall Function Check..........................................................................................1268 WITH CONSULT-II.............................................................................................1268 WITH GST....................................................................................................1269 Diagnostic Procedure............................................................................................1269 Removal and Installation........................................................................................1269 FUEL LEVEL SENSOR...........................................................................................1269 DTC P0462, P0463 FUEL LEVEL SENSOR..................................................................................1270 Component Description...........................................................................................1270 On Board Diagnostic Logic.......................................................................................1270 DTC Confirmation Procedure......................................................................................1270 WITH CONSULT-II.............................................................................................1270 WITH GST....................................................................................................1270 Diagnostic Procedure............................................................................................1271 Removal and Installation........................................................................................1271 FUEL LEVEL SENSOR...........................................................................................1271 DTC P0500 VSS.......................................................................................................1272 Description.....................................................................................................1272 On Board Diagnosis Logic........................................................................................1272 DTC Confirmation Procedure......................................................................................1272 WITH CONSULT-II.............................................................................................1272 Overall Function Check..........................................................................................1273 WITH GST....................................................................................................1273 Diagnostic Procedure............................................................................................1273 DTC P0506 ISC SYSTEM................................................................................................1274 Description.....................................................................................................1274 On Board Diagnosis Logic........................................................................................1274 DTC Confirmation Procedure......................................................................................1274 WITH CONSULT-II.............................................................................................1274 WITH GST....................................................................................................1274 Diagnostic Procedure............................................................................................1275 DTC P0507 ISC SYSTEM................................................................................................1276 Description.....................................................................................................1276 On Board Diagnosis Logic........................................................................................1276 DTC Confirmation Procedure......................................................................................1276 WITH CONSULT-II.............................................................................................1276 WITH GST....................................................................................................1276 Diagnostic Procedure............................................................................................1277 DTC P0550 PSP SENSOR................................................................................................1278 Component Description...........................................................................................1278 CONSULT-II Reference Value in Data Monitor Mode.................................................................1278 On Board Diagnosis Logic........................................................................................1278 DTC Confirmation Procedure......................................................................................1278 WITH CONSULT-II.............................................................................................1278 WITH GST....................................................................................................1278 Wiring Diagram..................................................................................................1279 Diagnostic Procedure............................................................................................1280 Component Inspection............................................................................................1282 POWER STEERING PRESSURE SENSOR..............................................................................1282 Removal and Installation........................................................................................1282 POWER STEERING PRESSURE SENSOR..............................................................................1282 DTC P0605 ECM.......................................................................................................1283 Component Description...........................................................................................1283 On Board Diagnosis Logic........................................................................................1283 FAIL-SAFE MODE..............................................................................................1283 DTC Confirmation Procedure......................................................................................1283 PROCEDURE FOR MALFUNCTION A.................................................................................1283 With CONSULT-II.........................................................................................1283 With GST................................................................................................1283 PROCEDURE FOR MALFUNCTION B.................................................................................1284 With CONSULT-II.........................................................................................1284 With GST................................................................................................1284 PROCEDURE FOR MALFUNCTION C.................................................................................1284 With CONSULT-II.........................................................................................1284 With GST................................................................................................1284 Diagnostic Procedure............................................................................................1284 DTC P1065 ECM POWER SUPPLY..........................................................................................1286 Component Description...........................................................................................1286 On Board Diagnosis Logic........................................................................................1286 DTC Confirmation Procedure......................................................................................1286 WITH CONSULT-II.............................................................................................1286 WITH GST....................................................................................................1286 Wiring Diagram..................................................................................................1287 Diagnostic Procedure............................................................................................1288 DTC P1111 IVT CONTROL SOLENOID VALVE................................................................................1290 Component Description...........................................................................................1290 CONSULT-II Reference Value in Data Monitor Mode.................................................................1290 On Board Diagnosis Logic........................................................................................1290 DTC Confirmation Procedure......................................................................................1290 WITH CONSULT-II.............................................................................................1290 WITH GST....................................................................................................1290 Wiring Diagram..................................................................................................1291 Diagnostic Procedure............................................................................................1292 Component Inspection............................................................................................1293 INTAKE VALVE TIMING CONTROL SOLENOID VALVE..................................................................1293 Removal and Installation........................................................................................1293 INTAKE VALVE TIMING CONTROL SOLENOID VALVE..................................................................1293 DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR........................................................................1294 Component Description...........................................................................................1294 On Board Diagnosis Logic........................................................................................1294 FAIL-SAFE MODE..............................................................................................1294 DTC Confirmation Procedure......................................................................................1294 PROCEDURE FOR MALFUNCTION A AND B...........................................................................1294 With CONSULT-II.........................................................................................1294 With GST................................................................................................1295 PROCEDURE FOR MALFUNCTION C.................................................................................1295 With CONSULT-II.........................................................................................1295 With GST................................................................................................1295 Diagnostic Procedure............................................................................................1295 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION........................................................................1296 Description.....................................................................................................1296 On Board Diagnosis Logic........................................................................................1296 FAIL-SAFE MODE..............................................................................................1296 DTC Confirmation Procedure......................................................................................1296 WITH CONSULT-II.............................................................................................1296 WITH GST....................................................................................................1296 Wiring Diagram..................................................................................................1297 Diagnostic Procedure............................................................................................1299 Component Inspection............................................................................................1303 THROTTLE CONTROL MOTOR RELAY................................................................................1303 THROTTLE CONTROL MOTOR......................................................................................1303 Remove and Installation.........................................................................................1303 ELECTRIC THROTTLE CONTROL ACTUATOR..........................................................................1303 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY.......................................................................1304 Component Description...........................................................................................1304 CONSULT-II Reference Value in Data Monitor Mode.................................................................1304 On Board Diagnosis Logic........................................................................................1304 FAIL-SAFE MODE..............................................................................................1304 DTC Confirmation Procedure......................................................................................1304 PROCEDURE FOR DTC P1124.....................................................................................1304 With CONSULT-II.........................................................................................1304 With GST................................................................................................1305 PROCEDURE FOR DTC P1126.....................................................................................1305 With CONSULT-II.........................................................................................1305 With GST................................................................................................1305 Wiring Diagram..................................................................................................1306 Diagnostic Procedure............................................................................................1307 Component Inspection............................................................................................1309 THROTTLE CONTROL MOTOR RELAY................................................................................1309 DTC P1128 THROTTLE CONTROL MOTOR....................................................................................1310 Component Description...........................................................................................1310 On Board Diagnosis Logic........................................................................................1310 FAIL-SAFE MODE..............................................................................................1310 DTC Confirmation Procedure......................................................................................1310 WITH CONSULT-II.............................................................................................1310 WITH GST....................................................................................................1310 Wiring Diagram..................................................................................................1311 Diagnostic Procedure............................................................................................1313 Component Inspection............................................................................................1314 THROTTLE CONTROL MOTOR......................................................................................1314 Removal and Installation........................................................................................1314 ELECTRIC THROTTLE CONTROL ACTUATOR..........................................................................1314 DTC P1143 HO2S1.....................................................................................................1315 Component Description...........................................................................................1315 CONSULT-II Reference Value in Data Monitor Mode.................................................................1315 On Board Diagnosis Logic........................................................................................1315 DTC Confirmation Procedure......................................................................................1316 WITH CONSULT-II.............................................................................................1316 Overall Function Check..........................................................................................1316 WITH GST....................................................................................................1316 Diagnostic Procedure............................................................................................1317 Component Inspection............................................................................................1319 HEATED OXYGEN SENSOR 1......................................................................................1319 With CONSULT-II.........................................................................................1319 Without CONSULT-II......................................................................................1320 Removal and Installation........................................................................................1320 HEATED OXYGEN SENSOR 1......................................................................................1320 DTC P1144 HO2S1.....................................................................................................1321 Component Description...........................................................................................1321 CONSULT-II Reference Value in Data Monitor Mode.................................................................1321 On Board Diagnosis Logic........................................................................................1321 DTC Confirmation Procedure......................................................................................1322 WITH CONSULT-II.............................................................................................1322 Overall Function Check..........................................................................................1322 WITH GST....................................................................................................1323 Diagnostic Procedure............................................................................................1323 Component Inspection............................................................................................1325 HEATED OXYGEN SENSOR 1......................................................................................1325 With CONSULT-II.........................................................................................1325 Without CONSULT-II......................................................................................1326 Removal and Installation........................................................................................1326 HEATED OXYGEN SENSOR 1......................................................................................1326 DTC P1146 HO2S2.....................................................................................................1327 Component Description...........................................................................................1327 CONSULT-II Reference Value in Data Monitor Mode.................................................................1327 On Board Diagnosis Logic........................................................................................1327 DTC Confirmation Procedure......................................................................................1328 WITH CONSULT-II.............................................................................................1328 Overall Function Check..........................................................................................1328 WITH GST....................................................................................................1328 Wiring Diagram..................................................................................................1330 Diagnostic Procedure............................................................................................1331 Component Inspection............................................................................................1333 HEATED OXYGEN SENSOR 2......................................................................................1333 With CONSULT-II.........................................................................................1333 Without CONSULT-II......................................................................................1334 Removal and Installation........................................................................................1334 HEATED OXYGEN SENSOR 2......................................................................................1334 DTC P1147 HO2S2.....................................................................................................1335 Component Description...........................................................................................1335 CONSULT-II Reference Value in Data Monitor Mode.................................................................1335 On Board Diagnosis Logic........................................................................................1335 DTC Confirmation Procedure......................................................................................1336 WITH CONSULT-II.............................................................................................1336 Overall Function Check..........................................................................................1336 WITH GST....................................................................................................1336 Wiring Diagram..................................................................................................1338 Diagnostic Procedure............................................................................................1339 Component Inspection............................................................................................1341 HEATED OXYGEN SENSOR 2......................................................................................1341 With CONSULT-II.........................................................................................1341 Without CONSULT-II......................................................................................1342 Removal and Installation........................................................................................1342 HEATED OXYGEN SENSOR 2......................................................................................1342 DTC P1148 CLOSED LOOP CONTROL.......................................................................................1343 On Board Diagnosis Logic........................................................................................1343 DTC Confirmation Procedure......................................................................................1343 WITH CONSULT-II.............................................................................................1343 Overall Function Check..........................................................................................1343 WITH GST....................................................................................................1343 Diagnostic Procedure............................................................................................1344 DTC P1211 TCS CONTROL UNIT..........................................................................................1345 Description.....................................................................................................1345 On Board Diagnosis Logic........................................................................................1345 DTC Confirmation Procedure......................................................................................1345 WITH CONSULT-II.............................................................................................1345 WITH GST....................................................................................................1345 Diagnostic Procedure............................................................................................1345 DTC P1212 TCS COMMUNICATION LINE....................................................................................1346 Description.....................................................................................................1346 On Board Diagnosis Logic........................................................................................1346 DTC Confirmation Procedure......................................................................................1346 WITH CONSULT-II.............................................................................................1346 WITH GST....................................................................................................1346 Diagnostic Procedure............................................................................................1346 DTC P1217 ENGINE OVER TEMPERATURE...................................................................................1347 Description.....................................................................................................1347 SYSTEM DESCRIPTION..........................................................................................1347 Cooling Fan Control.....................................................................................1347 Cooling Fan Operation...................................................................................1347 CONSULT-II Reference Value in Data Monitor Mode.................................................................1348 On Board Diagnosis Logic........................................................................................1348 Overall Function Check..........................................................................................1348 WITH CONSULT-II.............................................................................................1349 WITH GST....................................................................................................1349 Wiring Diagram..................................................................................................1351 Diagnostic Procedure............................................................................................1352 PROCEDURE A.................................................................................................1356 PROCEDURE B.................................................................................................1358 Main 12 Causes of Overheating...................................................................................1359 Component Inspection............................................................................................1360 COOLING FAN RELAYS-1 AND -3.................................................................................1360 COOLING FAN MOTOR-1.........................................................................................1360 COOLING FAN MOTOR-2.........................................................................................1361 DTC P1225 TP SENSOR.................................................................................................1362 Component Description...........................................................................................1362 On Board Diagnosis Logic........................................................................................1362 DTC Confirmation Procedure......................................................................................1362 WITH CONSULT-II.............................................................................................1362 WITH GST....................................................................................................1362 Diagnostic Procedure............................................................................................1363 Remove and Installation.........................................................................................1363 ELECTRIC THROTTLE CONTROL ACTUATOR..........................................................................1363 DTC P1226 TP SENSOR.................................................................................................1364 Component Description...........................................................................................1364 On Board Diagnosis Logic........................................................................................1364 DTC Confirmation Procedure......................................................................................1364 WITH CONSULT-II.............................................................................................1364 WITH GST....................................................................................................1364 Diagnostic Procedure............................................................................................1365 Remove and Installation.........................................................................................1365 ELECTRIC THROTTLE CONTROL ACTUATOR..........................................................................1365 DTC P1229 SENSOR POWER SUPPLY.......................................................................................1366 On Board Diagnosis Logic........................................................................................1366 FAIL-SAFE MODE..............................................................................................1366 DTC Confirmation Procedure......................................................................................1366 WITH CONSULT-II.............................................................................................1366 WITH GST....................................................................................................1366 Wiring Diagram..................................................................................................1367 Diagnostic Procedure............................................................................................1368 DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE.........................................................1371 Description.....................................................................................................1371 SYSTEM DESCRIPTION..........................................................................................1371 COMPONENT DESCRIPTION.......................................................................................1371 CONSULT-II Reference Value in Data Monitor Mode.................................................................1371 On Board Diagnosis Logic........................................................................................1372 DTC Confirmation Procedure......................................................................................1372 WITH CONSULT-II.............................................................................................1372 WITH GST....................................................................................................1372 Wiring Diagram..................................................................................................1373 Diagnostic Procedure............................................................................................1375 Component Inspection............................................................................................1377 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE...........................................................1377 With CONSULT-II.........................................................................................1377 Without CONSULT-II......................................................................................1378 Removal and Installation........................................................................................1378 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE...........................................................1378 DTC P1446 EVAP CANISTER VENT CONTROL VALVE..........................................................................1379 Component Description...........................................................................................1379 CONSULT-II Reference Value in Data Monitor Mode.................................................................1379 On Board Diagnosis Logic........................................................................................1379 DTC Confirmation Procedure......................................................................................1380 WITH CONSULT-II.............................................................................................1380 WITH GST....................................................................................................1380 Wiring Diagram..................................................................................................1381 Diagnostic Procedure............................................................................................1382 Component Inspection............................................................................................1384 EVAP CANISTER VENT CONTROL VALVE............................................................................1384 With CONSULT-II.........................................................................................1384 Without CONSULT-II......................................................................................1384 WATER SEPARATOR.............................................................................................1385 DTC P1564 ASCD STEERING SWITCH......................................................................................1386 Component Description...........................................................................................1386 CONSULT-II Reference Value in Data Monitor Mode.................................................................1386 On Board Diagnosis Logic........................................................................................1386 DTC Confirmation Procedure......................................................................................1387 WITH CONSULT-II.............................................................................................1387 WITH GST....................................................................................................1387 Wiring Diagram..................................................................................................1388 Diagnostic Procedure............................................................................................1390 Component Inspection............................................................................................1393 ASCD STEERING SWITCH........................................................................................1393 DTC P1572 ASCD BRAKE SWITCH.........................................................................................1394 Component Description...........................................................................................1394 CONSULT-II Reference Value in Data Monitor Mode.................................................................1394 On Board Diagnosis Logic........................................................................................1394 DTC Confirmation Procedure......................................................................................1395 WITH CONSULT-II.............................................................................................1395 WITH GST....................................................................................................1395 Wiring Diagram..................................................................................................1396 Diagnostic Procedure............................................................................................1398 Component Inspection............................................................................................1403 ASCD BRAKE SWITCH...........................................................................................1403 ASCD CLUTCH SWITCH..........................................................................................1403 STOP LAMP SWITCH............................................................................................1404 DTC P1574 ASCD VEHICLE SPEED SENSOR.................................................................................1405 Component Description...........................................................................................1405 On Board Diagnosis Logic........................................................................................1405 DTC Confirmation Procedure......................................................................................1405 WITH CONSULT-II.............................................................................................1405 WITH GST....................................................................................................1406 Diagnostic Procedure............................................................................................1406 DTC P1706 PNP SWITCH................................................................................................1407 Component Description...........................................................................................1407 CONSULT-II Reference Value in Data Monitor Mode.................................................................1407 On Board Diagnosis Logic........................................................................................1407 DTC Confirmation Procedure......................................................................................1407 WITH CONSULT-II.............................................................................................1407 Overall Function Check..........................................................................................1408 WITH GST....................................................................................................1408 Wiring Diagram..................................................................................................1409 Diagnostic Procedure............................................................................................1410 DTC P1800 VIAS CONTROL SOLENOID VALVE...............................................................................1412 Component Description...........................................................................................1412 CONSULT-II Reference Value in Data Monitor Mode.................................................................1412 On Board Diagnosis Logic........................................................................................1412 DTC Confirmation Procedure......................................................................................1412 WITH CONSULT-II.............................................................................................1412 WITH GST....................................................................................................1412 Wiring Diagram..................................................................................................1413 Diagnostic Procedure............................................................................................1414 Component Inspection............................................................................................1415 VIAS CONTROL SOLENOID VALVE.................................................................................1415 With CONSULT-II.........................................................................................1415 With GST................................................................................................1415 Removal and Installation........................................................................................1416 VIAS CONTROL SOLENOID VALVE.................................................................................1416 DTC P1805 BRAKE SWITCH..............................................................................................1417 Description.....................................................................................................1417 CONSULT-II Reference Value in Data Monitor Mode.................................................................1417 On Board Diagnosis Logic........................................................................................1417 FAIL-SAFE MODE..............................................................................................1417 DTC Confirmation Procedure......................................................................................1417 WITH CONSULT-II.............................................................................................1417 WITH GST....................................................................................................1417 Wiring Diagram..................................................................................................1418 Diagnostic Procedure............................................................................................1419 Component Inspection............................................................................................1421 STOP LAMP SWITCH............................................................................................1421 DTC P2122, P2123 APP SENSOR.........................................................................................1422 Component Description...........................................................................................1422 CONSULT-II Reference Value in Data Monitor Mode.................................................................1422 On Board Diagnosis Logic........................................................................................1422 FAIL-SAFE MODE..............................................................................................1422 DTC Confirmation Procedure......................................................................................1423 WITH CONSULT-II.............................................................................................1423 WITH GST....................................................................................................1423 Wiring