QUICK REFERENCE INDEX

GENERAL INFORMATION

MAINTENANCE

ENGINE MECHANICAL
ENGINE LUBRICATION &
COOLING SYSTEMS

ENGINE CONTROL SYSTEM ---

ACCELERATOR CONTROL, FUEl &
EXHAUST SYSTEMS ----

ClUTCH

NISSAN MANUAL TRANSMISSION

TRUCK
MODEL D21 SERIES
AUTOMATIC TRANSMISSION

TRANSFER
PROPELLER SHAFT &
DIFFERENTIAL CARRIER

FRONT AXLE & FRONT SUSPENSION - - - -

REAR AXlE & REAR SUSPENSION - - - -

BRAKE SYSTEM

STEERING SYSTEM

RESTRAINT SYSTEM

BODY & TRIM

HEATER & AIR CONDITIONER - - - - - -

ELECTRICAL SYSTEM - - - - - - -
•
© 19% N!SSAN NORTH AMERICA, INC.
ALPHABETICAL INDEX
Printed in U.S.A.
All rights rtStl'l'ed. No part of this Serl'kt Manual may be reproduced or sWred in a retrieval system, or tnmsmitttd in any form, or by any means,
eledroolc, mechanical, photocopying, reeording or otherwise. without the prior written permission of Nissan North America. Inc., Torrance; California. •
3
 FOREWORD
This manual contains maintenance and repair procedures for the 1997
Nissan TRUCK.

In order to assure your safety and the efficient functioning of the

vehicle, this manual should be read thoroughly. It is especially
important that the PRECAUTIONS in the Gl section be completely
understood before starting any repair task.

All information in this manual is based on the latest product information

at the time of publication. The right is reserved to make changes in
specifications and methods at any time without notice.

IMPORTANT SAFETY NOTICE

The proper performance of service is essential for both the safety of the
technician and the efficient functioning of the vehicle.
The service methods in this Service Manual are described in such a
manner that the service may be performed safely and accurately.
Service varies with the procedures used, the skills of the technician and
the tools and parts available. Accordingly, anyone using service
procedures, tools or parts which are not specifically recommended by
NISSAN must first be completely satisfied that neither personal safety
nor the vehicle's safety will be jeopardized by the service method
selected.

NISSAN NORTH AMERICA, INC.

Technical Service Information Department
Torrance, California

4
• PLEASE HELP MAKE THIS SERVICE MANUAL BETTER!

Your comments are important to NISSAN and will help us to improve our Service Manuals.
Use this form to report any issues or comments you may have regarding our Service Manuals.
Please photocopy this form and type or print your comments below. Mail or fax to:
Nissan North America, Inc.
Technical Service Information
39001 Sunrise Drive, P.O. Box 9200
Farmington Hills, Ml USA 48331
FAX: (81 0) 488-3910

SERVICE MANUAL: Model: Year:

PUBLICATION NO. (Please photocopy back cover):
VEHICLE INFORMATION VIN: Production Date:
Please describe any issues or problems in detail:
Page number(s) Note: Please include a copy of each page, marked with your comments.

Are the trouble diagnosis procedures logical and easy to use? (circle your answer) YES NO
If no, what page number(s)? Note: Please include a copy of each page, marked with your comments.
Please describe the issue or problem in detail:

Is the organization of the manual clear and easy to follow? (circle your answer) YES NO
Please comment:

What information should be included in NISSAN Service Manuals to better support you in servicing or
repairing customer vehicles?

DATE: YOUR NAME: POSITION:

DEALER: DEALER NO.: ADDRESS:
CITY: STATE/PROV./COUNTRY: ZIP/POSTAL CODE:

1241
QUICK REFERENCE CHART: TRUCK c _ _ _ __ _ ___J1997
['--------' Unit: mm (on)

Engine model KA24E Disc brake

Finng order 1-3-4-2 Pad m•nimum th•ckness 2.0 (0.079)

Idle speed rpm Rotor repair t•mit

MH 3QQ I 50 Run out 0.07 (0.0028) or less

AfT (in 'N" posil1on) BOO -1- 50 20.0 (0 787), CL28VA

Monimum th•ckness
24.0 (0.945), CL28VD
Ignition lim1ng
(degree BTD.C at 1dle speed)
10' ±2 Drum brake
Lin•ng m•nimum thickncs~ 1.5 (0.059)
Idle mi.ture screw is preset and seated
CO% at idle Drum repa.r i•m•t
at factory
261.5 (1 0.30), LT26B
Spark plug Max•mum •nner diameter 296.5 (11.67), LT306
Standard ZFRSE-11 Park•ng brake

Type Cold ZFR6E-11 Number of notches'! 10 -12

~o< ZFR4E-11 '1: At pulling Ioree: 196 N (20 kg, 44 Ib)

G'O mm (on)
'·' - 1 '1 (0.039 - 0.043)
[~------'
Drive belt defl.-ctlon (Coldj mm (in) Used belt

Deflect ton Defleclton FRONT WHEEL BEARING

L1m1t after o<
adjustment new belt
Model
Generator
17 (0.67)
" "
(0.39- 0.47)
'. "
(0.31 - 0.39) Item 2WD <We
., Tightenong torque
Air condolioner compressor 16 (0.63)
"
(0 39- 0 47) '"
(0 31 - 0.39) N m !k~~':"· _f!_:lb!_ __
Return angle degree
~4- 39 (3.5 • 4.0, 2~ · 29)

45° - 60°
_ ___::_______ _
9- II
Power steering 011 pump 15 (0.59)
(0 35- 0 43) ' '
(0.28 - 0.35) Wheel beanng lock nut 78-98
Tightening torque (8 -10,
Applied pressed Ioree N (kg, lb) 98(10, 22) 58. 72)
N-m (kg-m, 11-lb)
-98(0.8-1.0,11 - 14)
Radiator cap rel1ef pressure kPa (kg/cm2, psi)

