Nissan Note E11 Complete Service Manual – PDF DOWNLOAD
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Nissan Note E11 Complete Service Manual – PDF DOWNLOAD
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Nissan Note E11 Complete Service Manual – PDF DOWNLOAD
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Nissan Note E11 Complete Service Manual – PDF DOWNLOAD
Language : English
Pages : 2830
Downloadable : Yes
File Type : PDF
Size: 32.3 MB
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DESCRIPTION:
Nissan Note E11 Complete Service Manual – PDF DOWNLOAD
PRECAUTIONS
Description
Observe the following precautions to ensure safe and proper servicing. These precautions are not
described in each individual section.
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” BAS0002E
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
Precautions for NATS (NISSAN ANTI-THEFT SYSTEM) BAS0002F
NATS will immobilize the engine if someone tries to start it without the registered key of NATS.
Both of the originally supplied ignition key IDs have been NATS registered.
The security indicator is located on the instrument panel. The indicator blinks when the immobilizer system is
functioning.
Therefore, NATS warns outsiders that the vehicle is equipped with the anti-theft system.
l When NATS detects trouble, the security indicator lamp lights up while ignition switch is in “ON” position.
This lighting up indicates that the anti-theft is not functioning, so prompt service is required.
l When servicing NATS (trouble diagnoses, system initialization and additional registration of other NATS
ignition key IDs), CONSULT-II hardware and CONSULT-II NATS software is necessary.
Regarding the procedures of NATS initialization and NATS ignition key ID registration, refer to CONSULTII
operation manual, NATS.
TABLE OF CONTENTS:
Nissan Note E11 Complete Service Manual – PDF DOWNLOAD
01-General Information pdf 1
QUICK REFERENCE INDEX 0
GENERAL INFORMATION 1
PRECAUTIONS 3
Description 3
3
Precautions for NATS (NISSAN ANTI-THEFT SYSTEM) 3
Maintenance Information 3
RHD MODELS 3
LHD MODELS 4
Precautions for Procedures without Cowl Top Cover 4
General Precautions 4
Precautions for Three Way Catalyst 5
Precautions for Fuel 5
GASOLINE ENGINE (REGULAR GASOLINE) 5
GASOLINE ENGINE (PREMIUM GASOLINE) 6
DIESEL ENGINE 6
Precautions for Multiport Fuel Injection System or Engine Control System 6
Precautions for Turbocharger (If Equipped) 6
Precautions for Hoses 7
HOSE REMOVAL AND INSTALLATION 7
HOSE CLAMPING 7
Precautions for Engine Oils 7
Health Protection Precautions 7
Environmental Protection Precautions 8
Precautions for Air Conditioning 8
HOW TO USE THIS MANUAL 9
Description 9
Terms 9
Units 9
Contents 9
Relation between Illustrations and Descriptions 10
Components 11
SYMBOLS 11
How to Follow Trouble Diagnoses 12
DESCRIPTION 12
HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES 12
HARNESS WIRE COLOR AND CONNECTOR NUMBER INDICATION 13
TYPE 1: Harness Wire Color and Connector Number are Shown in Illustration 13
TYPE 2: Harness Wire Color and Connector Number are Shown in Text 14
KEY TO SYMBOLS SIGNIFYING MEASUREMENTS OR PROCEDURES 14
How to Read Wiring Diagrams 16
CONNECTOR SYMBOLS 16
SAMPLE/WIRING DIAGRAM – EXAMPL – 17
DESCRIPTION 18
Harness Indication 20
Component Indication 20
Switch Positions 20
Detectable Lines and Non-Detectable Lines 21
Multiple Switch 22
Reference Area 23
Abbreviations 23
SERVICE INFORMATION FOR ELECTRICAL INCIDENT 25
How to Perform Efficient Diagnosis for an Electrical Incident 25
WORK FLOW 25
INCIDENT SIMULATION TESTS 25
Introduction 25
Vehicle Vibration 26
Heat Sensitive 27
Freezing 27
Water Intrusion 27
Electrical Load 27
Cold or Hot Start Up 28
CIRCUIT INSPECTION 28
Introduction 28
28
29
Ground Inspection 30
Voltage Drop Tests 30
Control Unit Circuit Test 32
Control Units and Electrical Parts 33
PRECAUTIONS 33
SMJ INSTALLATION 34
CONSULT-II CHECKING SYSTEM 35
Description 35
Function and System Application 35
Nickel Metal Hydride Battery Replacement 35
Checking Equipment 36
CONSULT-II Start Procedure 36
CONSULT-II Data Link Connector (DLC) Circuit 38
INSPECTION PROCEDURE 39
LIFTING POINT 40
Commercial Service Tools 40
Garage Jack, Safety Stand and 2-Pole Lift 40
Board-On Lift 41
TOW TRUCK TOWING 42
Tow Truck Towing 42
TOWING AN AUTOMATIC TRANSAXLE MODEL WITH FOUR WHEELS ON GROUND 42
Vehicle Recovery (Freeing a Stuck Vehicle) 42
FRONT 42
REAR 43
TIGHTENING TORQUE OF STANDARD BOLTS 44
Tightening Torque Table 44
IDENTIFICATION INFORMATION 45
Model Variation 45
IDENTIFICATION NUMBER 46
IDENTIFICATION PLATE 47
ENGINE SERIAL NUMBER (CR ENGINE) 47
ENGINE SERIAL NUMBER (HR ENGINE) 47
ENGINE IDENTIFICATION (K9K ENGINE) 48
AUTOMATIC TRANSAXLE NUMBER 48
Dimensions 48
Wheels & Tyres 48
TERMINOLOGY 49
ISO 15031-2 Terminology List 49
02-Engine Mechanical pdf 53
QUICK REFERENCE INDEX 0
ENGINE MECHANICAL 53
CR 59
PRECAUTIONS 59
Precautions for Draining Coolant 59
Precautions for Disconnecting Fuel Piping 59
Precautions for Removal and Disassembly 59
Precautions for Inspections, Repairs, and Replacement 59
Precautions for Assembling and Installing 59
Parts Requiring Angle Tightening 59
Precautions for Liquid Gasket 60
REMOVAL OF LIQUID GASKET SEALING 60
LIQUID GASKET APPLICATION PROCEDURE 60
PREPARATION 61
Special Service Tools 61
Commercial Service Tools 63
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING 64
64
Use the Chart Below to Help You Find the Cause of the Symptom 65
DRIVE BELTS 66
Checking drive Belts 66
Tension Adjustment 66
ALTERNATOR AND A/C COMPRESSOR BELT (WITH A/C MODELS) 67
ALTERNATOR BELT (WITHOUT A/C MODELS) 67
WATER PUMP BELT 68
Removal and Installation 68
REMOVAL 68
INSTALLATION 68
Removal and Installation of Drive Belt Idler Pulley 68
REMOVAL 69
INSTALLATION 69
AIR CLEANER AND AIR DUCT 70
Removal and Installation 70
REMOVAL 70
INSTALLATION 71
Changing Air Cleaner Filter 73
REMOVAL 73
INSTALLATION 73
INTAKE MANIFOLD 74
Removal and Installation 74
REMOVAL 74
INSTALLATION 75
Attachment of the Intake Manifold 75
EXHAUST MANIFOLD AND THREE WAY CATALYST 76
Removal and Installation 76
REMOVAL 76
INSPECTION AFTER REMOVAL 77
Surface Distortion 77
INSTALLATION 77
Installation of Exhaust Manifold and Three Way Catalyst 77
Installation of Heated Oxygen Sensor 1 77
OIL PAN AND OIL STRAINER 78
Removal and Installation 78
REMOVAL 78
INSTALLATION 79
INSPECTION AFTER INSTALLATION 80
IGNITION COIL 81
Removal and Installation 81
REMOVAL 81
INSTALLATION 81
SPARK PLUG (PLATINUM-TIPPED TYPE) 82
Removal and Installation 82
REMOVAL 82
INSPECTION AFTER REMOVAL 82
INSTALLATION 83
FUEL INJECTOR AND FUEL TUBE 84
Removal and Installation 84
REMOVAL 84
INSTALLATION 85
INSPECTION AFTER INSTALLATION 86
ROCKER COVER 87
Removal and Installation 87
REMOVAL 87
INSTALLATION 88
CAMSHAFT 90
Removal and Installation 90
REMOVAL 90
INSTALLATION 93
INSPECTION AFTER REMOVAL 96
Camshaft Runout 96
Camshaft Cam Height 97
Camshaft Journal Clearance 97
Camshaft End Play 98
Camshaft Sprocket Runout 98
Valve Lifter 98
Valve Lifter Clearance 98
INSPECTION AFTER INSTALLATION 99
Inspection of Camshaft Sprocket (INT) Oil Groove 99
Valve Clearance 99
INSPECTION 99
ADJUSTMENT 101
TIMING CHAIN 102
Removal and Installation 102
REMOVAL 103
Operation Description 103
INSPECTION AFTER REMOVAL 105
INSTALLATION 105
INSPECTION AFTER INSTALLATION 108
OIL SEAL 109
Removal and Installation of Valve Oil Seal 109
REMOVAL 109
INSTALLATION 109
Removal and Installation of Front Oil Seal 109
REMOVAL 109
INSTALLATION 110
Removal and Installation of Rear Oil Seal 110
REMOVAL 110
INSTALLATION 110
CYLINDER HEAD 112
On Vehicle Inspection 112
COMPRESSION PRESSURE INSPECTION 112
Removal and Installation 113
REMOVAL 113
INSPECTION AFTER REMOVAL 114
Cylinder Head Bolt Outer Diameter 114
INSTALLATION 114
Disassembly and Assembly 115
DISASSEMBLY 116
ASSEMBLY 116
INSPECTION AFTER DISASSEMBLY 117
Cylinder Head Distortion 117
Valve Dimensions 117
Valve Guide Clearance 118
Valve Guide Replacement 118
Valve Seat Contact 119
Replacement of Valve Seat 119
Valve Spring Squareness 121
Valve Spring Dimensions and Valve Spring Pressure Load 121
ENGINE ASSEMBLY 122
Removal and Installation 122
REMOVAL 123
INSTALLATION 125
INSPECTION AFTER INSTALLATION 125
CYLINDER BLOCK 126
Disassembly and Assembly 126
DISASSEMBLY 127
ASSEMBLY 129
How to Select Piston and Bearing 134
DESCRIPTION 134
HOW TO SELECT PISTON 135
When New Cylinder Block is Used 135
When Cylinder Block is Reused 135
Piston selection Table 135
HOW TO SELECT MAIN BEARING 136
When New Cylinder Block and Crankshaft are Used 136
When Cylinder Block and Crankshaft are Reused 136
Main bearing Selection Table 136
Undersize Bearing Usage Guide 137
Inspection After Disassembly 137
CRANKSHAFT SIDE CLEARANCE 137
CONNECTING ROD SIDE CLEARANCE 137
PISTON AND PISTON PIN CLEARANCE 137
Inner Diameter of Piston Pin 137
Outer Diameter of Piston Pin 138
Piston and Piston pin Clearance 138
PISTON RING SIDE CLEARANCE 138
PISTON RING END GAP 138
CONNECTING ROD BEND AND TORSION 139
CONNECTING ROD BEARING HOUSING DIAMETER (BIG END) 139
CONNECTING ROD BUSHING OIL CLEARANCE DIAMETER (SMALL END) 139
Inner Diameter of Connecting Rod Bushing (Small End) 139
Outer Diameter of Piston Pin 140
Connecting Rod Bushing Oil Clearance (Small End) 140
CYLINDER BLOCK DISTORTION 140
INNER DIAMETER OF MAIN BEARING HOUSING 140
PISTON TO CYLINDER BORE CLEARANCE 141
Inner Diameter of Cylinder Bore 141
Outer Diameter of piston 141
Piston to Cylinder Bore Clearance 141
Reboring Cylinder Bore 142
OUTER DIAMETER OF CRANKSHAFT JOURNAL 142
OUTER DIAMETER OF CRANKSHAFT PIN 142
OUT-OF-ROUND AND TEPER OF CRANKSHAFT 142
CRANKSHAFT RUNOUT 143
OIL CLEARANCE OF CONNECTING ROD BEARING 143
Method of Measurement 143
Method of Using Plastigage 143
Undersize Bearing Usage Guide 143
OIL CLEARANCE OF MAIN BEARING 144
Method of Measurement 144
Method of Using Plastigage 144
CRUSH HEIGHT OF MAIN BEARING OR CONNECTING ROD BEARING 144
FLYWHEEL RUNOUT 145
SERVICE DATA AND SPECIFICATIONS (SDS) 146
Standard and Limit 146
GENERAL SPECIFICATIONS 146
INTAKE MANIFOLD AND EXHAUST MANIFOLD 146
DRIVE BELTS 147
SPARK PLUG 147
CYLINDER HEAD 147
VALVE 148
Valve Dimensions 148
Valve Clearance 148
Valve Guide 148
Valve Seat 149
Valve Spring 149
Valve Lifter 149
Available Valve Lifter 149
CAMSHAFT AND CAMSHAFT BEARING 151
CYLINDER BLOCK 151
PISTON, PISTON RING AND PISTON PIN 152
Available Piston 152
Piston Ring 152
Piston Pin 152
CONNECTING ROD 153
CRANKSHAFT 153
MAIN BEARING 153
Standard size 153
Undersize 154
Bearing Clearance 154
CONNECTING ROD BEARING 154
Standard Size 154
Undersize 154
Bearing Clearance 154
MISCELLANEOUS COMPONENTS 154
Tightening Torque 155
HR 157
PRECAUTIONS 157
Precautions for Procedures without Cowl Top Cover 157
Precautions for Draining Engine Coolant 157
Precautions for Disconnecting Fuel Piping 157
Precautions for Removal and Disassembly 157
Precautions for Inspection, Repair and Replacement 157
Precautions for Assembly and Installation 157
Parts Requiring Angle Tightening 157
Precautions For Liquid Gasket 158
REMOVAL OF LIQUID GASKET 158
LIQUID GASKET APPLICATION PROCEDURE 158
PREPARATION 160
Special Service Tools 160
Commercial Service Tools 162
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING 164
164
Use the Chart Below to Help You Find the Cause of the Symptom 165
DRIVE BELTS 166
Checking Drive Belts 166
Tension Adjustment 166
Removal and Installation 167
REMOVAL 167
INSTALLATION 167
Removal and Installation of Drive Belt Idler Pulley 168
REMOVAL 168
INSTALLATION 169
AIR CLEANER AND AIR DUCT 170
Components 170
Removal and Installation 170
REMOVAL 170
INSTALLATION 171
Changing Air Cleaner Filter 171
REMOVAL 171
INSPECTION AFTER REMOVAL 171
INSTALLATION 171
INTAKE MANIFOLD 172
Components 172
Removal and Installation 173
REMOVAL 173
INSTALLATION 174
Intake Manifold 174
Electric Throttle Control Actuator 175
EXHAUST MANIFOLD 176
Components 176
Removal and Installation 177
REMOVAL 177
INSPECTION AFTER REMOVAL 178
Mounting Surface Distortion 178
INSTALLATION 178
Exhaust Manifold 178
OIL PAN AND OIL STRAINER 179
Components 179
Removal and Installation 179
REMOVAL 179
INSTALLATION 180
INSPECTION AFTER INSTALLATION 183
IGNITION COIL 184
Components 184
Removal and Installation 184
REMOVAL 184
INSTALLATION 184
SPARK PLUG (PLATINUM-TIPPED TYPE) 185
Components 185
Removal and Installation 185
REMOVAL 185
INSPECTION AFTER REMOVAL 185
INSTALLATION 186
FUEL INJECTOR AND FUEL TUBE 187
Components 187
Removal and Installation 187
REMOVAL 187
INSTALLATION 189
INSPECTION AFTER INSTALLATION 191
Check on Fuel Leaks 191
ROCKER COVER 192
Components 192
Removal and Installation 192
REMOVAL 192
INSTALLATION 193
TIMING CHAIN 194
Components 194
Removal and Installation 195
REMOVAL 195
INSPECTION AFTER REMOVAL 198
Timing Chain 198
INSTALLATION 198
INSPECTION AFTER INSTALLATION 202
Inspection for Leaks 202
CAMSHAFT 203
Components 203
Removal and Installation 203
REMOVAL 203
INSPECTION AFTER REMOVAL 209
Oil Filter 209
Camshaft Runout 210
Camshaft Cam Height 210
Camshaft Journal Oil Clearance 210
Camshaft End Play 211
Camshaft Sprocket Runout 211
Valve Lifter 212
Valve Lifter Clearance 212
INSTALLATION 213
INSPECTION AFTER INSTALLATION 217
Inspection for Leaks 217
Inspection of Camshaft Sprocket (INT) Oil Groove 218
Valve Clearance 218
INSPECTION 218
ADJUSTMENT 220
OIL SEAL 222
Removal and Installation of Valve Oil Seal 222
REMOVAL 222
INSTALLATION 222
Removal and Installation of Front Oil Seal 223
REMOVAL 223
INSTALLATION 223
Removal and Installation of Rear Oil Seal 224
REMOVAL 224
INSTALLATION 224
CYLINDER HEAD 225
On-Vehicle Service 225
CHECKING COMPRESSION PRESSURE 225
Components 226
Removal and Installation 226
REMOVAL 226
INSPECTION AFTER REMOVAL 227
Cylinder Head Bolts Outer Diameter 227
Cylinder Head Distortion 227
INSTALLATION 228
INSPECTION AFTER INSTALLATION 228
Inspection for Leaks 228
Components 229
Disassembly and Assembly 230
DISASSEMBLY 230
ASSEMBLY 230
Inspection After Disassembly 231
VALVE DIMENSIONS 231
VALVE GUIDE CLEARANCE 231
Valve Stem Diameter 231
Valve Guide Inner Diameter 231
Valve Guide Clearance 231
VALVE GUIDE REPLACEMENT 232
VALVE SEAT CONTACT 233
VALVE SEAT REPLACEMENT 233
VALVE SPRING SQUARENESS 234
VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD 234
ENGINE ASSEMBLY 236
Components 236
Removal and Installation 236
REMOVAL 237
Outline 237
Preparation 237
Engine Room LH 237
Engine Room RH 237
Vehicle Underbody 238
Removal 238
Separation 239
INSTALLATION 239
INSPECTION AFTER INSTALLATION 240
Inspection for Leaks 240
CYLINDER BLOCK 241
Components 241
Disassembly and Assembly 242
DISASSEMBLY 242
ASSEMBLY 245
How to Select Piston and Bearing 251
DESCRIPTION 251
HOW TO SELECT CONNECTING ROD BEARING 251
When New Connecting Rod and Crankshaft Are Used 251
When Crankshaft and Connecting Rod Are Reused 252
Connecting Rod Bearing Selection Table 253
Connecting Rod Bearing Grade Table 254
Undersize Bearings Usage Guide 254
HOW TO SELECT MAIN BEARING 254
When New Cylinder Block and Crankshaft Are Used 254
When Cylinder Block and Crankshaft Are Reused 255
Main Bearing Selection Table 256
Main Bearing Grade Table 257
Use Undersize Bearing Usage Guide 257
Inspection After Disassembly 258
CRANKSHAFT END PLAY 258
CONNECTING ROD SIDE CLEARANCE 258
PISTON TO PISTON PIN OIL CLEARANCE 258
Piston Pin Hole Diameter 258
Piston Pin Outer Diameter 258
Piston to Piston Pin Oil Clearance 258
PISTON RING SIDE CLEARANCE 259
PISTON RING END GAP 259
CONNECTING ROD BEND AND TORSION 260
CONNECTING ROD BIG END DIAMETER 260
CONNECTING ROD BUSHING OIL CLEARANCE 260
Connecting Rod Bushing Inner Diameter 260
Piston Pin Outer Diameter 261
Connecting Rod Bushing Oil Clearance 261
CYLINDER BLOCK DISTORTION 261
MAIN BEARING HOUSING INNER DIAMETER 261
PISTON TO CYLINDER BORE CLEARANCE 262
Cylinder Bore Inner Diameter 262
Piston Skirt Diameter 262
Piston to Cylinder Bore Clearance 262
CRANKSHAFT MAIN JOURNAL DIAMETER 263
CRANKSHAFT PIN JOURNAL DIAMETER 263
OUT-OF-ROUND AND TAPER OF CRANKSHAFT 263
CRANKSHAFT RUNOUT 263
CONNECTING ROD BEARING OIL CLEARANCE 263
Method by Calculation 263
Method of Using Plastigage 264
MAIN BEARING OIL CLEARANCE 264
Method by Calculation 264
Method of Using Plastigage 264
MAIN BEARING CRUSH HEIGHT 265
CONNECTING ROD BEARING CRUSH HEIGHT 265
MAIN BEARING CAP BOLT OUTER DIAMETER 265
CONNECTING ROD BOLT OUTER DIAMETER 266
FLYWHEEL DEFLECTION 266
SERVICE DATA AND SPECIFICATIONS (SDS) 267
Standard and Limit 267
GENERAL SPECIFICATIONS 267
DRIVE BELT 267
EXHAUST MANIFOLD 267
SPARK PLUG (PLATINUM-TIPPED TYPE) 267
CYLINDER HEAD 267
VALVE 268
Valve Timing 268
Valve Dimensions 268
Valve Clearance 268
Available Valve Lifter 269
Valve Spring 270
Valve Lifter 270
Valve Guide 270
Valve Seat 271
CAMSHAFT AND CAMSHAFT BEARING 272
CYLINDER BLOCK 272
PISTON, PISTON RING AND PISTON PIN 273
Available Piston 273
Piston Ring 273
Piston Pin 273
CONNECTING ROD 274
CRANKSHAFT 274
MAIN BEARING 276
Undersize 276
Bearing Oil Clearance 276
CONNECTING ROD BEARING 277
Undersize 277
Bearing Oil Clearance 277
K9K 278
APPLICATION NOTICE 278
How to Check Vehicle Type 278
PRECAUTIONS 279
Precautions for Drain Coolant 279
Precautions for Disconnecting Fuel Piping 279
Precautions for Removal and Disassembly 279
Precautions for Inspection, Repair and Replacement 279
Precautions for Assembly and Installation 279
Parts Requiring Angular Tightening 279
Precautions For Liquid Gasket 280
REMOVAL OF LIQUID GASKET 280
LIQUID GASKET APPLICATION PROCEDURE 280
Precautions for Diesel Equipment 281
CLEANLINESS 281
SPECIAL FEATURES 283
PREPARATION 285
Special Service Tools 285
Commercial Service Tools 288
IDENTIFICATION INFORMATION 290
Engine Identification 290
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING 291
291
Use the Chart Below to Help You Find the Cause of the Symptom 292
ENGINE ROOM COVER 293
Removal and Installation 293
REMOVAL 293
INSTALLATION 293
DRIVE BELTS 294
Checking Drive Belts 294
Tension Adjustment 294
MODELS WITH A/C COMPRESSOR 294
MODELS WITHOUT A/C COMPRESSOR 294
Removal and Installation 295
REMOVAL 295
INSTALLATION 295
AIR CLEANER AND AIR DUCT 297
Removal and Installation 297
REMOVAL 297
INSTALLATION 297
Changing Air Cleaner Filter 298
REMOVAL 298
INSTALLATION 298
CHARGE AIR COOLER 299
Removal and Installation (For 50kW) 299
REMOVAL 299
INSPECTION AFTER REMOVAL 300
INSTALLATION 300
Removal and Installation (For 65kW) 301
REMOVAL 301
INSPECTION AFTER REMOVAL 302
INSTALLATION 302
EGR UNIT 303
Removal and Installation 303
REMOVAL 303
INSTALLATION 304
EXHAUST MANIFOLD, TURBOCHARGER, CATALYST 305
Removal and Installation 305
REMOVAL 305
INSTALLATION 306
INSPECTION AFTER INSTALLATION 306
Disassembly and Assembly 307
DISASSEMBLY 307
INSPECTION AFTER DISASSEMBLY 307
Turbocharger 307
ASSEMBLY 308
OIL PAN 309
Removal and Installation 309
REMOVAL 309
INSPECTION AFTER REMOVAL 311
INSTALLATION 311
INSPECTION AFTER INSTALLATION 311
GLOW PLUG 312
Removal and Installation 312
REMOVAL 312
INSTALLATION 312
VACUUM PUMP 313
Removal and Installation 313
INSPECTION BEFORE REMOVAL 313
REMOVAL 313
INSTALLATION 313
HIGH PRESSURE PIPES 314
Removal and Installation 314
REMOVAL 314
INSTALLATION 315
FUEL INJECTOR 318
Removal and Installation 318
REMOVAL 318
INSTALLATION 318
INJECTOR RAIL 319
Removal and Installation 319