Diagram..................................................................................................1424 Diagnostic Procedure............................................................................................1426 Component Inspection............................................................................................1428 ACCELERATOR PEDAL POSITION SENSOR...........................................................................1428 Removal and Installation........................................................................................1428 ACCELERATOR PEDAL...........................................................................................1428 DTC P2127, P2128 APP SENSOR.........................................................................................1429 Component Description...........................................................................................1429 CONSULT-II Reference Value in Data Monitor Mode.................................................................1429 On Board Diagnosis Logic........................................................................................1429 FAIL-SAFE MODE..............................................................................................1429 DTC Confirmation Procedure......................................................................................1430 WITH CONSULT-II.............................................................................................1430 WITH GST....................................................................................................1430 Wiring Diagram..................................................................................................1431 Diagnostic Procedure............................................................................................1433 Component Inspection............................................................................................1436 ACCELERATOR PEDAL POSITION SENSOR...........................................................................1436 Remove and Installation.........................................................................................1436 ACCELERATOR PEDAL...........................................................................................1436 DTC P2135 TP SENSOR.................................................................................................1437 Component Description...........................................................................................1437 CONSULT-II Reference Value in Data Monitor Mode.................................................................1437 On Board Diagnosis Logic........................................................................................1437 FAIL-SAFE MODE..............................................................................................1437 DTC Confirmation Procedure......................................................................................1437 WITH CONSULT-II.............................................................................................1437 WITH GST....................................................................................................1438 Wiring Diagram..................................................................................................1439 Diagnostic Procedure............................................................................................1441 Component Inspection............................................................................................1444 THROTTLE POSITION SENSOR....................................................................................1444 Remove and Installation.........................................................................................1444 ELECTRIC THROTTLE CONTROL ACTUATOR..........................................................................1444 DTC P2138 APP SENSOR................................................................................................1445 Component Description...........................................................................................1445 CONSULT-II Reference Value in Data Monitor Mode.................................................................1445 On Board Diagnosis Logic........................................................................................1445 FAIL-SAFE MODE..............................................................................................1445 DTC Confirmation Procedure......................................................................................1446 WITH CONSULT-II.............................................................................................1446 WITH GST....................................................................................................1446 Wiring Diagram..................................................................................................1447 Diagnostic Procedure............................................................................................1449 Component Inspection............................................................................................1452 ACCELERATOR PEDAL POSITION SENSOR...........................................................................1452 Remove and Installation.........................................................................................1452 ACCELERATOR PEDAL...........................................................................................1452 IGNITION SIGNAL.....................................................................................................1453 Component Description...........................................................................................1453 IGNITION COIL & POWER TRANSISTOR............................................................................1453 Wiring Diagram..................................................................................................1454 Diagnostic Procedure............................................................................................1457 Component Inspection............................................................................................1462 ECM RELAY...................................................................................................1462 IGNITION COIL WITH POWER TRANSISTOR.........................................................................1462 CONDENSER...................................................................................................1463 Removal and Installation........................................................................................1463 IGNITION COIL WITH POWER TRANSISTOR.........................................................................1463 VIAS................................................................................................................1464 Description.....................................................................................................1464 SYSTEM DESCRIPTION..........................................................................................1464 COMPONENT DESCRIPTION.......................................................................................1465 Power Valve Actuator....................................................................................1465 VIAS Control Solenoid Valve.............................................................................1465 CONSULT-II Reference Value in Data Monitor Mode.................................................................1465 Wiring Diagram..................................................................................................1466 Diagnostic Procedure............................................................................................1468 Component Inspection............................................................................................1472 ECM RELAY...................................................................................................1472 VIAS CONTROL SOLENOID VALVE.................................................................................1472 With CONSULT-II.........................................................................................1472 With GST................................................................................................1472 VACUUM TANK.................................................................................................1472 Removal and Installation........................................................................................1473 VIAS CONTROL SOLENOID VALVE.................................................................................1473 INJECTOR CIRCUIT....................................................................................................1474 Component Description...........................................................................................1474 CONSULT-II Reference Value in Data Monitor Mode.................................................................1474 Wiring Diagram..................................................................................................1475 Diagnostic Procedure............................................................................................1476 Component Inspection............................................................................................1479 FUEL INJECTOR...............................................................................................1479 Removal and Installation........................................................................................1479 FUEL INJECTOR...............................................................................................1479 FUEL PUMP CIRCUIT...................................................................................................1480 Description.....................................................................................................1480 SYSTEM DESCRIPTION..........................................................................................1480 COMPONENT DESCRIPTION.......................................................................................1480 CONSULT-II Reference Value in Data Monitor Mode.................................................................1480 Wiring Diagram..................................................................................................1481 Diagnostic Procedure............................................................................................1482 Component Inspection............................................................................................1485 FUEL PUMP RELAY.............................................................................................1485 FUEL PUMP...................................................................................................1485 CONDENSER...................................................................................................1485 Removal and Installation........................................................................................1485 FUEL PUMP...................................................................................................1485 REFRIGERANT PRESSURE SENSOR.........................................................................................1486 Component Description...........................................................................................1486 Wiring Diagram..................................................................................................1487 Diagnostic Procedure............................................................................................1488 Removal and Installation........................................................................................1491 REFRIGERANT PRESSURE SENSOR.................................................................................1491 ELECTRICAL LOAD SIGNAL..............................................................................................1492 CONSULT-II Reference Value in Data Monitor Mode.................................................................1492 Wiring Diagram..................................................................................................1493 HEADLAMP....................................................................................................1493 Diagnostic Procedure............................................................................................1494 Wiring Diagram..................................................................................................1499 HEATER FAN..................................................................................................1499 Diagnostic Procedure............................................................................................1500 Wiring Diagram..................................................................................................1502 REAR WINDOW DEFOGGER........................................................................................1502 Diagnostic Procedure............................................................................................1503 ASCD BRAKE SWITCH...................................................................................................1505 Component Description...........................................................................................1505 CONSULT-II Reference Value in Data Monitor Mode.................................................................1505 Wiring Diagram..................................................................................................1506 Diagnostic Procedure............................................................................................1508 Component Inspection............................................................................................1513 ASCD BRAKE SWITCH...........................................................................................1513 ASCD CLUTCH SWITCH..........................................................................................1513 STOP LAMP SWITCH............................................................................................1513 ASCD INDICATOR......................................................................................................1515 Component Description...........................................................................................1515 CONSULT-II Reference Value in Data Monitor Mode.................................................................1515 Wiring Diagram..................................................................................................1516 AWD.........................................................................................................1516 2WD.........................................................................................................1517 Diagnostic Procedure............................................................................................1518 SNOW MODE SWITCH....................................................................................................1519 Description.....................................................................................................1519 CONSULT-II Reference Value in the Data Monitor Mode.............................................................1519 Wiring Diagram..................................................................................................1520 Diagnostic Procedure............................................................................................1522 Component Inspection............................................................................................1525 SNOW MODE SWITCH............................................................................................1525 MIL AND DATA LINK CONNECTOR.........................................................................................1526 Wiring Diagram..................................................................................................1526 AWD.........................................................................................................1526 2WD.........................................................................................................1528 SERVICE DATA AND SPECIFICATIONS (SDS)...............................................................................1530 Fuel Pressure...................................................................................................1530 Idle Speed and Ignition Timing..................................................................................1530 Calculated Load Value...........................................................................................1530 Mass Air Flow Sensor............................................................................................1530 Intake Air Temperature Sensor...................................................................................1530 Engine Coolant Temperature Sensor...............................................................................1530 Heated Oxygen Sensor 1 Heater...................................................................................1530 Heated Oxygen Sensor 2 Heater...................................................................................1530 Crankshaft Position Sensor (POS)................................................................................1530 Camshaft Position Sensor (PHASE)................................................................................1530 Throttle Control Motor..........................................................................................1531 Fuel Injector...................................................................................................1531 Fuel Pump.......................................................................................................1531 ELECTRICAL UNITS.................................................................................................... 45 FUSE BLOCK - JUNCTION BOX (J/B)..................................................................................... 48 FUSE AND FUSIBLE LINK BOX........................................................................................... 49 ei..........................................................................................................................1532 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................1532 PRECAUTIONS.........................................................................................................1534 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”.....................1534 Precautions.....................................................................................................1534 PREPARATION.........................................................................................................1535 Special Service Tools...........................................................................................1535 Commercial Service Tools........................................................................................1535 SQUEAK AND RATTLE TROUBLE DIAGNOSES.................................................................................1536 Work Flow.......................................................................................................1536 CUSTOMER INTERVIEW..........................................................................................1536 DUPLICATE THE NOISE AND TEST DRIVE..........................................................................1537 CHECK RELATED SERVICE BULLETINS.............................................................................1537 LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE................................................................1537 REPAIR THE CAUSE............................................................................................1537 CONFIRM THE REPAIR..........................................................................................1538 Generic Squeak and Rattle Troubleshooting.......................................................................1538 INSTRUMENT PANEL............................................................................................1538 CENTER CONSOLE..............................................................................................1538 DOORS.......................................................................................................1538 TRUNK.......................................................................................................1539 SUNROOF/HEADLINING..........................................................................................1539 SEATS.......................................................................................................1539 UNDERHOOD...................................................................................................1539 Diagnostic Worksheet............................................................................................1540 CLIP AND FASTENER...................................................................................................1542 Clip and Fastener...............................................................................................1542 FRONT BUMPER........................................................................................................1545 Removal and Installation........................................................................................1545 REMOVAL.....................................................................................................1546 INSTALLATION................................................................................................1546 REAR BUMPER.........................................................................................................1547 Removal and Installation........................................................................................1547 REMOVAL.....................................................................................................1548 INSTALLATION................................................................................................1548 Removal of Fuel Tube Cover..............................................................................1548 Installation of Fuel Tube Cover.........................................................................1548 FRONT GRILLE........................................................................................................1549 Removal and Installation........................................................................................1549 REMOVAL.....................................................................................................1549 INSTALLATION................................................................................................1549 COWL TOP............................................................................................................1550 Removal and Installation........................................................................................1550 REMOVAL.....................................................................................................1550 INSTALLATION................................................................................................1550 FENDER PROTECTOR....................................................................................................1551 Removal and Installation........................................................................................1551 REMOVAL.....................................................................................................1551 INSTALLATION................................................................................................1551 DOOR OUTSIDE MOLDING................................................................................................1552 Removal and Installation........................................................................................1552 FRONT DOOR OUTSIDE MOLDING..................................................................................1552 Removal.................................................................................................1552 Installation............................................................................................1552 REAR DOOR OUTSIDE MOLDING...................................................................................1552 Removal.................................................................................................1552 Installation............................................................................................1553 SIDE GUARD MOLDING..................................................................................................1554 Removal and Installation........................................................................................1554 SIDE GUARD MOLDING (FRONT AND REAR).........................................................................1554 Removal.................................................................................................1554 Installation............................................................................................1554 DOOR OUTSIDE LOWER MOLDING..........................................................................................1555 Removal and Installation........................................................................................1555 DOOR OUTSIDE LOWER MOLDING (FRONT AND REAR).................................................................1555 Removal.................................................................................................1555 Installation............................................................................................1555 SIDE SILL PROTECTOR.................................................................................................1556 Removal and Installation........................................................................................1556 REMOVAL.....................................................................................................1556 INSTALLATION................................................................................................1556 MUDGUARD............................................................................................................1557 Removal and Installation........................................................................................1557 REMOVAL.....................................................................................................1557 INSTALLATION................................................................................................1557 WINDSHIELD MOLDING..................................................................................................1558 Removal and Installation........................................................................................1558 REMOVAL.....................................................................................................1558 INSTALLATION................................................................................................1558 ROOF RAIL...........................................................................................................1559 Removal and Installation........................................................................................1559 REMOVAL.....................................................................................................1559 INSTALLATION................................................................................................1560 ROOF SPOILER........................................................................................................1561 Removal and Installation........................................................................................1561 REMOVAL.....................................................................................................1561 INSTALLATION................................................................................................1561 LICENSE LAMP FINISHER...............................................................................................1562 Removal and Installation........................................................................................1562 REMOVAL.....................................................................................................1562 INSTALLATION................................................................................................1562 DOOR FINISHER.......................................................................................................1563 Removal and Installation........................................................................................1563 FRONT AND REAR DOOR FINISHER................................................................................1564 Removal.................................................................................................1564 Installation............................................................................................1565 BACK DOOR TRIM......................................................................................................1566 Removal and Installation........................................................................................1566 REMOVAL.....................................................................................................1566 INSTALLATION................................................................................................1566 Removal of High-Mounted Stop Lamp Cover.................................................................1566 Installation of High-Mounted Stop Lamp Cover............................................................1566 BODY SIDE TRIM......................................................................................................1567 Removal and Installation........................................................................................1567 FRONT PILLAR GARNISH........................................................................................1568 Removal.................................................................................................1568 Installation............................................................................................1568 DASH SIDE FINISHER..........................................................................................1568 Removal.................................................................................................1568 Installation............................................................................................1568 KICKING PLATE (FRONT/REAR)..................................................................................1568 Removal.................................................................................................1568 Installation............................................................................................1568 CENTER PILLAR LOWER GARNISH.................................................................................1568 Removal.................................................................................................1568 Installation............................................................................................1568 CENTER PILLAR UPPER GARNISH.................................................................................1568 Removal.................................................................................................1568 Installation............................................................................................1568 BODY SIDE WELT (FRONT/REAR).................................................................................1568 Removal.................................................................................................1568 Installation............................................................................................1568 REAR PILLAR FINISHER........................................................................................1568 Removal.................................................................................................1568 Installation............................................................................................1569 LUGGAGE SIDE LOWER FINISHER.................................................................................1569 Removal.................................................................................................1569 Installation............................................................................................1569 FLOOR TRIM..........................................................................................................1570 Removal and Installation........................................................................................1570 REMOVAL.....................................................................................................1570 INSTALLATION................................................................................................1570 HEADLINING..........................................................................................................1571 Removal and Installation........................................................................................1571 REMOVAL.....................................................................................................1571 INSTALLATION................................................................................................1572 em..........................................................................................................................1574 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................1574 PRECAUTIONS.........................................................................................................1576 Precautions for Drain Engine Coolant and Engine Oil.............................................................1576 Precautions for Disconnecting Fuel Piping.......................................................................1576 Precautions for Removal and Disassembly.........................................................................1576 Precautions for Inspection, Repair and Replacement..............................................................1576 Precautions for Assembly and Installation.......................................................................1576 Precautions for Angle Tightening................................................................................1576 Precautions for Liquid Gasket...................................................................................1577 REMOVAL OF LIQUID GASKET....................................................................................1577 LIQUID GASKET APPLICATION PROCEDURE.........................................................................1577 PREPARATION.........................................................................................................1578 Special Service Tools...........................................................................................1578 Commercial Service Tools........................................................................................1579 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING................................................................1582 NVH Troubleshooting — Engine Noise..............................................................................1582 Use the Chart Below to Help You Find the Cause of the Symptom...................................................1583 DRIVE BELTS.........................................................................................................1584 Checking Drive Belt.............................................................................................1584 Tension Adjustment..............................................................................................1584 Removal and Installation........................................................................................1584 REMOVAL.....................................................................................................1584 INSTALLATION................................................................................................1585 Removal and Installation of Drive Belt Auto-Tensioner...........................................................1585 REMOVAL.....................................................................................................1585 INSTALLATION................................................................................................1586 AIR CLEANER AND AIR DUCT............................................................................................1587 Removal and Installation........................................................................................1587 REMOVAL.....................................................................................................1587 INSPECTION AFTER REMOVAL....................................................................................1588 INSTALLATION................................................................................................1588 Changing Air Cleaner Filter.....................................................................................1588 REMOVAL.....................................................................................................1588 INSTALLATION................................................................................................1588 INTAKE MANIFOLD.....................................................................................................1589 Removal and Installation........................................................................................1589 REMOVAL.....................................................................................................1589 INSPECTION AFTER REMOVAL....................................................................................1591 Surface Distortion......................................................................................1591 INSTALLATION................................................................................................1591 Intake Manifold.........................................................................................1591 Intake Manifold Collector...............................................................................1592 Electric Throttle Control Actuator......................................................................1592 INSPECTION AFTER INSTALLATION...............................................................................1592 EXHAUST MANIFOLD AND THREE WAY CATALYST.............................................................................1593 Removal and Installation........................................................................................1593 REMOVAL.....................................................................................................1593 INSPECTION AFTER REMOVAL....................................................................................1594 Surface Distortion......................................................................................1594 INSTALLATION................................................................................................1594 Exhaust Manifold........................................................................................1594 Heated Oxygen Sensor....................................................................................1594 OIL PAN AND OIL STRAINER............................................................................................1595 Removal and Installation........................................................................................1595 REMOVAL.....................................................................................................1595 INSPECTION AFTER REMOVAL....................................................................................1597 INSTALLATION................................................................................................1597 INSPECTION AFTER INSTALLATION...............................................................................1599 IGNITION COIL.......................................................................................................1600 Removal and Installation........................................................................................1600 REMOVAL.....................................................................................................1600 INSTALLATION................................................................................................1600 SPARK PLUG (PLATINUM-TIPPED TYPE)...................................................................................1601 Removal and Installation........................................................................................1601 REMOVAL.....................................................................................................1601 INSPECTION AFTER REMOVAL....................................................................................1601 INSTALLATION................................................................................................1602 FUEL INJECTOR AND FUEL TUBE.........................................................................................1603 Removal and Installation........................................................................................1603 REMOVAL.....................................................................................................1603 INSTALLATION................................................................................................1605 INSPECTION AFTER INSTALLATION...............................................................................1607 Check on Fuel Leaks.....................................................................................1607 ROCKER COVER........................................................................................................1608 Removal and Installation........................................................................................1608 REMOVAL.....................................................................................................1608 INSTALLATION................................................................................................1609 CAMSHAFT............................................................................................................1610 Removal and Installation........................................................................................1610 REMOVAL.....................................................................................................1610 INSPECTION AFTER REMOVAL....................................................................................1613 Camshaft Runout.........................................................................................1613 Camshaft Cam