Cool•ng system leakage testong pressure

'" 157(1.6,23) New seal
98-284
(1 .0 - 2 9, 2.2- 6.4)
Retightenrng torque
after loosening wh~et
bearing lock nut
0.5. 1 5
(005-015,
kPa (kglcm2, psi)
N·m (kg·m, 11-lb) 0.4- 1.1)
Compress•on pressure Standard 1,324 (13.5, 192)/300 Axial end play
mm (•n) 0 (0)
kra (kg/cm2, ps•)/rpm
M•n•mum 981 (10, 142)/300
PreiO>ld (AIIlub boll) Start force at
f•ghtenmg torque Nm kg·m ft-lb N (kg, lb) wheel hub bolt A
N (kg, lb)
2.0 . 3.0 . 2~
Spark plug
'"20. "39 "
I
Turn•ng angle
Oil pan dra•n plug 3.0. 4.0 22. 29 9.8 - 23.5 degree
U$ed ;cal (1.0- 2.4, 2.2- 5.3) Starling force at
wheel hub bolt
N (kg, tb) '
Wh~el beanng preload 7.06 • 20.99
FRONT WHEEL ALIGNMENT (Unladen*1) at wheel hub bolt
B- A N (kg, Ib)
(0 72- 2 14,
1.59 • 4.72)

ALLOWABLE LIMIT ADJUSTING RANGE

Applied model <We 'wo 4~0 - -

REALL CAPACITIES [ \ __ _ _ __J
Camber degree -{)"20' . 1 ·t 0' -0 05' . 1•"25' -0°05' - 0°55' 0°10' -1"10'
(Dec•'Tlal degree) (-{).33' - 1.17°) (-0.08 - 1.42") (-0.08 - 0.92') (O.tr -1.1T)
Unit Liter US measure
Caster degree -0°23' - 1 07' 0'33' - 2~03' -{)'"08' - 0'52' 0°48'. 1'48'
Fuel lank 15 9 gal
(Dec•mal degree) (-{).38 - 1.12°) 10 55 - 2.05°) (-{).13 - 0.87') (0.80 -1.80")
""
K•ngpin inclinaHon
(Dec•m~l
deg"'"
degree)
8 20' · 9'50'
(8.33' · 9 83')
J021' - 8°51'
(7 35 - 8.85°)
8•"35 - 9 35'
(8.58 -~.58)
7'36"·A~6'

(f_:0~·-: __8:~
Cool~nl (witll r~sNvo.r)
'we
"·' 8-5/8 qt

<WO
'·" 9-1/2 qt

Toe-•n
Radial tire >We
With oil filter

W•thout oil !•Iter

'·" 4-1/8 qt

3-3/4 qt
A-6 mm(in) ' "
(0.04- 0.20)
,,' "
(0.08. 0.24) ' '
(0.08 . 0.16)
'.
,..
(0.12 -
0
0.20)
EngmP
With oil filter
'"
.., 4-3/8 qt
5'. 25' <0' . 20' - 24'
Total angle 2•· degree
(Dec.mal degree) (0.08° . 0.42 ") '"'
(0 15 - 0.48") (0.17' . 0.33') (0.23° 0.40°)
•we
Without oil filter
'" ',,
>We 4-1/4 pt
Wheel turning angle
lns•de Transaxle
MH
•we
'"
Degree minute
(Dec•mal degree)
34 00' . 36'00'
"00 - 35"00' 36°00' - 38'00' 33"00' - 35 00'
(34.00 • 38.00'") (31.00° 35 00°) (36.00' -38.00') (33.00' - 35.00'1 ~
'·'
7.9
10-3/8 pt

8-3/8 qt

Outside <We 2-3/8 qt

Degree minute
(Decimal degree)
31°00' - 35°00' 29'00' - 33"00' 33"00' - 3~- 00' 00' - 33" 00'
"
(31 oo- - 35 00") (29.00 - 33.00') (33.00 - :1~.00 1 (31.00 -33.00')
Transfer

H190A
''
<.e 3-1/8 pt
zwe
C200 u 2-3/4 pt
'1 Fuel, radiator coolant and ~ng•ne oil lui' Final drive
Spare tire. jack, hand tool$ and mats •n designated pos•trons. A180A u 2-3/4 pt
<We
H2336 5-7/8 pi
'"
CLUTCH PEDAL ~~----·]
Ma.nual stcaring system 0.62 1-3/8 pt

Power steering system

PB48S 0.0 ' ,,
Unit mm (in) P659K LO 1-1/8 qt

Pedal height 236 - 246 (9 29 - 9.69) Lubro~ant 6 8 II oz

,Pedal free play 9-16(0.35-063)