REMOVAL 319
INSTALLATION 319
HIGH PRESSURE PUMP 320
Removal and Installation 320
REMOVAL 320
INSTALLATION 321
ROCKER COVER 322
Removal and Installation 322
REMOVAL 322
INSTALLATION 323
TIMING BELT 324
Removal and Installation 324
REMOVAL 324
INSTALLATION 327
Timing Belt 327
CYLINDER HEAD 328
Removal and Installation 328
REMOVAL 328
INSTALLATION 329
Cylinder Head Bolts 329
Disassembly and Assembly 329
DISASSEMBLY 329
INSPECTION AFTER DISASSEMBLY 329
ASSEMBLY 330
ENGINE ASSEMBLY 331
Removal and Installation 331
REMOVAL 332
INSTALLATION 333
INSPECTION AFTER INSTALLATION 333
OVERHAUL 334
Tightening Torques 334
UPPER ENGINE 334
BOTTOM ENGINE 334
Standard Replacement 335
PREPARING USED ENGINE 335
Disassembly 336
REMOVING THE UPPER ENGINE 336
POSITIONING THE BELT AT THE TIMING POINT 337
DISASSEMBLY OF THE CYLINDER HEAD 340
Cleaning 343
Inspection 343
GASKET FACE 343
CAMSHAFT END PLAY 343
Valve Clearance 344
CHECKING AND ADJUSTING THE VALVE CLEARANCE 344
Assembly 345
ASSEMBLY OF THE CYLINDER HEAD 345
New Valve Stem Seals 345
Camshaft Seal 347
Disassembly of The Bottom Engine 349
REMOVAL 349
REPLACEMENT OF THE OIL JETS 352
Assembly 353
INSTALLATION OF OIL JETS 353
Installation of The Oil Jets For No 1 and No 3 Cylinders 353
Installation of The Oil Jets For No 1 and No 4 Cylinders 354
Orientation Of The Oil Jets (See Diagram Below) 354
METHOD FOR INSTALLING THE OIL COOLER AND OIL FILTER 354
Removing The Piston Pins 354
CONNECTING ROD BEARING 355
ON THE CONNECTING ROD BODY 355
ON THE CONNECTING ROD CAP 356
INSTALLATION OF MAIN BEARING 358
ON THE CYLINDER BLOCK 358
ON THE BEARING CAPS 359
INSTALLATION OF NO 1 BEARING 360
CONNECTING RODS / PISTON ASSEMBLY 360
Direction Of Installation Of The Connecting Rod In Relation To The Piston 360
DIRECTION FOR INSTALLATION THE SNAP RINGS ON THE PISTON 360
INSTALLATION OF THE SNAP RINGS 360
Orientation Of The Piston Rings In The Piston 361
CHECKING PISTON PROTRUSION 361
INSTALLATION OF REAR OIL SEAL RETAINER AND OIL PUMP 362
INSTALLATION OF THE CRANKSHAFT SEAL GASKETS 363
INSTALLATION OF THE CYLINDER HEAD 367
TIMING ADJUSTMENT 368
Models With A/C Compressor 372
Models Without A/C Compressor 372
BASIC INSPECTION 373
Cylinder Head 373
CYLINDER HEAD TIGHTENING PROCEDURE 373
THICKNESS OF THE CYLINDER HEAD GASKET 373
INSPECTION OF THE PISTON PROTRUSION 373
VALVE 374
Valve Dimensions 374
VALVE SEAT 374
VALVE GUIDE 374
VALVE SPRING 376
PISTON 376
INSPECTION OF VALVE CLEARANCE 376
CAMSHAFT 377
Piston 378
PISTON MARKING 378
TABLE OF PISTON PIN HEIGHT 378
MEASURING THE PISTON DIAMETER 378
PISTON RING 379
PISTON RING END GAP 379
Connecting Rod 379
DIRECTION OF INSTALLATION OF THE CONNECTING ROD IN RELATION TO THE PISTON 380
DIRECTION FOR INSTALLATION THE SNAP RINGS ON THE PISTON 380
Crankshaft 380
WORKING OUT THE CLASS OF MAIN BEARING (ORIGINAL FITMENT) 381
Marking (A) On The Crankshaft 381
Table Of Journal Diameter Classes 381
Cylinder Block 381
TABLE OF CYLINDER BLOCK MAIN BEARING HOUSING INNER DIAMETERS 381
MATCHING THE MAIN BEARING 382
Main Bearing and Cap 382
MAIN BEARING 382
CONNECTING ROD BEARING 383
Preparing the engine to be on the stand 383
Parts To Be Replaced After Removal 384
Installation of Thread Inserts 385
03-Engine Lubrication pdf 387
QUICK REFERENCE INDEX 0
ENGINE LUBRICATION SYSTEM 387
CR 389
PRECAUTIONS 389
Precautions For Liquid Gasket 389
REMOVAL OF LIQUID GASKET SEALING 389
LIQUID GASKET APPLICATION PROCEDURE 389
PREPARATION 390
Special Service Tools 390
Commercial Service Tool 390
LUBRICATION SYSTEM 391
Lubrication Circuit 391
ENGINE OIL 392
Inspection 392
OIL LEVEL AND CONTAMINATION 392
OIL LEAK 392
OIL PRESSURE CHECK 392
Changing Engine Oil 393
OIL FILTER 395
Removal and Installation 395
REMOVAL 395
INSTALLATION 395
INSPECTION AFTER INSTALLATION 395
OIL PUMP 396
Removal and Installation 396
REMOVAL 396
INSTALLATION 396
Disassembly and Assembly 396
DISASSEMBLY 396
INSPECTION AFTER DISASSEMBLY 396
Clearances of Oil Pump Parts 396
ASSEMBLY 397
SERVICE DATA AND SPECIFICATIONS (SDS) 398
Standard and Limit 398
OIL PRESSURE 398
OIL PUMP 398
OIL CAPACITY 398
TIGHTENING TORQUE 398
HR 399
PRECAUTIONS 399
Precautions for Liquid Gasket 399
REMOVAL OF LIQUID GASKET SEALING 399
LIQUID GASKET APPLICATION PROCEDURE 399
PREPARATION 400
Special Service Tools 400
Commercial Service Tool 400
LUBRICATION SYSTEM 401
Lubrication Circuit 401
ENGINE OIL 402
Inspection 402
OIL LEVEL AND CONTAMINATION 402
ENGINE OIL LEAKAGE 402
OIL PRESSURE CHECK 402
Changing Engine Oil 403
OIL FILTER 405
Removal and Installation 405
REMOVAL 405
INSTALLATION 405
INSPECTION AFTER INSTALLATION 405
SERVICE DATA AND SPECIFICATIONS (SDS) 406
Standard and Limit 406
OIL PRESSURE 406
OIL CAPACITY (APPROXIMATE) 406
TIGHTENING TORQUE 406
K9K 407
PRECAUTIONS 407
Precautions For Liquid Gasket 407
REMOVAL OF LIQUID GASKET 407
LIQUID GASKET APPLICATION PROCEDURE 407
PREPARATION 408
Special Service Tools 408
ENGINE OIL 409
Inspection 409
OIL LEVEL AND MUDDINESS 409
OIL LEAKAGE 409
OIL PRESSURE CHECK 409
Changing Engine Oil 410
OIL FILTER 411
Removal and Installation 411
REMOVAL 411
INSTALLATION 411
OIL PUMP 412
Removal and Installation 412
REMOVAL 412
INSTALLATION 412
Rear Oil Seal Retainer and Oil Pump 412
OIL COOLER 413
Removal and Installation 413
REMOVAL 413
INSPECTION 413
Oil Cooler 413
INSTALLATION 413
SERVICE DATA AND SPECIFICATIONS (SDS) 415
Standard and Limit 415
OIL PRESSURE 415
OIL CAPACITY (APPROXIMATE) 415
TIGHTENING TORQUE 415
04-Engine Cooling pdf 417
QUICK REFERENCE INDEX 0
ENGINE COOLING SYSTEM 417
CR 419
PRECAUTIONS 419
Precautions For Liquid Gasket 419
REMOVAL OF LIQUID GASKET SEALING 419
LIQUID GASKET APPLICATION PROCEDURE 419
PREPARATION 420
Special Service Tools 420
Commercial Service Tool 420
OVERHEATING CAUSE ANALYSIS 421
Troubleshooting Chart 421
COOLING SYSTEM 423
Cooling Circuit 423
ENGINE COOLANT 424
Inspection 424
LEVEL CHECK 424
Models without A/C 424
Models with A/C 424
LEAK CHECK 424
Model without A/C 424
Models with A/C 425
Changing Engine coolant 425
DRAINING ENGINE COOLANT 425
Models without A/C 425
Models with A/C 426
REFILLING ENGINE COOLANT 426
FLUSHING COOLING SYSTEM 427
RADIATOR 428
Removal and Installation 428
REMOVAL 429
INSTALLATION 430
Disassembly and Assembly of Cooling Fan 430
DISASSEMBLY 431
ASSEMBLY 431
Checking Radiator Cap (Models without A/C) 431
Checking Reservoir Tank Cap (Models with A/C) 432
Checking Cooling System Hoses 432
WATER PUMP 433
Removal and Installation 433
REMOVAL 433
INSPECTION AFTER REMOVAL 434
INSTALLATION 434
Water Suction Pipe Installation 434
Water Pump Installation 434
INSPECTION AFTER INSTALLATION 434
THERMOSTAT 435
Removal and Installation 435
REMOVAL 435
INSPECTION AFTER REMOVAL 435
INSTALLATION 436
Installation of Thermostat 436
Water Outlet Installation 436
Heater Pipe Installation 436
INSPECTION AFTER INSTALLATION 436
SERVICE DATA AND SPECIFICATIONS (SDS) 437
Standard and Limit 437
CAPACITY 437
THERMOSTAT 437
RADIATOR 437
Tightening Torque 437
HR 438
PRECAUTIONS 438
Precautions For Liquid Gasket 438
REMOVAL OF LIQUID GASKET SEALING 438
LIQUID GASKET APPLICATION PROCEDURE 438
PREPARATION 439
Special Service Tools 439
Commercial Service Tool 439
OVERHEATING CAUSE ANALYSIS 440
Troubleshooting Chart 440
COOLING SYSTEM 442
Cooling Circuit 442
ENGINE COOLANT 443
Inspection 443
LEVEL CHECK 443
All Models Except M/T with A/C 443
M/T with A/C Models 443
LEAK CHECK 443
All Models Except M/T with A/C 443
M/T with A/C Models 444
Changing Engine coolant 444
DRAINING ENGINE COOLANT 444
All Models Except M/T with A/C 444
M/T with A/C Models 445
REFILLING ENGINE COOLANT 445
FLUSHING COOLING SYSTEM 446
RADIATOR 447
Removal and Installation 447
REMOVAL 448
INSTALLATION 449
Disassembly and Assembly of Cooling Fan 449
DISASSEMBLY 450
ASSEMBLY 450
Checking Radiator Cap (All Models Except M/T with A/C) 450
Checking Reservoir Tank Cap (M/T with A/C Models) 451
Checking Radiator 451
Checking Cooling System Hoses 451
WATER PUMP 452
Removal and Installation 452
REMOVAL 452
INSPECTION AFTER REMOVAL 453
INSTALLATION 453
Water Pump 453
Water Pump Pulley 453
INSPECTION AFTER INSTALLATION 453
THERMOSTAT 454
Removal and Installation 454
REMOVAL 454
INSPECTION AFTER REMOVAL 454
INSTALLATION 455
Thermostat 455
Water Inlet 455
INSPECTION AFTER INSTALLATION 455
WATER OUTLET 456
Removal and Installation 456
REMOVAL 456
INSTALLATION 456
INSPECTION AFTER INSTALLATION 457
SERVICE DATA AND SPECIFICATIONS (SDS) 458
Standard and Limit 458
CAPACITY 458
THERMOSTAT 458
RADIATOR 458
K9K 459
PRECAUTIONS 459
Precautions For Liquid Gasket 459
REMOVAL OF LIQUID GASKET 459
LIQUID GASKET APPLICATION PROCEDURE 459
PREPARATION 460
Special Service Tools 460
OVERHEATING CAUSE ANALYSIS 461
Troubleshooting Chart 461
COOLING SYSTEM 463
Cooling Circuit 463
ENGINE COOLANT 464
Inspection 464
LEVEL CHECK 464
LEAK CHECK 464
Changing Engine Coolant 465
DRAINING ENGINE COOLANT 465
REFILLING ENGINE COOLANT 465
FLUSHING COOLING SYSTEM 466
RADIATOR 467
Removal and Installation 467
REMOVAL 467
INSTALLATION 468
Disassembly and Assembly Radiator Fan 468
DISASSEMBLY 469
ASSEMBLY 469
Checking Reservoir Tank Cap 469
Checking Radiator 469
WATER PUMP 470
Removal and Installation 470
REMOVAL 470
INSPECTION AFTER REMOVAL 470
INSTALLATION 471
INSPECTION AFTER INSTALLATION 471
THERMOSTAT 472
Inspection 472
WATER OUTLET 473
Removal and Installation 473
REMOVAL 473
INSTALLATION 473
06-Fuel System pdf 475
QUICK REFERENCE INDEX 0
FUEL SYSTEM 475
CR 476
PREPARATION 476
Special Service Tools 476
FUEL SYSTEM 477
Checking Fuel Lines 477
General Precautions 477
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY 478
Removal and Installation 478
REMOVAL 478
INSTALLATION 480
Installation of Fuel Level Sensor Unit 480
Installation of Fuel Level Sensor Unit, Fuel Filter and Fuel Pump Assembly 480
Fuel Feed Hose Installation 481
INSPECTION AFTER INSTALLATION 481
FUEL TANK 482
Removal and Installation 482
REMOVAL 482
INSTALLATION 484
Installation of Fuel Tank Mounting Band 484
Installation of fuel Filler Hose 484
Installation of EVAP Hose 485
INSPECTION AFTER INSTALLATION 485
SERVICE DATA AND SPECIFICATIONS (SDS) 486
Standard and Limit 486
Tightening Torque 486
HR 487
PREPARATION 487
Special Service Tools 487
FUEL SYSTEM 488
Checking Fuel Lines 488
General Precautions 488
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY 489
Removal and Installation 489
REMOVAL 489
INSTALLATION 491
Installation of Fuel Level Sensor Unit 491
Installation of Fuel Level Sensor Unit, Fuel Filter and Fuel Pump Assembly 491
Fuel Feed Hose Installation 492
INSPECTION AFTER INSTALLATION 492
FUEL TANK 493
Removal and Installation 493
REMOVAL 493
INSTALLATION 495
Installation of Fuel Tank Mounting Band 495
Installation of fuel Filler Hose 495
Installation of EVAP Hose 496
INSPECTION AFTER INSTALLATION 496
SERVICE DATA AND SPECIFICATIONS (SDS) 497
Standard and Limit 497
Tightening Torque 497
K9K 498
PREPARATION 498
Special Service Tool 498
FUEL SYSTEM 499
Checking Fuel Lines 499
FUEL FILTER 500
Removal and Installation 500
Water Draining from Fuel Filter 500
DRAINING WATER (RHD) 500
DRAINING WATER (LHD) 501
FUEL FILTER CHECK 501
Changing Fuel Filter 501
REMOVAL (RHD) 501
REMOVAL (LHD) 501
INSTALLATION 501
Bleeding Fuel Filter 502
FUEL LEVEL SENSOR UNIT 503
Removal and Installation 503
REMOVAL 503
INSTALLATION 504
FUEL TANK 505
Removal and Installation 505
REMOVAL 505
INSTALLATION 506
Installation of Fuel Tank Mounting Band 507
Installation of fuel Filler Hose 507
Installation of EVAP Hose 507
Installation of Vent Hose 507
INSPECTION AFTER INSTALLATION 507
SERVICE DATA AND SPECIFICATIONS (SDS) 508
Standard and Limit 508
Tightening Torque 508
07-Exhaust System pdf 509
QUICK REFERENCE INDEX 0
EXHAUST SYSTEM 509
PREPARATION 510
Special Service Tool 510
EXHAUST SYSTEM 511
Checking Exhaust System 511
Removal and Installation 511
CR ENGINE 511
HR ENGINE 512
K9K ENGINE 513
REMOVAL 513
Heated Oxygen Sensor 2 (CR, HR Engine) 513
Exhaust Front Tube (CR, HR Engine) 514
INSTALLATION (CR, HR ENGINE) 514
Three Way Catalyst to Exhaust Front Tube 514
Exhaust Front Tube to Center Muffler 515
INSTALLATION (K9K ENGINE) 515
Inspection After Installation 515
SERVICE DATA AND SPECIFICATIONS (SDS) 516
Tightening Torque 516
CR ENGINE 516
HR ENGINE 516
K9K ENGINE 516
08-Accelerator Control System pdf 517
QUICK REFERENCE INDEX 0
ACCELERATOR CONTROL SYSTEM 517
ACCELERATOR CONTROL SYSTEM 518
Removal and Installation 518
REMOVAL 518
INSTALLATION 518
INSPECTION AFTER INSTALLATION 518
SERVICE DATA AND SPECIFICATIONS (SDS) 519
Tightening Torque 519
09-Clutch pdf 521
QUICK REFERENCE INDEX 0
CLUTCH 521
APPLICATION NOTICE 522
How to Check Vehicle Type 522
PRECAUTIONS 523
Caution 523
PREPARATION 524
Special Service Tools 524
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING 525
NVH Troubleshooting Chart 525
CLUTCH 525
CLUTCH PEDAL 526
On Board Inspection 526
HEIGHT INSPECTION 526
PLAY INSPECTION 526
CLEARANCE CHECK 526
Removal and Installation 527
REMOVAL 527
INSPECTION AFTER REMOVAL 527
INSTALLATION 527
CLUTCH FLUID 528
Air Bleeding Procedure 528
CLUTCH MASTER CYLINDER 529
Removal and Installation 529
REMOVAL 529
INSTALLATION 529
CSC (CONCENTRIC SLAVE CYLINDER) 530
Removal and Installation 530
REMOVAL 530
INSPECTION 530
INSTALLATION 530
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL 531
Removal and Installation 531
REMOVAL 532
INSPECTION AND ADJUSTMENT AFTER REMOVAL (CR ENGINE) 532
Clutch Disc 532
Clutch Cover 532
Flywheel Runout 533
INSPECTION AND ADJUSTMENT AFTER REMOVAL (K9K ENGINE) 533
Clutch Disc 533
Flywheel Runout 533
INSTALLATION 533
SERVICE DATA AND SPECIFICATIONS (SDS) 535
Clutch Pedal 535
Clutch Disc 535
Clutch Cover 535
Clutch Control System 535
Clutch Master Cylinder 535
10-Manual Transaxle pdf 537
QUICK REFERENCE INDEX 0
MANUAL TRANSAXLE 537
PRECAUTIONS 539
Cautions 539
PREPARATION 540
Special Service Tools 540
JH3 542
DESCRIPTION 542
Cross-sectional View 542
REMOVAL AND INSTALLATION 543
Removal 543
Installation 543
TIGHTENING TORQUES 544
Description 544
COMPONENTS 545
Gear Components 545
Differential Gear 546
Shift Control Components 546
Case Components 547
Clutch Housing 547
CONTROL LINKAGE 548
Removal and Installation of Control Device and Cable 548
REMOVAL 548
INSTALLATION 548
RATIOS 549
NISSAN Gearbox 549
CONSUMABLES 550
Description 550
CAPACITIES – LUBRICANTS 551
Description 551
TROUBLE DIAGNOSIS 552
Symptom Chart 552
Back-Up Lamp Switch 552
Park/Neutral Position Switch 552
PRECAUTIONS 553
Precautions 553
PARTS TO BE REPLACED SYSTEMATICALLY 554
Description 554
CHECKING 555
Bearings 555
Gearing 555
Synchronizer Ring 555
Sliding Gear Hub 555
SEPARATING THE HOUSINGS 556
Removal 556
REPAIRING THE GEARBOX 558
Removal 558
MAINSHAFT 560
Removal 560
Refitting 561
TRANSAXLE CASE BEARING 562
Removal 562
Refitting 562
CLUTCH HOUSING BEARING 563
Removal 563
Refitting 563
SELECTOR SHAFT RINGS 564
Removal 564
Refitting 564
DIFFERENTIAL BEARINGS 565
Removal and Installation 565
SELECTOR SHAFT 566
Removal 566
Refitting 566
ASSEMBLY 567
Refitting 567
HOUSING ASSEMBLY 569
Assembly 569
JR5 572
DESCRIPTION 572
Cross-Sectional View 572
REMOVAL AND INSTALLATION 573
Removal 573
Installation 573
TIGHTENING TORQUES 574
Description 574
COMPONENTS 575
Gear Components 575
Differential Gear 576
Shift Control Components 576
Case Components 577
Clutch Housing 577
CONTROL LINKAGE 578
Removal and Installation of Control Device and Cable 578
REMOVAL 578
INSTALLATION 578
RATIOS 579
NISSAN Gearbox 579
CONSUMABLES 580
Description 580
CAPACITIES – LUBRICANTS 581
Description 581
TROUBLE DIAGNOSIS 582
Symptom Chart 582
Back-Up Lamp Switch 582
Park/Neutral Position Switch 582
PRECAUTIONS 583
Precautions 583
PARTS TO BE REPLACED SYSTEMATICALLY 584
Description 584
CHECKING 585
Bearings 585
Gearing 585
Synchronizer Ring 585
Sliding Gear Hub 585
SEPARATING THE HOUSINGS 586
Removal 586
REPAIRING THE GEARBOX 588
Removal 588
Removing the Gearing 589
Checking Parts 589
Refitting the Gearing 590
TRANSAXLE CASE BEARING 591
Removing the Bearing, Input Shaft Side 591
Refitting 591
CLUTCH HOUSING BEARING 592
Removal and Installation 592
SELECTOR SHAFT RINGS 593
Removal 593
Refitting 593
DIFFERENTIAL BEARINGS 594
Removal and Installation 594
SELECTOR SHAFT 595
Removal 595
Refitting 595
REPAIRING THE GEARBOX 596
Setting the Pre-tensioning of the Output Shaft Bearings 596
ASSEMBLY 597
Refitting 597
HOUSING ASSEMBLY 599
Assembly 599
11-Automatic Transaxle pdf 603
QUICK REFERENCE INDEX 0
AUTOMATIC TRANSAXLE 603
APPLICATION NOTICE 603
How to Check Vehicle Type 608
INDEX FOR DTC 608
Alphabetical Index 609
EURO-OBD MODELS 609
EXCEPT EURO-OBD MODELS 609
DTC No Index (For EURO-OBD models Only) 610
PRECAUTIONS 611
612
Precautions Necessary for Steering Wheel Rotation After Battery Disconnect 612
OPERATION PROCEDURE 612
Precautions for On Board Diagnostic (OBD) System of A/T and Engine (For EURO-OBD models Only) 612
Precautions 613
Service Notice or Precautions 613
TORQUE CONVERTER SERVICE 614
OBD SELF-DIAGNOSIS (FOR EURO-OBD MODELS ONLY) 614
PREPARATION 615
Special Service Tools 616
Commercial Service Tools 616
A/T FLUID 618
Checking A/T Fluid 620
Changing A/T Fluid 620
A/T CONTROL SYSTEM 621
Cross-Sectional View 622
Shift Mechanism 622
CONSTRUCTION 623
FUNCTION OF CLUTCH AND BRAKE 623
CLUTCH AND BAND CHART 623
POWER TRANSMISSION 624
“ 625
“ 625
“ 626
“ 627
“ 628
“ 629
“ 630
TCM Function 631
CONTROL SYSTEM OUTLINE 632
CONTROL SYSTEM DIAGRAM 632
Input/Output Signal of TCM 632
Line Pressure Control 633
NORMAL CONTROL 634
BACK-UP CONTROL (ENGINE BRAKE) 634
DURING SHIFT CHANGE 634
AT LOW FLUID TEMPERATURE 634
Shift Control 635
CONTROL OF SHIFT SOLENOID VALVES A AND B 635
RELATION BETWEEN SHIFT SOLENOID VALVES A AND B AND GEAR POSITIONS 635
CONTROL OF SHIFT VALVES A AND B 635
Lock-up Control 636
CONDITIONS FOR LOCK-UP OPERATION 636
TORQUE CONVERTER CLUTCH SOLENOID VALVE CONTROL 636
Lock-up Control System Diagram 636
Lock-up Released 636
Lock-up Applied 637
SMOOTH LOCK-UP CONTROL 637
Half-clutched State 637
Engine Brake Control (Overrun Clutch Control) 637
OVERRUN CLUTCH OPERATING CONDITIONS 637
OVERRUN CLUTCH SOLENOID VALVE CONTROL 637
OVERRUN CLUTCH CONTROL VALVE OPERATION 638
Control Valve 638
FUNCTION OF CONTROL VALVES 639
Centrifugal Cancel Mechanism 639
FUNCTION 640
STRUCTURE/OPERATION 640
When Clutch Pressure Is Not Applied 640
When Clutch Pressure Is Applied 640
CAN COMMUNICATION 640
System Description 641
CAN Communication Unit 641
TROUBLE DIAGNOSIS 641
DTC Inspection Priority Chart 642
Fail-safe 642
FAIL-SAFE FUNCTION 642
642
Accelerator Pedal Position Sensor Signal and Throttle Position Sensor Signal 642
PNP Switch 642
Shift Solenoid Valve A and B 642
Line Pressure Solenoid Valve 643
Torque Converter Clutch Solenoid Valve 643
Overrun Clutch Solenoid Valve 643
How to Perform Trouble Diagnoses for Quick and Accurate Repair 643
INTRODUCTION 644
WORK FLOW 644
Work Flow Chart 645
DIAGNOSTIC WORKSHEET 645
Information from Customer 647
Diagnostic Worksheet Chart 647
A/T Electrical Parts Location 648
Circuit Diagram 652
Inspections Before Trouble Diagnosis 654
A/T FLUID CHECK 655
Fluid Leakage and Fluid Level Check 655
Fluid Condition Check 655
STALL TEST 655
Stall Test Procedure 655
Judgement of Stall Test 655
LINE PRESSURE TEST 656
Line Pressure Test Ports 658
Line Pressure Test Procedure 658