Height.....................................................................................1613 Camshaft Journal Oil Clearance..........................................................................1613 Camshaft End Play.......................................................................................1614 Camshaft Sprocket Runout................................................................................1614 Valve Lifter............................................................................................1615 Valve Lifter Clearance..................................................................................1615 INSTALLATION................................................................................................1615 INSPECTION AFTER INSTALLATION...............................................................................1618 Inspection of Camshaft Sprocket (INT) Oil Groove........................................................1618 Valve Clearance.................................................................................................1619 INSPECTION..................................................................................................1619 ADJUSTMENT..................................................................................................1620 TIMING CHAIN........................................................................................................1622 Removal and Installation........................................................................................1622 REMOVAL.....................................................................................................1622 INSPECTION AFTER REMOVAL....................................................................................1626 Timing Chain............................................................................................1626 Balancer Unit Mounting Bolt Outer Diameter..............................................................1626 INSTALLATION................................................................................................1627 INSPECTION AFTER INSTALLATION...............................................................................1631 Inspection for Leaks....................................................................................1631 OIL SEAL............................................................................................................1632 Removal and Installation of Valve Oil Seal......................................................................1632 REMOVAL.....................................................................................................1632 INSTALLATION................................................................................................1632 Removal and Installation of Front Oil Seal......................................................................1633 REMOVAL.....................................................................................................1633 INSTALLATION................................................................................................1633 Removal and Installation of Rear Oil Seal.......................................................................1634 REMOVAL.....................................................................................................1634 INSTALLATION................................................................................................1634 CYLINDER HEAD.......................................................................................................1635 On-Vehicle Service..............................................................................................1635 CHECKING COMPRESSION PRESSURE...............................................................................1635 Removal and Installation........................................................................................1636 REMOVAL.....................................................................................................1636 INSPECTION AFTER REMOVAL....................................................................................1637 Cylinder Head Bolts Outer Diameter......................................................................1637 Cylinder Head Distortion................................................................................1637 INSTALLATION................................................................................................1638 INSPECTION AFTER INSTALLATION...............................................................................1638 Inspection for Leaks....................................................................................1638 Disassembly and Assembly........................................................................................1640 DISASSEMBLY.................................................................................................1640 ASSEMBLY....................................................................................................1641 Inspection After Disassembly....................................................................................1642 VALVE DIMENSIONS............................................................................................1642 VALVE GUIDE CLEARANCE.......................................................................................1643 Valve Stem Diameter.....................................................................................1643 Valve Guide Inner Diameter..............................................................................1643 Valve Guide Clearance...................................................................................1643 VALVE GUIDE REPLACEMENT.....................................................................................1643 VALVE SEAT CONTACT..........................................................................................1645 VALVE SEAT REPLACEMENT......................................................................................1645 VALVE SPRING SQUARENESS.....................................................................................1646 VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD......................................................1646 ENGINE ASSEMBLY.....................................................................................................1647 Removal and Installation (2WD Models)...........................................................................1647 REMOVAL.....................................................................................................1648 Outline.................................................................................................1648 Preparation.............................................................................................1648 Engine Room LH..........................................................................................1648 Engine Room RH..........................................................................................1648 Vehicle Underbody.......................................................................................1648 Removal.................................................................................................1648 INSTALLATION................................................................................................1649 INSPECTION AFTER INSTALLATION...............................................................................1650 Inspection for Leaks....................................................................................1650 Removal and Installation (AWD Models)...........................................................................1651 REMOVAL.....................................................................................................1651 Outline.................................................................................................1651 Preparation.............................................................................................1651 Engine Room LH..........................................................................................1652 Engine Room RH..........................................................................................1652 Vehicle Underbody.......................................................................................1652 Removal.................................................................................................1652 INSTALLATION................................................................................................1654 INSPECTION AFTER INSTALLATION...............................................................................1654 Inspection for Leaks....................................................................................1654 CYLINDER BLOCK......................................................................................................1655 Disassembly and Assembly........................................................................................1655 DISASSEMBLY.................................................................................................1656 ASSEMBLY....................................................................................................1659 How to Select Piston and Bearing................................................................................1664 DESCRIPTION.................................................................................................1664 HOW TO SELECT PISTON........................................................................................1665 When New Cylinder Block Is Used.........................................................................1665 When Cylinder Block Is Reused...........................................................................1665 Piston Selection Table..................................................................................1665 HOW TO SELECT CONNECTING ROD BEARING........................................................................1666 When New Connecting Rod and Crankshaft Are Used.........................................................1666 When Crankshaft and Connecting Rod Are Reused...........................................................1666 Connecting Rod Bearing Selection Table..................................................................1667 Connecting Rod Bearing Grade Table......................................................................1667 Undersize Bearings Usage Guide..........................................................................1667 HOW TO SELECT MAIN BEARING..................................................................................1668 When New Cylinder Block and Crankshaft Are Used.........................................................1668 When Cylinder Block and Crankshaft Are Reused...........................................................1668 Main Bearing Selection Table (No. 1, 3 and 5 Journals)..................................................1669 Main Bearing Selection Table (No. 2 and 4 Journals).....................................................1670 Main Bearing Grade Table (All Journals).................................................................1671 Use Undersize Bearing Usage Guide.......................................................................1671 Inspection After Disassembly....................................................................................1672 CRANKSHAFT END PLAY.........................................................................................1672 CONNECTING ROD SIDE CLEARANCE...............................................................................1672 PISTON TO PISTON PIN OIL CLEARANCE..........................................................................1672 Piston Pin Hole Diameter................................................................................1672 Piston Pin Outer Diameter...............................................................................1672 Piston to Piston Pin Oil Clearance......................................................................1672 PISTON RING SIDE CLEARANCE..................................................................................1673 PISTON RING END GAP.........................................................................................1673 CONNECTING ROD BEND AND TORSION.............................................................................1674 CONNECTING ROD BIG END DIAMETER.............................................................................1674 CONNECTING ROD BUSHING OIL CLEARANCE........................................................................1674 Connecting Rod Bushing Inner Diameter...................................................................1674 Piston Pin Outer Diameter...............................................................................1675 Connecting Rod Bushing Oil Clearance....................................................................1675 CYLINDER BLOCK DISTORTION...................................................................................1675 MAIN BEARING HOUSING INNER DIAMETER.........................................................................1676 PISTON TO CYLINDER BORE CLEARANCE...........................................................................1676 Cylinder Bore Inner Diameter............................................................................1676 Piston Skirt Diameter...................................................................................1677 Piston to Cylinder Bore Clearance.......................................................................1677 Re-boring Cylinder Bore.................................................................................1677 CRANKSHAFT MAIN JOURNAL DIAMETER............................................................................1677 CRANKSHAFT PIN JOURNAL DIAMETER.............................................................................1678 OUT-OF-ROUND AND TAPER OF CRANKSHAFT........................................................................1678 CRANKSHAFT RUNOUT...........................................................................................1678 CONNECTING ROD BEARING OIL CLEARANCE........................................................................1678 Method by Calculation...................................................................................1678 Method of Using Plastigage..............................................................................1678 MAIN BEARING OIL CLEARANCE..................................................................................1679 Method by Calculation...................................................................................1679 Method of Using Plastigage..............................................................................1679 MAIN BEARING CRUSH HEIGHT...................................................................................1680 CONNECTING ROD BEARING CRUSH HEIGHT.........................................................................1680 LOWER CYLINDER BLOCK MOUNTING BOLT OUTER DIAMETER...........................................................1680 CONNECTING ROD BOLT OUTER DIAMETER..........................................................................1680 FLYWHEEL DEFLECTION (M/T MODELS)............................................................................1681 MOVEMENT AMOUNT OF FLYWHEEL (M/T MODELS)....................................................................1681 Movement Amount of Thrust (Fore-and-Aft) Direction......................................................1681 Movement Amount in Radial (Rotation) Direction..........................................................1681 SERVICE DATA AND SPECIFICATIONS (SDS)...............................................................................1682 Standard and Limit..............................................................................................1682 GENERAL SPECIFICATIONS......................................................................................1682 DRIVE BELT..................................................................................................1682 INTAKE MANIFOLD AND EXHAUST MANIFOLD........................................................................1682 SPARK PLUG..................................................................................................1682 CYLINDER HEAD...............................................................................................1682 VALVE.......................................................................................................1683 Valve Timing............................................................................................1683 Valve Dimensions........................................................................................1683 Valve Clearance.........................................................................................1683 Available Valve Lifter..................................................................................1684 Valve Spring............................................................................................1684 Valve Lifter............................................................................................1685 Valve Guide.............................................................................................1685 Valve Seat..............................................................................................1686 CAMSHAFT AND CAMSHAFT BEARING...............................................................................1687 CYLINDER BLOCK..............................................................................................1687 PISTON, PISTON RING AND PISTON PIN..........................................................................1689 Available Piston........................................................................................1689 Piston Ring.............................................................................................1689 Piston Pin..............................................................................................1689 CONNECTING ROD..............................................................................................1690 CRANKSHAFT..................................................................................................1690 MAIN BEARING................................................................................................1692 Undersize...............................................................................................1692 Bearing Oil Clearance...................................................................................1692 CONNECTING ROD BEARING......................................................................................1693 Undersize...............................................................................................1693 Bearing Oil Clearance...................................................................................1693 ex..........................................................................................................................1694 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................1694 EXHAUST SYSTEM......................................................................................................1695 Checking Exhaust System.........................................................................................1695 Removal and Installation........................................................................................1696 REMOVAL.....................................................................................................1696 INSTALLATION................................................................................................1696 Seal Bearing (Exhaust Front Tube Side)..................................................................1697 Seal Bearing (Main Muffler Side)........................................................................1697 INSPECTION AFTER INSTALLATION...............................................................................1697 fax.........................................................................................................................1698 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................1698 PRECAUTIONS.........................................................................................................1699 Caution.........................................................................................................1699 PREPARATION.........................................................................................................1700 Special Service Tools [SST].....................................................................................1700 Commercial Service Tools........................................................................................1702 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING................................................................1703 NVH Troubleshooting Chart.......................................................................................1703 FRONT WHEEL HUB AND KNUCKLE.........................................................................................1704 On-Vehicle Inspection and Service...............................................................................1704 WHEEL BEARING INSPECTION....................................................................................1704 Removal and Installation........................................................................................1704 COMPONENT...................................................................................................1704 REMOVAL.....................................................................................................1704 INSPECTION AFTER REMOVAL....................................................................................1706 Ball Joint Inspection...................................................................................1706 INSTALLATION................................................................................................1706 Disassembly and Assembly........................................................................................1707 DISASSEMBLY.................................................................................................1707 INSPECTION AFTER DISASSEMBLY................................................................................1707 Wheel Hub...............................................................................................1707 Steering Knuckle........................................................................................1707 Snap Ring...............................................................................................1707 ASSEMBLY....................................................................................................1708 INSPECTION AFTER ASSEMBLY...................................................................................1709 FRONT DRIVE SHAFT...................................................................................................1710 On-Vehicle Inspection and Service...............................................................................1710 DRIVE SHAFT BOOT REPLACEMENT................................................................................1710 Removal and Installation (RH)...................................................................................1713 COMPONENT...................................................................................................1713 REMOVAL.....................................................................................................1713 INSPECTION AFTER REMOVAL....................................................................................1714 INSTALLATION................................................................................................1714 Removal and Installation (LH)...................................................................................1715 COMPONENT...................................................................................................1715 REMOVAL.....................................................................................................1715 INSPECTION AFTER REMOVAL....................................................................................1716 INSTALLATION................................................................................................1716 Disassembly and Assembly (Models with 2WD: RH)..................................................................1717 COMPONENT...................................................................................................1717 DISASSEMBLY.................................................................................................1717 Transaxle Side..........................................................................................1717 Wheel Side..............................................................................................1717 Support Bearing.........................................................................................1718 INSPECTION AFTER DISASSEMBLY................................................................................1719 Shaft...................................................................................................1719 Joint Sub-Assembly (Wheel Side).........................................................................1719 Housing Assembly (Transaxle Side).......................................................................1719 Support Bearing and Retainer............................................................................1719 Dynamic Damper..........................................................................................1719 ASSEMBLY....................................................................................................1719 Transaxle Side..........................................................................................1719 Wheel Side..............................................................................................1720 Support Bearing.........................................................................................1721 Disassembly and Assembly (Models with AWD: RH)..................................................................1722 COMPONENT...................................................................................................1722 DISASSEMBLY.................................................................................................1722 Transaxle Side..........................................................................................1722 Wheel Side..............................................................................................1722 INSPECTION AFTER DISASSEMBLY................................................................................1723 Shaft...................................................................................................1723 Joint Sub-Assembly (Wheel Side).........................................................................1723 Housing Assembly (Transaxle Side).......................................................................1723 Dynamic Damper..........................................................................................1723 ASSEMBLY....................................................................................................1723 Transaxle Side..........................................................................................1723 Wheel Side..............................................................................................1724 Disassembly and Assembly (LH)...................................................................................1725 COMPONENT...................................................................................................1725 DISASSEMBLY.................................................................................................1725 Transaxle Side..........................................................................................1725 Wheel Side..............................................................................................1725 INSPECTION AFTER DISASSEMBLY................................................................................1726 Shaft...................................................................................................1726 Joint Sub-Assembly (Wheel Side).........................................................................1726 Housing Assembly (Transaxle Side).......................................................................1726 Dynamic Damper..........................................................................................1726 ASSEMBLY....................................................................................................1726 Transaxle Side..........................................................................................1726 Wheel Side..............................................................................................1727 SERVICE DATA AND SPECIFICATIONS (SDS)...............................................................................1728 Wheel Bearing...................................................................................................1728 Drive Shaft.....................................................................................................1728 Dynamic Damper..................................................................................................1728 fl..........................................................................................................................1730 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................1730 PREPARATION.........................................................................................................1731 Commercial Service Tools........................................................................................1731 FUEL SYSTEM.........................................................................................................1732 Checking Fuel Lines.............................................................................................1732 General Precautions.............................................................................................1732 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY..........................................................1733 Removal and Installation........................................................................................1733 REMOVAL.....................................................................................................1733 INSPECTION AFTER REMOVAL....................................................................................1736 INSTALLATION................................................................................................1736 Chamber and Jet Pump....................................................................................1736 Main and Sub Fuel Level Sensor Unit.....................................................................1736 Quick Connector.........................................................................................1736 Inspection Hole Cover...................................................................................1737 INSPECTION AFTER INSTALLATION...............................................................................1737 Disassembly and Assembly........................................................................................1737 DISASSEMBLY.................................................................................................1737 ASSEMBLY....................................................................................................1738 Fuel Filter and Fuel Pump...............................................................................1738 Pressure Regulator......................................................................................1738 FUEL TANK...........................................................................................................1740 Removal and Installation........................................................................................1740 REMOVAL.....................................................................................................1740 INSTALLATION................................................................................................1741 INSPECTION AFTER INSTALLATION...............................................................................1742 SERVICE DATA AND SPECIFICATIONS (SDS)...............................................................................1743 Standard and Limit..............................................................................................1743 FUEL TANK...................................................................................................1743 fsu.........................................................................................................................1744 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................1744 PRECAUTIONS.........................................................................................................1745 Caution.........................................................................................................1745 PREPARATION.........................................................................................................1746 Special Service Tools [SST].....................................................................................1746 Commercial Service Tools........................................................................................1747 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING................................................................1748 NVH Troubleshooting Chart.......................................................................................1748 FRONT SUSPENSION ASSEMBLY...........................................................................................1749 On-Vehicle Inspection and Service...............................................................................1749 INSPECTION OF TRANSVERSE LINK BALL JOINT END PLAY...........................................................1749 STRUT INSPECTION............................................................................................1749 Wheel Alignment Inspection......................................................................................1749 DESCRIPTION.................................................................................................1749 PRELIMINARY CHECK...........................................................................................1749 INSPECTION OF CAMBER, CASTER AND KINGPIN INCLINATION ANGLES.................................................1749 Using a CCK Gauge.......................................................................................1749 Toe-In Inspection.......................................................................................1750 Components......................................................................................................1751 Remove and Installation.........................................................................................1752 REMOVAL.....................................................................................................1752 INSTALLATION................................................................................................1752 COIL SPRING AND STRUT...............................................................................................1754 Removal and Installation........................................................................................1754 REMOVAL.....................................................................................................1754 INSTALLATION................................................................................................1754 Disassembly and Assembly........................................................................................1755 DISASSEMBLY.................................................................................................1755 INSPECTION AFTER DISASSEMBLY................................................................................1755 Strut Inspection........................................................................................1755 Mounting Insulator and Rubber Parts Inspection..........................................................1755 Coil Spring Inspection..................................................................................1755 ASSEMBLY....................................................................................................1756 TRANSVERSE LINK.....................................................................................................1757 Removal and Installation........................................................................................1757 REMOVAL.....................................................................................................1757 INSPECTION AFTER REMOVAL....................................................................................1758 Visual Inspection.......................................................................................1758 Ball Joint Inspection...................................................................................1758 Swing Torque Inspection.................................................................................1758 Rotating Torque Inspection..............................................................................1758 Axial End Play Inspection...............................................................................1758 INSTALLATION................................................................................................1758 STABILIZER BAR......................................................................................................1759 Removal and Installation........................................................................................1759 REMOVAL.....................................................................................................1759 INSPECTION AFTER REMOVAL....................................................................................1759 INSTALLATION................................................................................................1759 FRONT SUSPENSION MEMBER.............................................................................................1760 Removal and Installation........................................................................................1760 REMOVAL.....................................................................................................1760 INSPECTION AFTER REMOVAL....................................................................................1760 INSTALLATION................................................................................................1760 SERVICE DATA AND SPECIFICATIONS (SDS)...............................................................................1761 Wheel Alignment (Unladen).......................................................................................1761 Ball Joint......................................................................................................1761 Wheelarch Height (Unladen*).....................................................................................1761 gi..........................................................................................................................1762 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................1762 PRECAUTIONS.........................................................................................................1764 Description.....................................................................................................1764 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”.....................1764 Precautions for NVIS/IVIS (NISSAN/INFINITI VEHICLE IMMOBILIZER SYSTEM - NATS) (If Equipped).....................1764 General Precautions.............................................................................................1765 Precautions for Three Way Catalyst..............................................................................1766 Precautions for Fuel (Unleaded Regular Gasoline Recommended)....................................................1766 Precautions for Multiport Fuel Injection System or Engine Control System........................................1767 Precautions for Hoses...........................................................................................1767 HOSE REMOVAL AND INSTALLATION...............................................................................1767 HOSE CLAMPING...............................................................................................1767 Precautions for Engine Oils.....................................................................................1768 HEALTH PROTECTION PRECAUTIONS...............................................................................1768 ENVIRONMENTAL PROTECTION PRECAUTIONS........................................................................1768 Precautions for Air Conditioning................................................................................1768 HOW TO USE THIS MANUAL..............................................................................................1769 Description.....................................................................................................1769 Terms...........................................................................................................1769 Units...........................................................................................................1769 Contents........................................................................................................1769 Components......................................................................................................1770 SYMBOLS.....................................................................................................1770 How to Follow Trouble Diagnoses.................................................................................1771 DESCRIPTION.................................................................................................1771 HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES..............................................................1771 HARNESS WIRE COLOR AND CONNECTOR NUMBER INDICATION..........................................................1772 TYPE 1: Harness Wire Color and Connector Number are Shown in Illustration...............................1772 TYPE 2: Harness Wire Color and Connector Number are Shown in Text.......................................1773 KEY TO SYMBOLS SIGNIFYING MEASUREMENTS OR PROCEDURES........................................................1773 