A" cond•tioner system
Refrigerant'
"
0.75 - 0.85 1.65-1.871b

'R·134a

1243
 Attachment No.1

TEST VALUE AND TEST LIMIT (GST ONLY — NOT APPLICABLE TO CONSULT-II)
The following is the information specified in Mode 6 of SAE J1979.
The test value is a parameter used to determine whether a system/circuit diagnostic test is “OK” or “NG” while
being monitored by the ECM during self-diagnosis. The test limit is a reference value which is specified as the
maximum or minimum value and is compared with the test value being monitored.
Items for which these data (test value and test limit) are displayed are the same as SRT code items.
These data (test value and test limit) are specified by Test ID (TID) and Component ID (CID) and can be dis-
played on the GST screen.
: Applicable ･: Not applicable
Test value
SRT item Self-diagnostic test item DTC (GST display) Te s t limit Application Unit
TID CID
P0420 01H 01H Max. X -
CATALYST Three way catalyst function
P0420★1 02H 81H Min. X -
EVAP control system (Small leak) P0440 05H 03H Max. X -
EVAP SYSTEM
EVAP control system purge flow monitoring P1447 06H 83H Min. X mV
P0130 09H 04H Max. X ms
P0130 0AH 84H Min. X mV
Heated oxygen sensor 1 P0130 0BH 04H Max. X mV
P0130 0CH 04H Max. X mV
HO2S P0130 0DH 04H Max. X s
P0136 19H 86H Min. X mV/500ms
P0136 1AH 86H Min. X mV
Heated oxygen sensor 2
P0136 1BH 06H Max. X mV
P0136 1CH 06H Max. X mV
P0135 29H 08H Max. X mV
Heated oxygen sensor 1 heater
P0135 2AH 88H Min. X mV
HO2S HTR
P0141 2DH 0AH Max. X mV
Heated oxygen sensor 2 heater
P0141 2EH 8AH Min. X mV
P0400 31H 8CH Min. X ℃
P0400 32H 8CH Min. X ℃
EGR function P0400 33H 8CH Min. X ℃
EGR SYSTEM P0400 34H 8CH Min. X ℃
P0400 35H 0CH Max. X ℃
P0402 36H 0CH Max. X -
EGRC-BPT valve function
P0402 37H 8CH Min. X -
★
1：Models B15 GA16DE engine 1997MY only.
 MAINTENANCE ],\[

SECTION MA
CONTENTS
PRECAUTIONS AND PREPARATION ............................ 2 Checking Clutch Fluid Level and Leaks .................... 16
Supplemental Restraint System (SRS) "AIR Checking Mff Oil ....................................................... 16
BAG"' ............................................................................ 2 Changing Mff Oil. ...................................................... 16 i:;;IL
Special Service Tool .............. ................ .. ...... 2 Checking Water Entry- For 4WD models .............. 16
GENERAl MAINTENANCE ............ .. .......................... 3 Checking AfT Fluid ............ ......... .. ........................ 16
PERIODIC MAINTENANCE ............................ . .. .. 5 . g AfT Fl u1"d .................................................. . 17
Ch ang1n ~."--/,'1!
Schedule 1 ................................................................6 Checking Transfer Fluid ............................................. 17
Schedule 2 .......... ................ .. .............. .. 7 Changing Transfer Fluid ............................................ 18
RECOMMENDED FlUIDS AND lUBRICANTS ....... ..... 8 Checking Propeller Shaft ......................................... 18 5c'J
Fluids and lubricants ............... . ........ 8 Checking Differential Gear Oil. .. .. ............... .. ... 18
SAE Viscosity Number ......................... . ..... 9 Changing Differential Gear Oil .. .. .. .. ... 19 lnc
Antifreeze Coolant Mixture Ratio. .. ........................ 9 Balancing Wheels.. .. .. ......... .. ............... .. .... 19
ENGINE MAINTENANCE ..................... ........................ 10 Tire Rotation ............................................................ 19
Checking Drive Belts ................................................ 10 Checking Brake Fluid Level and Leaks .................... 20
Changing Engine Coolant... ....................................... 11 Checking Brake System ........................................... 20
Checking Fuel Lines.................. .. ............... .. .. 12 Checking Disc Brake ................................................. 20
Changing Fuel Filter........ .. ................................. 12 Checking Drum Brake ........................................... .20 ~3~
Changing Air Cleaner Filter............ .. .. 12 Checking Steering Gear and Linkage ...................... 21
Changing Engine Oil........... .. ........ .... .. ............. 13 Checking Power Steering Fluid and Lines ............... 21
Changing Oil Filter.. .. .. .. ...... .. .. ..................... 13 Checking Steering Gear Oil Level and Leaks .......... 21
Changing Spark Plugs .............................................. 14 Lubricating Hood Latches, Locks and Hinges .......... 22
Checking EVAP Vapor Purge Lines ......................... 15 Checking Seat Belts, Buckles, Retractors,
Changing Positive Crankcase Ventilation (PCV) Anchors and Adjusters ............................................... 23
Filter... ................. ...................................... .. .... 15 SERVICE DATA AND SPECIFICATIONS (SDS) .......... 24
CHASSIS AND BODY MAINTENANCE ............... ....... 16 Engine Maintenance ................................................ 24 .,~
~;L
Checking Exhaust System ......................................... 16 Chassis and Body Maintenance ............................... 24

53
 PRECAUTIONS AND PREPARATION

Supplemental Restraint System (SRS) "AIR

BAG"
The Supplemental Restraint System "Air Bag", used along with a seat belt, helps to reduce the risk or sever-
ity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of an air bag mod-
ule (located in the center of the steering wheel), a diagnosis sensor unit, warning lamp, wiring harness, a crash
zone sensor (4WD models) and spiral cable. Information necessary to service the system safely is included
in the RS section of this Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed
by an authorized NISSAN dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses are covered with yellow insulation either just before the
harness connectors or for the complete harness, for easy identification.