Line Pressure 658
Judgement of Line Pressure Test 659
Road Test 659
DESCRIPTION 660
Check Before Engine is Started 660
Check at Idle 660
661
663
666
Vehicle Speed at Which Gear Shifting Occurs 667
Vehicle Speed at Which Lock-up Occurs/Releases 669
Symptom Chart 669
TCM Terminals and Reference Value 670
TCM CONNECTOR TERMINAL LAYOUT 682
TCM INSPECTION TABLE 682
CONSULT-II Function (A/T) 682
FUNCTION 685
CONSULT-II REFERENCE VALUE 685
CONSULT-II START PROCEDURE 685
SELF-DIAGNOSTIC RESULT MODE 687
Operation Procedure 687
Display Items List (For EURO-OBD models) 687
Display Items List (Except for EURO-OBD models) 687
How to Erase Self-diagnostic Results 688
DATA MONITOR MODE 689
Operation Procedure 690
Display Items List 690
CAN DIAGNOSTIC SUPPORT MONITOR MODE 690
Operation Procedure 692
DTC WORK SUPPORT MODE WITH CONSULT-II 692
Operation Procedure 692
Display Items List 692
Diagnostic Procedure Without CONSULT-II 695
TCM SELF-DIAGNOSTIC PROCEDURE 696
Description 696
Diagnostic Procedure 696
Judgement of Self-diagnosis Code 696
How to Erase Self-diagnostic Results 697
EURO-OBD 699
ON BOARD DIAGNOSTIC (OBD) SYSTEM 700
Introduction 700
OBD Function for A/T System 700
One or Two Trip Detection Logic of OBD 700
ONE TRIP DETECTION LOGIC 700
TWO TRIP DETECTION LOGIC 700
OBD Diagnostic Trouble Code (DTC) 700
HOW TO READ DTC AND 1ST TRIP DTC 700
Freeze Frame Data and 1st Trip Freeze Frame Data 700
HOW TO ERASE DTC 701
HOW TO ERASE DTC (WITH CONSULT-II) 701
HOW TO ERASE DTC (WITH GST) 702
HOW TO ERASE DTC (NO TOOLS) 702
Malfunction Indicator Lamp (MIL) 703
DESCRIPTION 703
DTC U1000 CAN COMMUNICATION LINE 703
Description 704
On Board Diagnosis Logic 704
Possible Cause 704
DTC Confirmation Procedure 704
WITH CONSULT-II 704
WITH GST 704
WITHOUT CONSULT-II 704
704
Diagnostic Procedure 705
DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH 706
Description 707
CONSULT-II Reference Value 707
On Board Diagnosis Logic 707
Possible Cause 707
DTC Confirmation Procedure 707
WITH CONSULT-II 707
WITH GST 707
707
Diagnostic Procedure 708
Component Inspection 709
PNP SWITCH 711
DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT 711
Description 712
CONSULT-II Reference Value 712
On Board Diagnosis Logic 712
Possible Cause 712
DTC Confirmation Procedure 712
WITH CONSULT-II 712
WITH GST 712
712
Diagnostic Procedure 713
Component Inspection 714
A/T FLUID TEMPERATURE SENSOR 716
716
Description 717
CONSULT-II Reference Value 717
On Board Diagnosis Logic 717
Possible Cause 717
DTC Confirmation Procedure 717
WITH CONSULT-II 717
WITH GST 717
WITHOUT CONSULT-II 717
718
Diagnostic Procedure 719
DTC P0725 ENGINE SPEED SIGNAL 720
Description 723
CONSULT-II Reference Value 723
On Board Diagnosis Logic 723
Possible Cause 723
DTC Confirmation Procedure 723
WITH CONSULT-II 723
WITH GST 723
WITHOUT CONSULT-II 723
723
Diagnostic Procedure 724
DTC P0731 A/T 1ST GEAR FUNCTION 725
Description 727
On Board Diagnosis Logic 727
Possible Cause 727
DTC Confirmation Procedure 727
WITH CONSULT-II 728
WITH GST 728
Diagnostic Procedure 728
DTC P0732 A/T 2ND GEAR FUNCTION 729
Description 731
On Board Diagnosis Logic 731
Possible Cause 731
DTC Confirmation Procedure 731
WITH CONSULT-II 732
WITH GST 732
Diagnostic Procedure 732
DTC P0733 A/T 3RD GEAR FUNCTION 733
Description 734
On Board Diagnosis Logic 734
Possible Cause 734
DTC Confirmation Procedure 734
WITH CONSULT-II 735
WITH GST 735
Diagnostic Procedure 735
DTC P0734 A/T 4TH GEAR FUNCTION 736
Description 738
CONSULT-II Reference Value 738
On Board Diagnosis Logic 738
Possible Cause 738
DTC Confirmation Procedure 738
WITH CONSULT-II 739
WITH GST 739
Diagnostic Procedure 739
DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE 740
Description 744
CONSULT-II Reference Value 744
On Board Diagnosis Logic 744
Possible Cause 744
DTC Confirmation Procedure 744
WITH CONSULT-II 744
WITH GST 744
WITHOUT CONSULT-II 744
744
Diagnostic Procedure 745
Component Inspection 746
TORQUE CONVERTER CLUTCH SOLENOID VALVE 748
Resistance Check 748
Operation Check 748
DTC P0744 A/T TCC S/V FUNCTION (LOCK-UP) 748
Description 749
CONSULT-II Reference Value 749
On Board Diagnosis Logic 749
Possible Cause 749
DTC Confirmation Procedure 749
WITH CONSULT-II 750
WITH GST 750
Diagnostic Procedure 750
DTC P0745 LINE PRESSURE SOLENOID VALVE 751
Description 755
CONSULT-II Reference Value 755
On Board Diagnosis Logic 755
Possible Cause 755
DTC Confirmation Procedure 755
WITH CONSULT-II 755
WITH GST 755
WITHOUT CONSULT-II 755
755
Diagnostic Procedure 756
Component Inspection 757
LINE PRESSURE SOLENOID VALVE 760
Resistance Check 760
Operation Check 760
DROPPING RESISTOR 760
DTC P0750 SHIFT SOLENOID VALVE A 760
Description 761
CONSULT-II Reference Value 761
On Board Diagnosis Logic 761
Possible Cause 761
DTC Confirmation Procedure 761
WITH CONSULT-II 761
WITH GST 761
WITHOUT CONSULT-II 761
761
Diagnostic Procedure 762
Component Inspection 763
SHIFT SOLENOID VALVE A 765
Resistance Check 765
Operation Check 765
DTC P0755 SHIFT SOLENOID VALVE B 765
Description 766
CONSULT-II Reference Value 766
On Board Diagnosis Logic 766
Possible Cause 766
DTC Confirmation Procedure 766
WITH CONSULT-II 766
WITH GST 766
WITHOUT CONSULT-II 766
766
Diagnostic Procedure 767
Component Inspection 768
SHIFT SOLENOID VALVE B 770
Resistance Check 770
Operation Check 770
DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR 770
Description 771
CONSULT-II Reference Value 771
On Board Diagnosis Logic 771
Possible Cause 771
DTC Confirmation Procedure 771
WITH CONSULT-II 771
WITH GST 771
WITHOUT CONSULT-II 771
Diagnostic Procedure 771
DTC P1760 OVERRUN CLUTCH SOLENOID VALVE 772
Description 773
CONSULT-II Reference Value 773
On Board Diagnosis Logic 773
Possible Cause 773
DTC Confirmation Procedure 773
WITH CONSULT-II 773
WITH GST 773
WITHOUT CONSULT-II 773
773
Diagnostic Procedure 774
Component Inspection 775
OVERRUN CLUTCH SOLENOID VALVE 777
Resistance Check 777
Operation Check 777
DTC VEHICLE SPEED SENSOR MTR 777
Description 778
CONSULT-II Reference Value 778
On Board Diagnosis Logic 778
Possible Cause 778
DTC Confirmation Procedure 778
WITH CONSULT-II 778
WITHOUT CONSULT-II 778
778
Diagnostic Procedure 779
DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) 780
Description 782
CONSULT-II Reference Value 782
On Board Diagnosis Logic 782
Possible Cause 782
DTC Confirmation Procedure 782
WITH CONSULT-II 782
WITHOUT CONSULT-II 782
782
Diagnostic Procedure 783
Component Inspection 784
A/T FLUID TEMPERATURE SENSOR 787
DTC TURBINE REVOLUTION SENSOR 787
Description 788
CONSULT-II Reference Value 788
On Board Diagnosis Logic 788
Possible Cause 788
DTC Confirmation Procedure 788
WITH CONSULT-II 788
WITHOUT CONSULT-II 788
788
Diagnostic Procedure 789
CONTROL UNIT (RAM), CONTROL UNIT (ROM) 790
Description 794
On Board Diagnosis Logic 794
Possible Cause 794
DTC Confirmation Procedure 794
WITH CONSULT-II 794
Diagnostic Procedure 794
MAIN POWER SUPPLY AND GROUND CIRCUIT 794
Description 795
On Board Diagnosis Logic 795
Possible Cause 795
DTC Confirmation Procedure 795
WITH CONSULT-II 795
795
Diagnostic Procedure 796
PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT 797
CONSULT-II Reference Value 799
TCM Terminals and Reference Value 799
Diagnostic Procedure 799
Component Inspection 800
OVERDRIVE CONTROL SWITCH 804
PNP SWITCH 804
EXC F/EURO-OBD 804
805
Description 805
CONSULT-II Reference Value 805
On Board Diagnosis Logic 805
Possible Cause 805
DTC Confirmation Procedure 805
WITH CONSULT-II 805
WITHOUT CONSULT-II 805
805
Diagnostic Procedure 807
VEHICLE SPEED SENSOR MTR 808
Description 811
CONSULT-II Reference Value 811
On Board Diagnosis Logic 811
Possible Cause 811
DTC Confirmation Procedure 811
WITH CONSULT-II 811
WITHOUT CONSULT-II 811
811
Diagnostic Procedure 812
ACCELERATOR PEDAL POSITION (APP) SENSOR 813
Description 815
CONSULT-II Reference Value 815
On Board Diagnosis Logic 815
Possible Cause 815
DTC Confirmation Procedure 815
WITH CONSULT-II 815
WITHOUT CONSULT-II 815
Diagnostic Procedure 815
SHIFT SOLENOID VALVE A 816
Description 817
CONSULT-II Reference Value 817
On Board Diagnosis Logic 817
Possible Cause 817
DTC Confirmation Procedure 817
WITH CONSULT-II 817
WITHOUT CONSULT-II 817
817
Diagnostic Procedure 818
Component Inspection 819
SHIFT SOLENOID VALVE A 821
Resistance Check 821
Operation Check 821
SHIFT SOLENOID VALVE B 821
Description 822
CONSULT-II Reference Value 822
On Board Diagnosis Logic 822
Possible Cause 822
DTC Confirmation Procedure 822
WITH CONSULT-II 822
WITHOUT CONSULT-II 822
822
Diagnostic Procedure 823
Component Inspection 824
SHIFT SOLENOID VALVE B 826
Resistance Check 826
Operation Check 826
OVERRUN CLUTCH SOLENOID VALVE 826
Description 827
CONSULT-II Reference Value 827
On Board Diagnosis Logic 827
Possible Cause 827
DTC Confirmation Procedure 827
WITH CONSULT-II 827
WITHOUT CONSULT-II 827
827
Diagnostic Procedure 828
Component Inspection 829
OVERRUN CLUTCH SOLENOID VALVE 831
Resistance Check 831
Operation Check 831
TORQUE CONVERTER CLUTCH SOLENOID VALVE 831
Description 832
CONSULT-II Reference Value 832
On Board Diagnosis Logic 832
Possible Cause 832
DTC Confirmation Procedure 832
WITH CONSULT-II 832
WITHOUT CONSULT-II 832
832
Diagnostic Procedure 833
Component Inspection 834
TORQUE CONVERTER CLUTCH SOLENOID VALVE 836
Resistance Check 836
Operation Check 836
BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) 836
Description 837
CONSULT-II Reference Value 837
On Board Diagnosis Logic 837
Possible Cause 837
DTC Confirmation Procedure 837
WITH CONSULT-II 837
WITHOUT CONSULT-II 837
837
Diagnostic Procedure 838
Component Inspection 839
A/T FLUID TEMPERATURE SENSOR 842
ENGINE SPEED SIGNAL 842
Description 843
CONSULT-II Reference Value 843
On Board Diagnosis Logic 843
Possible Cause 843
DTC Confirmation Procedure 843
WITH CONSULT-II 843
WITHOUT CONSULT-II 843
843
Diagnostic Procedure 844
TURBINE REVOLUTION SENSOR 845
Description 847
CONSULT-II Reference Value 847
On Board Diagnosis Logic 847
Possible Cause 847
DTC Confirmation Procedure 847
WITH CONSULT-II 847
WITHOUT CONSULT-II 847
847
Diagnostic Procedure 848
LINE PRESSURE SOLENOID VALVE 849
Description 853
CONSULT-II Reference Value 853
On Board Diagnosis Logic 853
Possible Cause 853
DTC Confirmation Procedure 853
WITH CONSULT-II 853
WITHOUT CONSULT-II 853
853
Diagnostic Procedure 854
Component Inspection 855
LINE PRESSURE SOLENOID VALVE 858
Resistance Check 858
Operation Check 858
DROPPING RESISTOR 858
CAN COMMUNICATION LINE 858
Description 859
On Board Diagnosis Logic 859
Possible Cause 859
DTC Confirmation Procedure 859
WITH CONSULT-II 859
WITHOUT CONSULT-II 859
859
Diagnostic Procedure 860
MAIN POWER SUPPLY AND GROUND CIRCUIT 861
Description 862
On Board Diagnosis Logic 862
Possible Cause 862
DTC Confirmation Procedure 862
WITH CONSULT-II 862
862
Diagnostic Procedure 863
A/T 1ST GEAR FUNCTION 864
Description 866
On Board Diagnosis Logic 866
Possible Cause 866
DTC Confirmation Procedure 866
WITH CONSULT-II 867
Diagnostic Procedure 867
A/T 2ND GEAR FUNCTION 868
Description 870
On Board Diagnosis Logic 870
Possible Cause 870
DTC Confirmation Procedure 870
WITH CONSULT-II 871
Diagnostic Procedure 871
A/T 3RD GEAR FUNCTION 872
Description 873
On Board Diagnosis Logic 873
Possible Cause 873
DTC Confirmation Procedure 873
WITH CONSULT-II 874
Diagnostic Procedure 874
A/T 4TH GEAR FUNCTION 875
Description 877
CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE 877
On Board Diagnosis Logic 877
Possible Cause 877
DTC Confirmation Procedure 877
WITH CONSULT-II 878
Diagnostic Procedure 878
A/T TCC S/V FUNCTION (LOCK-UP) 879
Description 883
CONSULT-II Reference Value 883
On Board Diagnosis Logic 883
Possible Cause 883
DTC Confirmation Procedure 883
WITH CONSULT-II 884
Diagnostic Procedure 884
CONTROL UNIT (RAM), CONTROL UNIT (ROM) 885
Description 889
On Board Diagnosis Logic 889
Possible Cause 889
DTC Confirmation Procedure 889
WITH CONSULT-II 889
Diagnostic Procedure 889
PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT 889
CONSULT-II Reference Value 890
TCM Terminals and Reference Value 890
Diagnostic Procedure 890
Component Inspection 891
OVERDRIVE CONTROL SWITCH 895
PNP SWITCH 895
ALL 895
TROUBLE DIAGNOSIS FOR SYMPTOMS 896
896
EURO-OBD 896
EXC F/EURO-OBD 896
OD OFF Indicator Lamp Does Not Come On 898
901
903
904
904
905
906
Vehicle Cannot Be Started from D 908
A/T Does Not Shift: D 909
A/T Does Not Shift: D 911
A/T Does Not Shift: D 913
A/T Does Not Perform Lock-up 916
A/T Does Not Hold Lock-up Condition 918
Lock-up Is Not Released 919
Engine Speed Does Not Return to Idle (Light Braking D 920
A/T Does Not Shift: D 920
A/T Does Not Shift: D 922
A/T Does Not Shift: 2 923
Vehicle Does Not Decelerate by Engine Brake 925
TCM Self-diagnosis Does Not Activate 927
DESCRIPTION 931
DIAGNOSTIC PROCEDURE 931
TRANSMISSION CONTROL MODULE 931
Removal and Installation (LHD) 932
COMPONENTS 932
REMOVAL 932
INSTALLATION 932
Removal and Installation (RHD) 932
COMPONENTS 933
REMOVAL 933
INSTALLATION 933
SHIFT CONTROL SYSTEM 933
Control Device Removal and Installation 934
CONTROL DEVICE COMPONENTS 934
CONTROL CABLE COMPONENTS 934
REMOVAL 935
INSTALLATION 935
Control Device Disassembly and Assembly 937
DISASSEMBLY 937
ASSEMBLY 937
Selector Lever Knob Removal and Installation 937
REMOVAL 938
INSTALLATION 938
Adjustment of A/T Position 938
Checking of A/T Position 938
A/T SHIFT LOCK SYSTEM 939
Description 940
Shift Lock System Parts Location 940
940
Diagnostic Procedure 941
KEY INTERLOCK CABLE 942
Removal and Installation 944
COMPONENTS 944
REMOVAL 944
INSTALLATION 944
ON-VEHICLE SERVICE 945
Control Valve Assembly and Accumulators 947
COMPONENTS 947
REMOVAL AND INSTALLATION 947
Removal 947
Inspection 947
Installation 950
Park/Neutral Position (PNP) Switch 950
COMPONENTS 951
REMOVAL AND INSTALLATION 951
Removal 951
Installation 951
PARK/NEUTRAL POSITION (PNP) SWITCH ADJUSTMENT 951
Revolution Sensor 952
COMPONENTS 952
REMOVAL AND INSTALLATION 952
Removal 952
Installation 952
Turbine Revolution Sensor (Power Train Revolution Sensor) 953
COMPONENTS 953
REMOVAL AND INSTALLATION 953
Removal 953
Installation 953
Differential Side Oil Seal 954
COMPONENTS 955
REMOVAL AND INSTALLATION 955
Removal 955
Installation 955
AIR BREATHER HOSE 956
Removal and Installation 957
COMPONENTS 957
REMOVAL 957
INSTALLATION 957
TRANSAXLE ASSEMBLY 957
Removal and Installation 958
COMPONENTS 958
REMOVAL 958
INSPECTION 958
Installation and Inspection of Torque Converter 960
I 960
OVERHAUL 960
Components 962
Oil Channel 962
Locations of Adjusting Shims, Needle Bearings and Thrust Washers 968
Locations of Snap Rings 969
DISASSEMBLY 970
Disassembly 971
REPAIR FOR COMPONENT PARTS 971
Manual Shaft 986
COMPONENTS 986
REMOVAL 986
INSPECTION 986
INSTALLATION 987
Oil Pump 988
COMPONENTS 990
DISASSEMBLY 990
INSPECTION 990
Oil Pump Housing, Oil Pump Cover, Inner Gear and Outer Gear 992
Side Clearances 992
Seal Ring Clearance 992
ASSEMBLY 992
Control Valve Assembly 993
COMPONENTS 994
DISASSEMBLY 994
INSPECTION 995
Control Valve Lower and Upper Bodies 998
Oil Strainer 998
998
A/T Fluid Temperature Sensor 998
Line Pressure Relief Valve Springs and Torque Converter Pressure Holding Spring 999
ASSEMBLY 999
Control Valve Upper Body 999
COMPONENTS 1003
DISASSEMBLY 1003
INSPECTION 1004
Valve Springs 1005
Control Valves 1005
ASSEMBLY 1005
1-2 Accumulator Valve 1005
Retainer Plate (Control Valve Upper Body) 1006
Control Valve Lower Body 1006
COMPONENTS 1007
DISASSEMBLY 1007
INSPECTION 1008
Valve Springs 1008
Control Valves 1008
ASSEMBLY 1008
Retainer Plate (Control Valve Lower Body) 1008
Reverse Clutch 1009
COMPONENTS 1010
DISASSEMBLY 1010
INSPECTION 1010
Reverse Clutch Snap Ring 1012
Reverse Clutch Drive Plates 1012
Reverse Clutch Dish Plates 1012
Reverse Clutch Spring Retainer Assembly 1012
Reverse Clutch Piston 1012
Reverse Clutch Drum 1012
ASSEMBLY 1012
High Clutch 1013
COMPONENTS 1015
DISASSEMBLY 1015
INSPECTION 1015
High Clutch Snap Ring 1017
High Clutch Drive Plates 1017
High Clutch Spring Retainer Assembly 1017
High Clutch Piston and Cancel Cover 1017
Input Shaft Assembly (High Clutch Drum) 1017
Seal Ring Clearance 1017
ASSEMBLY 1017
Forward and Overrun Clutches 1018
COMPONENTS 1021
DISASSEMBLY 1021
INSPECTION 1021
Forward Clutch and Overrun Clutch Snap Rings 1023
Forward Clutch and Overrun Clutch Drive Plates 1023
Forward Clutch and Overrun Clutch Dish Plates 1023
Forward Clutch and Overrun Clutch Spring Retainer Assembly 1023
Forward Clutch Drum 1024
Overrun Clutch Piston 1024
ASSEMBLY 1024
Low & Reverse Brake 1024
COMPONENTS 1028
DISASSEMBLY 1028
INSPECTION 1028
Low & Reverse Brake Snap Rings 1030
Low & Reverse Brake Drive Plates 1030
Low & Reverse Brake Dish Plates 1030
Low & Reverse Brake Spring Retainer Assembly 1030
ASSEMBLY 1030
Rear Internal Gear and Forward Clutch Hub 1030
COMPONENTS 1033
DISASSEMBLY 1033
INSPECTION 1033
Rear Internal Gear and Forward Clutch Hub 1035
End Bearings and Forward One-way Clutch 1035
ASSEMBLY 1035
Output Shaft, Output Gear, Idler Gear, Reduction Pinion Gear and Bearing Retainer 1035
COMPONENTS 1037
DISASSEMBLY 1037
INSPECTION 1037
Output Shaft, Output Gear, Idler Gear and Reduction Pinion Gear 1040
Bearings 1040
Seal Ring Clearance 1040
ASSEMBLY 1040
Band Servo Piston Assembly 1040
COMPONENTS 1043
DISASSEMBLY 1043
INSPECTION 1043
Pistons, Retainers and Piston Stem 1045
Return Springs 1045
ASSEMBLY 1045
Final Drive 1046
COMPONENTS 1049
DISASSEMBLY 1049
INSPECTION 1049
Gears, Washers, Pinion Mate Shaft and Differential Case 1050
Bearings 1050
ASSEMBLY 1051
ASSEMBLY 1051
Assembly (1) 1054
Adjustment (1) 1054
REDUCTION PINION GEAR BEARING PRELOAD 1055
OUTPUT SHAFT BEARING PRELOAD 1055
Assembly (2) 1057
Adjustment (2) 1059
TOTAL END PLAY 1064
REVERSE CLUTCH END PLAY 1064
Assembly (3) 1066
SERVICE DATA AND SPECIFICATIONS (SDS) 1067
General Specifications 1076
Vehicle Speed at Which Gear Shifting Occurs 1076
Vehicle Speed at When Lock-up Occurs/Releases 1076
Stall Speed 1076
Line Pressure 1076
Adjusting shims, Needle Bearings, Thrust Washers and Snap Rings 1076
OUTER DIAMETER AND INNER DIAMETER OF NEEDLE BEARINGS 1077
OUTER DIAMETER AND INNER DIAMETER OF THRUST WASHERS 1077
OUTER DIAMETER AND INNER DIAMETER OF BEARING RACES AND ADJUSTING SHIMS 1077
OUTER DIAMETER OF SNAP RINGS 1077
INNER DIAMETER OF SNAP RINGS 1077
Control Valves 1077
CONTROL VALVE SPRINGS 1078
Accumulator 1078
RETURN SPRINGS 1078
O-RINGS 1078
Clutches and Brakes 1078
REVERSE CLUTCH 1078
HIGH CLUTCH 1078
FORWARD CLUTCH 1079
OVERRUN CLUTCH 1079
LOW & REVERSE BRAKE 1079
BRAKE BAND 1079
Final Drive 1079
DIFFERENTIAL SIDE GEAR CLEARANCE 1080
DIFFERENTIAL SIDE BEARING END PLAY 1080
Planetary Carrier 1080
Oil Pump 1080
Input Shaft 1080
SEAL RING CLEARANCE 1080
SEAL RING 1080
Reduction Pinion Gear 1080
TURNING TORQUE 1080
Band Servo 1080
RETURN SPRINGS 1080
Output Shaft 1080
SEAL RING CLEARANCE 1080
SEAL RING 1080
TURNING TORQUE 1080
Bearing Retainer 1080
SEAL RING CLEARANCE 1081
Total End Play 1081
Reverse Clutch End Play 1081
Removal and Installation 1081
Shift Solenoid Valves 1081
Solenoid Valves 1081
A/T Fluid Temperature Sensor 1081
Revolution Sensor 1081
Dropping Resistor 1081
Turbine Revolution Sensor (Power Train Revolution Sensor) 1081
POWER SUPPLY ROUTING CIRCUIT 4
ELECTRICAL UNITS 89
SMJ (SUPER MULTIPLE JUNCTION) 91