How to Read Wiring Diagrams.....................................................................................1775 CONNECTOR SYMBOLS...........................................................................................1775 SAMPLE/WIRING DIAGRAM - EXAMPL -............................................................................1776 DESCRIPTION.................................................................................................1777 Harness Indication......................................................................................1779 Component Indication....................................................................................1779 Switch Positions........................................................................................1779 Detectable Lines and Non-Detectable Lines...............................................................1780 Multiple Switch.........................................................................................1781 Reference Area..........................................................................................1782 Abbreviations...................................................................................................1783 SERVICE INFORMATION FOR ELECTRICAL INCIDENT.........................................................................1784 How to Check Terminal...........................................................................................1784 CONNECTOR AND TERMINAL PIN KIT..............................................................................1784 HOW TO PROBE CONNECTORS.....................................................................................1784 Probing from Harness Side...............................................................................1784 Probing from Terminal Side..............................................................................1784 How to Check Enlarged Contact Spring of Terminal........................................................1785 Waterproof Connector Inspection.........................................................................1786 Terminal Lock Inspection................................................................................1786 How to Perform Efficient Diagnosis for an Electrical Incident...................................................1787 WORK FLOW...................................................................................................1787 INCIDENT SIMULATION TESTS...................................................................................1787 Introduction............................................................................................1787 Vehicle Vibration.......................................................................................1788 Heat Sensitive..........................................................................................1789 Freezing................................................................................................1789 Water Intrusion.........................................................................................1789 Electrical Load.........................................................................................1789 Cold or Hot Start Up....................................................................................1790 CIRCUIT INSPECTION..........................................................................................1790 Introduction............................................................................................1790 Testing for “Opens” in the Circuit......................................................................1790 Testing for “Shorts” in the Circuit.....................................................................1791 Ground Inspection.......................................................................................1792 Voltage Drop Tests......................................................................................1792 Control Unit Circuit Test...............................................................................1794 Control Units and Electrical Parts..............................................................................1795 PRECAUTIONS.................................................................................................1795 CONSULT-II CHECKING SYSTEM..........................................................................................1797 Description.....................................................................................................1797 Function and System Application.................................................................................1797 Nickel Metal Hydride Battery Replacement........................................................................1797 Checking Equipment..............................................................................................1798 CONSULT-II Start Procedure......................................................................................1798 CONSULT-II Data Link Connector (DLC) Circuit....................................................................1799 INSPECTION PROCEDURE........................................................................................1800 LIFTING POINT.......................................................................................................1801 Special Service Tools...........................................................................................1801 Garage Jack and Safety Stand....................................................................................1801 2-Pole Lift.....................................................................................................1802 Board- On Lift..................................................................................................1803 TOW TRUCK TOWING....................................................................................................1804 Tow Truck Towing................................................................................................1804 2WD MODELS..................................................................................................1804 AWD MODELS..................................................................................................1805 Vehicle Recovery (Freeing a Stuck Vehicle)......................................................................1805 TIGHTENING TORQUE OF STANDARD BOLTS.................................................................................1806 Description.....................................................................................................1806 Tightening Torque Table (New Standard Included).................................................................1806 PREVIOUS STANDARD...........................................................................................1806 NEW STANDARD BASED ON ISO...................................................................................1807 DISCRIMINATION OF BOLTS AND NUTS............................................................................1808 RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS..........................................................................1809 Recommended Chemical Products and Sealants......................................................................1809 IDENTIFICATION INFORMATION..........................................................................................1810 Model Variation.................................................................................................1810 IDENTIFICATION NUMBER.......................................................................................1811 IDENTIFICATION PLATE........................................................................................1811 ENGINE SERIAL NUMBER........................................................................................1812 AUTOMATIC TRANSAXLE NUMBER..................................................................................1812 MANUAL TRANSAXLE NUMBER.....................................................................................1812 Dimensions......................................................................................................1812 Wheels & Tires..................................................................................................1812 TERMINOLOGY.........................................................................................................1813 SAE J1930 Terminology List......................................................................................1813 gw..........................................................................................................................1818 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................1818 PRECAUTIONS.........................................................................................................1820 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”.....................1820 Handling for Adhesive and Primer................................................................................1820 PREPARATION.........................................................................................................1821 Special Service Tools...........................................................................................1821 Commercial Service Tools........................................................................................1821 SQUEAK AND RATTLE TROUBLE DIAGNOSES.................................................................................1822 Work Flow.......................................................................................................1822 CUSTOMER INTERVIEW..........................................................................................1822 DUPLICATE THE NOISE AND TEST DRIVE..........................................................................1823 CHECK RELATED SERVICE BULLETINS.............................................................................1823 LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE................................................................1823 REPAIR THE CAUSE............................................................................................1823 CONFIRM THE REPAIR..........................................................................................1824 Generic Squeak and Rattle Troubleshooting.......................................................................1824 INSTRUMENT PANEL............................................................................................1824 CENTER CONSOLE..............................................................................................1824 DOORS.......................................................................................................1824 TRUNK.......................................................................................................1825 SUNROOF/HEADLINING..........................................................................................1825 SEATS.......................................................................................................1825 UNDERHOOD...................................................................................................1825 Diagnostic Worksheet............................................................................................1826 WINDSHIELD GLASS AND MOLDING........................................................................................1828 Removal and Installation........................................................................................1828 REMOVAL.....................................................................................................1828 INSTALLATION................................................................................................1829 Repairing Water Leaks...................................................................................1829 SIDE WINDOW GLASS...................................................................................................1830 Removal and Installation........................................................................................1830 REMOVAL.....................................................................................................1830 INSTALLATION................................................................................................1830 REPAIRING WATER LEAKS.......................................................................................1831 BACK DOOR WINDOW GLASS..............................................................................................1832 Removal and Installation........................................................................................1832 REMOVAL.....................................................................................................1832 INSTALLATION................................................................................................1833 REAR WINDOW DEFOGGER................................................................................................1834 Component Parts and Harness Connector Location..................................................................1834 System Description..............................................................................................1834 Wiring Diagram — DEF —..........................................................................................1836 Terminals and Reference Value for Smart Entrance Control Unit...................................................1838 Work Flow.......................................................................................................1838 Trouble Diagnoses...............................................................................................1838 Check Rear Window Defogger Relay Power Supply...................................................................1838 Check Smart Entrance Control Unit Power Supply and Ground.......................................................1840 Check Rear Window Defogger Switch Circuit.......................................................................1841 Check Rear Window Defogger Circuit..............................................................................1843 Check Door Mirror Defogger Circuit..............................................................................1844 Check Rear Window Defogger Indicator Lamp Circuit...............................................................1846 Filament Check..................................................................................................1848 Filament Repair.................................................................................................1848 REPAIR EQUIPMENT............................................................................................1848 REPAIRING PROCEDURE.........................................................................................1849 POWER WINDOW SYSTEM.................................................................................................1850 Component Parts and Harness Connector Location..................................................................1850 System Description..............................................................................................1850 MANUAL OPERATION............................................................................................1851 Front Door (Driver Side)................................................................................1851 Front Door (Passenger Side).............................................................................1851 Rear Door LH............................................................................................1852 Rear Door RH............................................................................................1853 AUTO OPERATION..............................................................................................1854 POWER WINDOW LOCK...........................................................................................1854 TIMER FUNCTION..............................................................................................1854 DRIVER WINDOW ANTI–PINCH FUNCTION...........................................................................1854 Operation Conditions....................................................................................1854 Schematic.......................................................................................................1855 Wiring Diagram – WINDOW –.......................................................................................1856 Terminal and Reference Value for Power Window Main Switch.......................................................1860 Trouble Diagnoses Symptom Chart.................................................................................1861 Check Power Window Relay Power Supply and Ground Circuit........................................................1862 Check Power Window Main Switch Power Supply and Ground Circuit..................................................1863 Check Power Window Motor (Driver Side) Circuit..................................................................1863 Check Power Window Motor Circuit................................................................................1864 Check Power Window Switch Circuit...............................................................................1865 Check Power Window (Passenger Side) Circuit.....................................................................1866 Check Power Window (Rear LH) Circuit............................................................................1866 Check Power Window (Rear RH) Circuit............................................................................1867 Check Limit Switch Circuit......................................................................................1868 Check Encoder Circuit...........................................................................................1869 Check Door Switch Circuit.......................................................................................1871 FRONT DOOR GLASS AND REGULATOR......................................................................................1873 Removal and Installation........................................................................................1873 FRONT DOOR GLASS............................................................................................1873 Removal.................................................................................................1873 Installation............................................................................................1874 FRONT DOOR REGULATOR ASSEMBLY...............................................................................1874 Removal.................................................................................................1874 Installation............................................................................................1875 Inspection after Removal................................................................................1875 Disassembly.............................................................................................1875 Assembly................................................................................................1875 Inspection after Installation...........................................................................1875 Fitting Inspection..............................................................................................1875 REAR DOOR GLASS AND REGULATOR.......................................................................................1876 Removal and Installation........................................................................................1876 REAR DOOR GLASS.............................................................................................1876 Removal.................................................................................................1876 Installation............................................................................................1877 REAR DOOR REGULATOR ASSEMBLY................................................................................1878 Removal.................................................................................................1878 Installation............................................................................................1878 Inspection After Removal................................................................................1878 Disassembly.............................................................................................1878 Assembly................................................................................................1878 Fitting Inspection..............................................................................................1878 DOOR MIRROR.........................................................................................................1880 Wiring Diagram — MIRROR —.......................................................................................1880 Removal and Installation........................................................................................1881 REMOVAL.....................................................................................................1881 INSTALLATION................................................................................................1881 Disassembly and Assembly........................................................................................1882 DISASSEMBLY.................................................................................................1882 ASSEMBLY....................................................................................................1883 INSIDE MIRROR.......................................................................................................1884 Removal and Installation........................................................................................1884 REMOVAL.....................................................................................................1884 INSTALLATION................................................................................................1884 ELECTRICAL UNITS.................................................................................................... 45 FUSE BLOCK - JUNCTION BOX (J/B)..................................................................................... 48 FUSE AND FUSIBLE LINK BOX........................................................................................... 49 idx.........................................................................................................................1886 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................1887 Numerics............................................................................................................1887 A...................................................................................................................1887 B...................................................................................................................1887 C...................................................................................................................1888 D...................................................................................................................1888 E...................................................................................................................1888 F...................................................................................................................1889 G...................................................................................................................1889 H...................................................................................................................1889 I...................................................................................................................1890 J...................................................................................................................1890 K...................................................................................................................1890 L...................................................................................................................1890 M...................................................................................................................1890 N...................................................................................................................1890 O...................................................................................................................1890 P...................................................................................................................1891 R...................................................................................................................1891 S...................................................................................................................1891 T...................................................................................................................1892 V...................................................................................................................1892 W...................................................................................................................1892 ip..........................................................................................................................1893 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................1893 PRECAUTIONS.........................................................................................................1894 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”.....................1894 Precautions.....................................................................................................1894 PREPARATION.........................................................................................................1895 Special Service Tools...........................................................................................1895 Commercial Service Tools........................................................................................1895 SQUEAK AND RATTLE TROUBLE DIAGNOSES.................................................................................1896 Work Flow.......................................................................................................1896 CUSTOMER INTERVIEW..........................................................................................1896 DUPLICATE THE NOISE AND TEST DRIVE..........................................................................1897 CHECK RELATED SERVICE BULLETINS.............................................................................1897 LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE................................................................1897 REPAIR THE CAUSE............................................................................................1897 CONFIRM THE REPAIR..........................................................................................1898 Generic Squeak and Rattle Troubleshooting.......................................................................1898 INSTRUMENT PANEL............................................................................................1898 CENTER CONSOLE..............................................................................................1898 DOORS.......................................................................................................1898 TRUNK.......................................................................................................1899 SUNROOF/HEADLINING..........................................................................................1899 SEATS.......................................................................................................1899 UNDERHOOD...................................................................................................1899 Diagnostic Worksheet............................................................................................1900 INSTRUMENT PANEL ASSEMBLY...........................................................................................1902 Component Parts Location........................................................................................1902 Removal and Installation........................................................................................1903 WORK ITEM TABLE.............................................................................................1903 REMOVAL.....................................................................................................1904 Front Speaker Grille (LH/RH)............................................................................1904 Cluster Lid A...........................................................................................1904 Combination Meter.......................................................................................1904 Driver Box..............................................................................................1905 Steering Lock Escutcheon, Steering Column Cover (Upper/Lower)...........................................1905 Instrument Driver Lower Panel...........................................................................1905 Instrument Panel Finisher...............................................................................1905 A/T Control Finisher (A/T Models).......................................................................1906 Console Boot (M/T Models)...............................................................................1906 Center Console..........................................................................................1906 Cluster Lid C...........................................................................................1907 Pocket Deck.............................................................................................1907 Audio, A/C Controller...................................................................................1907 Instrument Lower Panel..................................................................................1907 Instrument Panel Lower Cover (LH/RH)....................................................................1907 Instrument Panel Stay Cover (LH/RH).....................................................................1908 Cluster Lid Finisher....................................................................................1908 Instrument Center Lower Panel...........................................................................1908 Glove Box...............................................................................................1908 Glove Box Cover.........................................................................................1909 Upper Glove Box.........................................................................................1909 Front Passenger Air Bag Module..........................................................................1909 Front Pillar Garnish....................................................................................1909 Instrument Panel........................................................................................1909 Side Ventilator Grille (LH/RH)..........................................................................1910 Cup Holder (LH/RH)......................................................................................1910 INSTALLATION................................................................................................1910 Disassembly and Assembly........................................................................................1911 CENTER CONSOLE..............................................................................................1911 Disassembly.............................................................................................1911 Assembly................................................................................................1912 lan.........................................................................................................................1913 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................1913 CAN.................................................................................................................1915 PRECAUTIONS.....................................................................................................1915 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”.................1915 Precautions for Trouble Diagnosis...........................................................................1915 CAN SYSTEM..............................................................................................1915 Precautions for Harness Repair..............................................................................1915 CAN SYSTEM..............................................................................................1915 TROUBLE DIAGNOSES WORK FLOW.....................................................................................1916 When Displaying CAN Communication System Errors.............................................................1916 WHEN A MALFUNCTION IS DETECTED BY CAN COMMUNICATION SYSTEM..............................................1916 WHEN A MALFUNCTION IS DETECTED EXCEPT CAN COMMUNICATION SYSTEM..........................................1916 TROUBLE DIAGNOSIS FLOW CHART............................................................................1917 Diagnosis Procedure.........................................................................................1918 SELECTING CAN SYSTEM TYPE (HOW TO USE SPECIFICATION TABLE)..............................................1918 ACQUISITION OF DATA BY CONSULT-II.......................................................................1919 HOW TO USE CHECK SHEET TABLE............................................................................1920 Example of Filling in Check Sheet When Initial Conditions Are Reproduced............................1921 Example of Filling in Check Sheet When Initial Conditions Are Not Reproduced........................1923 CAN Diagnostic Support Monitor..............................................................................1925 DESCRIPTION OF “CAN DIAG SUPPORT MNTR” SCREEN FOR ECM...................................................1925 DESCRIPTION OF “CAN DIAG SUPPORT MNTR” SCREEN FOR TCM...................................................1926 DESCRIPTION OF “CAN DIAG SUPPORT MNTR” SCREEN FOR ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT).........1926 DESCRIPTION OF “CAN DIAG SUPPORT MNTR” SCREEN FOR VDC/TCS/ABS CONTROL UNIT..............................1927 DESCRIPTION OF “CAN DIAG SUPPORT MNTR” SCREEN FOR AWD CONTROL UNIT......................................1927 CAN COMMUNICATION...............................................................................................1928 System Description..........................................................................................1928 CAN Communication Unit......................................................................................1928 TYPE 1..................................................................................................1928 System Diagram......................................................................................1928 Input/Output Signal Chart...........................................................................1929 TYPE 2..................................................................................................1929 System Diagram......................................................................................1929 Input/Output Signal Chart...........................................................................1930 TYPE 3..................................................................................................1930 System Diagram......................................................................................1930 Input/Output Signal Chart...........................................................................1930 TYPE 4..................................................................................................1931 System Diagram......................................................................................1931 Input/Output Signal Chart...........................................................................1931 TYPE 5..................................................................................................1932 System Diagram......................................................................................1932 Input/Output Signal Chart...........................................................................1932 CAN SYSTEM (TYPE 1).............................................................................................1934 Component Parts and Harness Connector Location..............................................................1934 Wiring Diagram — CAN —......................................................................................1935 Check Sheet.................................................................................................1937 CHECK SHEET RESULTS (EXAMPLE)...........................................................................1938 Case 1..............................................................................................1938 Case 2..............................................................................................1939 Case 3..............................................................................................1940 Case 4..............................................................................................1941 Case 5..............................................................................................1942 Case 6..............................................................................................1943 Between TCM and ABS Actuator and Electric Unit (Control Unit) Circuit Inspection............................1943 ECM Circuit Inspection......................................................................................1944 TCM Circuit Inspection......................................................................................1945 ABS Actuator and Electric Unit (Control Unit) Circuit Inspection............................................1945 Combination Meter Circuit Inspection........................................................................1946 CAN Communication Circuit Inspection........................................................................1947 CAN SYSTEM (TYPE 2).............................................................................................1951 Component Parts and Harness Connector Location..............................................................1951 Wiring Diagram — CAN —......................................................................................1952 Check Sheet.................................................................................................1954 CHECK SHEET RESULTS (EXAMPLE)...........................................................................1955 Case 1..............................................................................................1955 Case 2..............................................................................................1956 Case 3..............................................................................................1957 Case 4..............................................................................................1958 Case 5..............................................................................................1959 Case 6..............................................................................................1960 Between ABS Actuator and Electric Unit (Control Unit) and AWD Control Unit Circuit Inspection...............1960 ECM Circuit Inspection......................................................................................1961 ABS Actuator and Electric Unit (Control Unit) Circuit Inspection............................................1961 AWD Control Unit Circuit Inspection.........................................................................1962 Combination Meter Circuit Inspection........................................................................1962 CAN Communication Circuit Inspection........................................................................1963 CAN SYSTEM (TYPE 3).............................................................................................1967 Component Parts and Harness Connector Location..............................................................1967 Wiring Diagram — CAN —......................................................................................1968 Check Sheet.................................................................................................1970 CHECK SHEET RESULTS (EXAMPLE)...........................................................................1971 Case 1..............................................................................................1971 Case 2..............................................................................................1972 Case 3..............................................................................................1973 Case 4..............................................................................................1974 Case 5..............................................................................................1975 Case 6..............................................................................................1976 Case 7..............................................................................................1977 Case 8..............................................................................................1978 Between TCM and ABS Actuator and Electric Unit (Control Unit) Circuit Inspection............................1978 Between ABS Actuator and Electric Unit (Control Unit) and AWD Control Unit Circuit Inspection...............1979 ECM Circuit Inspection......................................................................................1980 TCM Circuit Inspection......................................................................................1981 ABS Actuator and Electric Unit (Control Unit) Circuit Inspection............................................1981 AWD Control Unit Circuit Inspection.........................................................................1982 Combination Meter Circuit Inspection........................................................................1982 CAN Communication Circuit Inspection........................................................................1983 CAN SYSTEM (TYPE 4).............................................................................................1988 Component Parts and Harness Connector Location..............................................................1988 Wiring Diagram — CAN —......................................................................................1989 Check Sheet.................................................................................................1991 CHECK SHEET RESULTS (EXAMPLE)...........................................................................1992 Case 1..............................................................................................1992 Case 2..............................................................................................1993 Case 3..............................................................................................1994 Case 4..............................................................................................1995 Case 5..............................................................................................1996 Case 6..............................................................................................1997 Case 7..............................................................................................1998 Between VDC/TCS/ABS Control Unit and AWD Control Unit Circuit Inspection....................................1998 ECM Circuit Inspection......................................................................................1999 VDC/TCS/ABS Control Unit Circuit Inspection.................................................................1999 Steering Angle Sensor Circuit Inspection....................................................................2000 AWD Control Unit Circuit Inspection.........................................................................2000 Combination Meter Circuit Inspection........................................................................2001 CAN Communication Circuit Inspection........................................................................2001 CAN SYSTEM (TYPE 5).............................................................................................2005 Component Parts and Harness Connector Location..............................................................2005 Wiring Diagram — CAN —......................................................................................2006 Check Sheet.................................................................................................2008 CHECK SHEET RESULTS (EXAMPLE)...........................................................................2009 Case 1..............................................................................................2009 Case 2..............................................................................................2010 Case 3..............................................................................................2011 Case 4..............................................................................................2012 Case 5..............................................................................................2013 Case 6..............................................................................................2014 Case 7..............................................................................................2015 Case 8..............................................................................................2016 Case 9..............................................................................................2017 Between TCM and VDC/TCS/ABS Control Unit Circuit Inspection.................................................2017 Between VDC/TCS/ABS Control Unit and AWD Control Unit Circuit Inspection....................................2018 ECM Circuit Inspection......................................................................................2019 TCM Circuit Inspection......................................................................................2019 VDC/TCS/ABS Control Unit Circuit Inspection.................................................................2020 Steering Angle Sensor Circuit Inspection....................................................................2020 AWD Control Unit Circuit Inspection.........................................................................2021 Combination Meter Circuit Inspection........................................................................2021 CAN Communication Circuit Inspection........................................................................2022 ELECTRICAL UNITS................................................................................................ 