Special Service Tool

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number
(Kent-Moore No.) Description
Tool name

KV10105900 Removing oil filter

(J34274)
Oil filter cap wrench

NTOOS

54 MA-2
 GENERAL MAINTENANCE

General maintenance includes those items which should be checked during the normal day-to-day operation CO'I
of the vehicle. They are essential if the vehicle is to continue operating properly. The owners can perform
checks and inspections themselves or they can have their NISSAN dealers do them.
Item Reference page
OUTSIDE THE VEHICLE
The maintenance items listed here should be periormed from time to time, unless otherwise
specified.
Tires Check the pressure, including the spare, with a gauge periodically when at a service
station, and adjust to the specified pressure if necessary. Check carefully for damage, cuts and
excess1ve wear.
Wheel nuts When checking the tires, make sure no nuts are missing, and check for any loose
nuts. Tighten if necessary.
Tire rotation Tires should be rotated every 12,000 km (7,500 miles) for 2WD models and every
MA-19
6,000 km (3.750 miles) for 4WD models.
Wheel alignment and balance If the vehicle pulls to either side whi!e driving on a straight and
level road, or if you detect uneven or abnormal tire wear, there may be a need for wheel align- MA-19.
ment If the steering wheel or seat vibrates at normal highway speeds, wheel balancing may be FA-8
needed,

Windshield wiper blades Check for cracks and wear if they do not wipe properly.
Doors and engine hood Check that all doors, engine hood and tailgate operate smoothly. Also
make sure that all latches lock securely. Lubricate if necessary. Make sure that the secondary
MA-22
latch keeps the hood from opening when the primary latch is released.
When driving in areas using road salt or other corrosive materials, check lubrication frequently.
Lamps Make sure that the headlamps, stop lamps, tail lamps, turn signal lamps, and other
lamps are all operating properly and installed securely. Also check headlamp aim.
INSIDE THE VEHICLE
The maintenance items listed here should be checked on a regular basis, such as when per-
forming periodic maintenance, cleaning the vehicle, etc.
Warning lamps and buzzers/chimes Make sure that all warning lamps and buzzers/chimes are
operating properly.
Windshield wiper and washer Check that the wipers and washer operate properly and that the
wipers do not streak.
Windshield defroster Check that the air comes out of the defroster outlets properly and in suffi-
cient quantity when operating the heater or air conditioner.
Steering wheel Check that it has the specified play. Be sure to check for changes in the steer-
ing condition, such as excessive play, hard steering or strange noises. ST-7
Free play: Less than 35 mm (1.38 in)
Seats Check seat position controls such as seat adjusters, seatback recliner, etc. to make sure
they operate smoothly and that all latches lock securely in every position. Check that the head
restraints move up and down smoothly and that the locks (if equipped) hold securely in all
latched positions. Check jump seats for smooth operation.
Seat belts Check that all parts of the seat belt system (e.g., buckles, anchors, adjusters and
retractors) operate properly and smoothly and are installed securely. Check the belt webbing for MA-23
cuts, fraying, wear and damage.
Clutch pedal Make sure the pedal operates smoothly and check that it has the proper free play. CL-5

Brakes Check that the brakes do not pull the vehicle to one side when applied.
Brake pedal and booster Check the pedal for smooth operation and make sure that it has the
proper distance under it when depressed fully. Check the brake booster function. Be sure to BR-11. 16
keep floor mats away from the pedal.
Parking brake Check that the lever has the proper travel and make sure that the vehicle is held
BR-27
securely on a fairly steep hill when only the parking brake is applied.

MA-3 55
 GENERAL MAINTENANCE

Item Reference page

Automatic transmission "Park" mechanism Check that the lock release button on the selec-
tor lever operates properly and smoothly. On a fairly steep hill check that the vehicle is held
securely with the selector lever in the "P" position without applying any brakes.
UNDER THE HOOD AND VEHICLE
The maintenance items listed here should be checked periodically (e.g., each time you check
the engine oil or refuel).
Windshield washer fluid Check that there is adequate fluid in the tank.
Engine coolant level Check the coolant level when the engine is cold. MA-11
Radiator and hoses Check the front of the radiator and clean off any dirt, insects, leaves, etc.,
that may have accumulated. Make sure that the hoses have no cracks, deformation, deteriora~
lion or loose connections.
Brake and clutch fluid levels Make sure that the brake and clutch fluid levels are between the
MA-16, 20
"MAX" and "MIN" lines on the reservoirs.
Battery Check the fluid level in each cell. It should be between the "MAX" and "MIN" lines.
Engine drive belts Make sure that no belt is frayed, worn, cracked or oily. MA-10
Engine oil level Check the level on the dipstick after parking the vehicle on a level spot and
MA-13
turning off the engine.
Power steering fluid level and lines Check the level on the dipstick with the engine off. Check
MA-21
the lines for improper attachment, leaks, cracks, etc.
Automatic transmission fluid level Check the level on the dipstick after putting the selector
MA-16
lever in "P" with the engine idling.
Exhaust system Make sure that there are no loose supports, cracks or holes. If the sound of
the exhaust seems unusual or there is a smell of exhaust fumes, immediately locate the trouble MA-16
and correct it.
Underbody The underbody is frequently exposed to corrosive substances such as those used
on icy roads or to control dust. It is very important to remove these substances, otherwise rust
will form on the floor pan, frame, fuel lines and around the exhaust system. At the end of winter,
the underbody should be thoroughly flushed with plain water, being careful to clean those areas
where mud and dirt can easily accumulate.
Fluid leaks Check under the vehicle for fuel, oil, water and other fluid leaks after the vehicle
has been parked for a while. Water dripping from the air conditioner after use is normal. If any
leaks or gasoline fumes are evident, check for the cause and correct it immediately.

56 MA-4
 PERIODIC MAINTENANCE

Two different maintenance schedules are provided, and should be used, depending upon the conditions under @ll
which the vehicle is mainly operated. After 60,000 miles (96,000 km) or 48 months, continue the periodic
maintenance at the same mileage/lime intervals.

SCHEDULE 1
Follow Periodic Maintenance Schedule 1 if your driving habits frequently include one or more of the following
driving conditions:
• Repeated short trips of less than 5 miles (8 km).
• Repeated short trips of less than 10 miles (16 km) with outside temperatures remaining below freezing.
• Operating in hot weather in stop-and-go "rush hour" traffic.
• Extensive idling and/or low speed driving tor long distances, such as police, taxi or door-to-door delivery
use.
• Driving in dusty conditions.
• Driving on rough, muddy, or salt spread roads.
• Towing a trailer, using a camper or a car-top carrier.