STANDARDIZED RELAY 92
FUSE BLOCK 94
FUSE, FUSIBLE LINK AND RELAY BOX 95
12-Front Axle PDF 1083
QUICK REFERENCE INDEX 0
FRONT AXLE 1083
PRECAUTIONS 1084
Cautions 1084
Precautions for Brake System 1084
PREPARATION 1085
Special Service Tools 1085
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING 1087
NVH Troubleshooting Chart 1087
FRONT WHEEL HUB AND KNUCKLE 1088
On-Vehicle Inspection 1088
FRONT WHEEL BEARING 1088
Removal and Installation 1088
REMOVAL 1088
INSTALLATION 1089
Disassembly and Assembly 1089
DISASSEMBLY 1089
INSPECTION AFTER DISASSEMBLY 1090
Wheel Hub 1090
Steering Knuckle 1090
Snap Rings 1090
ASSEMBLY 1090
INSPECTION AFTER ASSEMBLY 1091
FRONT DRIVE SHAFT 1092
On-Vehicle Inspection and Service 1092
DRIVE SHAFT BOOT 1092
Replacement 1092
Removal and Installation 1095
REMOVAL 1096
INSPECTION AFTER REMOVAL 1096
INSTALLATION 1097
Disassembly and Assembly 1098
INSPECTION BEFORE DISASSEMBLY 1098
DISASSEMBLY (CR AND HR16 ENGINE MODELS) 1098
Transaxle Side 1098
Wheel Side 1098
Dynamic Damper 1099
DISASSEMBLY (K9K ENGINE MODELS) 1100
Transaxle Side 1100
Wheel Side 1101
Dynamic Damper 1101
Support Bearing 1101
INSPECTION AFTER DISASSEMBLY (CR AND HR16 ENGINE MODELS) 1102
Shaft 1102
Joint Subassembly (Fixed Joint) 1102
Joint Assembly (Sliding Joint) 1102
Housing (Slide Joint) 1102
Dynamic Damper 1102
INSPECTION AFTER DISASSEMBLY (K9K ENGINE MODELS) 1102
Drive Shaft 1102
Boot 1102
Joint Assembly (Transaxle side) 1102
Joint Assembly (Wheel side) 1102
Support Bearing 1102
Support Bearing Bracket 1103
Dynamic Damper 1103
ASSEMBLY (CR AND HR16 ENGINE MODELS) 1103
Wheel Side 1103
Dynamic Damper (Right Drive Shaft) 1103
Transaxle Side 1103
ASSEMBLY (K9K ENGINE MODELS) 1105
Wheel Side 1105
Dynamic Damper 1106
Transaxle Side 1106
Support Bearing 1107
SERVICE DATA AND SPECIFICATIONS (SDS) 1109
Wheel Bearing 1109
Drive shaft 1109
Dynamic Damper 1109
Tightening Torque 1109
13-Rear Axle PDF 1111
QUICK REFERENCE INDEX 0
REAR AXLE 1111
PRECAUTIONS 1112
Caution 1112
Precautions for Brake System 1112
PREPARATION 1113
Special Service Tools 1113
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING 1114
NVH Troubleshooting Chart 1114
WHEEL HUB 1115
On-Vehicle Inspection 1115
REAR WHEEL BEARING 1115
Removal and Installation 1115
REMOVAL 1115
INSTALLATION 1116
Disassembly and Assembly 1116
DISASSEMBLY 1116
INSPECTION AFTER DISASSEMBLY 1117
ASSEMBLY 1117
INSPECTION AFTER ASSEMBLY 1117
SERVICE DATA AND SPECIFICATIONS (SDS) 1118
Wheel Bearing 1118
Tightening Torque 1118
14-Front Suspension PDF 1119
QUICK REFERENCE INDEX 0
FRONT SUSPENSION 1119
PRECAUTIONS 1120
Precautions for Procedures without Cowl Top Cover 1120
Precautions for Brake System 1120
Cautions 1120
PREPARATION 1121
Special Service Tools 1121
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING 1122
NVH Troubleshooting Chart 1122
FRONT SUSPENSION ASSEMBLY 1123
Components 1123
On-Vehicle Inspection and Service 1124
LOOSENESS, BACKLASH, AND DAMAGE OF MOUNTING PARTS AND CONNECTIONS 1124
Wheel Alignment 1124
DESCRIPTION 1124
PRELIMINARY INSPECTION 1124
INSPECTION OF CAMBER, CASTER, AND KINGPIN INCLINATION ANGLES 1124
Toe-in 1125
STEERING ANGLE INSPECTION 1125
COIL SPRING AND SHOCK ABSORBER 1126
Removal and Installation 1126
REMOVAL 1126
INSTALLATION 1126
Disassembly and Assembly 1126
DISASSEMBLY 1126
INSPECTION AFTER DISASSEMBLY 1127
Strut Inspection 1127
Insulator and Rubber Parts Inspection 1127
Coil Spring Inspection 1127
ASSEMBLY 1127
TRANSVERSE LINK 1128
Removal and Installation 1128
REMOVAL 1128
INSPECTION AFTER REMOVAL 1128
Visual Inspection 1128
Ball Joint Inspection 1128
Oscillating Torque Inspection 1128
Axial End Play Inspection 1128
INSTALLATION 1128
STABILIZER BAR 1129
Removal and Installation 1129
REMOVAL 1129
INSPECTION AFTER REMOVAL 1130
INSTALLATION 1130
FRONT SUSPENSION MEMBER 1131
Removal and Installation 1131
REMOVAL 1131
INSPECTION AFTER REMOVAL 1131
INSTALLATION 1132
SERVICE DATA AND SPECIFICATIONS (SDS) 1133
Wheel Alignment 1133
Ball Joint 1133
Tightening Torque 1133
15-Rear Suspension PDF 1135
QUICK REFERENCE INDEX 0
REAR SUSPENSION 1135
PRECAUTIONS 1136
Cautions 1136
Precautions for Brake System 1136
PREPARATION 1137
Special Service Tools 1137
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING 1138
NVH Troubleshooting Chart 1138
REAR SUSPENSION ASSEMBLY 1139
Components 1139
On-Vehicle Inspection and Service 1139
Wheel Alignment 1140
DESCRIPTION 1140
PRELIMINARY INSPECTION 1140
CAMBER 1140
TOE-IN 1140
SHOCK ABSORBER 1141
Removal and Installation 1141
REMOVAL 1141
INSPECTION AFTER REMOVAL 1141
Shock Absorber 1141
Bound Bumper and Bushing 1141
INSTALLATION 1142
COIL SPRING 1143
Removal and Installation 1143
REMOVAL 1143
INSPECTION AFTER REMOVAL 1143
INSTALLATION 1143
REAR SUSPENSION BEAM 1144
Removal and Installation 1144
REMOVAL 1144
INSPECTION AFTER REMOVAL 1144
INSTALLATION 1144
SERVICE DATA AND SPECIFICATIONS (SDS) 1145
Wheel Alignment 1145
Tightening Torque 1145
16-Road Wheels and Tires PDF 1147
QUICK REFERENCE INDEX 0
ROAD WHEELS & TYRES 1147
PRECAUTIONS 1148
1148
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING 1149
NVH Troubleshooting Chart 1149
ROAD WHEEL 1150
Inspection 1150
ALUMINUM WHEEL 1150
STEEL WHEEL 1150
ROAD WHEEL AND TYRE ASSEMBLY 1151
Balancing Wheels (Bonding Weight Type) 1151
REMOVAL 1151
WHEEL BALANCE ADJUSTMENT 1151
Balancing Wheels (Drive-in Weight Type) 1152
WHEEL BALANCE ADJUSTMENT 1152
Rotation 1153
SERVICE DATA 1154
Road Wheel 1154
Tyre 1154
17-Brake System PDF 1155
QUICK REFERENCE INDEX 0
BRAKE SYSTEM 1155
PRECAUTIONS 1157
1157
Precautions for Procedures without Cowl Top Cover 1157
Precautions for Brake System 1157
PREPARATION 1158
Special Service Tools 1158
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING 1159
NVH Troubleshooting Chart 1159
BRAKE PEDAL 1160
Inspection and Adjustment 1160
PLAY AND CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR PANEL WITH PEDAL DEPRESSED 1160
Removal and Installation 1161
COMPONENTS 1161
REMOVAL 1161
INSPECTION AFTER REMOVAL 1162
INSTALLATION 1162
BRAKE FLUID 1163
Level Inspection 1163
Checking Brake Line 1163
Drain and Refill 1163
Bleeding Brake System 1164
BRAKE PIPING AND HOSE 1165
Hydraulic Circuit 1165
Removal and Installation of Front Brake Piping and Brake Hose 1165
REMOVAL 1165
INSTALLATION 1166
Removal and Installation of Rear Brake Piping and Brake Hose 1166
REMOVAL 1166
INSTALLATION 1166
Inspection 1167
BRAKE MASTER CYLINDER 1168
Removal and Installation 1168
REMOVAL 1168
INSTALLATION 1168
Disassembly and Assembly 1168
Disassembly 1169
Inspection After Disassembly 1169
Assembly 1169
BRAKE BOOSTER 1171
On-Vehicle Service 1171
OPERATING CHECK 1171
AIRTIGHTNESS INSPECTION 1171
Removal and Installation 1171
COMPONENTS 1171
REMOVAL 1171
INSTALLATION 1172
VACUUM LINES 1173
Components 1173
Removal and Installation 1173
VACUUM HOSE 1173
VACUUM PUMP 1173
Inspection 1174
VISUAL INSPECTION 1174
CHECK VALVE INSPECTION 1174
Airtightness Inspection 1174
FRONT DISC BRAKE 1175
On Board Inspection 1175
PAD WEAR INSPECTION 1175
Components 1175
Removal and Installation of Brake Pad 1176
REMOVAL 1176
INSTALLATION 1176
Removal and Installation of Brake Caliper Assembly 1177
REMOVAL 1177
INSTALLATION 1177
Disassembly and Assembly of Brake Caliper Assembly 1177
DISASSEMBLY 1177
BRAKE CALIPER INSPECTION 1178
Cylinder Body 1178
Torque Member 1178
Piston 1178
Sliding Pin and Pin Boots 1178
ASSEMBLY 1178
Removal and Installation of Disc Rotor 1179
REMOVAL 1179
INSTALLATION 1179
DISC ROTOR INSPECTION 1179
Visual Inspection 1179
Runout Inspection 1179
Thickness Inspection 1180
BRAKE BURNISHING PROCEDURE 1180
REAR DRUM BRAKE 1181
Components 1181
Removal and Installation of Drum Brake Assembly 1182
REMOVAL 1182
INSPECTION AFTER REMOVAL 1182
Lining Thickness Inspection 1182
Drum Inner Diameter Inspection 1182
Wheel Cylinder Leakage Inspection 1183
Other Inspections 1183
INSTALLATION 1183
Removal and Installation of Wheel Cylinder 1184
REMOVAL 1184
INSTALLATION 1184
Disassembly and Assembly of Wheel Cylinder 1184
DISASSEMBLY 1184
ASSEMBLY 1184
Wheel Cylinder Inspection 1185
SERVICE DATA AND SPECIFICATIONS (SDS) 1186
General Specifications 1186
Brake Pedal 1186
Brake Booster 1186
Check Valve 1186
Front Disc Brake 1187
Rear Drum Brake 1187
18-Parking Brake System PDF 1189
QUICK REFERENCE INDEX 0
PARKING BRAKE SYSTEM 1189
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING 1190
NVH Troubleshooting Chart 1190
PARKING BRAKE SYSTEM 1191
On Board Inspection and Service 1191
LEVER STROKE 1191
Adjustment 1191
Components 1192
Removal and Installation 1192
REMOVAL 1192
INSTALLATION 1193
SERVICE DATA AND SPECIFICATIONS (SDS) 1194
Parking Brake 1194
19-Brake Control System PDF 1195
QUICK REFERENCE INDEX 0
BRAKE CONTROL SYSTEM 1195
ABS 1195
PRECAUTIONS 1197
1197
Precautions for Brake System 1197
Precautions for Brake Control 1197
Precaution for Harness Repair 1197
CAN SYSTEM 1198
PREPARATION 1198
Special Service Tools 1199
SYSTEM DESCRIPTION 1199
System Diagram 1200
System Components 1200
ABS Function 1200
EBD Function 1201
Fail-Safe Function 1201
Hydraulic Circuit Diagram 1201
TROUBLE DIAGNOSIS 1201
Diagnosis Procedure 1202
BASIC CONCEPT 1202
DIAGNOSIS FLOW 1202
QUESTIONNAIRE 1203
EXAMPLE OF DIAGNOSIS SHEET 1204
Component Parts Location 1204
Schematic 1205
1206
CONSULT-II Functions (ABS) 1207
CONSULT-II MAIN FUNCTION 1213
CONSULT-II BASIC OPERATION PROCEDURE 1213
Self-Diagnosis 1213
OPERATION PROCEDURE 1213
ERASE MEMORY 1213
DISPLAY ITEM LIST 1213
Data Monitor 1214
OPERATION PROCEDURE 1215
DISPLAY ITEM LIST 1215
Active Test 1215
OPERATION PROCEDURE 1216
1216
1216
CAN Communication 1217
SYSTEM DESCRIPTION 1218
For Fast and Accurate Diagnosis 1218
PRECAUTIONS FOR TROUBLE DIAGNOSIS 1219
Basic Inspection 1219
BASIC INSPECTION 1: BRAKE FLUID LEVEL, LEAK AND BRAKE PAD INSPECTION 1220
BASIC INSPECTION 2: INSPECTION OF POWER SUPPLY SYSTEM TERMINAL LOOSENESS AND BATTERY 1220
BASIC INSPECTION 3: ABS WARNING LAMP AND BRAKE WARNING LAMP INSPECTION 1220
Inspection 1 Wheel Sensor System 1220
Inspection 2 Engine System 1221
Inspection 3 ABS Actuator and Electric Unit (Control Unit) System 1223
Inspection 4 ABS Actuator and Electric Unit Power and Ground System 1223
Inspection 5 Stop Lamp Switch System 1223
Inspection 6 CAN Communication Circuit 1225
Symptom 1 ABS Works Frequently 1227
Symptom 2 Unexpected Pedal Reaction 1227
Symptom 3 Longer Stopping Distance 1228
Symptom 4 ABS Does Not Work 1228
Symptom 5 Pedal Vibration and ABS Operation Noise 1229
WHEEL SENSORS 1229
Removal and Installation 1230
REMOVAL 1230
INSTALLATION 1230
SENSOR ROTOR 1230
Removal and Installation 1231
FRONT 1231
REAR 1231
ACTUATOR AND ELECTRIC UNIT (ASSEMBLY) 1231
Removal and Installation 1232
REMOVAL 1232
INSTALLATION 1232
ESP/TCS/ABS 1232
PRECAUTIONS 1233
1233
Precautions for Brake System 1233
Precautions for Brake Control 1233
Diagnosis Precaution 1233
CAN SYSTEM 1234
Precaution for Harness Repair 1234
CAN SYSTEM 1234
PREPARATION 1234
Special Service Tools 1235
ON-VEHICLE SERVICE 1235
Adjustment of Steering Angle Sensor Neutral Position 1236
OPERATION PROCEDURE 1236
SYSTEM DESCRIPTION 1236
System Diagram 1239
ESP Function 1239
TCS Function 1239
ABS Function 1239
EBD Function 1239
Fail-Safe Function 1240
ESP / TCS SYSTEM 1240
ABS, EBD SYSTEM 1240
Hydraulic Circuit Diagram 1240
CAN COMMUNICATION 1241
System Description 1242
TROUBLE DIAGNOSIS 1242
How to Proceed With Diagnosis 1243
BASIC CONCEPT 1243
DIAGNOSIS FLOWCHART 1243
ASKING COMPLAINTS 1244
EXAMPLE OF DIAGNOSIS SHEET 1245
Component Installation Location 1245
Schematic 1246
1247
CONSULT-II Functions (ABS) 1248
CONSULT-II MAIN FUNCTION 1256
CONSULT-II BASIC OPERATION PROCEDURE 1256
Self-Diagnosis 1256
OPERATION PROCEDURE 1256
ERASE MEMORY 1256
DISPLAY ITEM LIST 1256
Data Monitor 1257
OPERATION PROCEDURE 1258
DISPLAY ITEM LIST 1258
Active Test 1258
OPERATION PROCEDURE 1260
SOLENOID VALVE OPERATION CHART 1260
ABS MONITOR 1261
For Fast and Accurate Diagnosis 1261
PRECAUTIONS FOR DIAGNOSIS 1262
ON and OFF Timing for ABS Warning Lamp, ESP OFF Indicator Lamp, SLIP Indicator Lamp, Brake Warnin 1262
Basic Inspection 1263
BASIC INSPECTION 1: BRAKE FLUID AMOUNT, LEAKS, AND BRAKE PADS INSPECTION 1263
BASIC INSPECTION 2: POWER SYSTEM TERMINAL LOOSENESS AND BATTERY INSPECTION 1263
BASIC INSPECTION 3: ABS WARNING LAMP, ESP OFF INDICATOR LAMP and SLIP INDICATOR LAMP INSPECTION 1263
Inspection 1: Wheel Sensor System 1264
Inspection 2: Engine System 1264
Inspection 3: ESP/TCS/ABS Control Unit System 1267
Inspection 4: Steering Angle Sensor System 1267
Inspection 5: Yaw Rate/Side G-Sensor System 1267
Inspection 6: ABS Actuator and Electric Unit (Control Unit) Power Supply and Ground System 1269
Inspection 7: Stop Lamp Switch System 1271
Inspection 8: Brake Fluid Level Switch System 1273
Inspection 9: CAN Communication System 1275
Component Inspection 1275
ESP OFF SWITCH 1276
Symptom 1: Excessive ABS Function Operation Frequency 1276
Symptom 2: Unexpected Pedal Reaction 1276
Symptom 3: The Braking Distance Is Long 1276
Symptom 4: The ABS Function Does Not Operate 1277
Symptom 5: Pedal Vibration or ABS Operation Sound Occurs 1277
Symptom 6: Vehicle Jerks During ESP/TCS/ABS Control 1277
WHEEL SENSORS 1278
Removal and Installation 1280
REMOVAL 1280
INSTALLATION 1280
SENSOR ROTOR 1280
Removal and Installation 1281
FRONT 1281
REAR 1281
ACTUATOR AND ELECTRIC UNIT (ASSEMBLY) 1281
Removal and Installation 1282
REMOVAL 1282
INSTALLATION 1282
YAW RATE/SIDE G SENSOR 1282
Removal and Installation 1283
REMOVAL 1283
INSTALLATION 1283
STEERING ANGLE SENSOR 1283
Removal and Installation 1284
REMOVAL 1284
INSTALLATION 1284
POWER SUPPLY ROUTING CIRCUIT 4
ELECTRICAL UNITS 89
SMJ (SUPER MULTIPLE JUNCTION) 91
STANDARDIZED RELAY 92
FUSE BLOCK 94
FUSE, FUSIBLE LINK AND RELAY BOX 95
20-Power Steering System PDF 1285
QUICK REFERENCE INDEX 0
POWER STEERING SYSTEM 1285
PRECAUTIONS 1286
1286
Caution: 1286
PREPARATION 1287
Special Service Tools 1287
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING 1288
NVH Trouble Shooting Chart 1288
STEERING WHEEL 1289
On Board Inspection and Service 1289
PLAY INSPECTION 1289
NEUTRAL POSITION INSPECTION 1289
STEERING TORQUE INSPECTION 1289
STEERING ANGLE INSPECTION 1289
Removal and Installation 1290
REMOVAL 1290
INSTALLATION 1290
STEERING COLUMN 1291
Removal and Installation 1291
REMOVAL OF STEERING COLUMN ASSEMBLY 1291
INSPECTION AFTER REMOVAL OF STEERING COLUMN ASSEMBLY 1292
INSTALLATION OF STEERING COLUMN ASSEMBLY 1292
CHECK AFTER STEERING COLUMN ASSEMBLY INSTALLATION 1292
POWER STEERING GEAR AND LINKAGE 1293
Removal and Installation 1293
REMOVAL 1293
INSTALLATION 1293
Disassembly and Assembly 1294
COMPONENT PARTS LOCATION (R24T TYPE) 1294
DISASSEMBLY 1294
INSPECTION AFTER DISASSEMBLY 1294
Rack 1294
Bulkhead Sealing 1294
Tie-Rod Ball Joint 1294
ASSEMBLY 1295
SERVICE DATA AND SPECIFICATIONS (SDS) 1297
Wheel 1297
Steering Angle 1297
Steering Column 1297
Steering Linkage 1297
Tightening Torque 1298
21-Steering Control System PDF 1299
QUICK REFERENCE INDEX 0
STEERING CONTROL SYSTEM 1299
EPS 1299
PRECAUTIONS 1300
Maintenance Information 1300
RHD MODELS 1300
LHD MODELS 1300
SYSTEM DESCRIPTION 1300
Components 1301
Electric Power Steering Function 1301
Fail-Safe Function 1301
TROUBLE DIAGNOSIS 1301
How to Perform Trouble Diagnosis 1302
BASIC CONCEPT 1302
Component Parts Location 1302
Schematic 1303
1304
Control Unit Input/Output Signal Standard 1305
CIRCUIT TESTER REFERENCE VALUE 1308
STANDARD BY CONSULT-II 1308
CONSULT-II Function (EPS) 1308
CONSULT-II MAIN FUNCTION 1309
CONSULT-II START PROCEDURE 1309
SELF-DIAGNOSIS 1309
Operation Procedure 1309
Erase Memory 1309
Display Item List 1309
DATA MONITOR 1310
Operation Procedure 1310
Display Item List 1310
ECU PART NUMBER 1310
Operation Procedure 1311
CAN COMMUNICATION 1311
System Description 1311
For Fast and Accurate Trouble Diagnosis 1311
Basic Inspection 1311
BASIC INSPECTION 1: POWER SUPPLY CIRCUIT TERMINAL LOOSENESS AND BATTERY 1311
BASIC INSPECTION 2: EPS WARNING LAMP INSPECTION 1311
BASIC INSPECTION 3: EPS CONTROL UNIT POWER SUPPLY CIRCUIT AND GROUND CIRCUIT INSPECTION 1311
Inspection 1: Battery Voltage Malfunction 1312
Inspection 2: Torque Sensor Malfunction 1313
Inspection 3: Motor Malfunction 1314
Inspection 4: EEPROM Malfunction 1315
Inspection 5: Control unit malfunction 1316
Inspection 6: Vehicle Speed Signal Malfunction 1316
Inspection 7: Engine Signal Malfunction 1317
Inspection 8: CAN Communication Circuit 1317
Symptom 1: Steering is Heavy or Light 1318
Symptom 2: There is a Difference in the Steering Turning/Returning Force of Left and Right (Biase 1318
Symptom 3: Steering Wheel Turning Force is Uneven (Torque Variation) 1319
Symptom 4: EPS Warning Lamp Stays ON 1319
POWER SUPPLY ROUTING CIRCUIT 4
ELECTRICAL UNITS 89
SMJ (SUPER MULTIPLE JUNCTION) 91
STANDARDIZED RELAY 92
FUSE BLOCK 94
FUSE, FUSIBLE LINK AND RELAY BOX 95
22-Seat Belts PDF 1321
QUICK REFERENCE INDEX 0
SEAT BELTS 1321
PRECAUTIONS 1322
1322
Precaution for Seat Belt Service 1322
AFTER A COLLISION 1322
SEAT BELTS 1323
System Description 1323
SEAT BELT WARNING LAMP 1323
SEAT BELT WARNING CHIME 1323
Removal and Installation of Front Seat Belt 1323
REMOVAL 1323
Seat Belt Retractor 1323
Seat Belt Buckle 1324
INSTALLATION 1324
Removal and Installation of Rear Seat Belt 1324
REMOVAL 1324
Seat Belt Retractor (side seats) 1324
Seat Belt Retractor (centre seat) 1325
Seat Belt Buckle 1325
INSTALLATION 1325
Inspection 1325
POST-ACCIDENT INSPECTION 1325
INSPECTION FOR SEAT BELT RETRACTOR 1325
INSPECTION OF ELR AND SEAT BELT WITH CHILD SAFETY SEAT ANCHOR SYSTEM 1326
ELR and Seat Belt With Child Safety Seat Anchor System 1326
ELR Static Inspection 1326
Inspection for Child Safety Seat Anchor System 1326
ELR Dynamic Inspection 1326
ISO FIX CHILD RESTRAINT ANCHORAGE 1327
Removal and Installation 1327
23-Supplemental Restraint System (SRS) PDF 1329
QUICK REFERENCE INDEX 0
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 1329
PRECAUTIONS 1329
1331
1331
PREPARATION 1331
Special Service Tools 1332
Commercial Service Tools 1332
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 1332
SRS Configuration 1333
Front Seat Belt Pre-tensioner with Load Limiter 1333
Front Side Air Bag 1334
Side Curtain Air Bag 1334
Front Passenger Air Bag Cut OFF Switch 1334
Front Passenger Air Bag OFF Indicator 1334
TROUBLE DIAGNOSIS 1335
Trouble Diagnosis Introduction 1336
DIAGNOSIS FUNCTION 1336
HOW TO PERFORM TROUBLE DIAGNOSES FOR QUICK AND ACCURATE REPAIR 1336
Information from Customer 1336
Preliminary Check 1336
WORK FLOW 1336
Component Parts Location 1337
Schematic 1338
1339
CONSULT-II Function 1340
DIAGNOSIS MODE FOR CONSULT-II 1344
HOW TO CHANGE SELF-DIAGNOSIS MODE WITH CONSULT-II 1344
From User Mode to Diagnosis Mode 1344
From Diagnosis Mode to User Mode 1344
HOW TO ERASE SELF-DIAGNOSIS RESULTS 1344
Self-Diagnosis Function (Without CONSULT-II) 1345
HOW TO CHANGE SELF-DIAGNOSIS MODE WITHOUT CONSULT-II 1345
HOW TO ERASE SELF-DIAGNOSIS RESULTS 1345
SRS Operation Check 1345
DIAGNOSTIC PROCEDURE 1 1346
1346
Trouble Diagnosis with CONSULT-II 1346
DIAGNOSTIC PROCEDURE 2 1348
1348
DIAGNOSTIC PROCEDURE 3 1349
DIAGNOSTIC PROCEDURE 4 (CONTINUED FROM DIAGNOSTIC PROCEDURE 2) 1352
DIAGNOSTIC PROCEDURE 5 1354
1354
Trouble Diagnosis without CONSULT-II 1355
DIAGNOSTIC PROCEDURE 6 1358