45 FUSE BLOCK - JUNCTION BOX (J/B)................................................................................. 48 FUSE AND FUSIBLE LINK BOX....................................................................................... 49 lt..........................................................................................................................2027 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................2027 PRECAUTION..........................................................................................................2029 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”.....................2029 Precaution......................................................................................................2029 Wiring Diagrams and Trouble Diagnosis...........................................................................2029 HEADLAMP - DAYTIME LIGHT SYSTEM -...................................................................................2030 Component Parts and Harness Connector Location..................................................................2030 System Description..............................................................................................2030 DESCRIPTION.................................................................................................2030 OUTLINE.....................................................................................................2031 DAYTIME LIGHT OPERATION.....................................................................................2031 HEADLAMP OPERATION (DAYTIME LIGHT CANCEL OPERATION).........................................................2032 OPERATION TABLE.............................................................................................2032 Schematic.......................................................................................................2033 Wiring Diagram — H/LAMP —.......................................................................................2034 Terminals and Reference Value for Daytime Light Control Unit....................................................2037 Trouble Diagnoses...............................................................................................2038 Check Daytime Light Relay.......................................................................................2040 Aiming Adjustment of Headlamp...................................................................................2041 PREPARATION BEFORE ADJUSTING................................................................................2041 LOW BEAM AND HIGH BEAM......................................................................................2041 Bulb Replacement................................................................................................2042 HEADLAMP....................................................................................................2042 Removal and Installation of Headlamp............................................................................2042 REMOVAL.....................................................................................................2042 INSTALLATION................................................................................................2042 TURN SIGNAL AND HAZARD WARNING LAMPS................................................................................2043 System Description..............................................................................................2043 TURN SIGNAL OPERATION.......................................................................................2043 LH Turn.................................................................................................2043 RH Turn.................................................................................................2043 HAZARD LAMP OPERATION.......................................................................................2044 Wiring Diagram — TURN —.........................................................................................2045 Trouble Diagnoses...............................................................................................2047 Electrical Components Inspection................................................................................2047 COMBINATION FLASHER UNIT CHECK..............................................................................2047 HAZARD SWITCH CHECK.........................................................................................2048 Bulb Replacement................................................................................................2048 FRONT TURN SIGNAL LAMP......................................................................................2048 SIDE TURN SIGNAL LAMP.......................................................................................2048 REAR TURN SIGNAL LAMP.......................................................................................2048 Removal and Installation of Front Turn Signal Lamp..............................................................2048 Removal and Installation of Side Turn Signal Lamp...............................................................2048 REMOVAL.....................................................................................................2048 INSTALLATION................................................................................................2049 Removal and Installation of Rear Turn Signal Lamp...............................................................2049 LIGHTING AND TURN SIGNAL SWITCH.....................................................................................2050 Removal and Installation........................................................................................2050 REMOVAL.....................................................................................................2050 INSTALLATION................................................................................................2050 HAZARD SWITCH.......................................................................................................2051 Removal and Installation........................................................................................2051 REMOVAL.....................................................................................................2051 INSTALLATION................................................................................................2051 STOP LAMP...........................................................................................................2052 Wiring Diagram — STOP/L —.......................................................................................2052 Bulb Replacement................................................................................................2053 STOP LAMP...................................................................................................2053 HIGH-MOUNTED STOP LAMP......................................................................................2053 Removal and Installation of Stop Lamp...........................................................................2053 Removal and Installation of High-Mounted Stop Lamp..............................................................2053 REMOVAL.....................................................................................................2053 INSTALLATION................................................................................................2053 BACK-UP LAMP........................................................................................................2054 Wiring Diagram — BACK/L —.......................................................................................2054 Bulb Replacement................................................................................................2055 Removal and Installation........................................................................................2055 PARKING, LICENSE PLATE AND TAIL LAMPS...............................................................................2056 Wiring Diagram — TAIL/L —.......................................................................................2056 Bulb Replacement................................................................................................2058 PARKING LAMP................................................................................................2058 LICENSE PLATE LAMP..........................................................................................2058 TAIL LAMP...................................................................................................2058 Removal and Installation of Parking Lamp........................................................................2058 REMOVAL.....................................................................................................2058 INSTALLATION................................................................................................2058 Removal and Installation of License Plate Lamp..................................................................2059 REMOVAL.....................................................................................................2059 INSTALLATION................................................................................................2059 Removal and Installation of Tail Lamp...........................................................................2059 SIDE MARKER LAMP....................................................................................................2060 Bulb Replacement................................................................................................2060 FRONT SIDE MARKER LAMP......................................................................................2060 REAR SIDE MARKER LAMP.......................................................................................2060 Removal and Installation of Front Side Marker Lamp..............................................................2061 REMOVAL.....................................................................................................2061 INSTALLATION................................................................................................2061 Removal and Installation of Rear Side Marker Lamp...............................................................2061 REMOVAL.....................................................................................................2061 INSTALLATION................................................................................................2061 FRONT FOG LAMP......................................................................................................2062 System Description..............................................................................................2062 DESCRIPTION.................................................................................................2062 FOG LAMP OPERATION..........................................................................................2062 Wiring Diagram — F/FOG —........................................................................................2063 Aiming Adjustment...............................................................................................2064 Bulb Replacement................................................................................................2065 Removal and Installation........................................................................................2065 REMOVAL.....................................................................................................2065 INSTALLATION................................................................................................2065 HIGH-MOUNTED STOP LAMP..............................................................................................2066 Bulb Replacement................................................................................................2066 Removal and Installation........................................................................................2066 REAR COMBINATION LAMP...............................................................................................2067 Bulb Replacement................................................................................................2067 Removal and Installation........................................................................................2067 REMOVAL.....................................................................................................2067 INSTALLATION................................................................................................2067 COMBINATION SWITCH..................................................................................................2068 Removal and Installation........................................................................................2068 Switch Circuit Inspection.......................................................................................2068 INTERIOR ROOM LAMP..................................................................................................2069 System Description..............................................................................................2069 POWER SUPPLY AND GROUND.....................................................................................2069 SWITCH OPERATION............................................................................................2070 BATTERY SAVER...............................................................................................2071 Schematic.......................................................................................................2072 Wiring Diagram —ROOM/L—.........................................................................................2073 Interior Room Lamp Timer Does Not Operate.......................................................................2077 Interior Room Lamp Timer Does Not Cancel........................................................................2080 Bulb Replacement................................................................................................2082 INTERIOR ROOM LAMP..........................................................................................2082 LUGGAGE ROOM LAMP...........................................................................................2082 Removal and Installation of Interior Room Lamp..................................................................2082 REMOVAL.....................................................................................................2082 INSTALLATION................................................................................................2082 Removal and Installation of Luggage Room Lamp...................................................................2082 STEP LAMP...........................................................................................................2083 Wiring Diagram — STEP/L —.......................................................................................2083 Bulb Replacement................................................................................................2084 Removal and Installation........................................................................................2084 REMOVAL.....................................................................................................2084 INSTALLATION................................................................................................2084 MAP LAMP............................................................................................................2085 Wiring Diagram —INT/L—..........................................................................................2085 Bulb Replacement................................................................................................2086 MAP LAMP (WITHOUT SUNROOF)..................................................................................2086 MAP LAMP (WITH SUNROOF).....................................................................................2086 Removal and Installation of Map Lamp (Without Sunroof)..........................................................2086 REMOVAL.....................................................................................................2086 INSTALLATION................................................................................................2086 Removal and Installation of Map Lamp (With Sunroof).............................................................2086 REMOVAL.....................................................................................................2086 INSTALLATION................................................................................................2086 ILLUMINATION........................................................................................................2087 System Description..............................................................................................2087 Schematic.......................................................................................................2088 Wiring Diagram -ILL-............................................................................................2089 BULB SPECIFICATIONS.................................................................................................2093 Headlamp........................................................................................................2093 Exterior Lamp...................................................................................................2093 Interior Lamp/Illumination......................................................................................2093 ELECTRICAL UNITS.................................................................................................... 45 FUSE BLOCK - JUNCTION BOX (J/B)..................................................................................... 48 FUSE AND FUSIBLE LINK BOX........................................................................................... 49 lu..........................................................................................................................2095 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................2095 PRECAUTIONS.........................................................................................................2096 Precautions for Liquid Gasket...................................................................................2096 LIQUID GASKET APPLICATION PROCEDURE.........................................................................2096 PREPARATION.........................................................................................................2097 Special Service Tools...........................................................................................2097 Commercial Service Tools........................................................................................2097 LUBRICATION SYSTEM..................................................................................................2098 Lubrication Circuit.............................................................................................2098 System Chart....................................................................................................2099 ENGINE OIL..........................................................................................................2100 Inspection......................................................................................................2100 ENGINE OIL LEVEL............................................................................................2100 ENGINE OIL APPEARANCE.......................................................................................2100 ENGINE OIL LEAKAGE..........................................................................................2100 OIL PRESSURE CHECK..........................................................................................2100 Changing Engine Oil.............................................................................................2101 OIL FILTER..........................................................................................................2103 Removal and Installation........................................................................................2103 REMOVAL.....................................................................................................2103 INSTALLATION................................................................................................2103 INSPECTION AFTER INSTALLATION...............................................................................2103 OIL COOLER..........................................................................................................2104 Removal and Installation........................................................................................2104 REMOVAL.....................................................................................................2104 INSPECTION AFTER REMOVAL....................................................................................2104 Oil Cooler..............................................................................................2104 Relief Valve............................................................................................2104 INSTALLATION................................................................................................2104 INSPECTION AFTER INSTALLATION...............................................................................2104 OIL PUMP............................................................................................................2106 Removal and Installation........................................................................................2106 REMOVAL.....................................................................................................2106 INSTALLATION................................................................................................2106 INSPECTION AFTER INSTALLATION...............................................................................2106 Disassembly and Assembly........................................................................................2106 DISASSEMBLY.................................................................................................2106 INSPECTION AFTER DISASSEMBLY................................................................................2107 Clearance of Oil Pump Parts.............................................................................2107 Regulator Valve Clearance...............................................................................2108 ASSEMBLY....................................................................................................2108 SERVICE DATA AND SPECIFICATIONS (SDS)...............................................................................2109 Standard and Limit..............................................................................................2109 OIL PRESSURE................................................................................................2109 ENGINE OIL CAPACITY (APPROXIMATE)...........................................................................2109 OIL PUMP....................................................................................................2109 REGULATOR VALVE.............................................................................................2109 ma..........................................................................................................................2111 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................2111 PREPARATION.........................................................................................................2113 Special Service Tools...........................................................................................2113 Commercial Service Tools........................................................................................2113 GENERAL MAINTENANCE.................................................................................................2114 Explanation of General Maintenance..............................................................................2114 PERIODIC MAINTENANCE................................................................................................2116 Introduction of Periodic Maintenance............................................................................2116 Schedule 1......................................................................................................2117 EMISSION CONTROL SYSTEM MAINTENANCE.........................................................................2117 CHASSIS AND BODY MAINTENANCE................................................................................2118 Schedule 2......................................................................................................2119 EMISSION CONTROL SYSTEM MAINTENANCE.........................................................................2119 CHASSIS AND BODY MAINTENANCE................................................................................2119 RECOMMENDED FLUIDS AND LUBRICANTS...................................................................................2121 Fluids and Lubricants...........................................................................................2121 SAE Viscosity Number............................................................................................2122 GASOLINE ENGINE OIL.........................................................................................2122 Anti-Freeze Coolant Mixture Ratio...............................................................................2122 ENGINE MAINTENANCE..................................................................................................2123 Checking Drive Belt.............................................................................................2123 Tension Adjustment..............................................................................................2123 Changing Engine Coolant.........................................................................................2123 DRAINING ENGINE COOLANT.....................................................................................2123 REFILLING ENGINE COOLANT....................................................................................2124 FLUSHING COOLING SYSTEM.....................................................................................2125 Checking Fuel Lines.............................................................................................2125 Changing Air Cleaner Filter.....................................................................................2125 VISCOUS PAPER TYPE..........................................................................................2125 Changing Engine Oil.............................................................................................2126 Changing Oil Filter.............................................................................................2127 REMOVAL.....................................................................................................2127 INSTALLATION................................................................................................2127 INSPECTION AFTER INSTALLATION...............................................................................2127 Changing Spark Plugs (Platinum-Tipped Type).....................................................................2128 REMOVAL.....................................................................................................2128 INSPECTION AFTER REMOVAL....................................................................................2128 INSTALLATION................................................................................................2129 Checking EVAP Vapor Lines.......................................................................................2129 CHASSIS AND BODY MAINTENANCE........................................................................................2130 Checking Exhaust System.........................................................................................2130 Checking Clutch Fluid Level and Leaks...........................................................................2130 Checking Clutch System..........................................................................................2130 Checking M/T Oil................................................................................................2130 Changing M/T Oil................................................................................................2131 Checking A/T Fluid..............................................................................................2131 Changing A/T Fluid..............................................................................................2132 Checking Transfer Oil...........................................................................................2132 Changing Transfer Oil...........................................................................................2133 Checking Propeller Shaft........................................................................................2133 Checking Differential Gear Oil..................................................................................2133 Changing Differential Gear Oil..................................................................................2134 Balancing Wheels (Bonding Weight Type)..........................................................................2134 REMOVAL.....................................................................................................2134 WHEEL BALANCE ADJUSTMENT....................................................................................2134 Tire Rotation...................................................................................................2135 Checking Brake Fluid Level and Leaks............................................................................2136 Checking Brake Lines and Cables.................................................................................2136 Changing Brake Fluid............................................................................................2136 Checking Disc Brake.............................................................................................2136 ROTOR.......................................................................................................2136 CALIPER.....................................................................................................2136 PAD.........................................................................................................2137 Checking Steering Gear and Linkage..............................................................................2137 STEERING GEAR...............................................................................................2137 STEERING LINKAGE............................................................................................2137 Checking Power Steering Fluid and Lines.........................................................................2137 Axle and Suspension Parts.......................................................................................2138 Drive Shaft.....................................................................................................2138 Lubricating Locks, Hinges and Hood Latch........................................................................2139 Checking Seat Belt, Buckles, Retractors, Anchors and Adjusters..................................................2139 SERVICE DATA AND SPECIFICATIONS (SDS)...............................................................................2140 Standard and Limit..............................................................................................2140 BELT DEFLECTION AND TENSION.................................................................................2140 ENGINE COOLANT CAPACITY (APPROXIMATE).......................................................................2140 RADIATOR....................................................................................................2140 ENGINE OIL CAPACITY (APPROXIMATE)...........................................................................2140 SPARK PLUG (PLATINUM-TIPPED TYPE)...........................................................................2140 WHEEL BALANCE...............................................................................................2140 mt..........................................................................................................................2141 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................2141 PRECAUTIONS.........................................................................................................2143 Service Notice or Precautions...................................................................................2143 PREPARATION.........................................................................................................2144 Special Service Tools...........................................................................................2144 Commercial Service Tools........................................................................................2146 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING................................................................2148 NVH Troubleshooting Chart.......................................................................................2148 DESCRIPTION.........................................................................................................2149 Cross-Sectional View............................................................................................2149 DOUBLE-CONE SYNCHRONIZER....................................................................................2150 TRIPLE-CONE SYNCHRONIZER....................................................................................2150 REVERSE GEAR NOISE PREVENTION FUNCTION (SYNCHRONIZING METHOD)...............................................2150 M/T OIL.............................................................................................................2151 Changing M/T Oil................................................................................................2151 DRAINING....................................................................................................2151 FILLING.....................................................................................................2151 Checking M/T Oil................................................................................................2151 OIL LEAKAGE AND OIL LEVEL...................................................................................2151 SIDE OIL SEAL.......................................................................................................2152 Removal and Installation........................................................................................2152 REMOVAL.....................................................................................................2152 INSTALLATION................................................................................................2152 POSITION SWITCH.....................................................................................................2153 Checking........................................................................................................2153 BACK-UP LAMP SWITCH.........................................................................................2153 PARK/NEUTRAL POSITION (PNP) SWITCH..........................................................................2153 CONTROL LINKAGE.....................................................................................................2154 Components of Control Device and Cable..........................................................................2154 Removal and Installation........................................................................................2155 AIR BREATHER HOSE...................................................................................................2156 Removal and Installation........................................................................................2156 TRANSAXLE ASSEMBLY..................................................................................................2157 Removal and Installation........................................................................................2157 COMPONENTS..................................................................................................2157 REMOVAL.....................................................................................................2157 INSTALLATION................................................................................................2158 Disassembly and Assembly........................................................................................2159 COMPONENTS..................................................................................................2159 Case and Housing Components.............................................................................2159 Gear Components.........................................................................................2160 Shift Control Components................................................................................2162 Final Drive Components..................................................................................2163 DISASSEMBLY.................................................................................................2163 ASSEMBLY....................................................................................................2167 ADJUSTMENT..................................................................................................2173 Differential Side Bearing Preload.......................................................................2173 Reverse Idler Gear End Play.............................................................................2174 Input Shaft End Play....................................................................................2174 Mainshaft End Play......................................................................................2175 INPUT SHAFT AND