SCHEDULE 2
Follow Periodic Maintenance Schedule 2 it none of the driving conditions shown in Schedule 1 apply to your ©!b
driving habits.

Maintenance for off-road driving (f: tt: 1 only)

Whenever you drive off-road through sand, mud or water, more frequent maintenance may be required of the
following items:
-" Brake pads and discs
-" Brake lining and drums
-" Brake lines and hoses
-" Wheel bearing grease and free-running hub grease
-" Differential gear oil, transmission and transfer fluid
-" Steering linkage
-" Propeller shaft and drive shafts
-" Air cleaner filter
-" Clutch housing (Check water entry. Refer to MA-16.)

MA-5 57
58

Abbreviations: R = Replace I= Inspect. Correct or replace if necessary. I ]: At the mileage intervals only

MAINTENANCE OPERATION MAINTENANCE INTERVAL

Miles x 1,000 3.75 7.5 11.25 15 18.75 22.5 26.25 30 33.75 37.5 41.25 45 48.75 52.5 56.25 60
Perform at number of miles, kilometers or months, Reference page
(km x 1 ,000) (6) (12) (18) (24) (30) (36) (42) (48) (54) (60) (66) (72) (78) (84) (90) {96)
whichever comes first.
Months 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48

Emission control system maintenance

Drive belts I' I' MA-10
Air cleaner filter See NOTE (1) [R[ [R[ MA-12
Positive crankcase ventilation (PCV) filter See NOTE (2) [R[ [R[ MA-15
Vapor lines I' I' MA-15
Fuel lines I' I' MA-12
Fuel filter See NOTE (2)' MA-12
Engine coolant See NOTE (3) R' MA-11
Engine oil R R R R R R R R R R R R R R R R MA-13
"tl
Engine oil filter R R R R R R R R R R R R R R R R MA-13 m
Spark plugs [R] [R] MA-14 ::0
fJ)
Chassis and body maintenance 0 0
I I I I MA-20
:::T c
Brake lines & cables
Brake pads, rotors, drums & linings I I I I I I I MA-20
CD
c. 0
s: Automatic transmission, transfer fluid & manual
r::: s:
)> transmission, differential gear 011 (exc. LSD)
See NOTE (4) I I I I MA-16, 17, 18, 19
iD ~
'
en Limited-slip differential (LSD) gear oil See NOTE (4) I R R MA-19 ...... z
I I I I MA-21, FA-5, RA 4 -1
Steering gear (box) & linkage. (steering damper~ ), axle & suspension parts I
m
Drive shaft boots & propeller shaft (~ ) I I I I I I I MA-18, FA-14. PD-9 z
)>
Steering linkage ball joints & front suspension ball joints I I I I I I I MA-21, FA-5

Front wheel bearing grease (4x2) I I FA 6

z
(')
Front wheel bearing grease & free-running hub grease See NOTE (5) R I R FA-7, 17, 1.9 m
(l'i:l!l'i])
I I I I I I I MA-16
Exhaust system
Air bag system See NOTE {6)

NOTE: (1) If operating mainly in dusty conditions, more frequent maintenance may be required.
(2) If vehicle is operated under extremely adverse weather conditions or in areas where ambient temperatures are either extremely low or extremely high, the
filters might become clogged. In such an event, replace them immediately.
(3) After 60,000 miles (96,000 km) or 48 months, replace every 30,000 miles (48,000 km) or 24 months.
(4) If towing a trailer, using a camper or a car-top carrier, or driving on rough or muddy roads, change (not just inspect) oil at every 30,000 miles (48,000 km)
or 24 months except tor LSD. Change LSD gear oil every 15,000 miles (24,000 km) or 12 months.
(5) If operating frequently in water, replace grease every 3,750 miles (6,000 km) or 3 months.
(6) Inspect the air bag system 10 years after the date of manufacture noted on the FMVSS certification label.
*
Maintenance items and intervals with "*" are recommended by NISSAN for reliable vehicle operation. The owner need not perform such maintenance in
order to maintain the emission warranty or manufacturer recall liability. Other maintenance items and intervals are required.
 Abbreviations: R = Replace I = Inspect. Correct or replace if necessary.
I ]: At the mileage intervals only
MAINTENANCE OPERATION MAINTENANCE INTERVAL

Miles x 1,000 7.5 15 22.5 30 37.5 45 52.5 60

Perform at number of m1les, kilometers or months, Reference page
whichever comes first
(km x 1,000) (12) (24) (36) (48} (60) (72} (84) }96)

Months 6 12 18 24 30 36 42 48

Emission control system maintenance

Drive belts I' I' MA-10

Air cleaner filter [R] [R] MA-12

Positive crankcase ventilation (PCV) filter See NOTE (1) [R] [R] MA-15

Vapor lines I' I' MA-15

Fuel lines I' I' MA-"12

Fuel filter

Engine coolant
See NOTE (1 )*

See NOTE (2) R'

MA-12

MA-11
.,m
Engine oil R R R R R R R R MA-13 JJ
Engine oil filter R R R R R R R R MA-13
en
(') 0
Spark plugs [R] [R] MA-14
:r
ID
5!
a. 0
:s:: Chassis and body maintenance
)>
s::: :s::
Bre.ke lines & cables MA-20 iii ~
.:.. Brake pads, rotors, drums & linings MA-20
1\) z
-1
Automatic transmission, transfer fluid & manual transmission, differential gear oil (exc. LSD) MA-16, 17, 18, 19 m
Limited-slip differential (LSD) gear oil R R MA-19 z
)>
Steering gear (box) & linkage, (steering damper r::::m:::1 }, axle & suspension parts MA-21, FA-5, RA-4 z
Drive shaft boots & propeller shaft (r::::m:::l ) MA-18, FA-14, PD-9 0
m
Steering linkage ball joints & front suspension ball joints MA-21, FA-5