1358
WARNING LAMP FLASH CODE CHART 1358
1358
DIAGNOSTIC PROCEDURE 7 1362
1362
DIAGNOSTIC PROCEDURE 8 1363
DRIVER AIR BAG MODULE 1363
Removal and Installation 1364
REMOVAL 1364
INSTALLATION 1364
SPIRAL CABLE 1365
Removal and Installation 1366
REMOVAL 1366
INSTALLATION 1366
FRONT PASSENGER AIR BAG MODULE 1367
Removal and Installation 1368
REMOVAL 1368
INSTALLATION 1368
FRONT SIDE AIR BAG MODULE 1369
Removal and Installation 1370
REMOVAL 1370
INSTALLATION 1370
SIDE CURTAIN AIR BAG MODULE 1371
Removal and Installation 1372
REMOVAL 1372
INSTALLATION 1372
CRASH ZONE SENSOR 1372
Removal and Installation 1373
REMOVAL 1373
INSTALLATION 1373
SIDE AIR BAG (SATELLITE) SENSOR 1373
Removal and Installation 1374
REMOVAL 1374
INSTALLATION 1374
SEAT BELT PRE-TENSIONER 1374
Removal and Installation 1375
DIAGNOSIS SENSOR UNIT 1375
Removal and Installation 1376
REMOVAL 1376
INSTALLATION 1376
ECU DISCRIMINATED NO 1376
DISPOSAL OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER 1376
Caution for Air Bag Module and Seat Belt Pre-tensioner 1377
CHECKING DEPLOYMENT TOOL 1377
Connecting to Battery 1377
Deployment Tool Check 1377
Air Bag Deployment Tool Lamp Illumination Chart (Battery Connected) 1377
DEPLOYMENT PROCEDURES FOR AIR BAG MODULE <OUTSIDE OF VEHICLE> 1378
Deployment of Driver Air Bag Module <Outside of Vehicle> 1378
Deployment of Front Passenger Air Bag Module <Outside of Vehicle> 1378
Deployment of Front Side Air Bag Module <Outside of Vehicle> 1379
1380
DEPLOYMENT PROCEDURES FOR SEAT BELT PRE-TENSIONER <OUTSIDE OF VEHICLE> 1381
DEPLOYMENT PROCEDURES FOR FRONT SEAT BELT PRE-TENSIONER 2 (OUTSIDE OF VEHICLE) 1382
DEPLOYMENT OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER WHILE MOUNTED IN VEHICLE 1383
DISPOSING OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER 1385
COLLISION DIAGNOSIS 1385
For Frontal Collision 1386
SRS INSPECTION (FOR FRONTAL COLLISION) 1386
For Side Collision 1386
WHEN THE SIDE AIR BAG IS ACTIVATED IN THE SIDE COLLISION: 1388
WHEN SRS IS NOT ACTIVATED IN THE SIDE COLLISION: 1388
SRS INSPECTION (FOR SIDE COLLISION) 1388
POWER SUPPLY ROUTING CIRCUIT 4
ELECTRICAL UNITS 89
SMJ (SUPER MULTIPLE JUNCTION) 91
STANDARDIZED RELAY 92
FUSE BLOCK 94
FUSE, FUSIBLE LINK AND RELAY BOX 95
24-Body, Lock and Security System PDF 1391
QUICK REFERENCE INDEX 0
BODY, LOCK & SECURITY SYSTEM 1391
PRECAUTIONS 1391
1395
Maintenance Information 1395
RHD MODELS 1395
LHD MODELS 1395
Precautions 1395
CLIP AND FASTENER 1395
List of Table 1396
HOOD 1396
Fitting Adjustment 1397
FRONT END HEIGHT ADJUSTMENT AND LATERAL/LONGITUDINAL CLEARANCE ADJUSTMENT 1397
SURFACE MISMATCH ADJUSTMENT 1397
Removal and Installation 1397
REMOVAL 1398
Hood Assembly 1398
Hood Hinge 1398
INSTALLATION 1398
Removal and Installation of Hood Lock Control 1399
REMOVAL 1399
Hood Lock 1399
Hood Lock Mounting Reinforcement 1399
Hood Lock Cable 1400
INSTALLATION 1400
Hood Lock Mounting Reinforcement 1400
Hood Lock Cable 1400
Hood Lock Control Inspection 1401
RADIATOR CORE SUPPORT 1401
Removal and Installation 1403
REMOVAL 1403
Radiator Core Upper Support 1403
Radiator Core Lower Support 1403
INSTALLATION 1403
FRONT FENDER 1404
Removal and Installation 1405
REMOVAL 1405
INSTALLATION 1405
POWER DOOR LOCK SYSTEM 1405
Component Parts and Harness Connector Location 1406
System Description 1406
OPERATION 1407
DOOR LOCK AND UNLOCK SWITCH OPERATION 1407
BACK DOOR SWITCH OPERATION 1408
BACK DOOR RELEASE ACTUATOR OPERATION 1408
BACK DOOR SWITCH OPERATION 1408
KEY REMINDER SYSTEM 1408
UNLOCK LINK FUNCTION 1408
Selectable Function 1408
BACK DOOR OPENER OPERTION 1408
AUTO RE-LOCK FUNCTION 1409
ANTI-HIJACK FUNCTION 1409
CAN Communication 1409
SYSTEM DESCRIPTION 1409
CAN Communication Unit 1409
Schematic (Without Intelligent Key System) 1409
1410
Schematic (With Intelligent Key System) 1411
1416
Terminal and Reference Value for BCM 1417
CONSULT- II Inspection Procedure 1423
CONSULT- II Application Items 1424
WORK SUPPORT 1424
Security Door Lock Set 1424
Auto Lock Set 1424
DATA MONITOR 1424
ACTIVE TEST 1424
Work Flow 1424
TROUBLE DIAGNOSES CHART BY SYMPTOM/WITHOUT INTELLIGENT KEY SYSTEM 1425
TROUBLE DIAGNOSES CHART BY SYMPTOM/WITH INTELLIGENT KEY SYSTEM 1425
Check Power Supply and Ground Circuit of BCM 1426
Check Door Lock / Unlock Switch 1427
Check Key Switch /Without Intelligent Key System 1428
Check Key Switch and Ignition Knob Switch/With Intelligent Key System 1429
Check Door Lock Actuator Circuit 1430
Check Door Lock Actuator 1431
DRIVER SIDE 1432
PASSENGER SIDE 1432
REAR LH SIDE 1433
REAR RH SIDE 1434
Check Door Switch 1435
DRIVER SIDE 1436
PASSENGER SIDE 1436
REAR LH SIDE 1438
REAR RH SIDE 1440
BACK DOOR SWITCH 1442
Check Back Door Switch 1443
Check Back Door Release Actuator 1445
Check Door Lock/Unlock Switch Indicator 1447
1448
Component Parts and Harness Connector Location 1449
System Description 1449
OPERATION 1450
DOOR LOCK AND UNLOCK SWITCH OPERATION 1450
BACK DOOR SWITCH OPERATION 1451
BACK DOOR RELEASE ACTUATOR OPERATION 1451
BACK DOOR SWITCH OPERATION 1451
KEY REMINDER SYSTEM 1451
UNLOCK LINK FUNCTION 1451
Selectable Function 1451
BACK DOOR OPENER OPERTION 1451
AUTO RE-LOCK FUNCTION 1451
ANTI-HIJACK FUNCTION 1452
SUPER LOCK OPERATION 1452
OUTLINE 1452
OPERATION 1452
Power Door Lock / Unlock and Super Lock Set / Release Operation by Remote Controller or Intellige 1452
Power Door Lock / Unlock and Super Lock Release Operation by Door Key Cylinder 1452
Power Door Lock and Super Lock Release Operation 1452
CAN Communication 1452
SYSTEM DESCRIPTION 1453
CAN Communication Unit 1453
1453
1454
1455
1461
Terminal and Reference Value for BCM 1462
CONSULT- II Inspection Procedure 1468
CONSULT- II Application Items 1469
WORK SUPPORT 1469
Security Door Lock Set 1469
Auto Lock Set 1469
DATA MONITOR 1469
ACTIVE TEST 1469
Work Flow 1469
Trouble Diagnoses 1469
PRELIMINARY CHECK/WITHOUT INTELLIGENT KEY SYSTEM 1471
SYMPTOM CHART/WITHOUT INTELLIGENT KEY SYSTEM 1471
PRELIMINARY CHECK/WITH INTELLIGENT KEY SYSTEM 1472
SYMPTOM CHART/WITH INTELLIGENT KEY SYSTEM 1473
Check Power Supply and Ground Circuit 1474
Check Door Lock / Unlock Switch 1475
Check Key Switch /Without Intelligent Key System 1476
Check Key Switch And Ignition Knob Switch/With Intelligent Key System 1477
Check Power Door Lock / Unlock Output Signal 1478
Check Super Lock Output Signal 1479
Check Door Lock Actuator 1480
DRIVER SIDE 1481
PASSENGER SIDE 1481
REAR LH SIDE 1482
REAR RH SIDE 1483
Check Super Lock Actuator 1484
DRIVER SIDE 1485
PASSENGER SIDE 1485
REAR LH SIDE 1486
REAR RH SIDE 1487
Check Door Switch 1488
DRIVER SIDE 1489
PASSENGER SIDE 1489
REAR LH SIDE 1491
REAR RH SIDE 1493
Check Back Door Switch 1495
Check Back Door Release Actuator 1497
MULTI-REMOTE CONTROL SYSTEM 1499
Component Parts and Harness Connector Location 1501
System Description 1501
INPUTS 1502
OUTLINE 1502
Power Door Lock Operation 1502
Answer Back 1502
Remote Controller ID Code Entry 1503
Schematic 1503
1504
Terminal and Reference Value for BCM 1505
CONSULT- II Inspection Procedure 1509
CONSULT- II Application Items 1510
DATA MONITOR 1510
Work Flow 1510
Trouble Diagnosis Chart by Symptom 1510
Check Remote controller 1511
Check Door Switch 1512
DOOR SWITCH DRIVER SIDE 1512
DOOR SWITCH PASSENGER SIDE 1512
DOOR SWITCH REAR LH 1513
DOOR SWITCH REAR RH 1514
BACK DOOR RELEASE ACTUATOR (BACK DOOR SWITCH) 1515
Key Switch Check 1516
Hazard Reminder Check 1517
Remote Controller Battery Replacement 1518
INTELLIGENT KEY SYSTEM 1519
Component Parts and Harness Connector Location 1520
System Description 1520
DOOR LOCK FUNCTION 1522
Operation Description 1522
Operation Condition 1522
Operation Range 1523
Auto Door Lock Function 1523
Key Reminder Function 1523
Intelligent Key Lock-in Prevention Function 1523
REMOTE CONTROL ENTRY FUNCTIONS 1523
Door Lock Function 1523
MT vehicle Key Interlock function 1523
LOCK condition 1524
UNLOCK condition 1524
Map Lamp Function 1524
ENGINE STARTUP FUNCTION 1524
Operation Description 1524
Operation Range 1524
Active Check Function 1524
WARNING AND ALARM FUNCTION 1524
Operation Description 1525
Operation Condition 1525
Warning Procedure 1525
CHANGE SETTINGS FUNCTION 1526
Changing Anti-Hijack Function Settings With the Intelligent Key 1527
Changing Settings Using CONSULT-II 1527
INTELLIGENT KEY REGISTRATION 1527
STEERING LOCK UNIT REGISTRATION 1527
Steering Lock Unit ID Registration 1527
1527
1528
Terminals and Reference Value for INTELLIGENT KEY UNIT 1529
Terminals and Reference Value for Steering Lock unit 1539
Terminal and Reference Value for BCM 1541
Trouble Diagnosis Procedure 1541
PRELIMINALY CHECK 1543
WORK FLOW 1543
CONSULT-II Function (INTELLIGENT KEY) 1544
CONSULT-II Inspection Procedure 1545
BASIC OPERATION 1545
CONSULT-II Application Items 1545
SELF-DIAGNOSTIC RESULTS 1545
DATA MONITOR 1545
ACTIVE TEST 1545
WORK SUPPORT 1546
Trouble Diagnosis Symptom Chart 1546
KEY WARNING LAMP (GREEN) ILLUMINATES 1547
Conditions of Vehicle (Operating Conditions) 1547
KEY WARNING LAMP (RED) ILLUMINATES 1547
Conditions of Vehicle (Operating Conditions) 1547
KEY WARNING LAMP DOES NOT ILLUMINATE 1547
Conditions of Vehicle (Operating Conditions) 1548
SELF-DIAGNOSIS RESULTS ARE NOT DISPLAYED 1548
Conditions of Vehicle (Operating Conditions) 1548
ENGINE START CONDITION CHECK 1548
DOOR LOCK/UNLOCK FUNCTION MALFUNCTION 1548
Conditions of Vehicle (Operating Conditions) 1549
REMOTE KEYLESS ENTRY FUNCTION MALFUNCTION 1549
Conditions of Vehicle (Operating Conditions) 1549
HAZARD AND BUZZER REMINDER FUNCTION MALFUNCTION 1550
Conditions of Vehicle (Operating Conditions) 1551
WARNING CHIME FUNCTION MALFUNCTION 1551
WARNING LAMP FUNCTION MALFUNCTION 1551
Check CAN Communication System 1553
Check Power Supply and Ground Circuit 1553
Check Ignition Switch Signal Circuit 1554
Check Key Switch (Intelligent Key Unit Input) 1554
Check Key Switch (BCM Input) 1555
Check Ignition Knob Switch 1557
Check Door Request Switch 1558
Check Back Door Request Switch 1560
Check Door Switch 1562
DRIVER SIDE 1564
PASSENGER SIDE 1564
REAR LH SIDE 1566
REAR RH SIDE 1568
BACK DOOR SWITCH 1570
Check Intelligent Key Warning Buzzer Circuit 1571
Check Outside Key Antenna (Driver Side and Passenger Side) 1573
Check Outside Key Antenna (Back Door) 1574
Check Inside Key Antenna 1575
Check Steering Lock Unit 1577
Check Warning Lamp 1578
Check Warning Buzzer in Combination Meter 1581
Check Hazard Function 1581
Check Headlamp Function 1581
Check Stop Lamp Switch 1581
Removal and Installation of Intelligent key unit 1582
REMOVAL 1583
INSTALLATION 1583
Intelligent Key Inspection 1583
INTELLIGENT KEY DISASSEMBLY AND ASSEMBLY 1583
REMOTE CONTROLLER BATTERY INSPECTION 1583
DOOR 1584
Fitting Adjustment 1585
FRONT DOOR 1585
Longitudinal Gap and Front End Height Difference Adjustment 1585
REAR DOOR 1585
Longitudinal Gap and Front End Height Difference Adjustment 1586
STRIKER ADJUSTMENT 1586
Removal and Installation 1586
REMOVAL OF FRONT DOOR 1586
INSTALLATION 1586
REMOVAL OF REAR DOOR 1586
INSTALLATION 1587
Front Door Weatherstrip 1587
REMOVAL 1588
INSTALLATION 1588
Front Door Weatherstrip 1588
REMOVAL 1589
INSTALLATION 1589
FRONT DOOR LOCK 1589
Component Parts Location 1590
Removal and Installation 1590
REMOVAL 1590
Disassembly and Assembly 1590
DOOR KEY CYLINDER ASSEMBLY 1593
OUTSIDE HANDLE 1593
REAR DOOR LOCK 1593
Component Parts Location 1594
Removal and Installation 1594
REMOVAL 1594
BACK DOOR 1594
Fitting Adjustment 1597
VERTICAL/LATERAL CLEARANCE (SURFACE DIFFERENCE) ADJUSTMENT 1597
Back Door Assembly 1597
REMOVAL 1598
INSTALLATION 1598
INSPECTION 1598
Back Door Striker 1598
REMOVAL 1598
INSTALLATION 1598
Back Door Stay Assembly 1599
REMOVAL 1599
INSTALLATION 1599
Removal and Installation of Back Door Weatherstrip 1599
REMOVAL 1600
INSTALLATION 1600
BACK DOOR LOCK 1600
Removal and Installation 1601
BACK DOOR LOCK ASSEMBLY 1601
Removal 1601
Installation 1601
BACK DOOR HANDLE ASSEMBLY 1601
Removal 1601
Installation 1601
Disassembly and Assembly 1601
FUEL FILLER LID OPENER 1601
Removal and Installation of Fuel Filler Lid Opener 1602
REMOVAL 1602
INSTALLATION 1602
THEFT WARNING SYSTEM 1603
1604
NATS (Nissan Anti-Theft System) 1604
Component Parts and Harness Connector Location (Hatchback) 1605
System Description 1605
OPERATING DESCRIPTION 1607
SECURITY INDICATOR 1607
Condition of Security Indicator (Normal) 1607
System Composition 1607
ECM Re-communicating Function 1608
1608
WITHOUT INTELLIGENT KEY SYSTEM 1609
WITH INTELLIGENT KEY SYSTEM 1609
Terminals and Reference Value for Steering Lock Unit/With Intelligent Key System 1610
Terminals and Reference Value for Intelligent Key Unit/With Intelligent Key System 1612
Terminals and Reference Value for BCM/Without Intelligent Key System 1612
CONSULT-II 1613
CONSULT-II INSPECTION PROCEDURE 1614
CONSULT-II DIAGNOSTIC TEST MODE FUNCTION 1614
CHECK RESULT ITEM CHART FOR NATS IMMU FUNCTION 1614
Diagnosis Procedure 1615
WORK FLOW 1616
Trouble Diagnosis Symptom Chart 1616
MODELS WITHOUT INTELLIGENT KEY SYSTEM 1617
MODELS WITH INTELLIGENT KEY SYSTEM 1617
Security Indicator Inspection 1618
Diagnostic Procedure 1 1618
Diagnostic Procedure 2 1619
MODELS WITHOUT INTELLIGENT KEY SYSTEM 1619
MODELS WITH INTELLIGENT KEY SYSTEM 1619
Diagnostic Procedure 3 1621
Diagnostic Procedure 4 1623
Diagnostic Procedure 5 1623
Diagnostic Procedure 6 1624
Diagnostic Procedure 7 1624
Removal and Installation NATS Antenna Amp 1626
REMOVAL 1627
INSTALLATION 1627
POWER SUPPLY ROUTING CIRCUIT 4
ELECTRICAL UNITS 89
SMJ (SUPER MULTIPLE JUNCTION) 91
STANDARDIZED RELAY 92
FUSE BLOCK 94
FUSE, FUSIBLE LINK AND RELAY BOX 95
25-Glasses, Window System and Mirrors PDF 1629
QUICK REFERENCE INDEX 0
GLASSES, WINDOW SYSTEM & MIRRORS 1629
PRECAUTIONS 1629
1631
Maintenance Information 1631
RHD MODELS 1631
LHD MODELS 1631
Precautions for Procedures without Cowl Top Cover 1631
Precautions 1631
WINDSHIELD GLASS 1631
Removal and Installation 1633
REMOVAL 1633
INSTALLATION 1633
Repairing Water Leaks 1634
SIDE WINDOW GLASS 1634
Removal and Installation 1636
REMOVAL 1636
INSTALLATION 1636
Repairing Water Leaks 1636
BACK DOOR WINDOW GLASS 1637
Removal and Installation 1638
REMOVAL 1638
INSTALLATION 1638
Repairing Water Leaks 1639
REAR WINDOW DEFOGGER 1639
Component Parts and Harness Connector Location 1640
System Description 1640
CAN Communication 1640
SYSTEM DESCRIPTION 1642
CAN Communication Unit 1642
Schematic 1642
1643
Terminal and Reference Value for BCM 1644
Terminal and Reference Value for IPDM E/R 1647
Work Flow 1647
CONSULT-II Inspection Procedure 1647
DATA MONITOR 1647
Display Item List 1647
ACTIVE TEST 1647
Display Item List 1648
Trouble Diagnoses Symptom Chart 1648
Check BCM Power Supply and Ground Circuit 1648
Check Rear Window Defogger Switch Circuit / With Auto A/C 1649
Check Rear Window Defogger Switch Circuit / Without Auto A/C 1650
Check Rear Window Defogger Power Supply Circuit 1651
Check Rear Window Defogger Circuit 1653
Check Door Mirror Defogger Power Supply Circuit 1654
Check Driver Side Door Mirror Defogger Circuit 1655
Check Passenger Side Door Mirror Defogger Circuit 1656
Filament Check 1657
Filament Repair 1658
REPAIR EQUIPMENT 1659
REPAIRING PROCEDURE 1659
POWER WINDOW SYSTEM 1659
Component Parts and Harness Connector Location 1660
System Description (With Front Power Window) 1660
DRIVER DOOR 1660
Window Up 1660
Window Down 1660
PASSENGER DOOR [FRONT POWER WINDOW SWITCH (PASSENGER SIDE) OPERATION] 1661
Window Up 1661
Window Down 1661
PASSENGER DOOR (POWER WINDOW MAIN SWITCH OPERATION) 1661
Window Up 1661
Window Down 1661
AUTO OPERATION 1662
POWER WINDOW LOCK 1662
ANTI-PINCH SYSTEM 1662
INITIALIZATION 1662
System Description (With Front & Rear Power Window) 1662
DRIVER DOOR 1663
Window Up 1663
Window Down 1663
PASSENGER DOOR [FRONT POWER WINDOW SWITCH (PASSENGER SIDE) OPERATION] 1663
Window Up 1664
Window Down 1664
PASSENGER DOOR (POWER WINDOW MAIN SWITCH OPERATION) 1664
Window Up 1664
Window Down 1664
REAR DOOR (RH OR LH) [REAR POWER WINDOW SWITCH (RH OR LH) OPERATION] 1664
Window Up 1665
Window Down 1665
REAR DOOR (RH OR LH) (POWER WINDOW MAIN SWITCH OPERATION) 1665
Window Up 1665
Window Down 1665
AUTO OPERATION 1666
POWER WINDOW LOCK 1666
ANTI-PINCH SYSTEM 1666
INITIALIZATION 1666
Schematic/With Front Power Window 1666
1668
Schematic/With Front & Rear Power Window 1669
1672
Terminal and Reference Value for BCM 1673
Terminal and Reference Value for Power Window Main Switch/With Front Power Window (For LHD Models) 1677
Terminal and Reference Value for Power Window Main Switch/With Front Power Window (For RHD Models) 1677
Terminal and Reference Value for Power Window Main Switch/With Front & Rear Power Window 1678
Work Flow 1679
Trouble Diagnosis Symptom Chart 1680
Check BCM Power Supply and Ground Circuit 1681
Check Power Window Main Switch Power Supply and Ground Circuit 1682
WITH FRONT POWER WINDOW 1683
WITH FRONT & REAR POWER WINDOW 1683
Check Front Power Window Motor (Driver Side) Circuit 1684
WITH FRONT POWER WINDOW 1686
WITH FRONT & REAR POWER WINDOW 1686
Check Front Power Window Motor (Passenger Side) Circuit 1688
WITH FRONT POWER WINDOW 1689
WITH FRONT & REAR POWER WINDOW 1689
Check Rear Power Window Motor RH Circuit 1693
Check Rear Power Window Motor LH Circuit 1696
Check Limit Switch Circuit (Driver Side) 1699
WITH FRONT POWER WINDOW 1703
WITH RFONT & REAR POWER WINDOW 1703
Check Encoder Circuit (Driver Side) 1706
WITH FRONT POWER WINDOW 1708
WITH FRONT & REAR POWER WINDOW 1708
Check Power Window Lock Switch 1713
FRONT DOOR GLASS AND REGULATOR 1716
Removal and Installation 1717
DOOR GLASS 1717
Removal 1717
Installation 1717
REGULATOR ASSENBLY 1718
Removal 1718
Installation 1718
Inspection after Removal 1719
Inspection after Installation 1719
SYSTEM INITIALIZATION 1719
Initialization 1719
INSPECT THE FUNCTION OF THE ANTI-PINCH SYSTEM 1719
FITTING INSPECTION 1720
REAR DOOR GLASS AND REGULATOR 1720
Removal and Installation 1721
DOOR GLASS 1721
Removal 1721
Installation 1721
REGULATOR ASSEMBLY 1722
Removal 1722
Installation 1722
Installation after Removal 1722
Inspection after Installation 1723
FITTING INSPECTION 1723
DOOR MIRROR 1723
1724
1724
1726
Removal and Installation 1728
REMOVAL 1729
INSTALLATION 1729
Disassembly and Assembly 1729
DISASSEMBLY 1730
ASSEMBLY 1730
INSIDE MIRROR 1731
Removal and Installation 1732
REMOVAL 1732
INSTALLATION 1732
Removal and Installation (With Rain Sensor) 1732
REMOVAL 1732
INSTALLATION 1732
POWER SUPPLY ROUTING CIRCUIT 4
ELECTRICAL UNITS 89
SMJ (SUPER MULTIPLE JUNCTION) 91
STANDARDIZED RELAY 92
FUSE BLOCK 94
FUSE, FUSIBLE LINK AND RELAY BOX 95
26-Exterior and Interior PDF 1733
QUICK REFERENCE INDEX 0
EXTERIOR & INTERIOR 1733
PRECAUTIONS 1734
1734
Precautions for Procedures without Cowl Top Cover 1734
Precautions 1734
CLIP AND FASTENER 1735
Clip and Fastener 1735
FRONT BUMPER 1736
Removal and Installation 1736
REMOVAL 1738
INSTALLATION 1739
REAR BUMPER 1740
Removal and Installation 1740
REMOVAL 1741
INSTALLATION 1741
FRONT GRILLE 1742
Removal and Installation 1742
REMOVAL 1742
INSTALLATION 1742
FRONT DEFLECTOR 1743
Removal and Installation 1743
REMOVAL 1743
INSTALLATION 1743
COWL TOP 1744
Removal and Installation 1744
REMOVAL 1744
INSTALLATION 1745
FENDER PROTECTOR 1746
Removal and Installation 1746
MUDGUARD 1747
Removal and Installation 1747
ROOF SIDE MOLDING 1748
Removal and Installation 1748