GEARS...............................................................................................2177 Disassembly and Assembly........................................................................................2177 DISASSEMBLY.................................................................................................2177 INSPECTION AFTER DISASSEMBLY................................................................................2178 Input Shaft and Gears...................................................................................2178 Synchronizer............................................................................................2179 Bearing.................................................................................................2180 ASSEMBLY....................................................................................................2181 MAINSHAFT AND GEARS.................................................................................................2186 Disassembly and Assembly........................................................................................2186 DISASSEMBLY.................................................................................................2186 INSPECTION AFTER DISASSEMBLY................................................................................2187 Mainshaft and Gears.....................................................................................2187 Synchronizer............................................................................................2188 Bearing.................................................................................................2190 ASSEMBLY....................................................................................................2190 REVERSE IDLER SHAFT AND GEARS.......................................................................................2195 Disassembly and Assembly........................................................................................2195 DISASSEMBLY.................................................................................................2195 INSPECTION AFTER DISASSEMBLY................................................................................2195 Reverse Idler Shaft and Gears...........................................................................2195 Synchronizer............................................................................................2195 Bearing.................................................................................................2196 ASSEMBLY....................................................................................................2196 FINAL DRIVE.........................................................................................................2197 Disassembly and Assembly........................................................................................2197 PRE-INSPECTION..............................................................................................2197 DISASSEMBLY.................................................................................................2197 INSPECTION AFTER DISASSEMBLY................................................................................2198 Gear, Washer, Shaft and Case............................................................................2198 Bearing.................................................................................................2198 ASSEMBLY....................................................................................................2198 SHIFT CONTROL.......................................................................................................2201 Inspection......................................................................................................2201 SHIFT FORK..................................................................................................2201 SERVICE DATA AND SPECIFICATIONS (SDS)...............................................................................2202 General Specifications..........................................................................................2202 TRANSAXLE...................................................................................................2202 FINAL GEAR..................................................................................................2203 Gear End Play...................................................................................................2203 Baulk Ring Clearance............................................................................................2203 Available Snap Rings............................................................................................2204 INPUT SHAFT BEARING SPACER..................................................................................2204 5TH MAIN GEAR...............................................................................................2204 Available C-Rings...............................................................................................2205 MAINSHAFT C-RING............................................................................................2205 Available Thrust Washer.........................................................................................2205 INPUT SHAFT THRUST WASHER...................................................................................2205 DIFFERENTIAL SIDE GEAR THRUST WASHER........................................................................2205 Available Adjusting Shims.......................................................................................2206 4TH MAIN GEAR ADJUSTING SHIM................................................................................2206 INPUT SHAFT REAR BEARING ADJUSTING SHIM.....................................................................2206 MAINSHAFT REAR BEARING ADJUSTING SHIM.......................................................................2206 REVERSE IDLER GEAR ADJUSTING SHIM...........................................................................2207 Available Shims.................................................................................................2207 BEARING PRELOAD.............................................................................................2207 DIFFERENTIAL SIDE BEARING ADJUSTING SHIM(S).................................................................2207 mtc.........................................................................................................................2209 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................2209 PRECAUTIONS.........................................................................................................2212 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”.....................2212 Precautions for Working with HFC-134a (R-134a)..................................................................2212 CONTAMINATED REFRIGERANT....................................................................................2213 General Refrigerant Precautions.................................................................................2213 Lubricant Precautions...........................................................................................2213 Precautions for Refrigerant Connection..........................................................................2214 FEATURES OF NEW TYPE REFRIGERANT CONNECTION.................................................................2214 O-RING AND REFRIGERANT CONNECTION...........................................................................2215 O-Ring Part Numbers and Specifications..................................................................2215 Precautions for Servicing Compressor............................................................................2217 Precautions for Service Equipment...............................................................................2217 RECOVERY/RECYCLING EQUIPMENT................................................................................2217 ELECTRONIC LEAK DETECTOR....................................................................................2217 VACUUM PUMP.................................................................................................2217 MANIFOLD GAUGE SET..........................................................................................2217 SERVICE HOSES...............................................................................................2218 SERVICE COUPLERS............................................................................................2218 REFRIGERANT WEIGHT SCALE....................................................................................2218 CHARGING CYLINDER...........................................................................................2218 Precautions for Leak Detection Dye..............................................................................2218 IDENTIFICATION..............................................................................................2219 IDENTIFICATION LABEL FOR VEHICLE............................................................................2219 Wiring Diagrams and Trouble Diagnosis...........................................................................2219 PREPARATION.........................................................................................................2220 Special Service Tools...........................................................................................2220 HFC-134a (R-134a) Service Tools and Equipment...................................................................2221 Commercial Service Tools........................................................................................2223 REFRIGERATION SYSTEM................................................................................................2224 Refrigerant Cycle...............................................................................................2224 REFRIGERANT FLOW............................................................................................2224 FREEZE PROTECTION...........................................................................................2224 Refrigerant System Protection...................................................................................2224 REFRIGERANT PRESSURE SENSOR.................................................................................2224 PRESSURE RELIEF VALVE.......................................................................................2224 V-6 Variable Displacement Compressor............................................................................2225 GENERAL INFORMATION.........................................................................................2225 DESCRIPTION.................................................................................................2226 General.................................................................................................2226 Operation...............................................................................................2227 Component Layout................................................................................................2229 LUBRICANT...........................................................................................................2230 Maintenance of Lubricant Quantity in Compressor.................................................................2230 LUBRICANT...................................................................................................2230 LUBRICANT RETURN OPERATION..................................................................................2230 LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COMPRESSOR..................................2231 LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT....................................................2231 AIR CONDITIONER CONTROL.............................................................................................2233 Control Operation...............................................................................................2233 FAN CONTROL DIAL............................................................................................2233 TEMPERATURE CONTROL DIAL....................................................................................2233 MODE CONTROL DIAL...........................................................................................2233 RECIRCULATION (REC) SWITCH..................................................................................2233 A/C SWITCH..................................................................................................2233 Discharge Air Flow..............................................................................................2234 System Description..............................................................................................2235 SWITCHES AND THEIR CONTROL FUNCTION.........................................................................2235 TROUBLE DIAGNOSIS...................................................................................................2236 How to Perform Trouble Diagnoses for Quick and Accurate Repair..................................................2236 WORK FLOW...................................................................................................2236 SYMPTOM TABLE...............................................................................................2236 Component Parts and Harness Connector Location..................................................................2237 ENGINE COMPARTMENT..........................................................................................2237 PASSENGER COMPARTMENT.......................................................................................2238 Schematic —A/C, M—..............................................................................................2239 Wiring Diagram — A/C, M —.......................................................................................2240 Operational Check...............................................................................................2244 CHECKING BLOWER.............................................................................................2244 CHECKING DISCHARGE AIR......................................................................................2244 CHECKING RECIRCULATION......................................................................................2244 CHECKING TEMPERATURE DECREASE...............................................................................2245 CHECKING TEMPERATURE INCREASE...............................................................................2245 CHECKING A/C SWITCH.........................................................................................2245 Mode Door.......................................................................................................2246 INSPECTION FLOW.............................................................................................2246 Air Mix Door....................................................................................................2247 INSPECTION FLOW.............................................................................................2247 Intake Door Motor Circuit.......................................................................................2248 INSPECTION FLOW.............................................................................................2248 COMPONENT DESCRIPTION.......................................................................................2248 Intake Door Motor.......................................................................................2248 DIAGNOSTIC PROCEDURE FOR INTAKE DOOR MOTOR..................................................................2249 Blower Motor Circuit............................................................................................2251 INSPECTION FLOW.............................................................................................2251 DIAGNOSTIC PROCEDURE FOR BLOWER MOTOR.......................................................................2251 COMPONENT INSPECTION........................................................................................2254 Blower Motor............................................................................................2254 Fan Switch..............................................................................................2254 Fan Resistor............................................................................................2254 Magnet Clutch Circuit...........................................................................................2255 INSPECTION FLOW.............................................................................................2255 DIAGNOSTIC PROCEDURE FOR MAGNET CLUTCH......................................................................2256 ELECTRICAL COMPONENT INSPECTION.............................................................................2260 A/C Relay...............................................................................................2260 Refrigerant Pressure Sensor.............................................................................2261 Insufficient Cooling............................................................................................2262 INSPECTION FLOW.............................................................................................2262 PERFORMANCE TEST DIAGNOSIS..................................................................................2263 PERFORMANCE CHART...........................................................................................2265 Test Condition..........................................................................................2265 Test Reading............................................................................................2265 TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE......................................................................2266 Both High and Low-pressure Sides are Too High...........................................................2266 High-pressure Side is Too High and Low-pressure Side is Too Low.........................................2266 High-pressure Side is Too Low and Low-pressure Side is Too High.........................................2267 Both High and Low-pressure Sides are Too Low............................................................2267 Low-pressure Side Sometimes Becomes Negative............................................................2268 Low-pressure Side Becomes Negative......................................................................2268 Insufficient Heating............................................................................................2269 INSPECTION FLOW.............................................................................................2269 Noise...........................................................................................................2270 INSPECTION FLOW.............................................................................................2270 CONTROLLER..........................................................................................................2271 Removal and Installation........................................................................................2271 REMOVAL.....................................................................................................2271 INSTALLATION................................................................................................2271 Disassembly and Assembly........................................................................................2271 BLOWER UNIT.........................................................................................................2272 Removal and Installation........................................................................................2272 REMOVAL.....................................................................................................2272 INSTALLATION................................................................................................2272 Disassembly and Assembly........................................................................................2273 BLOWER MOTOR........................................................................................................2274 Removal and Installation........................................................................................2274 REMOVAL.....................................................................................................2274 INSTALLATION................................................................................................2274 INTAKE DOOR MOTOR...................................................................................................2275 Removal and Installation........................................................................................2275 REMOVAL.....................................................................................................2275 INSTALLATION................................................................................................2275 BLOWER FAN RESISTOR.................................................................................................2276 Removal and Installation........................................................................................2276 REMOVAL.....................................................................................................2276 INSTALLATION................................................................................................2276 IN-CABIN MICROFILTER................................................................................................2277 Removal and Installation........................................................................................2277 FUNCTION....................................................................................................2277 REPLACEMENT TIMING..........................................................................................2277 REPLACEMENT PROCEDURES......................................................................................2277 HEATER & COOLING UNIT ASSEMBLY......................................................................................2278 Removal and Installation........................................................................................2278 REMOVAL.....................................................................................................2278 INSTALLATION................................................................................................2279 Disassembly and Assembly........................................................................................2280 MODE DOOR...........................................................................................................2281 Control Linkage Adjustment......................................................................................2281 MODE DOOR CONTROL CABLE.....................................................................................2281 AIR MIX DOOR........................................................................................................2282 Control Linkage Adjustment......................................................................................2282 AIR MIX DOOR CONTROL CABLE..................................................................................2282 HEATER CORE.........................................................................................................2283 Removal and Installation........................................................................................2283 REMOVAL.....................................................................................................2283 INSTALLATION................................................................................................2283 DUCTS AND GRILLES...................................................................................................2284 Removal and Installation........................................................................................2284 REMOVAL.....................................................................................................2284 Removal of Center Ventilator Grille.....................................................................2284 Removal of Side Ventilator Grille.......................................................................2285 Removal of Driver Ventilator Grille.....................................................................2285 Removal of Defroster Nozzle, Duct and Side Ventilator Duct..............................................2285 Removal of Adaptor......................................................................................2286 Removal of Multi-Box Duct...............................................................................2286 Removal of Foot Duct....................................................................................2286 Removal of Floor Duct...................................................................................2287 INSTALLATION................................................................................................2287 REFRIGERANT LINES...................................................................................................2288 HFC-134a (R-134a) Service Procedure.............................................................................2288 SETTING OF SERVICE TOOLS AND EQUIPMENT......................................................................2288 Discharging Refrigerant.................................................................................2288 Evacuating System and Charging Refrigerant..............................................................2288 Components......................................................................................................2290 Removal and Installation of Compressor..........................................................................2290 REMOVAL.....................................................................................................2290 INSTALLATION................................................................................................2291 Removal and Installation of Compressor Clutch...................................................................2292 REMOVAL.....................................................................................................2292 Overhaul................................................................................................2292 Inspection..............................................................................................2293 INSTALLATION................................................................................................2294 Break-In Operation......................................................................................2295 Removal and Installation of Low-Pressure Flexible Hose..........................................................2295 REMOVAL.....................................................................................................2295 INSTALLATION................................................................................................2295 Removal and Installation of High-Pressure Flexible Hose.........................................................2296 REMOVAL.....................................................................................................2296 INSTALLATION................................................................................................2296 Removal and Installation of High-Pressure Pipe..................................................................2296 REMOVAL.....................................................................................................2296 INSTALLATION................................................................................................2297 Removal and Installation of Condenser...........................................................................2297 REMOVAL.....................................................................................................2297 INSTALLATION................................................................................................2298 Removal and Installation of Liquid Tank.........................................................................2298 REMOVAL.....................................................................................................2298 INSTALLATION................................................................................................2298 Removal and Installation for Refrigerant Pressure Sensor........................................................2299 REMOVAL.....................................................................................................2299 INSTALLATION................................................................................................2299 Removal and Installation of Evaporator..........................................................................2299 REMOVAL.....................................................................................................2299 INSTALLATION................................................................................................2300 Removal and Installation of Expansion Valve.....................................................................2300 REMOVAL.....................................................................................................2300 INSTALLATION................................................................................................2300 Checking for Refrigerant Leaks..................................................................................2300 Checking System for Leaks Using the Fluorescent Leak Detector...................................................2301 Dye Injection...................................................................................................2301 Electronic Refrigerant Leak Detector............................................................................2301 PRECAUTIONS FOR HANDLING LEAK DETECTOR......................................................................2301 CHECKING PROCEDURE..........................................................................................2302 SERVICE DATA AND SPECIFICATIONS (SDS)...............................................................................2304 Compressor......................................................................................................2304 Lubricant.......................................................................................................2304 Refrigerant.....................................................................................................2304 Engine Idling Speed.............................................................................................2304 Belt Tension....................................................................................................2304 ELECTRICAL UNITS.................................................................................................... 45 FUSE BLOCK - JUNCTION BOX (J/B)..................................................................................... 48 FUSE AND FUSIBLE LINK BOX........................................................................................... 49 pb..........................................................................................................................2305 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................2305 PREPARATION.........................................................................................................2306 Commercial Service Tools........................................................................................2306 PARKING BRAKE SYSTEM................................................................................................2307 On-Vehicle Service..............................................................................................2307 LEVER STROKE................................................................................................2307 INSPECT COMPONENTS..........................................................................................2307 ADJUSTMENT..................................................................................................2307 PARKING BRAKE CONTROL...............................................................................................2308 Components......................................................................................................2308 Removal and Installation........................................................................................2308 REMOVAL.....................................................................................................2308 INSTALLATION................................................................................................2308 PARKING BRAKE SHOE..................................................................................................2309 Components......................................................................................................2309 Removal and Installation........................................................................................2309 REMOVAL.....................................................................................................2309 INSPECTION AFTER REMOVAL....................................................................................2310 Lining Thickness Inspection.............................................................................2310 Drum Inner Diameter Inspection..........................................................................2310 Other Inspections.......................................................................................2310 INSTALLATION................................................................................................2311 SERVICE DATA AND SPECIFICATIONS (SDS)...............................................................................2312 Parking Drum Brake..............................................................................................2312 Parking Brake Control...........................................................................................2312 pg..........................................................................................................................2313 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................2313 POWER SUPPLY ROUTING................................................................................................2314 Schematic.......................................................................................................2314 Wiring Diagram - POWER -........................................................................................2315 BATTERY POWER SUPPLY - IGNITION SW. IN ANY POSITION.........................................................2315 ACCESSORY POWER SUPPLY - IGNITION SW. IN “ACC” OR “ON”......................................................2319 IGNITION POWER SUPPLY - IGNITION SW. IN “ON” AND/OR “START”.................................................2320 Fuse............................................................................................................2324 Fusible Link....................................................................................................2324 Circuit Breaker.................................................................................................2324 GROUND..............................................................................................................2325 Ground Distribution.............................................................................................2325 MAIN HARNESS................................................................................................2325 ENGINE ROOM HARNESS.........................................................................................2327 ENGINE CONTROL HARNESS......................................................................................2329 BODY HARNESS................................................................................................2330 BODY NO. 2 HARNESS..........................................................................................2331 BACK DOOR SUB HARNESS/REAR WINDOW DEFOGGER HARNESS..........................................................2332 HARNESS.............................................................................................................2333 Harness Layout..................................................................................................2333 HOW TO READ HARNESS LAYOUTS.................................................................................2333 To Use the Grid Reference...............................................................................2333 OUTLINE.....................................................................................................2334 MAIN HARNESS................................................................................................2335 ENGINE ROOM HARNESS.........................................................................................2337 Engine Compartment for 2WD Models.......................................................................2337 Engine Compartment for AWD Models.......................................................................2339 Passenger Compartment...................................................................................2341 ENGINE CONTROL HARNESS......................................................................................2342 A/T Models..............................................................................................2342 M/T Models..............................................................................................2343 BODY HARNESS................................................................................................2344 BODY NO. 2 HARNESS..........................................................................................2345 ROOM LAMP HARNESS...........................................................................................2346 FRONT DOOR HARNESS..........................................................................................2347 LH Side.................................................................................................2347 RH Side.................................................................................................2347 REAR DOOR HARNESS...........................................................................................2348 LH Side.................................................................................................2348 RH Side.................................................................................................2348 BACK DOOR HARNESS...........................................................................................2349 Wiring Diagram Codes (Cell Codes)...............................................................................2350 ELECTRICAL UNITS LOCATION...........................................................................................2353 Electrical Units Location.......................................................................................2353 ENGINE COMPARTMENT..........................................................................................2353 PASSENGER COMPARTMENT.......................................................................................2354 HARNESS CONNECTOR...................................................................................................2356 Description.....................................................................................................2356 HARNESS CONNECTOR (TAB-LOCKING TYPE)........................................................................2356 HARNESS CONNECTOR (SLIDE-LOCKING TYPE)......................................................................2357 ELECTRICAL UNITS....................................................................................................2358 Terminal Arrangement............................................................................................2358 STANDARDIZED RELAY..................................................................................................2359 Description.....................................................................................................2359 NORMAL OPEN, NORMAL CLOSED AND MIXED TYPE RELAYS............................................................2359 TYPE OF STANDARDIZED RELAYS.................................................................................2359 FUSE BLOCK - JUNCTION BOX (J/B).....................................................................................2361 Terminal Arrangement............................................................................................2361 FUSE AND FUSIBLE LINK BOX...........................................................................................2362 Terminal Arrangement............................................................................................2362 pr..........................................................................................................................2363 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................2363 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING................................................................2364 NVH Troubleshooting Chart.......................................................................................2364 REAR PROPELLER SHAFT................................................................................................2365 On-Vehicle Inspection...........................................................................................2365 APPEARANCE AND NOISE INSPECTION.............................................................................2365 PROPELLER SHAFT VIBRATION...................................................................................2365 Removal and Installation........................................................................................2366 COMPONENTS..................................................................................................2366 REMOVAL.....................................................................................................2366 INSPECTION..................................................................................................2367 INSTALLATION................................................................................................2368 SERVICE DATA AND SPECIFICATIONS (SDS)...............................................................................2369 General Specifications..........................................................................................2369 