Front wheel bearing grease (4x2) FA-6

Front wheel bearing grease & free-running hub grease (r::::m:::l ) R R FA-7, 17, 18

Exhaust system MA-16

Air bag system See NOTE (3)

NOTE: (1) If vehicle is operated under extremely adverse weather conditions or in areas where ambient temperatures are either extremely low or extremely high, the
filters might become clogged. In such an event, replace them immediately.
(2) After 60,000 miles (96,000 km) or 48 months, replace every 30,000 miles (48,000 km) or 24 months.
(3) Inspect the air bag system 10 years after the date of manufacture noted on the FMVSS certification label.
*
Maintenance items and intervals with ""'" are recommended by NISSAN for reliable vehicle operation. The owner need not perform such maintenance in
order to maintain the emission warranty or manufacturer recall liability. Other maintenance items and intervals are required.

p
59

IFJil
~l ~ Cf? J1Fl
c-{1 OW]
su
~1
~-:::;_:
lrlill

"
~-~
'i}'.'
~g_oJ
~
({i;;)
@I!
~
Lo~~
;:!:OJ
52
'j?· ~~ ""'g "" 9 IF rr);'" «;::) :s?;, ~
 RECOMMENDED FLUIDS AND LUBRICANTS

Fluids and Lubricants

Capacity (Approximate)

us Imp Recommended Fluids and Lubricants

Liter
measure measure

Engine oil (Refill)

With oil filter 4-1/8 qt 3-3/8 qt

2WD
Without oil filter 3-3/4 qt 3-1/8 qt
With oil filter 4-3/8 qt 3-5/8 qt
4WD
Without oil filter 4 qt 3-3/8 qt 3.8

Cooling system (With reservoir)

2WD 8-5/8 qt 7-1/8 qt 8.1 Antifreeze coolant

4WD 9-1/2 qt 7-7/8 qt 9 _0 (Ethylene glycol base) 50/50 mixture

2WD 4-1/4 pt 3-1/2 pt 2.0

Manual transmission gear oil FS5W71C API GL-4*1
4WD 10-3/8 pt 8-5/8 pt 4.9

Transfer fluid 2-3/8 qt 2 qt 2.2 Type DEXRON™

Manual steering fluid 1-3/8 pt 1-1/8 pt 0.62 API GL-4•1

Differential carrier gear oil

H190A 3-1/8 pt 2-5/8 pt 1.5

Rear: C200 2-3/4 pt 2-1/4 pt 1.3

H2338 5-7/8 pt 4-7/8 pt 2.8

Front {4WD): R180A 2-3/4 pt 2-1/4 pt 1.3

Nissan Matic "D" (Continental U.S.

Automatic transmission fluid 8-3/8 qt 7 qt 7.9 and Alaska) or Genuine Nissan Auto-
matic Transmission Fluid (Canadar2

PB48S 30.4-33.8 fl oz 31.7-35.2 fl oz 0.9-1.0 Type DEXRON™ liE, DEXRON™ Ill

Power steering fluid
PB59K 33.8-37.2 fl oz 35.2-38.7 fl oz 1.0-1.1 or equivalent

Genuine Nissan Brake Fluid*3 or

Brake and clutch fluid equivalent
DOT 3 (US FMVSS No. 116)

Multi-purpose grease NLGI No. 2 (Lithium soap base)

Free-running hub grease (Auto-lock) Genuine Nissan grease or equivalent

*1: For further details, see "SAE Viscosity Number".

*2: Dexron® 111/Mercon® or equivalent may also be used. Outside the continental United States and Alaska contact a NISSAN dealership for more
information regarding suitable fluids, including recommended brand(s) of Dexron@ 111/Mercon® or Dexron·i' IIE/Mercon® Automatic Transmission
Fluid.
*3: Available in mainland U.S.A. through your Nissan dealer.
*4: SAE 90 is acceptable in ambient temperatures above -18°C {0°F).
*5: Contact a Nissan dealer for a list of approved oils.

60 MA-8
 RECOMMENDED FLUIDS AND LUBRICANTS

SAE Viscosity Number

Outside Temperature Range Outside Temperature Range
Anticipated Before Next Oil Change Anticipated Before Next Oil Change

GASOLINE ENGINE OIL GEAR OIL

Of 140
'C 90
+38 100
+40

-l 30 +86

-18 0
10W-30
-29 -20

SW-30
75W BOW 75W-90
SOW-90

SMA796CB TI0003
L-------------------~
SAE 5W-30 viscosity oil is preferred for all 75W-90 for transmission, and SOW-90 for J,,[
temperatures. SAE 10W-30 viscosity oil may be differential are preferable if the ambient tem-
used if the ambient temperature is above -18'C perature is below 40'C (1 04 'F).
(O'F).

Antifreeze Coolant Mixture Ratio

The engine cooling system is filled at the factory with a high-quality,
year-round, antifreeze coolant solution. The antifreeze solution
contains rust and corrosion inhibitors. Additional cooling system
additives are not necessary. l'ffi,
CAUTION:
When adding or replacing coolant, be sure to use only an
ethylene glycol antifreeze with the proper mixture ratio of 50%
antifreeze 50% soft water.

Outside temperature
down to Anti- Soft
freeze water
oc OF
-35 -30 50% 50%

-Q'.'(5l

Other types of coolant solutions may damage the cooling sys- c/.0!
tem.