REMOVAL 1748
INSTALLATION 1748
WINDSHIELD MOLDING 1749
Removal and Installation 1749
REMOVAL 1749
INSTALLATION 1750
DOOR OUTSIDE MOLDING 1751
Removal and Installation 1751
REMOVAL 1751
INSTALLATION 1751
DOOR FINISHER 1752
Removal and Installation 1752
REMOVAL 1753
INSTALLATION 1753
BACK DOOR TRIM 1754
Removal and Installation 1754
REMOVAL 1754
INSTALLATION 1755
LICENSE PLATE FINISHER 1756
Removal and Installation 1756
REMOVAL 1756
INSTALLATION 1757
BODY SIDE TRIM 1758
Removal and Installation 1758
REMOVAL 1758
Front Body Side Welt 1758
Dashboard Side Finisher 1758
Front Pillar Garnish 1758
Center Pillar Lower Garnish 1759
Center Pillar Upper Garnish 1759
Rear Pillar Garnish 1759
INSTALLATION 1759
REAR PARCEL SHELF FINISHER 1760
Component Parts Location 1760
FLOOR TRIM 1761
Removal and Installation 1761
REMOVAL 1761
INSTALLATION 1761
HEADLINER 1762
Removal and Installation 1762
REMOVAL 1762
INSTALLATION 1763
LUGGAGE FLOOR TRIM 1764
Removal and Installation 1764
REMOVAL 1765
Luggage Side Finisher 1765
Luggage Rear Kickplate 1765
INSTALLATION 1765
27-Instrument Panel PDF 1767
QUICK REFERENCE INDEX 0
INSTRUMENT PANEL 1767
PRECAUTIONS 1768
1768
Precautions 1768
CLIP AND FASTENER 1769
List of Table 1769
INSTRUMENT PANEL ASSEMBLY 1770
Component Parts Location 1770
Removal and Installation 1771
WORK ITEM TABLE 1771
REMOVAL 1772
A Front Pillar Garnish 1772
B Upper Instrument Panel 1772
C Steering Lock Escutcheon 1772
D Instrument Finisher Lower 1772
E Switch Panel Finisher 1772
F Steering Column Cover Upper 1773
G Steering Column Cover Lower 1773
H Combination Switch 1773
I Cluster Lid A 1773
J Combination Meter 1773
K Cluster Lid C 1774
L Air Conditioner Finisher 1775
M Instrument Pad (Driver Side) 1775
N Center Console 1775
O Instrument Panel Stay Cover 1775
P Glove Box Lid 1775
Q Glove Box Cover Assembly 1776
R Instrument Side Mask 1776
S Steering Wheel 1776
T Instrument Panel 1776
U Instrument Pad (Passenger Side) 1776
REMOVAL AND INSTALLATION OF INSTRUMENT PAD 1776
Driver Side: 1776
Passenger Side: 1776
Installation 1777
Disassembly and Assembly 1777
GLOVE BOX ASSEMBLY 1778
Removal And Installation 1778
REMOVAL 1778
INSTALLATION 1778
Disassembly And Assembly 1778
DISASSEMBLY 1778
ASSEMBLY 1778
CENTER CONSOLE ASSEMBLY 1779
Removal And Installation 1779
REMOVAL 1779
INSTALLATION 1779
Disassembly And Assembly 1779
28-Seat PDF 1781
QUICK REFERENCE INDEX 0
SEAT 1781
PRECAUTIONS 1781
1782
Precautions 1782
CLIP AND FASTENER 1782
List of Table 1783
HEATED SEAT 1783
Description 1784
1784
FRONT SEAT 1785
Component Parts Location 1787
Removal and Installation 1787
REMOVAL 1788
INSTALLATION 1788
Disassembly and Assembly of Seatback 1788
SEATBACK TRIM PAD 1788
Disassembly 1788
Assembly 1788
SEATBACK FRAME 1789
Disassembly 1789
Assembly 1789
Disassembly and Assembly of Seat Cushion 1790
SEAT CUSHION TRIM PAD 1790
Disassembly 1790
Assembly 1790
SEAT CUSHION FRAME 1790
Disassembly 1790
Assembly 1790
REAR SEAT 1791
Removal and Installation 1792
REMOVAL 1792
INSTALLATION 1792
Rear Seat Disassembly and Assembly 1792
POWER SUPPLY ROUTING CIRCUIT 4
ELECTRICAL UNITS 89
SMJ (SUPER MULTIPLE JUNCTION) 91
STANDARDIZED RELAY 92
FUSE BLOCK 94
FUSE, FUSIBLE LINK AND RELAY BOX 95
29-Automatic Air Conditioner PDF 1795
QUICK REFERENCE INDEX 0
AUTOMATIC AIR CONDITIONER 1795
PRECAUTIONS 1795
1798
Precautions for Procedures without Cowl Top Cover 1798
Precautions for Working with HFC-134a (R-134a) 1798
General Refrigerant Precautions 1798
Lubricant Precautions 1798
Precautions for Refrigerant Connection 1799
FEATURES OF NEW TYPE REFRIGERANT CONNECTION 1799
O-RING AND REFRIGERANT CONNECTION 1799
O-Ring Part Numbers and Specifications (CR Engine Models) 1800
O-Ring Part Numbers and Specifications (HR Engine Models) 1800
O-Ring Part Numbers and Specifications (K9K Engine Models) 1800
Precautions for Servicing Compressor 1801
Precautions for Service Equipment 1802
RECOVERY/RECYCLING EQUIPMENT 1802
ELECTRONIC LEAK DETECTOR 1802
VACUUM PUMP 1802
MANIFOLD GAUGE SET 1803
SERVICE HOSES 1803
SERVICE COUPLERS 1803
REFRIGERANT WEIGHT SCALE 1804
CALIBRATING ACR4 WEIGHT SCALE 1804
CHARGING CYLINDER 1804
Precautions for Leak Detection Dye 1804
IDENTIFICATION 1805
IDENTIFICATION LABEL FOR VEHICLE 1805
PREPARATION 1805
HFC-134a (R-134a) Service Tools and Equipment 1806
Commercial Service Tools 1806
REFRIGERATION SYSTEM 1808
Refrigerant Cycle 1809
REFRIGERANT FLOW 1809
FREEZE PROTECTION 1809
Refrigerant System Protection 1809
REFRIGERANT PRESSURE SENSOR 1809
PRESSURE RELIEF VALVE 1809
Component Layout 1809
LUBRICANT 1810
Maintenance of Lubricant Quantity in Compressor 1811
LUBRICANT 1811
LUBRICANT RETURN OPERATION 1811
LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COMPRESSOR 1811
LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT 1812
AIR CONDITIONER CONTROL 1812
System Construction 1814
AIR MIX DOOR CONTROL (AUTOMATIC TEMPERATURE CONTROL) 1814
FAN SPEED CONTROL 1814
INTAKE DOOR CONTROL 1814
OUTLET DOOR CONTROL 1814
MAGNET CLUTCH CONTROL 1814
SELF-DIAGNOSTIC SYSTEM 1815
Description of Control System 1815
Control Operation 1816
DISPLAY SCREEN 1816
AUTO SWITCH 1817
TEMPERATURE CONTROL SWITCH (POTENTIO TEMPERATURE CONTROL) 1817
RECIRCULATION (REC) SWITCH 1817
FRESH (FRE) SWITCH 1817
DEFROSTER (DEF) SWITCH 1817
REAR WINDOW DEFOGGER SWITCH 1817
OFF SWITCH 1817
A/C SWITCH 1817
MODE SWITCH 1817
FAN SWITCH 1817
Discharge Air Flow 1817
System Description 1818
SWITCHES AND THEIR CONTROL FUNCTION 1819
CAN Communication System Description 1819
TROUBLE DIAGNOSIS 1819
CONSULT-II Function (BCM) 1820
CONSULT-II BASIC OPERATION 1820
DATA MONITOR 1820
Operation Procedure 1820
Display Item List 1820
How to Perform Trouble Diagnosis for Quick and Accurate Repair 1820
WORK FLOW 1821
SYMPTOM TABLE 1821
Component Parts and Harness Connector Location 1821
ENGINE COMPARTMENT 1822
PASSENGER COMPARTMENT 1822
Circuit Diagram 1823
1824
1825
1829
1833
Auto Amp Terminals and Reference Value 1837
PIN CONNECTOR TERMINAL LAYOUT 1838
TERMINALS AND REFERENCE VALUE FOR AUTO AMP 1838
Self-diagnosis Function 1838
DESCRIPTION 1840
FUNCTION CONFIRMATION PROCEDURE 1840
AUXILIARY MECHANISM: TEMPERATURE SETTING TRIMMER 1842
Operational Check 1848
CHECKING MEMORY FUNCTION 1849
CHECKING BLOWER 1849
CHECKING DISCHARGE AIR 1849
CHECKING RECIRCULATION 1849
CHECKING TEMPERATURE INCREASE 1850
CHECKING TEMPERATURE DECREASE 1850
CHECK A/C SWITCH 1850
CHECKING AUTO MODE 1850
Power Supply and Ground Circuit for Auto Amp 1851
INSPECTION FLOW 1851
COMPONENT DESCRIPTION 1851
Auto Amp (Automatic Amplifier) 1852
Potentio Temperature Control (PTC) 1852
DIAGNOSTIC PROCEDURE FOR A/C SYSTEM 1852
Mode Door Motor Circuit 1852
INSPECTION FLOW 1854
SYSTEM DESCRIPTION 1854
Component Parts 1855
System Operation 1855
Drive System of Step Motor Type Door Motor 1855
Mode Door Control Specification 1856
COMPONENT DESCRIPTION 1856
Mode Door Motor 1856
DIAGNOSTIC PROCEDURE FOR MODE DOOR MOTOR 1856
Air Mix Door Motor Circuit 1857
INSPECTION FLOW 1858
SYSTEM DESCRIPTION 1858
Component Parts 1859
System Operation 1859
Drive System of Step Motor Type Door Motor 1859
Air Mix Door Control Specification 1859
COMPONENT DESCRIPTION 1860
Air Mix Door Motor 1860
DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR 1860
Intake Door Motor Circuit 1861
INSPECTION FLOW 1862
SYSTEM DESCRIPTION 1862
Component Parts 1863
System Operation 1863
Intake Door Control Specification 1863
COMPONENT DESCRIPTION 1863
Intake Door Motor 1864
DIAGNOSTIC PROCEDURE FOR INTAKE DOOR MOTOR 1864
Blower Motor Circuit 1864
INSPECTION FLOW 1865
SYSTEM DESCRIPTION 1865
Component Parts 1866
System Operation 1866
Automatic Mode 1866
Starting Fan Speed Control 1866
Blower Speed Compensation 1866
Fan Speed Control Specification 1867
DIAGNOSTIC PROCEDURE FOR BLOWER MOTOR 1867
COMPONENT INSPECTION 1867
Blower Motor 1871
Magnet Clutch Circuit 1871
INSPECTION FLOW 1872
SYSTEM DESCRIPTION 1872
Low Temperature Protection Control 1873
DIAGNOSTIC PROCEDURE FOR MAGNET CLUTCH 1873
COMPONENT INSPECTION 1873
Refrigerant Pressure Sensor 1879
Insufficient Cooling 1879
INSPECTION FLOW 1880
PERFORMANCE TEST DIAGNOSIS 1880
PERFORMANCE CHART 1882
Test Condition 1884
Test Reading 1884
TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE 1884
Both High- and Low-pressure Sides are Too High 1885
High-pressure Side is Too High and Low-pressure Side is Too Low 1885
High-pressure Side is Too Low and Low-pressure Side is Too High 1885
Both High- and Low-pressure Sides are Too Low 1886
Low-pressure Side Sometimes Becomes Negative 1886
Low-pressure Side Becomes Negative 1887
Insufficient Heating 1887
INSPECTION FLOW 1888
Noise 1888
INSPECTION FLOW 1890
Self-diagnosis 1890
INSPECTION FLOW 1891
Memory Function 1891
INSPECTION FLOW 1892
Ambient Sensor Circuit 1892
COMPONENT DESCRIPTION 1893
Ambient Sensor 1893
AMBIENT TEMPERATURE INPUT PROCESS 1893
DIAGNOSTIC PROCEDURE FOR AMBIENT SENSOR 1893
COMPONENT INSPECTION 1893
Ambient Sensor 1895
In-vehicle Sensor Circuit 1895
COMPONENT DESCRIPTION 1896
In-vehicle Sensor 1896
Aspirator 1896
DIAGNOSTIC PROCEDURE FOR IN-VEHICLE SENSOR 1896
COMPONENT INSPECTION 1896
In-vehicle Sensor 1898
Sunload Sensor Circuit 1898
COMPONENT DESCRIPTION 1899
Sunload Sensor 1899
SUNLOAD INPUT PROCESS 1899
DIAGNOSTIC PROCEDURE FOR SUNLOAD SENSOR 1899
COMPONENT INSPECTION 1899
Sunload Sensor 1901
Intake Sensor Circuit 1901
COMPONENT DESCRIPTION 1902
Intake Sensor 1902
DIAGNOSTIC PROCEDURE FOR INTAKE SENSOR 1902
COMPONENT INSPECTION 1902
Intake Sensor 1904
Engine Coolant Temperature Circuit 1904
CONTROLLER 1905
Removal and Installation of Controller 1906
REMOVAL 1906
INSTALLATION 1906
Disassembly and Assembly of Controller 1906
DISASSEMBLY 1906
ASSEMBLY 1906
AMBIENT SENSOR 1907
Removal and Installation 1908
REMOVAL 1908
INSTALLATION 1908
IN-VEHICLE SENSOR 1908
Removal and Installation 1909
REMOVAL 1909
INSTALLATION 1909
SUNLOAD SENSOR 1909
Removal and Installation 1910
REMOVAL 1910
INSTALLATION 1910
INTAKE SENSOR 1910
Removal and Installation 1911
REMOVAL 1911
INSTALLATION 1911
A/C UNIT ASSEMBLY 1911
Removal and Installation 1912
REMOVAL 1912
INSTALLATION 1912
Disassembly and Assembly 1914
BLOWER MOTOR 1915
Removal and Installation 1917
REMOVAL 1917
INSTALLATION 1917
INTAKE DOOR MOTOR 1917
Removal and Installation 1918
REMOVAL 1918
INSTALLATION 1918
AIR MIX DOOR MOTOR 1918
Removal and Installation 1919
REMOVAL 1919
INSTALLATION 1919
MODE DOOR MOTOR 1919
Removal and Installation 1920
REMOVAL 1920
INSTALLATION 1920
POWER TRANSISTOR 1920
Removal and Installation 1921
REMOVAL 1921
INSTALLATION 1921
HEATER CORE 1921
Removal and Installation 1922
REMOVAL 1922
INSTALLATION 1922
AIR CONDITIONER FILTER 1922
Removal and Installation 1923
FUNCTION 1923
REPLACEMENT TIMING 1923
REPLACEMENT PROCEDURES 1923
DUCTS AND GRILLES 1923
Removal and Installation 1924
REMOVAL 1924
Removal of Center Ventilator Grilles 1924
Removal of Side Ventilator Grilles 1924
Removal of Defroster Nozzle and Ducts 1925
Removal of Side Ventilator Ducts 1925
Removal of Center Ventilator Ducts 1926
Removal of Foot Ducts 1926
Removal of Floor Ducts 1926
INSTALLATION 1927
REFRIGERANT LINES 1928
HFC-134a (R-134a) Service Procedure 1929
SETTING OF SERVICE TOOLS AND EQUIPMENT 1929
Discharging Refrigerant 1929
Evacuating System and Charging Refrigerant 1929
Components 1929
CR ENGINE MODELS 1931
HR ENGINE MODELS 1931
K9K ENGINE MODELS 1932
Removal and Installation of Compressor 1933
REMOVAL 1934
INSTALLATION 1934
CHECK DISC TO PULLEY CLEARANCE 1934
Removal and Installation for Pipe and Hose 1935
REMOVAL 1935
INSTALLATION 1935
Removal and Installation for Refrigerant Pressure Sensor 1935
REMOVAL AND INSTALLATION 1936
Removal and Installation for Condenser (Models without Integrated Condenser) 1936
REMOVAL 1936
INSTALLATION 1936
Removal and Installation for Condenser (Models with Integrated Condenser) 1937
REMOVAL 1937
INSTALLATION 1937
Removal and Installation for Liquid Tank (HR Engine with A/T Models) 1937
REMOVAL 1938
INSTALLATION 1938
Removal and Installation for Liquid Tank (Except HR Engine with A/T Models) 1938
REMOVAL 1938
INSTALLATION 1938
Removal and Installation for Evaporator 1939
REMOVAL 1939
INSTALLATION 1939
Removal and Installation for Expansion Valve 1939
REMOVAL 1939
INSTALLATION 1939
Checking for Refrigerant Leaks 1940
Checking System for Leaks Using the Fluorescent Leak Detector 1941
Dye Injection 1941
Electronic Refrigerant Leak Detector 1941
PRECAUTIONS FOR HANDLING LEAK DETECTOR 1942
CHECKING PROCEDURE 1942
SERVICE DATA AND SPECIFICATIONS (SDS) 1943
COMPRESSOR 1945
LUBRICANT 1945
REFRIGERANT 1945
ENGINE IDLING SPEED 1945
BELT TENSION 1945
POWER SUPPLY ROUTING CIRCUIT 4
ELECTRICAL UNITS 89
SMJ (SUPER MULTIPLE JUNCTION) 91
STANDARDIZED RELAY 92
FUSE BLOCK 94
FUSE, FUSIBLE LINK AND RELAY BOX 95
30-Manual Air Conditioner PDF 1947
QUICK REFERENCE INDEX 0
MANUAL AIR CONDITIONER 1947
PRECAUTIONS 1947
1950
Precautions for Procedures without Cowl Top Cover 1950
Precautions for Working with HFC-134a (R-134a) 1950
General Refrigerant Precautions 1950
Lubricant Precautions 1950
Precautions for Refrigerant Connection 1951
FEATURES OF NEW TYPE REFRIGERANT CONNECTION 1951
O-RING AND REFRIGERANT CONNECTION 1951
O-Ring Part Numbers and Specifications (CR Engine Models) 1952
O-Ring Part Numbers and Specifications (HR Engine Models) 1952
O-Ring Part Numbers and Specifications (K9K Engine Models) 1952
Precautions for Servicing Compressor 1953
Precautions for Service Equipment 1954
RECOVERY/RECYCLING EQUIPMENT 1954
ELECTRONIC LEAK DETECTOR 1954
VACUUM PUMP 1954
MANIFOLD GAUGE SET 1955
SERVICE HOSES 1955
SERVICE COUPLERS 1955
REFRIGERANT WEIGHT SCALE 1956
CALIBRATING ACR4 WEIGHT SCALE 1956
CHARGING CYLINDER 1956
Precautions for Leak Detection Dye 1956
IDENTIFICATION 1957
IDENTIFICATION LABEL FOR VEHICLE 1957
PREPARATION 1957
HFC-134a (R-134a) Service Tools and Equipment 1958
Commercial Service Tools 1958
REFRIGERATION SYSTEM 1960
Refrigerant Cycle 1961
REFRIGERANT FLOW 1961
FREEZE PROTECTION 1961
Refrigerant System Protection 1961
REFRIGERANT PRESSURE SENSOR 1961
PRESSURE RELIEF VALVE 1961
Component Layout 1961
LUBRICANT 1962
Maintenance of Lubricant Quantity in Compressor 1963
LUBRICANT 1963
LUBRICANT RETURN OPERATION 1963
LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COMPRESSOR 1963
LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT 1964
AIR CONDITIONER CONTROL 1964
Control Operation 1966
FAN CONTROL DIAL 1966
TEMPERATURE CONTROL DIAL 1966
MODE CONTROL DIAL 1966
INTAKE DOOR LEVER 1966
REAR WINDOW DEFOGGER SWITCH 1966
A/C SWITCH 1966
Discharge Air Flow 1966
System Description 1967
SWITCHES AND THEIR CONTROL FUNCTION 1968
CAN Communication System Description 1968
TROUBLE DIAGNOSIS 1968
CONSULT-II Function (BCM) 1969
CONSULT-II BASIC OPERATION 1969
DATA MONITOR 1969
Operation Procedure 1969
Display Item List 1969
How to Perform Trouble Diagnosis for Quick and Accurate Repair 1969
WORK FLOW 1970
SYMPTOM TABLE 1970
Component Parts and Harness Connector Location 1970
1971
1972
1973
1975
1977
Operational Check 1979
CHECKING BLOWER 1980
CHECKING DISCHARGE AIR 1980
CHECKING RECIRCULATION 1980
CHECKING TEMPERATURE DECREASE 1980
CHECKING TEMPERATURE INCREASE 1981
CHECKING A/C SWITCH 1981
Mode Door 1981
INSPECTION FLOW 1982
Air Mix Door 1982
INSPECTION FLOW 1983
Intake Door 1983
INSPECTION FLOW 1984
Blower Motor Circuit 1984
INSPECTION FLOW 1985
DIAGNOSTIC PROCEDURE FOR BLOWER MOTOR 1985
COMPONENT INSPECTION 1985
Blower Motor 1988
Magnet Clutch Circuit 1988
INSPECTION FLOW 1989
SYSTEM DESCRIPTION 1989
Low Temperature Protection Control 1990
DIAGNOSTIC PROCEDURE FOR MAGNET CLUTCH 1990
COMPONENT INSPECTION 1990
Refrigerant Pressure Sensor 1997
Insufficient Cooling 1997
INSPECTION FLOW 1998
PERFORMANCE TEST DIAGNOSIS 1998
PERFORMANCE CHART 1999
Test Condition 2001
Test Reading 2001
TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE 2001
Both High- and Low-pressure Sides are Too High 2002
High-pressure Side is Too High and Low-pressure Side is Too Low 2002
High-pressure Side is Too Low and Low-pressure Side is Too High 2002
Both High- and Low-pressure Sides are Too Low 2003
Low-pressure Side Sometimes Becomes Negative 2003
Low-pressure Side Becomes Negative 2004
Insufficient Heating 2004
INSPECTION FLOW 2005
Noise 2005
INSPECTION FLOW 2006
CONTROLLER 2006
Removal and Installation 2008
REMOVAL 2008
INSTALLATION 2008
Disassembly and Assembly 2008
THERMO CONTROL AMPLIFIER 2009
Removal and Installation 2010
REMOVAL 2010
INSTALLATION 2010
A/C UNIT ASSEMBLY 2010
Removal and Installation 2011
REMOVAL 2011
INSTALLATION 2011
Disassembly and Assembly 2012
BLOWER MOTOR 2013
Removal and Installation 2015
REMOVAL 2015
INSTALLATION 2015
INTAKE DOOR 2015
Intake Door Cable Adjustment 2016
AIR MIX DOOR 2016
Air Mix Door Cable Adjustment 2017
MODE DOOR 2017
Mode Door Cable Adjustment 2018
BLOWER FAN RESISTOR 2018
Removal and Installation 2019
REMOVAL 2019
INSTALLATION 2019
HEATER CORE 2019
Removal and Installation 2020
REMOVAL 2020
INSTALLATION 2020
AIR CONDITIONER FILTER 2020
Removal and Installation 2021
FUNCTION 2021
REPLACEMENT TIMING 2021
REPLACEMENT PROCEDURES 2021
DUCTS AND GRILLES 2021
Removal and Installation 2022
REMOVAL 2022
Removal of Center Ventilator Grilles 2022
Removal of Side Ventilator Grilles 2022
Removal of Defroster Nozzle and Ducts 2023
Removal of Side Ventilator Ducts 2023
Removal of Center Ventilator Ducts 2024
Removal of Foot Ducts 2024
Removal of Floor Ducts 2024
INSTALLATION 2025
REFRIGERANT LINES 2026
HFC-134a (R-134a) Service Procedure 2027
SETTING OF SERVICE TOOLS AND EQUIPMENT 2027
Discharging Refrigerant 2027
Evacuating System and Charging Refrigerant 2027
Components 2027
CR ENGINE MODELS 2029
HR ENGINE MODELS 2029
K9K ENGINE MODELS 2030
Removal and Installation of Compressor 2031
REMOVAL 2032
INSTALLATION 2032
CHECK DISC TO PULLEY CLEARANCE 2032
Removal and Installation for Pipe and Hose 2033
REMOVAL 2033
INSTALLATION 2033
Removal and Installation for Refrigerant Pressure Sensor 2033
REMOVAL AND INSTALLATION 2034
Removal and Installation for Condenser (Models without Integrated Condenser) 2034
REMOVAL 2034
INSTALLATION 2034
Removal and Installation for Condenser (Models with Integrated Condenser) 2035
REMOVAL 2035
INSTALLATION 2035
Removal and Installation for Liquid Tank (HR Engine with A/T Models) 2035
REMOVAL 2036
INSTALLATION 2036
Removal and Installation for Liquid Tank (Except HR Engine with A/T Models) 2036
REMOVAL 2036
INSTALLATION 2036
Removal and Installation for Evaporator 2037
REMOVAL 2037
INSTALLATION 2037
Removal and Installation for Expansion Valve 2037
REMOVAL 2037
INSTALLATION 2037
Checking for Refrigerant Leaks 2038
Checking System for Leaks Using the Fluorescent Leak Detector 2039
Dye Injection 2039
Electronic Refrigerant Leak Detector 2039
PRECAUTIONS FOR HANDLING LEAK DETECTOR 2040
CHECKING PROCEDURE 2040
SERVICE DATA AND SPECIFICATIONS (SDS) 2041
COMPRESSOR 2043
LUBRICANT 2043
REFRIGERANT 2043
ENGINE IDLING SPEED 2043
BELT TENSION 2043
POWER SUPPLY ROUTING CIRCUIT 4
ELECTRICAL UNITS 89
SMJ (SUPER MULTIPLE JUNCTION) 91
STANDARDIZED RELAY 92
FUSE BLOCK 94
FUSE, FUSIBLE LINK AND RELAY BOX 95
31-Starting and Charging System PDF 2045
QUICK REFERENCE INDEX 0
STARTING & CHARGING SYSTEM 2045
PRECAUTIONS 2045
2047
PREPARATION 2047
Special Service Tools 2048