Journal Axial Play..............................................................................................2369 Propeller Shaft Runout..........................................................................................2369 rax.........................................................................................................................2371 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................2371 2WD.................................................................................................................2372 PREPARATION.....................................................................................................2372 Special Service Tools [SST].................................................................................2372 Commercial Service Tools....................................................................................2373 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING............................................................2374 NVH Troubleshooting Chart...................................................................................2374 WHEEL HUB.......................................................................................................2375 On-Vehicle Inspection and Service...........................................................................2375 WHEEL BEARING INSPECTION................................................................................2375 Removal and Installation....................................................................................2375 COMPONENT...............................................................................................2375 REMOVAL.................................................................................................2375 INSPECTION AFTER REMOVAL................................................................................2376 INSTALLATION............................................................................................2376 Disassembly and Assembly....................................................................................2377 DISASSEMBLY.............................................................................................2377 INSPECTION AFTER DISASSEMBLY............................................................................2378 Wheel Hub...........................................................................................2378 Axle Housing........................................................................................2378 Snap Ring...........................................................................................2378 Back Plate..........................................................................................2378 ASSEMBLY................................................................................................2378 INSPECTION AFTER ASSEMBLY...............................................................................2379 SERVICE DATA AND SPECIFICATIONS (SDS)...........................................................................2380 Wheel Bearing...............................................................................................2380 AWD.................................................................................................................2381 PRECAUTIONS.....................................................................................................2381 Caution.....................................................................................................2381 PREPARATION.....................................................................................................2382 Special Service Tools [SST].................................................................................2382 Commercial Service Tools....................................................................................2383 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING............................................................2384 NVH Troubleshooting Chart...................................................................................2384 WHEEL HUB.......................................................................................................2385 On-Vehicle Inspection and Service...........................................................................2385 WHEEL BEARING INSPECTION................................................................................2385 Removal and Installation....................................................................................2385 COMPONENT...............................................................................................2385 REMOVAL.................................................................................................2385 INSPECTION AFTER REMOVAL................................................................................2387 INSTALLATION............................................................................................2387 Disassembly and Assembly....................................................................................2387 DISASSEMBLY.............................................................................................2387 INSPECTION AFTER DISASSEMBLY............................................................................2387 Wheel Hub...........................................................................................2387 Axle Housing........................................................................................2388 Snap Ring...........................................................................................2388 Back Plate..........................................................................................2388 ASSEMBLY................................................................................................2388 INSPECTION AFTER ASSEMBLY...............................................................................2389 REAR DRIVE SHAFT................................................................................................2390 Removal and Installation....................................................................................2390 COMPONENT...............................................................................................2390 REMOVAL.................................................................................................2390 INSPECTION AFTER REMOVAL................................................................................2390 INSTALLATION............................................................................................2390 Disassembly and Assembly....................................................................................2391 COMPONENT...............................................................................................2391 DISASSEMBLY.............................................................................................2391 Final Drive Side....................................................................................2391 Wheel Side..........................................................................................2392 INSPECTION AFTER DISASSEMBLY............................................................................2393 Shaft...............................................................................................2393 Joint Sub-Assembly (Wheel Side).....................................................................2393 Housing and Spider Assembly (Final Drive Side)......................................................2393 ASSEMBLY................................................................................................2393 Final Drive Side....................................................................................2393 Wheel Side..........................................................................................2394 SERVICE DATA AND SPECIFICATIONS (SDS)...........................................................................2396 Wheel Bearing...............................................................................................2396 Drive Shaft.................................................................................................2396 rf..........................................................................................................................2397 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................2397 PRECAUTIONS.........................................................................................................2398 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”.....................2398 Precautions.....................................................................................................2398 PREPARATION.........................................................................................................2399 Special Service Tools...........................................................................................2399 Commercial Service Tools........................................................................................2399 SQUEAK AND RATTLE TROUBLE DIAGNOSES.................................................................................2400 Work Flow.......................................................................................................2400 CUSTOMER INTERVIEW..........................................................................................2400 DUPLICATE THE NOISE AND TEST DRIVE..........................................................................2401 CHECK RELATED SERVICE BULLETINS.............................................................................2401 LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE................................................................2401 REPAIR THE CAUSE............................................................................................2401 CONFIRM THE REPAIR..........................................................................................2402 Generic Squeak and Rattle Troubleshooting.......................................................................2402 INSTRUMENT PANEL............................................................................................2402 CENTER CONSOLE..............................................................................................2402 DOORS.......................................................................................................2402 TRUNK.......................................................................................................2403 SUNROOF/HEADLINING..........................................................................................2403 SEATS.......................................................................................................2403 UNDERHOOD...................................................................................................2403 Diagnostic Worksheet............................................................................................2404 SUNROOF.............................................................................................................2406 System Description..............................................................................................2406 RESUMING OPERATION..........................................................................................2406 Component Parts Location........................................................................................2406 Wiring Diagram — SROOF —........................................................................................2407 Terminal and Reference Value for Sunroof Switch.................................................................2409 Wind Deflector Inspection.......................................................................................2409 Glass Lid Weatherstrip Inspection...............................................................................2409 Link and Wire Assembly Inspection...............................................................................2409 Fitting Adjustment..............................................................................................2410 LONGITUDINAL/LATERAL CLEARANCE ADJUSTMENT...................................................................2410 SURFACE MISMATCH ADJUSTMENT.................................................................................2410 Removal and Installation........................................................................................2411 SUNROOF UNIT................................................................................................2412 Removal.................................................................................................2412 Installation............................................................................................2413 GLASS LID...................................................................................................2413 Removal.................................................................................................2413 Installation............................................................................................2413 SUNSHADE....................................................................................................2413 Removal.................................................................................................2413 Installation............................................................................................2414 WIND DEFLECTOR..............................................................................................2414 Removal.................................................................................................2414 Installation............................................................................................2414 SUNROOF MOTOR...............................................................................................2414 Removal.................................................................................................2414 Installation............................................................................................2414 ELECTRICAL UNITS.................................................................................................... 45 FUSE BLOCK - JUNCTION BOX (J/B)..................................................................................... 48 FUSE AND FUSIBLE LINK BOX........................................................................................... 49 rfd.........................................................................................................................2415 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................2415 PRECAUTIONS.........................................................................................................2416 Service Notice or Precautions...................................................................................2416 PREPARATION.........................................................................................................2417 Special Service Tools...........................................................................................2417 Commercial Service Tools........................................................................................2419 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING................................................................2420 NVH Troubleshooting Chart.......................................................................................2420 DESCRIPTION.........................................................................................................2421 Cross-Sectional View............................................................................................2421 DIFFERENTIAL GEAR OIL...............................................................................................2422 Changing Differential Gear Oil..................................................................................2422 DRAINING....................................................................................................2422 FILLING.....................................................................................................2422 Checking Differential Gear Oil..................................................................................2422 OIL LEAKAGE AND OIL LEVEL...................................................................................2422 FRONT OIL SEAL......................................................................................................2423 Removal and Installation........................................................................................2423 REMOVAL.....................................................................................................2423 INSTALLATION................................................................................................2423 SIDE OIL SEAL.......................................................................................................2425 Removal and Installation........................................................................................2425 REMOVAL.....................................................................................................2425 INSTALLATION................................................................................................2425 ELECTRIC CONTROLLED COUPLING........................................................................................2426 Removal and Installation........................................................................................2426 REMOVAL.....................................................................................................2426 INSTALLATION................................................................................................2427 REAR FINAL DRIVE ASSEMBLY...........................................................................................2428 Removal and Installation........................................................................................2428 COMPONENTS..................................................................................................2428 REMOVAL.....................................................................................................2428 INSTALLATION................................................................................................2429 Disassembly and Assembly........................................................................................2430 COMPONENTS..................................................................................................2430 ASSEMBLY INSPECTION AND ADJUSTMENT..........................................................................2431 Total Preload Torque....................................................................................2431 Drive Gear Runout.......................................................................................2431 Tooth Contact...........................................................................................2432 Backlash................................................................................................2434 Companion Flange Runout.................................................................................2434 DISASSEMBLY.................................................................................................2435 Electric Controlled Coupling Assembly...................................................................2435 Differential Assembly...................................................................................2436 Drive Pinion Assembly...................................................................................2437 INSPECTION AFTER DISASSEMBLY................................................................................2438 ASSEMBLY....................................................................................................2439 Drive Pinion Assembly...................................................................................2439 Differential Assembly...................................................................................2442 Electric Controlled Coupling Assembly...................................................................2445 SERVICE DATA AND SPECIFICATIONS (SDS)...............................................................................2448 General Specifications..........................................................................................2448 Inspection and Adjustment.......................................................................................2448 DRIVE GEAR RUNOUT...........................................................................................2448 DIFFERENTIAL SIDE GEAR CLEARANCE............................................................................2448 PRELOAD TORQUE..............................................................................................2448 BACKLASH....................................................................................................2448 COMPANION FLANGE RUNOUT.....................................................................................2448 SELECTIVE PARTS.............................................................................................2448 Side Gear Thrust Washer.................................................................................2448 Drive Pinion Adjusting Shim.............................................................................2449 Side Bearing Adjusting Shim.............................................................................2449 rsu.........................................................................................................................2451 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................2451 PRECAUTIONS.........................................................................................................2452 Caution.........................................................................................................2452 PREPARATION.........................................................................................................2453 Special Service Tools [SST].....................................................................................2453 Commercial Service Tools........................................................................................2453 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING................................................................2454 NVH Troubleshooting Chart.......................................................................................2454 REAR SUSPENSION ASSEMBLY............................................................................................2455 On-Vehicle Inspection and Service...............................................................................2455 STRUT INSPECTION............................................................................................2455 Wheel Alignment Inspection......................................................................................2455 DESCRIPTION.................................................................................................2455 PREMINARY CHECK.............................................................................................2455 CAMBER INSPECTION...........................................................................................2455 TOE-IN......................................................................................................2455 Component.......................................................................................................2457 Removal and Installation........................................................................................2458 REMOVAL.....................................................................................................2458 INSTALLATION................................................................................................2459 COIL SPRING AND STRUT...............................................................................................2460 Removal and Installation........................................................................................2460 REMOVAL.....................................................................................................2460 INSTALLATION................................................................................................2460 Disassembly and Assembly........................................................................................2461 DISASSEMBLY.................................................................................................2461 INSPECTION AFTER DISASSEMBLY................................................................................2461 Strut Inspection........................................................................................2461 Mounting Insulator and Rubber Parts Inspection..........................................................2461 Coil Spring Inspection..................................................................................2461 ASSEMBLY....................................................................................................2462 FRONT PARALLEL LINK.................................................................................................2463 Removal and Installation........................................................................................2463 REMOVAL.....................................................................................................2463 INSPECTION AFTER REMOVAL....................................................................................2463 INSTALLATION................................................................................................2463 REAR PARALLEL LINK..................................................................................................2464 Removal and Installation........................................................................................2464 REMOVAL.....................................................................................................2464 INSPECTION AFTER REMOVAL....................................................................................2464 INSTALLATION................................................................................................2464 RADIUS ROD..........................................................................................................2465 Removal and Installation........................................................................................2465 REMOVAL.....................................................................................................2465 INSPECTION AFTER REMOVAL....................................................................................2465 INSTALLATION................................................................................................2465 STABILIZER BAR......................................................................................................2466 Removal and Installation........................................................................................2466 REMOVAL.....................................................................................................2466 INSPECTION AFTER REMOVAL....................................................................................2466 INSTALLATION................................................................................................2466 REAR SUSPENSION MEMBER..............................................................................................2467 Removal and Installation........................................................................................2467 REMOVAL.....................................................................................................2467 INSPECTION AFTER REMOVAL....................................................................................2467 INSTALLATION................................................................................................2467 SERVICE DATA AND SPECIFICATIONS (SDS)...............................................................................2468 Wheel Alignment (Unladen).......................................................................................2468 Wheelarch Height (Unladen*).....................................................................................2468 sb..........................................................................................................................2469 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................2469 PRECAUTIONS.........................................................................................................2470 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”.....................2470 Precautions for Seat Belt Service...............................................................................2470 AFTER A COLLISION...........................................................................................2470 SEAT BELTS..........................................................................................................2471 System Description..............................................................................................2471 SEAT BELT WARNING LAMP......................................................................................2471 Removal and Installation of Front Seat Belt.....................................................................2471 REMOVAL OF SEAT BELT RETRACTOR..............................................................................2471 INSTALLATION OF SEAT BELT RETRACTOR.........................................................................2471 REMOVAL OF SEAT BELT BUCKLE.................................................................................2472 INSTALLATION OF SEAT BELT BUCKLE............................................................................2472 Removal and Installation of Rear Seat Belt......................................................................2472 REMOVAL OF LH/RH SEAT BELT..................................................................................2472 INSTALLATION OF LH/RH SEAT BELT.............................................................................2472 REMOVAL OF CENTER SEAT BELT.................................................................................2473 INSTALLATION OF CENTER SEAT BELT............................................................................2473 Seat Belt Inspection............................................................................................2474 AFTER A COLLISION...........................................................................................2474 PRELIMINARY CHECKS..........................................................................................2474 SEAT BELT RETRACTOR ON-VEHICLE CHECK........................................................................2475 Emergency Locking Retractors (ELR) and Automatic Locking Retractors (ALR)...............................2475 ELR Function Stationary Check...........................................................................2475 ALR Function Stationary Check...........................................................................2475 ELR Function Moving Check...............................................................................2475 SEAT BELT RETRACTOR OFF-VEHICLE CHECK.......................................................................2476 TOP TETHER STRAP CHILD RESTRAINT....................................................................................2477 Removal and Installation........................................................................................2477 REMOVAL.....................................................................................................2477 INSTALLATION................................................................................................2477 sc..........................................................................................................................2479 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................2479 PRECAUTIONS.........................................................................................................2480 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”.....................2480 Wiring Diagrams and Trouble Diagnosis...........................................................................2480 PREPARATION.........................................................................................................2481 Special Service Tools...........................................................................................2481 Commercial Service Tools........................................................................................2481 BATTERY.............................................................................................................2482 How to Handle Battery...........................................................................................2482 METHODS OF PREVENTING OVER-DISCHARGE........................................................................2482 CHECKING ELECTROLYTE LEVEL..................................................................................2483 Sulphation..............................................................................................2483 SPECIFIC GRAVITY CHECK......................................................................................2483 Hydrometer Temperature Correction.......................................................................2483 CHARGING THE BATTERY........................................................................................2484 Charging Rates..........................................................................................2484 Trouble Diagnoses with Battery/Starting/Charging System Tester..................................................2484 DIAGNOSTIC RESULT ITEM CHART................................................................................2486 Removal and Installation........................................................................................2486 STARTING SYSTEM.....................................................................................................2487 System Description..............................................................................................2487 M/T MODELS..................................................................................................2487 A/T MODELS..................................................................................................2487 Wiring Diagram — START — / M/T Models...........................................................................2488 Wiring Diagram — START — / A/T Models...........................................................................2489 Trouble Diagnoses with Battery/Starting/Charging System Tester..................................................2490 DIAGNOSTIC RESULT ITEM CHART................................................................................2490 WORK FLOW...................................................................................................2491 DIAGNOSTIC PROCEDURE 1......................................................................................2492 Check “B” Terminal Circuit..............................................................................2492 DIAGNOSTIC PROCEDURE 2......................................................................................2493 Check “S” Connector Circuit.............................................................................2493 MINIMUM SPECIFICATION OF CRANKING VOLTAGE REFERENCING COOLANT TEMPERATURE...................................2493 Removal and Installation........................................................................................2494 M/T MODELS..................................................................................................2494 Removal.................................................................................................2494 Installation............................................................................................2494 A/T MODELS..................................................................................................2495 Removal.................................................................................................2495 Installation............................................................................................2495 Disassembly and Assembly........................................................................................2496 M/T MODELS..................................................................................................2496 A/T MODELS..................................................................................................2497 INSPECTION AFTER DISASSEMBLY................................................................................2497 Pinion/Clutch Check.....................................................................................2497 CHARGING SYSTEM.....................................................................................................2498 System Description..............................................................................................2498 DESCRIPTION.................................................................................................2498 MALFUNCTION INDICATOR.......................................................................................2498 Wiring Diagram — CHARGE —.......................................................................................2499 Trouble Diagnoses with Battery/Starting/Charging System Tester..................................................2500 DIAGNOSTIC RESULT ITEM CHART................................................................................2501 WORK FLOW...................................................................................................2502 PRELIMINARY INSPECTION......................................................................................2503 DIAGNOSTIC PROCEDURE 1......................................................................................2504 Check “L” Terminal Circuit (Open).......................................................................2504 DIAGNOSTIC PROCEDURE 2......................................................................................2504 Check “L” Terminal Circuit (Short)......................................................................2504 DIAGNOSTIC PROCEDURE 3......................................................................................2505 Check “S” Terminal Circuit..............................................................................2505 DIAGNOSTIC PROCEDURE 4......................................................................................2506 Check “B” Terminal Circuit..............................................................................2506 Removal and Installation........................................................................................2507 REMOVAL.....................................................................................................2507 ALTERNATOR PULLEY INSPECTION................................................................................2507 One-Way Clutch Pulley Check.............................................................................2507 INSTALLATION................................................................................................2508 Disassembly and Assembly........................................................................................2508 DISASSEMBLY FOR ALTERNATOR PULLEY...........................................................................2508 ASSEMBLY FOR ALTERNATOR PULLEY..............................................................................2509 SERVICE DATA AND SPECIFICATIONS (SDS)...............................................................................2510 Battery.........................................................................................................2510 Starter.........................................................................................................2510 Alternator......................................................................................................2510 ELECTRICAL UNITS.................................................................................................... 45 FUSE BLOCK - JUNCTION BOX (J/B)..................................................................................... 