MA-9 61
 ENGINE MAINTENANCE

Checking Drive Belts

~ 16-21
(1.6- 2.1,
12- 15)

Air conditioner
compressor

Idler pulley

... : Check point for deflection

~ 16-22 (1.6- 2.2, 12 -16) ~ : N -m (kg-m, ft-lb)

AMA086

1. Inspect for cracks, fraying, wear and oil. If necessary, replace

with a new one.
2. Inspect drive belt deflections by pushing midway between pul-
leys.
Inspect drive belt deflections when engine is cold.
Adjust if belt deflections exceed the limit.
Belt deflection:
Unit: mm (in)

Used belt deflection

Deflection of new
Deflection after belt
L1mit
adjustment
10- 12 8- 10
Generator 17 (0.67)
(0.39 - 0.47) (0.31 - 0.39)
Air conditioner 10 - 12 8- 10
16 (0.63)
compressor (0.39 - 0.47) (0.31 - 0.39)
Power steering oil 9 - 11 7-9
15 (0.59)
pump (0.35- 0.43) (0.28- 0.35)
Applied pushing
98 N (10 kg. 22 lb)
force

62 MA-10
 ENGINE MAINTENANCE

Changing Engine Coolant

WARNING: •
To avoid being scalded, never change the coolant when the ,
engine is hot.
1. Move heater temperature control lever all the way to "HOT"
position or the highest temperature position. ~till
2. Open drain cock at the bottom of radiator, and remove radia-
tor cap.
Be careful not to allow coolant to contact drive belts.

3. Remove cylinder block drain plug.

4. Close drain cock and tighten drain plug securely.
• Apply sealant to the thread of drain plug .
tDJ: 34 - 44 N·m (3.5 - 4.5 kg-m, 25 - 33 ft-lb)
5. Open air relief plug.
6. Fill radiator with water and close air relief plug and radiator
cap. en.
7. Run engine and warm it up sufficiently.
8. Rev engine 2 or 3 times under no-load.
9. Stop engine and wait until it cools down.
10. Repeat step 2 through step 9 until clear water begins to drain
from radiator.
11. Drain water.

12. Open radiator cap and air relief plug.

13. Fill radiator with coolant up to specified level.
For coolant mixture ratio, refer to MA-9. Unit: 1. (US qt. Imp qt) ~H

Coolant capacity
2WD 4WD
Without reservoir tank 7.3 (7-3/4, 6-3/8) 8.2 (8-5/8, 7-1/4)
II III II Reservoir tank 0.8 (7/8, 3/4)
I I I III II III II
III I I II I II I I I Pour coolant through coolant ftller neck slowly to allow atr m
SMA182B system to escape.
14. Close air relief plug.
15. Remove reservoir tank, drain coolant, then clean reservoir
tank.
16. Install reservoir tank and fill it with coolant up to "MAX" level
and then install radiator cap.
MAX. 17. Run engine and warm it up sufficiently.
18. Rev engine 2 or 3 times under no-load.
MIN. 19. Stop engine and cool it down, then add coolant as necessary.
• Clean excess coolant from engine .

SMA412B

MA-11 63
 ENGINE MAINTENANCE

Checking Fuel Lines

Inspect fuel lines and tank for improper attachment, leaks, cracks,
damage, chafing and deterioration.
If necessary, repair or replace.

SMA215C

Unit: mm (in)
CAUTION:
Tighten high-pressure rubber hose clamp so that clamp end is
3 mm (0.12 in) from hose end.
Tightening torque specifications are the same for all rubber
hose clamps.
Ensure that the screw does not contact adjacent parts.
28 (1.10)

~ Fuel hose clamps

1.0 - 1.5 N·m
(0.10 - 0.15 kg-m,
8.7- 13.0 in-lb)
MMA104A

Changing Fuel Filter

WARNING:
Before removing fuel filter, release fuel pressure from fuel line.
1 ue pump
1. Remove fuse for fuel pump.
2. Start engine.
;-,1 yI .))
C/, 7L
Tll 11. l.
-'+ 3. After engine stalls, crank engine two or three times to make
sure that fuel pressure is released.
'\
I~ 4. Turn ignition switch OFF and install fuse for fuel pump.

WARNING:
Use rubber gloves to prevent fuel from contacting skin when
removing fuel hoses and filter.
5. Loosen fuel hose clamps.
6. Replace fuel filter.
• Be careful not to spill fuel over engine compartment. Place
a shop towel to absorb fuel.
• Use a high-pressure fuel filter. Do not use a synthetic res-
inous fuel filter.
• When tightening fuel hose clamps, refer to "Checking Fuel
Lines", MA-12.

Changing Air Cleaner Filter

~
The viscous paper filter does not need cleaning between
replacement intervals.

e
•
~MA243C
64 MA-12
 ENGINE MAINTENANCE

Changing Engine Oil

WARNING: •
• Be careful not to burn yourself, as the engine oil is hot. ,
• Prolonged and repeated contact with used engine oil may
cause skin cancer; try to avoid direct skin contact with
used oil. If skin contact is made, wash thoroughly with ~~/1
soap or hand cleaner as soon as possible.
1. Warm up engine, and check for oil leakage from engine com-
ponents. iL'C:
2. Remove drain plug and oil filler cap.
L _ _ _ _ _·_D_ca_in...:P_'u::.g_ _ _::.s::-M...:AB:::::s:::::Jsc 3. Drain oil and refill with new engine oil.
Oil specification and viscosity: !QG
• API SG or SH and Energy Conserving II
• API Certification Mark
• Refer to "RECOMMENDED FLUIDS AND LUBRICANTS", r;g
MA-8.
Refill oil capacity (Approximately):
Unit· I (US qt Imp qt) \[;~

2WD 4WD
With oil filter change 3.9 (4·1/8, 3·3/8) 4.1 (4·3/8, 3·5/8)
Without oil filter change 3.5 (3·3/4, 3·1/8) 3.8 (4, 3-3/8)

CAUTION: JJ
• Be sure to clean drain plug and install with new washer.
Drain plug:
~: 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb) If'
• The refill capacity changes depending on the oil tempera-
ture and drain time. Use these values as a reference and
be certain to check with the dipstick when changing the c~I'J
oil.