BATTERY 2048
How to Handle Battery 2049
METHODS OF PREVENTING OVER-DISCHARGE 2049
CHECKING ELECTROLYTE LEVEL 2049
Sulphation 2049
SPECIFIC GRAVITY CHECK 2050
Battery Test and Charging Chart 2050
CHART I 2051
CHART II 2051
Fig 1 Discharging Current (Load Tester) 2052
A: SLOW CHARGE 2052
Fig 2 Initial Charging Current Setting (Slow Charge) 2053
Fig 3 Additional Charge (Slow Charge) 2054
B: STANDARD CHARGE 2054
Fig 4 Initial Charging Current Setting (Standard Charge) 2055
Fig 5 Additional Charge (Standard Charge) 2055
C: QUICK CHARGE 2056
Fig 6 Initial Charging Current Setting and Charging Time (Quick Charge) 2056
Removal and Installation 2057
REMOVAL 2058
INSTALLATION 2058
CHARGING SYSTEM 2058
System Description (CR Engine Models) 2059
System Description (HR Engine Models) 2059
System Description (K9K Engine Models) 2059
2059
2060
2061
Trouble Diagnoses (CR Engine Models) 2062
DIAGNOSIS PROCEDURE 2064
PRE-DIAGNOSIS INSPECTION 2064
DIAGNOSIS CHART BY SYMPTOM 2064
INSPECTION FLOW BY CHARGE WARNING LAMP 2064
CHARGE WARNING LAMP LINE INSPECTION 2064
INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION 2065
INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION 2066
DARK CURRENT INSPECTION 2067
OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II 2067
Trouble Diagnoses (HR Engine Models) 2068
DIAGNOSIS PROCEDURE 2069
PRE-DIAGNOSIS INSPECTION 2069
DIAGNOSIS CHART BY SYMPTOM 2069
INSPECTION FLOW BY CHARGE WARNING LAMP 2069
CHARGE WARNING LAMP LINE INSPECTION 2069
VOLTAGE DETECTION LINE AND CHARGE WARNING LAMP INSPECTION 2070
INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION 2071
INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION 2072
DARK CURRENT INSPECTION 2073
OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II 2074
Trouble Diagnoses (K9K Engine Models) 2075
DIAGNOSIS PROCEDURE 2076
PRE-DIAGNOSIS INSPECTION 2076
DIAGNOSIS CHART BY SYMPTOM 2076
INSPECTION FLOW BY CHARGE WARNING LAMP 2076
CHARGE WARNING LAMP LINE INSPECTION 2076
VOLTAGE DETECTION LINE AND CHARGE WARNING LAMP INSPECTION 2077
INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION 2078
INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION 2080
DARK CURRENT INSPECTION 2080
OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II 2081
Removal and Installation (CR Engine Models) 2082
REMOVAL 2083
INSTALLATION 2083
Removal and Installation (HR Engine Models) 2084
REMOVAL 2084
INSTALLATION 2084
Removal and Installation (K9K Engine Models) 2085
REMOVAL 2086
INSTALLATION 2086
Disassembly 2086
REAR COVER 2086
REAR BEARING 2086
Inspection 2087
ROTOR CHECK 2087
BRUSH CHECK 2087
STATOR CHECK 2087
Assembly 2087
RING FITTING IN REAR BEARING 2088
REAR COVER INSTALLATION 2088
STARTING SYSTEM 2088
System Description 2089
M/T MODELS 2089
A/T MODELS 2089
2089
2090
Trouble Diagnoses 2092
Removal and Installation (CR Engine Models) 2094
REMOVAL 2095
INSTALLATION 2095
Removal and Installation (HR Engine Models) 2095
REMOVAL 2095
INSTALLATION 2095
Removal and Installation (K9K Engine Models) 2096
REMOVAL 2096
INSTALLATION 2096
Disassembly and Assembly 2096
Inspection 2096
MAGNETIC SWITCH CHECK 2099
PINION/CLUTCH CHECK 2099
BRUSH CHECK 2099
Brush 2099
Brush Spring Check 2099
Brush Holder 2100
YOKE CHECK 2100
ARMATURE CHECK 2101
Assembly 2101
PINION PROTRUSION LENGTH ADJUSTMENT 2102
Clearance 2102
SERVICE DATA AND SPECIFICATIONS (SDS) 2102
Battery 2104
Starter 2104
Alternator 2104
POWER SUPPLY ROUTING CIRCUIT 4
ELECTRICAL UNITS 89
SMJ (SUPER MULTIPLE JUNCTION) 91
STANDARDIZED RELAY 92
FUSE BLOCK 94
FUSE, FUSIBLE LINK AND RELAY BOX 95
32-Lighting System PDF 2105
QUICK REFERENCE INDEX 0
LIGHTING SYSTEM 2105
PRECAUTIONS 2105
2109
Maintenance Information 2109
RHD MODELS 2109
LHD MODELS 2109
General Precautions for Service Operations 2109
HEADLAMP -CONVENTIONAL TYPE- 2109
Component Parts and Harness Connector Location 2111
System Description 2111
OUTLINE 2111
HEADLAMP OPERATION 2111
Low Beam Operation 2112
High Beam Operation/Flash-to-Pass Operation 2112
COMBINATION SWITCH READING FUNCTION 2112
AUTO LIGHT OPERATION 2113
FRIENDRY LIGHTING FUNCTION 2113
EXTERIOR LAMP BATTERY SAVER CONTROL 2113
FAIL-SAFE FUNCTION 2113
CAN Communication System Description 2113
CAN Communication Unit 2113
Schematic 2113
2114
Terminals and Reference Values for BCM 2115
Terminals and Reference Values for IPDM E/R 2119
How to Perform Trouble Diagnoses 2121
Preliminary Check 2121
CHECK POWER SUPPLY AND GROUND CIRCUIT 2122
CONSULT-II Functions (BCM) 2122
CONSULT-II INSPECTION PROCEDURE 2123
CONSULT-II Application Items (BCM) 2123
WORK SUPPORT 2123
Operation Procedure 2123
Display Item List 2123
DATA MONITOR 2123
ACTIVE TEST 2123
CONSULT-II Functions (IPDM E/R) 2124
CONSULT-II INSPECTION PROCEDURE 2124
CONSULT-II Application Items (IPDM E/R) 2124
DATA MONITOR 2124
All Signals, Main Signals, Selection From Menu 2124
ACTIVE TEST 2124
Headlamp High Beam Does Not Illuminate (Both Sides) 2124
Headlamp High Beam Does Not Illuminate (One Side) 2125
Headlamp Low Beam Does Not Illuminate (Both Sides) 2127
Headlamp Low Beam Does Not Illuminate (One Side) 2129
Headlamps Do Not Turn OFF 2131
Aiming Adjustment 2133
PREPARATION BEFORE ADJUSTING 2134
LOW BEAM AND HIGH BEAM 2134
Bulb Replacement 2134
HEADLAMP (HIGH/LOW) 2136
PARKING (CLEARANCE) LAMP 2136
FRONT TURN SIGNAL LAMP 2136
Removal and Installation 2136
REMOVAL 2136
INSTALLATION 2136
Disassembly and Assembly 2137
DISASSEMBLY 2138
ASSEMBLY 2138
HEADLAMP – DAYTIME LIGHT SYSTEM – 2138
Component Parts and Harness Connector Location 2139
System Description 2139
OUTLINE 2139
HEADLAMP OPERATION 2139
Low Beam Operation 2140
High Beam Operation (When Daytime Light Does Not Operate)/Flash-to-Pass Operation 2140
DAYTIME LIGHT OPERATION 2140
COMBINATION SWITCH READING FUNCTION 2141
AUTO LIGHT OPERATION 2141
FRIENDRY LIGHTING FUNCTION 2141
EXTERIOR LAMP BATTERY SAVER CONTROL 2141
FAIL-SAFE FUNCTION 2141
CAN Communication System Description 2141
CAN Communication Unit 2141
Schematic 2141
2142
Terminals and Reference Values for BCM 2143
Terminals and Reference Values for IPDM E/R 2146
How to Perform Trouble Diagnosis 2147
Preliminary Check 2147
INSPECTION FOR POWER SUPPLY AND GROUND CIRCUIT 2148
CONSULT-II Functions (BCM) 2148
CONSULT-II INSPECTION PROCEDURE 2149
CONSULT-II Application Items (BCM) 2149
WORK SUPPORT 2149
Operation Procedure 2149
Display Item List 2149
DATA MONITOR 2149
ACTIVE TEST 2149
CONSULT-II Functions (IPDM E/R) 2150
CONSULT-II INSPECTION PROCEDURE 2150
CONSULT-II Application Items (IPDM E/R) 2150
DATA MONITOR 2150
All Signals, Main Signals, Selection From Menu 2150
ACTIVE TEST 2150
Daytime Light Control Does Not Operate Properly 2150
RH High beam Does Not Illuminate 2151
RH Low Beam Does Not Illuminate 2152
Headlamp High Beam Does Not Illuminate (Both Sides) 2154
Headlamp Low Beam Does Not Illuminate (Both Sides) 2155
Headlamp LH High Beam Does Not Illuminate 2155
Headlamp LH Low Beam Does Not Illuminate 2155
Headlamps Do Not Turn OFF 2155
Aiming Adjustment 2155
Bulb Replacement 2155
Removal and Installation 2155
Disassembly and Assembly 2155
AUTO LIGHT SYSTEM 2155
Component Parts and Harness Connector Location 2156
System Description 2156
OUTLINE 2156
COMBINATION SWITCH READING FUNCTION 2156
FRIENDRY LIGHTING FUNCTION 2157
EXTERIOR LAMP BATTERY SAVER CONTROL 2157
CAN Communication System Description 2157
CAN Communication Unit 2157
Major Components and Functions 2157
Schematic 2157
2158
Terminals and Reference Values for BCM 2159
Terminals and Reference Values for IPDM E/R 2163
How to Proceed With Trouble Diagnosis 2165
Preliminary Check 2165
CHECK POWER SUPPLY AND GROUND CIRCUIT 2166
CONSULT-II Functions (BCM) 2166
CONSULT-II INSPECTION PROCEDURE 2167
CONSULT-II Application Items 2167
WORK SUPPORT 2167
Operation Procedure 2167
Display Item List 2167
DATA MONITOR 2167
ACTIVE TEST 2168
Light and rain sensor System Inspection 2168
Removal and Installation of Light and Rain Sensor 2169
REMOVAL 2171
INSTALLATION OF LIGHT AND RAIN SENSOR 2171
INSTALLATION OF LIGHT AND RAIN SENSOR HOUSING 2171
HEADLAMP AIMING CONTROL 2171
Schematic 2172
2172
Removal and Installation 2173
REMOVAL 2176
INSTALLATION 2176
Switch Circuit Inspection 2176
FRONT FOG LAMP 2176
Component Parts and Harness Connector Location 2177
System Description 2177
OUTLINE 2177
FOG LAMP OPERATION 2177
COMBINATION SWITCH READING FUNCTION 2178
EXTERIOR LAMP BATTERY SAVER CONTROL 2178
FAIL-SAFE FUNCTION 2178
CAN Communication System Description 2178
CAN Communication Unit 2178
Schematic 2178
2179
Terminals and Reference Values for BCM 2180
Terminals and Reference Values for IPDM E/R 2183
How to Proceed With Trouble Diagnosis 2184
Preliminary Check 2184
CHECK POWER SUPPLY AND GROUND CIRCUIT 2185
CONSULT-II Functions (BCM) 2185
CONSULT-II Functions (IPDM E/R) 2186
Front Fog lamps Do Not Illuminate (Both Sides) 2186
Front Fog Lamp Does Not Illuminate (One Side) 2186
Aiming Adjustment 2189
Bulb Replacement 2190
Removal and Installation 2190
REMOVAL 2191
INSTALLATION 2191
REAR FOG LAMP 2191
Component Parts and Harness Connector Location 2192
System Description 2192
OUTLINE 2192
REAR FOG LAMP OPERATION 2192
COMBINATION SWITCH READING FUNCTION 2192
CAN Communication System Description 2193
CAN Communication Unit 2193
2193
Terminals and Reference Values for BCM 2194
How to Proceed With Trouble Diagnosis 2196
Preliminary Check 2197
CHECK POWER SUPPLY AND GROUND CIRCUIT 2198
CONSULT-II Functions (BCM) 2198
Rear Fog Lamp Does Not Operate 2198
Bulb Replacement 2199
Removal and Installation 2201
REMOVAL 2201
INSTALLATION 2201
TURN SIGNAL AND HAZARD WARNING LAMPS 2201
Component Parts and Harness Connector Location 2202
System Description 2202
TURN SIGNAL OPERATION 2202
LH Turn Signal Lamp 2202
RH Turn Signal Lamp 2202
HAZARD LAMP OPERATION 2203
COMBINATION SWITCH READING FUNCTION 2203
CAN Communication System Description 2204
CAN Communication Unit 2204
2204
Terminals and Reference Values for BCM 2205
How to Proceed With Trouble Diagnosis 2207
Preliminary Check 2208
CHECK POWER SUPPLY AND GROUND CIRCUIT 2209
CONSULT-II Functions (BCM) 2209
CONSULT-II INSPECTION PROCEDURE 2210
CONSULT-II Application Items 2210
WORK SUPPORT 2210
Hazard Lamp Set 2210
DATA MONITOR 2210
ACTIVE TEST 2210
Turn Signal Lamp Does Not Operate 2210
Hazard Warning Lamp Does Not Operate But Turn Signal Lamp Operates 2211
Bulb Replacement (Front Turn Signal Lamp) 2213
Bulb Replacement (Rear Turn Signal Lamp) 2215
Bulb Replacement (Side Turn Signal Lamp) 2215
Removal and Installation of Front Turn Signal Lamp 2215
Removal and Installation of Rear Turn Signal Lamp 2215
Removal and Installation of Side Turn Signal Lamp 2215
REMOVAL 2215
INSTALLATION 2215
LIGHTING AND TURN SIGNAL SWITCH 2215
Removal and Installation 2216
REMOVAL 2216
INSTALLATION 2216
HAZARD SWITCH 2216
Removal and Installation 2217
REMOVAL 2217
INSTALLATION 2217
COMBINATION SWITCH 2217
System Description 2218
COMBINATION SWITCH READING FUNCTION 2218
Operation 2218
BCM – Operation Table of Combination Switches 2218
Sample Operation: (When Lighting Switch 1st Position Turned ON) 2219
Operation Mode 2219
2220
Terminals and Reference Values for BCM 2221
Reference Values for BCM (Input) 2222
CONSULT-II Function (BCM) 2225
CONSULT-II INSPECTION PROCEDURE 2228
CONSULT-II Application Items 2228
DATA MONITOR 2228
Combination Switch Inspection 2228
Removal and Installation 2229
STOP LAMP 2232
2233
Bulb Replacement of High-Mounted Stop Lamp 2233
Bulb Replacement of Rear Combination Lamp (Stop Lamp) 2234
Removal and Installation of High-Mounted Stop Lamp 2234
REMOVAL 2234
INSTALLATION 2234
Removal and Installation of Rear Combination Lamp (Stop Lamp) 2234
BACK-UP LAMP 2234
2235
Bulb Replacement 2235
Removal and Installation 2237
PARKING, LICENSE PLATE AND TAIL LAMPS 2237
Component Parts and Harness Connector Location 2238
System Description 2238
OPERATION BY LIGHTING SWITCH 2238
COMBINATION SWITCH READING FUNCTION 2238
EXTERIOR LAMP BATTERY SAVER CONTROL 2239
FAIL-SAFE FUNCTION 2239
CAN Communication System Description 2239
CAN Communication Unit 2239
Schematic 2239
2240
Terminals and Reference Values for BCM 2241
Terminals and Reference Values for IPDM E/R 2244
How to Proceed With Trouble Diagnosis 2245
Preliminary Check 2245
CHECK POWER SUPPLY AND GROUND CIRCUIT 2246
CONSULT-II Functions (BCM) 2246
CONSULT-II Functions (IPDM E/R) 2247
Parking, License Plate and Tail Lamps Do Not Illuminate 2247
Parking, License Plate and Tail Lamps Do Not Turn OFF (After Approx 10 Minutes) 2247
Bulb Replacement 2251
PARKING LAMP 2252
LICENSE PLATE LAMP 2252
TAIL LAMP 2252
Removal and Installation 2252
PARKING LAMP 2252
LICENSE PLATE LAMP 2252
Removal 2252
Installation 2252
TAIL LAMP 2252
Removal 2252
REAR COMBINATION LAMP 2252
Bulb Replacement 2253
Removal and Installation 2253
REMOVAL 2253
INSTALLATION 2253
INTERIOR ROOM LAMP 2253
Component Parts and Harness Connector Location 2254
System Description 2254
POWER SUPPLY AND GROUND 2254
SWITCH OPERATION 2254
Models With Personal Lamp 2255
INTERIOR ROOM LAMP TIMER OPERATION 2256
INTERIOR ROOM LAMP BATTERY SAVER CONTROL 2256
Schematic 2256
— 2257
— 2257
2258
— 2259
— 2259
Terminals and Reference Values for BCM 2263
How to Proceed With Trouble Diagnosis 2267
Preliminary Check 2268
CHECK POWER SUPPLY AND GROUND CIRCUIT 2269
CONSULT-II Functions (BCM) 2269
CONSULT-II INSPECTION PROCEDURE 2270
CONSULT-II Application Items 2270
DATA MONITOR 2270
ACTIVE TEST 2270
Map Lamp Control Does Not Operate 2270
Personal Lamp Control Does Not Operate (Models With Personal Lamp) 2271
Bulb Replacement 2273
MAP LAMP, PERSONAL LAMP 2275
LUGGAGE LOOM LAMP 2275
Removal and Installation 2275
MAP LAMP, PERSONAL LAMP 2275
Removal 2275
Installation 2275
LUGGAGE ROOM LAMP 2275
Removal 2276
Installation 2276
ILLUMINATION 2276
System Description 2277
ILLUMINATION OPERATION BY LIGHTING SWITCH 2277
EXTERIOR LAMP BATTERY SAVER CONTROL 2277
CAN Communication System Description 2278
CAN Communication Unit 2278
Schematic 2278
2279
BULB SPECIFICATIONS 2280
Headlamp 2287
Exterior Lamp 2287
Interior Lamp/Illumination 2287
POWER SUPPLY ROUTING CIRCUIT 4
ELECTRICAL UNITS 89
SMJ (SUPER MULTIPLE JUNCTION) 91
STANDARDIZED RELAY 92
FUSE BLOCK 94
FUSE, FUSIBLE LINK AND RELAY BOX 95
33-Driver Information System PDF 2289
QUICK REFERENCE INDEX 0
DRIVER INFORMATION SYSTEM 2289
PRECAUTIONS 2289
2291
Maintenance Information 2291
RHD MODELS 2291
LHD MODELS 2291
COMBINATION METERS 2291
Component Parts and Harness Connector Location 2292
System Description 2292
UNIFIED METER CONTROL UNIT 2292
POWER SUPPLY AND GROUND CIRCUIT 2292
SPEEDOMETER 2292
TACHOMETER 2292
LOW WATER TEMPERATURE INDICATOR LAMP, HIGH WATER TEMPERATURE WARNING LAMP 2292
FUEL GAUGE 2292
ODO/TRIP METER 2293
How to Change the Display 2293
CAN Communication 2293
SYSTEM DESCRIPTION 2293
CAN Communication Unit 2293
Arrangement of Combination Meter 2293
Schematic 2294
2295
Terminals and Reference Value for Combination Meter 2296
Combination Meter Self-Diagnosis 2297
PERFORMING SELF-DIAGNOSIS MODE 2298
2298
Trouble Diagnoses 2300
PRELIMINARY CHECK 2301
SYMPTOM CHART 2301
Symptom Chart 1 2303
Symptom Chart 2 2303
Symptom Chart 3 2303
Check Power Supply and Ground Circuit 2303
Check Vehicle Speed Signal 2303
Check Engine Revolution Signal 2304
Check Fuel Level Sensor Signal 2305
Check Water Temperature Warning/indicator Lamp 2305
Check Fuel Gauge Fluctuation 2307
Fuel Gauge Does Not Move to FULL position 2307
Check Electrical Components 2307
CHECK FUEL LEVEL SENSOR UNIT 2307
Removal and Installation for Combination Meter 2307
REMOVAL 2308
INSTALLATION 2308
Disassembly and Assembly for Combination Meter 2308
DISASSEMBLY 2308
ASSEMBLY 2308
DRIVE COMPUTER 2308
Component Parts and Harness Connector Location 2309
System Description 2309
DRIVE COMPUTER 2309
Range 2309
Average Fuel Consumption 2310
Average Speed 2310
Journey Time 2310
SERVICE REMINDER 2310
OIL LEVEL WARNING 2310
OUTSIDE AIR TEMPERATURE 2310
CAN Communication 2310
SYSTEM DESCRIPTION 2311
CAN Communication Unit 2311
2311
Terminals and Reference Value for Combination Meter 2312
Check Ambient Sensor Signal 2314
Check Steering Wheel Switch 2314
Check Oil Level sensor 2317
WARNING LAMPS 2318
System Description 2320
OIL PRESSURE WARNING LAMP 2320
Oil Pressure Warning 2320
Component Parts and Harness Connector Location 2320
Schematic 2320
2321
2322
Oil Pressure Warning Lamp Stays Off (Ignition Switch ON) 2328
Oil Pressure Warning Lamp Does Not Turn Off (Oil Pressure Is Normal) 2333
Electrical Components Inspection 2334
OIL PRESSURE SWITCH CHECK 2335
A/T INDICATOR 2335
System Description 2336
FEATURE DESCRIPTION 2336
2336
A/T Indicator Does Not Illuminate 2337
WARNING CHIME 2339
Component Parts and Harness Connector Location 2340
System Description 2340
POWER SUPPLY AND GROUND CIRCUIT 2341
IGNITION KEY WARNING CHIME 2341
INTELLIGENT KEY SYSTEM WARNING CHIME 2341
LIGHT WARNING CHIME 2341
SEAT BELT WARNING CHIME 2341
PARKING BRAKE WARNING CHIME 2342
CAN Communication 2342
SYSTEM DESCRIPTION 2342
CAN Communication Unit 2342
Schematic 2342
2343
Terminals and Reference Value for BCM 2344
Terminals and Reference Value for Combination Meter 2348
Trouble Diagnosis 2350
HOW TO PERFORM TROUBLE DIAGNOSIS 2351
PRELIMINARY INSPECTION 2351
SYMPTOM CHART 2351
Check Front Door Switch (Driver Side) Signal 2351
Check Seat Belt Buckle Switch Signal 2351
Check Parking Break Switch Signal 2352
POWER SUPPLY ROUTING CIRCUIT 4
ELECTRICAL UNITS 89
SMJ (SUPER MULTIPLE JUNCTION) 91
STANDARDIZED RELAY 92
FUSE BLOCK 94
FUSE, FUSIBLE LINK AND RELAY BOX 95
34-Wiper, Washer and Horn PDF 2357
QUICK REFERENCE INDEX 0
WIPER, WASHER & HORN 2357
PRECAUTIONS 2357
2359
Maintenance Information 2359
RHD MODELS 2359
LHD MODELS 2359
Precautions for Procedures without Cowl Top Cover 2359
FRONT WIPER AND WASHER SYSTEM 2359
Components Parts and Harness Connector Location 2360
System Description 2360
OUTLINE 2360
LOW SPEED WIPER OPERATION 2360
HIGH SPEED WIPER OPERATION 2361
INTERMITTENT OPERATION 2361
Wiper Intermittent Dial Position Setting 2361
AUTO WIPER OPERATION (MODELS WITH LIGHT AND RAIN SENSOR) 2362
AUTO STOP OPERATION 2362
MIST OPERATION 2362
WASHER OPERATION 2362
FAIL-SAFE FUNCTION 2363
COMBINATION SWITCH READING FUNCTION 2363
Operation 2364
BCM – Operation Table of Combination Switches 2364
Sample Operation: (When Wiper Switch is Turned to LOW Position) 2364
Operation Mode 2365
Intermittent Operation 2365
CAN Communication 2366
SYSTEM DESCRIPTION 2367
CAN Communication Unit 2367
Schematic 2367
2368
Terminals and Reference Values for BCM 2369
Reference Values for BCM (Input) 2372
Terminals and Reference Values for IPDM E/R 2376
CONSULT-II Function (BCM) 2379
CONSULT-II BASIC OPERATION 2380
WORK SUPPORT 2380
DATA MONITOR 2380
ACTIVE TEST 2380
CONSULT-II Function (IPDM E/R) 2380
CONSULT-II BASIC OPERATION 2381
DATA MONITOR 2381
ACTIVE TEST 2381
Diagnosis Chart by Symptom 2381
Front Wiper Does Not Operate 2382
Front Wiper Does Not Return to Stop Position (After Front Wiper Operate for 10 Seconds, They Stop 2384
Only Front Wiper Low Does Not Operate 2387
Only Front Wiper Hi Does Not Operate 2389
Only Front Wiper Intermittent Does Not Operate 2391
Only Front Wiper Auto Dose Not Operate 2393
Front Wiper Interval Time Is Not Controlled by Vehicle Speed 2394