48 FUSE AND FUSIBLE LINK BOX........................................................................................... 49 se..........................................................................................................................2511 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................2511 PRECAUTIONS.........................................................................................................2512 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”.....................2512 Service Notice..................................................................................................2512 Precautions.....................................................................................................2512 PREPARATION.........................................................................................................2513 Special Service Tools...........................................................................................2513 Commercial Service Tools........................................................................................2513 SQUEAK AND RATTLE TROUBLE DIAGNOSES.................................................................................2514 Work Flow.......................................................................................................2514 CUSTOMER INTERVIEW..........................................................................................2514 DUPLICATE THE NOISE AND TEST DRIVE..........................................................................2515 CHECK RELATED SERVICE BULLETINS.............................................................................2515 LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE................................................................2515 REPAIR THE CAUSE............................................................................................2515 CONFIRM THE REPAIR..........................................................................................2516 Generic Squeak and Rattle Troubleshooting.......................................................................2516 INSTRUMENT PANEL............................................................................................2516 CENTER CONSOLE..............................................................................................2516 DOORS.......................................................................................................2516 TRUNK.......................................................................................................2517 SUNROOF/HEADLINING..........................................................................................2517 SEATS.......................................................................................................2517 UNDERHOOD...................................................................................................2517 Diagnostic Worksheet............................................................................................2518 POWER SEAT..........................................................................................................2520 Wiring Diagram — SEAT —.........................................................................................2520 HEATED SEAT.........................................................................................................2522 Schematic.......................................................................................................2522 Wiring Diagram — HSEAT —........................................................................................2523 FRONT SEAT..........................................................................................................2527 Component Parts Drawing.........................................................................................2527 MANUAL SEAT.................................................................................................2527 POWER SEAT..................................................................................................2528 Removal and Installation........................................................................................2529 REMOVAL.....................................................................................................2529 INSTALLATION................................................................................................2529 Disassembly and Assembly of Seatback............................................................................2529 MANUAL SEAT.................................................................................................2529 Disassembly.............................................................................................2529 Assembly................................................................................................2530 Removal of Seatback Assembly............................................................................2530 Installation of Seatback Assembly.......................................................................2530 POWER SEAT..................................................................................................2531 Disassembly.............................................................................................2531 Assembly................................................................................................2531 Removal of Seatback Assembly............................................................................2531 Installation of Seatback Assembly.......................................................................2532 Disassembly and Assembly of Seat Cushion........................................................................2532 MANUAL SEAT.................................................................................................2532 Disassembly.............................................................................................2532 Assembly................................................................................................2533 POWER SEAT..................................................................................................2533 Disassembly.............................................................................................2533 Assembly................................................................................................2533 REAR SEAT...........................................................................................................2534 Component Parts Drawing.........................................................................................2534 STANDARD SEAT...............................................................................................2534 SEAT WITH ARMREST...........................................................................................2535 Removal and Installation........................................................................................2536 SEAT CUSHION................................................................................................2536 SEATBACK....................................................................................................2536 REAR SEAT STRIKER (SIDE)....................................................................................2537 REAR SEAT CENTER BRACKET....................................................................................2537 REAR SEAT STRIKER (FLOOR)...................................................................................2537 Disassembly and Assembly........................................................................................2537 REAR SEATBACK LOCK KNOB.....................................................................................2537 ARMREST.....................................................................................................2537 ELECTRICAL UNITS.................................................................................................... 45 FUSE BLOCK - JUNCTION BOX (J/B)..................................................................................... 48 FUSE AND FUSIBLE LINK BOX........................................................................................... 49 srs.........................................................................................................................2539 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................2539 PRECAUTIONS.........................................................................................................2540 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”.....................2540 Precautions for SRS “AIR BAG” and “SEAT BELT PRE-TENSIONER” Service.............................................2540 Wiring Diagrams and Trouble Diagnosis...........................................................................2540 PREPARATION.........................................................................................................2541 Commercial Service Tools........................................................................................2541 SUPPLEMENTAL RESTRAINT SYSTEM (SRS).................................................................................2542 SRS Configuration...............................................................................................2542 Front Seat Belt Pre-Tensioner with Load Limiter.................................................................2542 Front Side Air Bag..............................................................................................2543 TROUBLE DIAGNOSIS...................................................................................................2544 Trouble Diagnosis Introduction..................................................................................2544 DIAGNOSIS FUNCTION..........................................................................................2544 HOW TO PERFORM TROUBLE DIAGNOSES FOR QUICK AND ACCURATE REPAIR..............................................2544 Information from Customer...............................................................................2544 Preliminary Check.......................................................................................2544 WORK FLOW...................................................................................................2545 Component Parts Location........................................................................................2546 Wiring Diagram — SRS —..........................................................................................2547 CONSULT-II Function.............................................................................................2549 DIAGNOSIS MODE FOR CONSULT-II...............................................................................2549 HOW TO CHANGE SELF-DIAGNOSIS MODE WITH CONSULT-II...........................................................2549 From User Mode to Diagnosis Mode........................................................................2549 From Diagnosis Mode to User Mode........................................................................2549 HOW TO ERASE SELF-DIAGNOSIS RESULTS.........................................................................2550 Self-Diagnosis Function (Without CONSULT-II)....................................................................2550 HOW TO CHANGE SELF-DIAGNOSIS MODE WITHOUT CONSULT-II........................................................2550 HOW TO ERASE SELF-DIAGNOSIS RESULTS.........................................................................2550 SRS Operation Check.............................................................................................2551 DIAGNOSTIC PROCEDURE 1......................................................................................2551 Checking Air Bag Operation by Using “AIR BAG” Warning Lamp — User Mode..................................2551 Trouble Diagnosis with CONSULT–II...............................................................................2553 DIAGNOSTIC PROCEDURE 2......................................................................................2553 Inspecting SRS Malfunctioning Parts by Using CONSULT-II — DIAGNOSIS MODE................................2553 CONSULT-II Diagnostic Code Chart (“SELF-DIAG [CURRENT]”)................................................2554 DIAGNOSTIC PROCEDURE 3......................................................................................2557 DIAGNOSTIC PROCEDURE 4 (CONTINUED FROM DIAGNOSTIC PROCEDURE 2)..............................................2559 DIAGNOSTIC PROCEDURE 5......................................................................................2559 CONSULT-II Diagnostic Code Chart (“SELF-DIAG [PAST]” or “TROUBLE DIAG RECORD”)..........................2561 Trouble Diagnosis without CONSULT-II............................................................................2562 DIAGNOSTIC PROCEDURE 6......................................................................................2562 Inspecting SRS Malfunctioning Parts By Using “AIR BAG” Warning Lamp — Diagnosis Mode....................2562 WARNING LAMP FLASH CODE CHART...............................................................................2564 Trouble Diagnosis: “AIR BAG” Warning Lamp Does Not Turn OFF.....................................................2567 DIAGNOSTIC PROCEDURE 7......................................................................................2567 Trouble Diagnosis: “AIR BAG” Warning Lamp Does Not Turn ON......................................................2568 DIAGNOSTIC PROCEDURE 8......................................................................................2568 DRIVER AIR BAG MODULE...............................................................................................2569 Removal and Installation........................................................................................2569 REMOVAL.....................................................................................................2569 INSTALLATION................................................................................................2570 SPIRAL CABLE........................................................................................................2572 Removal and Installation........................................................................................2572 REMOVAL.....................................................................................................2572 INSTALLATION................................................................................................2573 FRONT PASSENGER AIR BAG MODULE......................................................................................2574 Removal and Installation........................................................................................2574 REMOVAL.....................................................................................................2574 INSTALLATION................................................................................................2574 SIDE AIR BAG (SATELLITE) SENSOR.....................................................................................2575 Removal and Installation........................................................................................2575 REMOVAL.....................................................................................................2575 INSTALLATION................................................................................................2575 FRONT SEAT BELT PRE-TENSIONER.......................................................................................2576 Removal and Installation........................................................................................2576 DIAGNOSIS SENSOR UNIT...............................................................................................2577 Removal and Installation........................................................................................2577 REMOVAL.....................................................................................................2577 INSTALLATION................................................................................................2577 ECU DISCRIMINATED NO........................................................................................2577 COLLISION DIAGNOSIS.................................................................................................2578 For Frontal Collision...........................................................................................2578 SRS INSPECTION (FOR FRONTAL COLLISION)......................................................................2578 For Side Collision..............................................................................................2579 WHEN THE SIDE AIR BAG IS ACTIVATED IN THE SIDE COLLISION:...................................................2579 WHEN SRS IS NOT ACTIVATED IN THE SIDE COLLISION:............................................................2579 SRS INSPECTION (FOR SIDE COLLISION).........................................................................2580 ELECTRICAL UNITS.................................................................................................... 45 FUSE BLOCK - JUNCTION BOX (J/B)..................................................................................... 48 FUSE AND FUSIBLE LINK BOX........................................................................................... 49 tf..........................................................................................................................2581 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................2581 PRECAUTIONS.........................................................................................................2583 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”.....................2583 Precautions.....................................................................................................2583 Service Notice or Precautions...................................................................................2584 Wiring Diagrams and Trouble Diagnosis...........................................................................2584 PREPARATION.........................................................................................................2585 Special Service Tools...........................................................................................2585 Commercial Service Tools........................................................................................2587 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING................................................................2588 NVH Troubleshooting Chart.......................................................................................2588 TRANSFER OIL........................................................................................................2589 Changing Transfer Oil...........................................................................................2589 DRAINING....................................................................................................2589 FILLING.....................................................................................................2589 Checking Transfer Oil...........................................................................................2589 OIL LEAKAGE AND OIL LEVEL...................................................................................2589 AWD SYSTEM..........................................................................................................2590 Power Transfer Diagram..........................................................................................2590 System Description..............................................................................................2590 ELECTRIC CONTROLLED COUPLING................................................................................2590 Operation Principle.....................................................................................2590 AWD CONTROL UNIT............................................................................................2590 AWD MODE SWITCH.............................................................................................2591 AUTO Mode...............................................................................................2591 LOCK Mode...............................................................................................2591 2WD Mode................................................................................................2591 AWD INDICATOR LAMP AND LOCK INDICATOR LAMP..................................................................2591 AWD WARNING LAMP............................................................................................2591 AWD Warning Lamp Indication.............................................................................2591 System Diagram..................................................................................................2592 COMPONENTS FUNCTION DESCRIPTION.............................................................................2593 CAN Communication...............................................................................................2593 SYSTEM DESCRIPTION..........................................................................................2593 TROUBLE DIAGNOSIS...................................................................................................2594 Fail-Safe Function..............................................................................................2594 How to Perform Trouble Diagnosis................................................................................2594 BASIC CONCEPT...............................................................................................2594 Location of Electrical Parts....................................................................................2595 Circuit Diagram.................................................................................................2596 Wiring Diagram — AWD —..........................................................................................2597 Trouble Diagnosis Chart for Symptoms............................................................................2600 AWD Control Unit Input/Output Signal Reference Values...........................................................2601 AWD CONTROL UNIT INSPECTION TABLE...........................................................................2601 Specifications with CONSULT-II..........................................................................2601 CONSULT-II Function (ALL MODE AWD/4WD)..........................................................................2602 FUNCTION....................................................................................................2602 CONSULT-II SETTING PROCEDURE................................................................................2602 SELF-DIAG RESULTS MODE......................................................................................2603 Operation Procedure.....................................................................................2603 Display Item List.......................................................................................2603 How to Erase Self-Diagnosis Results.....................................................................2604 DATA MONITOR MODE...........................................................................................2604 Operation Procedure.....................................................................................2604 Display Item List.......................................................................................2604 ACTIVE TEST MODE............................................................................................2605 Description.............................................................................................2605 Test Item...............................................................................................2605 AWD CONTROL UNIT PART NUMBER................................................................................2605 TROUBLE DIAGNOSIS FOR SYSTEM........................................................................................2606 Power Supply Circuit for AWD Control Unit.......................................................................2606 CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE.............................................................2606 DIAGNOSTIC PROCEDURE........................................................................................2606 AWD Control Unit................................................................................................2607 DIAGNOSTIC PROCEDURE........................................................................................2607 ABS System......................................................................................................2608 DIAGNOSTIC PROCEDURE........................................................................................2608 AWD Solenoid....................................................................................................2608 CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE.............................................................2608 DIAGNOSTIC PROCEDURE........................................................................................2609 COMPONENT INSPECTION........................................................................................2611 AWD Actuator Relay..............................................................................................2612 CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE.............................................................2612 DIAGNOSTIC PROCEDURE........................................................................................2612 AWD Mode Switch.................................................................................................2613 CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE.............................................................2613 DIAGNOSTIC PROCEDURE........................................................................................2613 COMPONENT INSPECTION........................................................................................2615 Engine Control Signal...........................................................................................2615 DIAGNOSTIC PROCEDURE........................................................................................2615 CAN Communication Line..........................................................................................2616 DIAGNOSTIC PROCEDURE........................................................................................2616 TROUBLE DIAGNOSIS FOR SYMPTOMS......................................................................................2617 AWD Indicator Lamp and LOCK Indicator Lamp Do Not Turn ON for Approx. 1 Second When Ignition Swit...............2617 DIAGNOSTIC PROCEDURE........................................................................................2617 AWD Warning Lamp Does Not Turn ON When Ignition Switch Is Turned to ON..........................................2618 DIAGNOSTIC PROCEDURE........................................................................................2618 AWD Warning Lamp Does Not Turn OFF Several Seconds After Engine Started.........................................2619 DIAGNOSTIC PROCEDURE........................................................................................2619 AWD Mode Cannot Be Switched After Engine Is Started.............................................................2620 DIAGNOSTIC PROCEDURE........................................................................................2620 Heavy Tight-Corner Braking Symptom Occurs When Vehicle Is Driven in AUTO Mode and Steering Wheel ...............2621 DIAGNOSTIC PROCEDURE........................................................................................2621 Vehicle Does Not Enter AWD Mode Even Though AWD Warning Lamp Turned to OFF......................................2622 DIAGNOSTIC PROCEDURE........................................................................................2622 While Driving, AWD Warning Lamp Flashes Rapidly (When Flashing in Approx. 1 Minute and Then Turni...............2623 While Driving, AWD Warning Lamp Flashes Slowly (When Continuing to Flash Until Turning Ignition S...............2623 DIAGNOSTIC PROCEDURE........................................................................................2623 AWD CONTROL UNIT....................................................................................................2625 Removal and Installation........................................................................................2625 REMOVAL.....................................................................................................2625 INSTALLATION................................................................................................2625 SIDE OIL SEAL.......................................................................................................2626 Removal and Installation........................................................................................2626 REMOVAL.....................................................................................................2626 INSTALLATION................................................................................................2626 AIR BREATHER HOSE...................................................................................................2627 Components......................................................................................................2627 Removal and Installation........................................................................................2627 TRANSFER ASSEMBLY...................................................................................................2628 Removal and Installation........................................................................................2628 COMPONENTS..................................................................................................2628 REMOVAL.....................................................................................................2628 INSTALLATION................................................................................................2629 Disassembly and Assembly........................................................................................2630 COMPONENTS..................................................................................................2630 ASSEMBLY INSPECTION.........................................................................................2631 Backlash................................................................................................2631 Tooth Contact...........................................................................................2631 Pinion Bearing Preload Torque...........................................................................2633 Total Preload Torque....................................................................................2634 Companion Flange Runout.................................................................................2634 DISASSEMBLY.................................................................................................2635 Pinion Sleeve Assembly..................................................................................2635 Adapter Case............................................................................................2636 Drive Gear Assembly.....................................................................................2638 Transfer Case...........................................................................................2638 INSPECTION AFTER DISASSEMBLY................................................................................2639 Gears...................................................................................................2639 Bearings................................................................................................2639 Washers and Shims.......................................................................................2639 Oil Seals...............................................................................................2639 SELECTING ADJUSTING SHIMS...................................................................................2640 Gear Ring Bearing Adjusting Shim (Transfer Case Side)...................................................2640 Gear Ring Bearing Adjusting Shim (Adapter Case Side)....................................................2640 Pinion Sleeve Shim......................................................................................2641 ASSEMBLY....................................................................................................2642 Transfer Case...........................................................................................2642 Drive Gear Assembly.....................................................................................2643 Adapter Case............................................................................................2644 Pinion Sleeve Assembly..................................................................................2645 SERVICE DATA AND SPECIFICATIONS (SDS)...............................................................................2647 General Specifications..........................................................................................2647 Inspection and Adjustment.......................................................................................2647 PRELOAD TORQUE BEFORE DISASSEMBLY...........................................................................2647 PRELOAD TORQUE AFTER DISASSEMBLY AND REASSEMBLY.............................................................2647 BACKLASH....................................................................................................2647 COMPANION FLANGE RUNOUT.....................................................................................2647 SELECTIVE PARTS.............................................................................................2647 Gear Ring Bearing Adjusting Shim (Transfer Case Side)...................................................2647 Gear Ring Bearing Adjusting Shim (Adapter Case Side)....................................................2648 Pinion Sleeve Shim......................................................................................2648 ELECTRICAL UNITS.................................................................................................... 45 FUSE BLOCK - JUNCTION BOX (J/B)..................................................................................... 48 FUSE AND FUSIBLE LINK BOX........................................................................................... 49 wt..........................................................................................................................2649 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................2649 PREPARATION.........................................................................................................2650 Commercial Service Tools........................................................................................2650 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING................................................................2651 NVH Troubleshooting Chart.......................................................................................2651 ROAD WHEEL..........................................................................................................2652 Inspection......................................................................................................2652 ALUMINUM WHEEL..............................................................................................2652 STEEL WHEEL.................................................................................................2652 ROAD WHEEL TIRE ASSEMBLY............................................................................................2653 Balancing Wheels (Bonding Weight Type)..........................................................................2653 REMOVAL.....................................................................................................2653 WHEEL BALANCE ADJUSTMENT....................................................................................2653 Rotation........................................................................................................2654 SERVICE DATA AND SPECIFICATIONS (SDS)...............................................................................2655 Road Wheel......................................................................................................2655 Tire............................................................................................................2655 ww..........................................................................................................................2657 QUICK REFERENCE INDEX................................................................................................... 0 Table of Contents.......................................................................................................2657 PRECAUTIONS.........................................................................................................2658 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”.....................2658 Wiring Diagrams and Trouble Diagnosis...........................................................................2658 FRONT WIPER AND WASHER SYSTEM.......................................................................................2659 System Description..............................................................................................2659 WIPER OPERATION.............................................................................................2659 Low and High Speed Wiper Operation......................................................................2659 Auto Stop Operation.....................................................................................2659 Intermittent Operation..................................................................................2659 WASHER OPERATION............................................................................................2660 Wiring Diagram — WIPER —........................................................................................2661 Terminal and Reference Values for Combination Switch............................................................2662 Removal and Installation of Front Wiper Arms, Adjustment of Wiper Arms Stop Location............................2662 Removal and Installation of Wiper Motor and Linkage.............................................................2663 REMOVAL.....................................................................................................2663 INSTALLATION................................................................................................2663 Front Washer Nozzle Adjustment..................................................................................2664 Front Washer Tube Layout........................................................................................2665 Removal and Installation of Front Washer Nozzle.................................................................2665 REMOVAL.....................................................................................................2665 INSTALLATION................................................................................................2665 Inspection of Front Washer Nozzle...............................................................................2665 CHECK VALVE.................................................................................................2665 Removal and Installation of Wiper and Washer Switch.............................................................2666 REMOVAL.....................................................................................................2666 INSTALLATION................................................................................................2666 Removal and Installation of Washer Tank.........................................................................2666 REMOVAL.....................................................................................................2666 INSTALLATION................................................................................................2666 Removal and Installation of Washer Motor........................................................................2666 REMOVAL.....................................................................................................2666 INSTALLATION................................................................................................2667 REAR WIPER AND WASHER SYSTEM........................................................................................2668 Wiring Diagram — WIP/R —........................................................................................2668 Terminal and Reference Values for Combination Switch............................................................2670 Removal and Installation of Rear Wiper Arms, Adjustment for Wiper Arms Stop Location............................2670 Removal and Installation of Wiper Motor and Linkage.............................................................2671 REMOVAL.....................................................................................................2671 INSTALLATION................................................................................................2671 Washer Nozzle Adjustment........................................................................................2672 Removal and Installation of Rear Washer Nozzle..................................................................2672 REMOVAL.....................................................................................................2672 INSTALLATION................................................................................................2672 Inspection of Rear Washer Nozzle................................................................................2672 CHECK VALVE.................................................................................................2672 Removal and Installation of Wiper and Washer Switch.............................................................2673 Removal and Installation of Washer Tank.........................................................................2673 Removal and Installation of Washer Motor........................................................................2673 Rear Washer Tube Layout.........................................................................................2673 HORN................................................................................................................2674 Wiring Diagram — HORN —.........................................................................................2674 Removal and Installation........................................................................................2675 REMOVAL.....................................................................................................2675 INSTALLATION................................................................................................2675 POWER SOCKET........................................................................................................2676 Wiring Diagram –POWER SOCKET–...................................................................................2676 Removal and Installation of Front Power Socket..................................................................2677 REMOVAL.....................................................................................................2677 INSTALLATION................................................................................................2677 Removal and Installation of Rear Power Socket...................................................................2677 REMOVAL.....................................................................................................2677 INSTALLATION................................................................................................2677 ELECTRICAL UNITS.................................................................................................... 45 FUSE BLOCK - JUNCTION BOX (J/B)..................................................................................... 48 FUSE AND FUSIBLE LINK BOX........................................................................................... 49
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DESCRIPTION:
2005 NISSAN X-TRAIL T30 Series Service Manual PDF DOWNLOAD
FOREWORD
- This manual contains maintenance and repair procedure for the 2005 NISSAN X-TRAIL.
- 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 personal safety nor the vehicle’s safety will be jeopardized by the service method selected
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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