Front Wiper Intermittent Operation Switch Position Cannot Be Adjusted 2396
Wiper Does Not Wipe When Front Washer Operates 2396
Front Wiper Does Not Stop 2397
Removal and Installation of Front Wiper Arms, Adjustment of Wiper Arms Stop Location 2397
REMOVAL 2398
INSTALLATION 2398
ADJUSTMENT 2398
Removal and Installation of Front Wiper Drive Assembly 2398
REMOVAL 2399
INSTALLATION 2399
Washer Nozzle Adjustment 2400
Washer Tube Routing 2400
Removal and Installation of Front Washer Nozzle 2401
REMOVAL 2401
INSTALLATION 2401
Inspection for Washer Nozzle 2401
CHECK VALVE INSPECTION 2402
Inspection of Front Wiper and Washer Switch Circuit 2402
Removal and Installation of Front Wiper and Washer Switch 2402
REMOVAL 2402
INSTALLATION 2402
Removal and Installation of Washer Tank 2402
REMOVAL 2402
INSTALLATION 2402
Removal and Installation of Front Washer Motor 2403
REMOVAL 2403
INSTALLATION 2403
Removal and Installation of Light and Rain Sensor 2403
REMOVAL 2403
INSTALLATION OF RAIN SENSOR 2403
INSTALLATION OF LIGHT AND RAIN SENSOR HOUSING 2403
REAR WIPER AND WASHER SYSTEM 2404
Components Parts and Harness Connector Location 2405
System Description 2405
OUTLINE 2405
REAR WIPER OPERATION 2405
INTERMITTENT OPERATION 2405
AUTO STOP OPERATION 2406
WASHER OPERATION 2406
REAR WIPER REVERSE RANGE OPERATION (If auto wiper is equipped) 2406
COMBINATION SWITCH READING FUNCTION 2406
CAN Communication 2406
SYSTEM DESCRIPTION 2406
CAN Communication Unit 2406
2406
WITHOUT RAIN SENSOR 2407
Schematic 2407
WITH RAIN SENSOR 2409
2409
WITH RAIN SENSOR 2410
Terminals and Reference Values for BCM 2410
Reference Values for BCM (Input) 2413
Terminals and Reference Values for IPDM E/R 2416
CONSULT-II Function (BCM) 2418
Diagnosis Chart by Symptom 2419
Rear Wiper Does Not Operate 2420
Rear Wiper Does Not Return to Stop Position 2421
Only Rear Wiper ON Does Not Operate 2423
Only Rear Wiper Intermittent Does Not Operate 2424
Wiper Does Not Wipe When Rear Washer Operates 2425
Removal and Installation of Rear Wiper Arm, Adjustment of Wiper Arm Stop Location 2425
REMOVAL 2425
INSTALLATION 2425
Removal and Installation of Rear Wiper Motor 2425
REMOVAL 2426
INSTALLATION 2426
Rear Washer Nozzle Adjustment 2426
Rear Washer Tube Layout 2427
Removal and Installation of Rear Washer Nozzle 2427
REMOVAL 2427
INSTALLATION 2427
CHECK VALVE INSPECTION 2427
Inspection of Rear Wiper and Washer Switch Circuit 2428
Removal and Installation of Rear Wiper and Washer Switch 2428
Removal and Installation of Rear Wiper and Washer Tank 2428
Removal and Installation of Rear Wiper and Washer Pump 2428
HEADLAMP WASHER 2428
Components Parts and Harness Connector Location 2429
System Description 2429
OUTLINE 2429
HEADLAMP WASHER OPERATION 2429
CAN Communication 2430
CAN Communication Unit 2430
2430
Terminals and Reference Values for BCM 2431
Reference Values for BCM (Input) 2433
Terminals and Reference Values for IPDM E/R 2436
CONSULT-II Function (BCM) 2438
CONSULT-II Function (IPDM E/R) 2439
Diagnosis Chart by Symptom 2439
Headlamp Washer Does Not Operate 2439
Removal and Installation for Headlamp Washer Nozzle 2440
REMOVAL 2444
INSTALLATION 2444
Removal and Installation for Washer Tank 2444
Removal and Installation for Headlamp Washer Motor 2444
Headlamp Washer Tube Layout 2444
HORN 2444
2445
Removal and Installation 2445
REMOVAL 2446
INSTALLATION 2446
POWER SOCKET 2446
2447
Removal and Installation 2447
REMOVAL 2448
INSTALLATION 2448
Removal and Installation of Console Power Socket 2448
REMOVAL 2448
INSTALLATION 2448
Removal and Installation of Luggage Room Power Socket 2448
REMOVAL 2448
INSTALLATION 2448
POWER SUPPLY ROUTING CIRCUIT 4
ELECTRICAL UNITS 89
SMJ (SUPER MULTIPLE JUNCTION) 91
STANDARDIZED RELAY 92
FUSE BLOCK 94
FUSE, FUSIBLE LINK AND RELAY BOX 95
35-Body Control System PDF 2449
QUICK REFERENCE INDEX 0
BODY CONTROL SYSTEM 2449
PRECAUTIONS 2449
2450
Maintenance Information 2450
RHD MODELS 2450
LHD MODELS 2450
BCM (BODY CONTROL MODULE) 2450
System Description 2451
BCM FUNCTION 2451
COMBINATION SWITCH READING FUNCTION 2451
SYSTEMS CONTROLLED BY BCM 2451
SYSTEMS CONTROLLED BY BCM AND IPDM E/R 2451
SYSTEMS CONTROLLED BY BCM AND INTELLIGENT KEY UNIT 2451
INPUT/OUTPUT 2451
CAN COMMUNICATION CONTROL 2452
BCM STATUS CONTROL 2453
CAN Communication 2453
SYSTEM DESCRIPTION 2454
CAN Communication Unit 2454
Schematic 2454
CONSULT-II Function (BCM) 2455
2457
ITEMS OF EACH PART 2457
Configuration 2457
DESCRIPTION 2458
READ CONFIGURATION PROCEDURE 2458
WRITE CONFIGURATION PROCEDURE 2458
CAN Communication Inspection With CONSULT-II (Self-Diagnosis) 2461
Removal and Installation of BCM 2465
REMOVAL 2465
INSTALLATION 2465
POWER SUPPLY ROUTING CIRCUIT 4
ELECTRICAL UNITS 89
SMJ (SUPER MULTIPLE JUNCTION) 91
STANDARDIZED RELAY 92
FUSE BLOCK 94
FUSE, FUSIBLE LINK AND RELAY BOX 95
36-LAN System PDF 2467
QUICK REFERENCE INDEX 0
LAN SYSTEM 2467
CAN 2467
PRECAUTIONS 2469
2469
Maintenance Information 2469
RHD MODELS 2469
LHD MODELS 2469
Precautions When Using CONSULT-II 2469
CHECK POINTS FOR USING CONSULT-II 2469
Precautions for Trouble Diagnosis 2469
CAN SYSTEM 2470
Precautions for Harness Repair 2470
CAN SYSTEM 2470
TROUBLE DIAGNOSES WORK FLOW 2470
When Displaying CAN Communication System Errors 2471
WHEN A MALFUNCTION IS DETECTED BY CAN COMMUNICATION SYSTEM 2471
WHEN A MALFUNCTION IS DETECTED EXCEPT CAN COMMUNICATION SYSTEM 2471
TROUBLE DIAGNOSIS FLOW CHART 2471
Diagnosis Procedure 2472
SELECTING CAN SYSTEM TYPE (HOW TO USE SPECIFICATION TABLE) 2473
ACQUISITION OF DATA BY CONSULT-II 2473
HOW TO USE CHECK SHEET TABLE 2474
Example of Filling in Check Sheet When Initial Conditions Are Reproduced 2475
Example of Filling in Check Sheet When Initial Conditions Are Not Reproduced 2476
CAN Diagnostic Support Monitor 2479
2481
CR14DE/HR16DE model 2481
K9K model 2481
2482
2483
2483
2484
ABS model 2484
ESP model 2484
2485
2486
CAN COMMUNICATION 2486
System Description 2487
Component Parts and Harness Connector Location 2487
LHD MODEL 2487
RHD MODEL 2487
2488
CR14DE/HR16DE MODEL 2489
K9K MODEL 2489
CAN Communication Unit 2491
TYPE 1/TYPE 2 2493
System diagram 2494
Input/output signal chart 2494
TYPE 3/TYPE 4 2494
System diagram 2496
Input/output signal chart 2496
TYPE 5/TYPE 6 2496
System diagram 2498
Input/output signal chart 2498
TYPE 7/TYPE 8 2498
System diagram 2500
Input/output signal chart 2500
TYPE 9/TYPE 10 2501
System diagram 2502
Input/output signal chart 2502
CAN SYSTEM (TYPE 1) 2502
Component Parts and Harness Connector Location 2504
2504
Check Sheet 2504
Check Sheet 2504
CHECK SHEET RESULTS (EXAMPLE) 2505
Case 1 2507
Case 2 2507
Case 3 2508
Case 4 2509
Case 5 2510
Case 6 2511
Case 7 2512
Case 8 2513
Case 9 2514
Case 10 2515
Case 11 2515
CAN SYSTEM (TYPE 2) 2516
Component Parts and Harness Connector Location 2517
2517
Check Sheet 2517
Check Sheet 2517
CHECK SHEET RESULTS (EXAMPLE) 2518
Case 1 2520
Case 2 2520
Case 3 2521
Case 4 2522
Case 5 2523
Case 6 2524
Case 7 2525
Case 8 2526
Case 9 2527
Case 10 2528
Case 11 2529
Case 12 2529
CAN SYSTEM (TYPE 3) 2530
Component Parts and Harness Connector Location 2531
2531
Check Sheet 2531
Check Sheet 2531
CHECK SHEET RESULTS (EXAMPLE) 2532
Case 1 2534
Case 2 2534
Case 3 2535
Case 4 2536
Case 5 2537
Case 6 2538
Case 7 2539
Case 8 2540
Case 9 2541
Case 10 2542
Case 11 2543
Case 12 2543
CAN SYSTEM (TYPE 4) 2544
Component Parts and Harness Connector Location 2545
2545
Check Sheet 2545
Check Sheet 2545
CHECK SHEET RESULTS (EXAMPLE) 2546
Case 1 2548
Case 2 2548
Case 3 2549
Case 4 2550
Case 5 2551
Case 6 2552
Case 7 2553
Case 8 2554
Case 9 2555
Case 10 2556
Case 11 2557
Case 12 2558
Case 13 2558
CAN SYSTEM (TYPE 5) 2559
Component Parts and Harness Connector Location 2560
2560
Check Sheet 2560
Check Sheet 2560
CHECK SHEET RESULTS (EXAMPLE) 2561
Case 1 2563
Case 2 2563
Case 3 2564
Case 4 2565
Case 5 2566
Case 6 2567
Case 7 2568
Case 8 2569
Case 9 2570
Case 10 2571
Case 11 2572
Case 12 2572
CAN SYSTEM (TYPE 6) 2573
Component Parts and Harness Connector Location 2574
2574
Check Sheet 2574
Check Sheet 2574
CHECK SHEET RESULTS (EXAMPLE) 2575
Case 1 2577
Case 2 2577
Case 3 2578
Case 4 2579
Case 5 2580
Case 6 2581
Case 7 2582
Case 8 2583
Case 9 2584
Case 10 2585
Case 11 2586
Case 12 2587
Case 13 2587
CAN SYSTEM (TYPE 7) 2588
Component Parts and Harness Connector Location 2589
2589
Check Sheet 2589
Check Sheet 2589
CHECK SHEET RESULTS (EXAMPLE) 2590
Case 1 2592
Case 2 2592
Case 3 2593
Case 4 2594
Case 5 2595
Case 6 2596
Case 7 2597
Case 8 2598
Case 9 2599
Case 10 2600
Case 11 2600
CAN SYSTEM (TYPE 8) 2601
Component Parts and Harness Connector Location 2602
2602
Check Sheet 2602
Check Sheet 2602
CHECK SHEET RESULTS (EXAMPLE) 2603
Case 1 2605
Case 2 2605
Case 3 2606
Case 4 2607
Case 5 2608
Case 6 2609
Case 7 2610
Case 8 2611
Case 9 2612
Case 10 2613
Case 11 2614
Case 12 2614
CAN SYSTEM (TYPE 9) 2615
Component Parts and Harness Connector Location 2616
2616
Check Sheet 2616
Check Sheet 2616
CHECK SHEET RESULTS (EXAMPLE) 2617
Case 1 2619
Case 2 2619
Case 3 2620
Case 4 2621
Case 5 2622
Case 6 2623
Case 7 2624
Case 8 2625
Case 9 2626
Case 10 2627
Case 11 2628
Case 12 2628
CAN SYSTEM (TYPE 10) 2629
Component Parts and Harness Connector Location 2630
2630
Check Sheet 2630
Check Sheet 2630
CHECK SHEET RESULTS (EXAMPLE) 2631
Case 1 2633
Case 2 2633
Case 3 2634
Case 4 2635
Case 5 2636
Case 6 2637
Case 7 2638
Case 8 2639
Case 9 2640
Case 10 2641
Case 11 2642
Case 12 2643
Case 13 2643
TROUBLE DIAGNOSIS FOR SYSTEM 2644
Inspection Between Data Link Connector and ABS Actuator and Electric Unit (Control Unit) Circuit 2645
ECM Circuit Inspection 2645
Data Link Connector Circuit Inspection 2646
Data Link Connector and CAN Communication Circuit Inspection 2648
Combination Meter Circuit Inspection 2648
Intelligent Key Unit Circuit Inspection 2650
Steering Angle Sensor Circuit Inspection 2650
EPS Control Unit Circuit Inspection 2651
BCM Circuit Inspection 2651
ABS Actuator and Electric Unit (Control Unit) Circuit Inspection 2652
TCM Circuit Inspection 2652
IPDM E/R Circuit Inspection 2653
CAN Communication Circuit Inspection 2654
IPDM E/R Ignition Relay Circuit Inspection 2654
POWER SUPPLY ROUTING CIRCUIT 4
ELECTRICAL UNITS 89
SMJ (SUPER MULTIPLE JUNCTION) 91
STANDARDIZED RELAY 92
FUSE BLOCK 94
FUSE, FUSIBLE LINK AND RELAY BOX 95
37-Audio, Visual and Telephone System PDF 2657
QUICK REFERENCE INDEX 0
AUDIO, VISUAL & TELEPHONE SYSTEM 2657
PRECAUTIONS 2657
2658
AUDIO 2658
System Description 2659
SPEED DEPENDENT VOLUME SYSTEM 2659
Component parts Location 2659
2659
Terminals and Reference Value for Audio Unit 2660
Symptom Chart 2662
Steering Switch Resistance Check 2664
Removal and Installation of Audio Unit 2665
REMOVAL 2665
INSTALLATION 2665
Removal and Installation of Front Door Speaker 2665
REMOVAL 2665
INSTALLATION 2665
Removal and Installation of Rear Door Speaker 2665
REMOVAL 2665
INSTALLATION 2665
Removal and Installation of Tweeter 2666
REMOVAL 2666
INSTALLATION 2666
AUDIO ANTENNA 2666
Location of Antenna 2667
Removal and Installation of Roof Antenna 2667
REMOVAL 2667
INSTALLATION 2667
POWER SUPPLY ROUTING CIRCUIT 4
ELECTRICAL UNITS 89
SMJ (SUPER MULTIPLE JUNCTION) 91
STANDARDIZED RELAY 92
FUSE BLOCK 94
FUSE, FUSIBLE LINK AND RELAY BOX 95
38-Power Supply, Gound and Circuit Elements PDF 2669
QUICK REFERENCE INDEX 0
POWER SUPPLY, GROUND & CIRCUIT ELEMENTS 2669
PRECAUTIONS 2671
2671
Maintenance Information 2671
RHD MODELS 2671
LHD MODELS 2671
POWER SUPPLY ROUTING CIRCUIT 2672
Schematic 2672
2673
2673
2679
2680
Fuse 2685
Fusible Link 2685
Circuit Breaker 2685
IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) 2686
System Description 2686
SYSTEMS CONTROLLED BY IPDM E/R 2686
CAN COMMUNICATION LINE CONTROL 2686
Fail-safe Control 2686
IPDM E/R STATUS CONTROL 2686
CAN Communication System Description 2687
CAN Communication Unit 2687
Function of Detecting Ignition Relay Malfunction 2687
CONSULT-II Function (IPDM E/R) 2688
CONSULT-II BASIC OPERATION 2688
SELF-DIAG RESULTS 2688
Operation Procedure 2688
Display Item List 2688
DATA MONITOR 2688
Operation Procedure 2688
All Signals, Main Signals, Selection From Menu 2689
CAN DIAG SUPPORT MNTR 2689
ACTIVE TEST 2689
Operation Procedure 2689
Auto Active Test 2690
DESCRIPTION 2690
OPERATION PROCEDURE 2690
INSPECTION IN AUTO ACTIVE TEST MODE 2691
Concept of Auto Active Test 2691
Diagnosis Chart in Auto Active Test Mode 2692
Configuration 2693
DESCRIPTION 2693
READ CONFIGURATION PROCEDURE 2693
WRITE CONFIGURATION PROCEDURE 2695
Schematic 2699
IPDM E/R Terminal Arrangement 2700
Inspection With CONSULT-II (Self-Diagnosis) 2701
IPDM E/R Terminal Inspection 2702
Check IPDM E/R Power Supply and Ground Circuit 2702
Diagnosis of IPDM E/R Integrated Relay 2704
Removal and Installation of IPDM E/R 2705
REMOVAL 2705
INSTALLATION 2705
GROUND 2706
Ground Distribution 2706
MAIN HARNESS 2706
ENGINE ROOM HARNESS 2709
ENGINE CONTROL HARNESS/CR AND HR ENGINE MODELS 2713
BODY HARNESS 2714
HARNESS 2716
Harness Layout 2716
HOW TO READ HARNESS LAYOUT 2716
To Use the Grid Reference 2716
HARNESS OUTLINE/CR AND HR ENGINE MODELS 2717
HARNESS OUTLINE/K9K ENGINE MODELS 2718
MAIN HARNESS/LHD MODELS 2719
MAIN HARNESS/RHD MODELS 2721
ENGINE ROOM HARNESS/CR ENGINE MODELS 2723
ENGINE ROOM HARNESS/HR ENGINE MODELS 2725
ENGINE ROOM HARNESS/K9K ENGINE MODELS 2727
ENGINE CONTROL HARNESS/CR ENGINE MODELS 2729
ENGINE CONTROL HARNESS/HR ENGINE MODELS 2731
ENGINE CONTROL HARNESS/K9K ENGINE MODELS 2733
BODY HARNESS (RH SIDE) 2735
BODY HARNESS (LH SIDE) 2737
ROOM LAMP HARNESS 2739
FRONT DOOR HARNESS LH SIDE/LHD MODELS 2740
FRONT DOOR HARNESS LH SIDE/RHD MODELS 2741
FRONT DOOR HARNESS RH SIDE/LHD MODELS 2742
FRONT DOOR HARNESS RH SIDE/RHD MODELS 2743
REAR DOOR HARNESS LH SIDE 2744
REAR DOOR HARNESS RH SIDE 2745
BACK DOOR HARNESS 2746
Wiring Diagram Codes (Cell Codes) 2747
ELECTRICAL UNITS LOCATION 2750
Electrical Units Location 2750
ENGINE COMPARTMENT 2750
PASSENGER COMPARTMENT/LHD MODELS 2752
PASSENGER COMPARTMENT/RHD MODELS 2754
HARNESS CONNECTOR 2756
Description 2756
HARNESS CONNECTOR (TAB-LOCKING TYPE) 2756
HARNESS CONNECTOR (SLIDE-LOCKING TYPE) 2757
ELECTRICAL UNITS 2758
Terminal Arrangement 2758
SMJ (SUPER MULTIPLE JUNCTION) 2760
Terminal Arrangement 2760
STANDARDIZED RELAY 2761
Description 2761
NORMAL OPEN, NORMAL CLOSED AND MIXED TYPE RELAYS 2761
TYPE OF STANDARDIZED RELAYS 2761
FUSE BLOCK 2763
Terminal Arrangement 2763
FUSE, FUSIBLE LINK AND RELAY BOX 2764
Terminal Arrangement 2764
39-Maintenance PDF 2765
QUICK REFERENCE INDEX 0
MAINTENANCE 2765
PREPARATION 2767
Special Service Tools 2767
Commercial Service Tool 2768
DESCRIPTION 2769
Pre-delivery Inspection Items 2769
GENERAL MAINTENANCE 2771
General Maintenance 2771
PERIODIC MAINTENANCE 2772
Periodic Maintenance 2772
ENGINE AND EMISSION CONTROL MAINTENANCE (CR ENGINE) 2772
CHASSIS AND BODY MAINTENANCE (CR ENGINE) 2773
ENGINE AND EMISSION CONTROL MAINTENANCE (HR ENGINE) 2774
CHASSIS AND BODY MAINTENANCE (HR ENGINE) 2775
ENGINE AND EMISSION CONTROL MAINTENANCE (K9K ENGINE) 2776
CHASSIS AND BODY MAINTENANCE (K9K ENGINE) 2777
MAINTENANCE UNDER SEVERE DRIVING CONDITIONS 2778
ENGINE AND EMISSION CONTROL MAINTENANCE (CR ENGINE) 2780
CHASSIS AND BODY MAINTENANCE (CR ENGINE) 2781
ENGINE AND EMISSION CONTROL MAINTENANCE (HR ENGINE) 2782
CHASSIS AND BODY MAINTENANCE (HR ENGINE) 2783
ENGINE AND EMISSION CONTROL MAINTENANCE (K9K ENGINE) 2784
CHASSIS AND BODY MAINTENANCE (K9K ENGINE) 2785
MAINTENANCE UNDER SEVERE DRIVING CONDITIONS 2786
RECOMMENDED FLUIDS AND LUBRICANTS 2788
Fluids and Lubricants 2788
SAE Viscosity Number 2789
GASOLINE ENGINE 2789
DIESEL ENGINE 2789
Engine Coolant Mixture Ratio 2790
ENGINE MAINTENANCE (CR) 2791
Checking Drive Belts 2791
Tension Adjustment 2791
ALTERNATOR AND A/C COMPRESSOR BELT (WITH A/C MODELS) 2792
ALTERNATOR BELT (WITHOUT A/C MODELS) 2792
WATER PUMP BELT 2793
Changing Engine coolant 2793
DRAINING ENGINE COOLANT 2793
Models without A/C 2793
Models with A/C 2793
REFILLING ENGINE COOLANT 2793
FLUSHING COOLING SYSTEM 2795
Checking Cooling System 2795
CHECKING COOLING SYSTEM HOSES 2795
CHECKING RADIATOR 2795
CHECKING COOLING SYSTEM FOR LEAKS 2796
Models without A/C 2796
Models with A/C 2796
Checking Radiator Cap (Models without A/C) 2796
Checking Reservoir Tank Cap (Models with A/C) 2797
Checking Fuel Lines 2797
Changing Air Cleaner Filter 2798
REMOVAL 2798
INSTALLATION 2798
Changing Engine Oil 2798
Changing Oil Filter 2799
Changing Spark Plugs 2800
REMOVAL 2800
INSPECTION AFTER REMOVAL 2800
INSTALLATION 2801
Checking EVAP Vapor Lines 2801
ENGINE MAINTENANCE (HR16DE) 2802
Checking Drive Belts 2802
Tension Adjustment 2802
Changing Engine Coolant 2803
DRAINING ENGINE COOLANT 2803
M/T Models without A/C and A/T models 2803
M/T Models with A/C 2803
REFILLING ENGINE COOLANT 2804
FLUSHING COOLING SYSTEM 2805
Checking Cooling System 2805
CHECKING COOLING SYSTEM HOSES 2806
CHECKING RADIATOR 2806
CHECKING COOLING SYSTEM FOR LEAKS 2806
M/T Models without A/C and A/T Models 2806
M/T Models with A/C 2806
Checking Radiator Cap (M/T Models without A/C and A/T Models) 2807
Checking Reservoir Tank Cap (M/T Models with A/C) 2808
Checking Fuel Lines 2808
Changing Air Cleaner Filter 2808
REMOVAL 2808
INSPECTION AFTER REMOVAL 2808
INSTALLATION 2809
Changing Engine Oil 2809
Changing Oil Filter 2810
REMOVAL 2810
INSTALLATION 2810
INSPECTION AFTER INSTALLATION 2810
Changing Spark Plug (Platinum-Tipped Type) 2811
REMOVAL 2811
INSPECTION AFTER REMOVAL 2811
INSTALLATION 2812
Checking EVAP Vapor Lines 2812
ENGINE MAINTENANCE (K9K) 2813
Checking Drive Belts 2813
TENTION ADJUSTMENT 2813
Models With A/C Compressor 2813
Models Without A/C Compressor 2813
Changing Engine coolant 2813
DRAINING ENGINE COOLANT 2813
REFILLING ENGINE COOLANT 2814
FLUSHING COOLING SYSTEM 2814
Checking Cooling System 2815
CHECKING COOLING SYSTEM HOSES 2815
CHECKING RADIATOR 2815
Checking Reservoir Tank Cap 2815
Checking Radiator 2816
Checking Fuel Lines 2816
Changing Air Cleaner Filter 2816
REMOVAL 2816
INSTALLATION 2817
Changing Engine Oil 2817
Changing Oil Filter 2818
REMOVAL 2818
INSTALLATION 2818
CHASSIS AND BODY MAINTENANCE 2819
Checking Exhaust System 2819
Checking Clutch Fluid Level and Leaks 2819
Checking Clutch System 2819
Checking M/T Oil 2819
Changing M/T Oil 2820
Checking A/T Fluid 2820
Changing A/T Fluid 2821
Rotation 2821
Checking Brake Fluid Level and Leaks 2822
Checking Brake Lines and Cables 2822
Changing Brake Fluid 2822
Checking Disc Brake 2822
ROTOR 2822
CALIPER 2823
PAD 2823
Checking Drum Brake 2823
WHEEL CYLINDER 2823
DRUM 2823
LINING 2823
Checking Steering Gear and Linkage 2824
STEERING GEAR 2824
STEERING LINKAGE 2824
Axle and Suspension Parts 2824
Drive Shaft 2824
Lubricating Locks, Hinges and Hood Latches 2825
Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters 2825
Checking Body Corrosion 2825
HEMMED PANELS 2826
PANEL JOINT 2826
PANEL EDGE 2826
PARTS CONTACT 2826
PROTECTORS 2826
ANTI-CORROSION MATERIALS 2826
DRAIN HOLES 2826
SERVICE DATA AND SPECIFICATIONS (SDS) 2827
Standard and Limit 2827
BELT DEFLECTION AND TENSION 2827
CR Engine 2827
HR Engine 2827
K9K Engine 2827
ENGINE COOLANT CAPACITY 2828
CR Engine 2828
HR Engine 2828
K9K Engine 2828
ENGINE OIL CAPACITY 2828
CR Engine 2828
HR Engine 2828
K9K Engine 2828
SPARK PLUG 2829
CR Engine 2829
SPARK PLUG (PLATINUM-TIPPED TYPE) 2829
HR Engine 2829
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