4. Check oil level.

5. Start engine and check area around drain plug and oil filter for
oil leakage.
6. Run engine for a few minutes, then turn it off. After several ~~
minutes, check oil level.

Refill oil to "H" level.

SMA885B

;KV10105900
Changing Oil Filter
/ (J34274) 1. Remove oil filter with Tool.
WARNING:
Be careful not to burn yourself. Engine and engine oil are hot.

SMA582C

MA-13 65
 ENGINE MAINTENANCE
Changing Oil Filter (Cont'd)
2. Clean oil filter mounting surface on cylinder block. Coat rubber
seal of new oil filter with engine oil.

SMA010

3. Screw in the oil filter until a slight resistance is felt, then tighten
additionally more than 2/3 of a turn.
4. Add engine oil.
Refer to "Changing Engine Oil", MA-13.
2/3 of a turn • Clean excess oil from engine.

Changing Spark Plugs

1. Disconnect ignition wires from spark plugs at boot.
Do not pull on the wire.

g
16mm
(0.63 in)
2. Remove spark plugs with spark plug wrench.
Spark plug:
Make
Standard type
NGK
ZFR5E-11
ZFR4E-11
Hot type
Cold type ZFR6E-11

Use standard type spark plug under normal conditions. The hot
type spark plug is suitable when fouling occurs with the standard
SMA581C spark plug under conditions such as:
• frequent engine starts
Side electrode • low ambient temperature
The cold type spark plug is suitable when spark knock occurs with
the standard spark plug under conditions such as:
• extended highway driving
• frequent high engine revolution
3. Check plug gap of each new spark plug.
Gap: 1.0 - 1.1 mm (0.039 - 0.043 in)
4. Install spark plugs. Reconnect ignition wires according to num-
bers indicated on them.
Spark plug:
~: 20- 29 N·m (2.0- 3.0 kg-m, 14- 22 ft-lb)
SMA476

66 MA-14
ENGINE MAINTENANCE

Checking EVAP Vapor Purge Lines

1. Visually inspect EVAP vapor purge lines for improper attach-
ment and for cracks, damage, loose connections, chafing and
deterioration.
2. Inspect fuel tank filler cap vacuum relief valve lor clogging,
sticking, etc. ~~:~:~
Refer to EC section ("EVAPORATIVE EMISSION SYS-
TEM").

Changing Positive Crankcase Ventilation (PCV)

Filter
Remove air cleaner cover and take out PCV filter located inside air TIF
cleaner cover. Then install new PCV filter.

MA-15 67
 CHASSIS AND BODY MAINTENANCE

Checking Exhaust System

Check exhaust pipes, muffler and mounting for improper
attachment, leaks, cracks, damage, loose connections, chafing and
deterioration.

SMA211A

Checking Clutch Fluid Level and Leaks

If fluid level is extremely low, check clutch system for leaks.

Checking MIT Oil

Check for oil leakage and oil level.
Never start engine while checking oil level.
Filler plug:
~: 25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)

Changing MIT Oil

1. Drain oil from drain plug and refill with new gear oil.
2. Check oil level.
SMA103
Oil grade and viscosity:
API GL-4. Refer to "RECOMMENDED FLUIDS AND
LUBRICANTS", MA-8.
Oil capacity:
FS5W71C
Engine 2WD 2.0 r (4-1/4 US pt, 3-112 Imp pt)
4WD 4.0 r (8-112 US pt, 7 Imp pt)
Drain plug:
~: 25- 34 N·m (2.5- 3.5 kg-m, 18- 25 ft-lb)

Checking Water Entry - For 4WD models

Check water entry in the clutch housing by removing the seal-
SMA369B ing grommet whenever driving in deep water or mud.
• Front side
Hot: 50 - sooc
Checking AfT Fluid
(122- 176°F) L~[H 1. Warm up engine.
2. Check for fluid leakage.
c I HOT~']:::)::!=== 3. Before driving, fluid level can be checked at fluid temperatures
of 30 to 50°C (86 to 122°F) using "COLD" range on dipstick.
a. Park vehicle on level surface and set parking brake.
( ===
!ii:1§:jcoLD I [:::c' b. Start engine and move selector lever through each gear posi-
L J [ H • Reverse side
Cold: 30 - 50°C c.
tion. Leave selector lever in "P" position.
Check fluid level with engine idling.
(86 - 122°F} d. Remove dipstick and note reading. If level is at low side of
SMA514CA either range, add fluid to the charging pipe.

68 MA-16
 CHASSIS AND BODY MAINTENANCE
Checking Arr Fluid (Cont'd)
e. Reinsert dipstick into charging pipe as far as it will go. <llll
f. Remove dipstick and note reading. If reading is at low side of
range. add fluid to the charging pipe.
Do not overfill.
4. Drive vehicle for approximately 5 minutes in urban areas.
5. Recheck fluid level at fluid temperatures of 50° to sooc (1 22° I~Wu
to 176°F) using "HOT" range on dipstick.
6. Check fluid condition.
• If fluid is very dark or smells burned, refer to AT section for
checking operation of AfT. Flush cooling system after repair of ILCi
AfT.
• If AfT fluid contains frictional material (clutches, bands, etc.),
replace radiator and flush cooler line using cleaning solvent ~G
and compressed air after repair of AfT. Refer to LC section
("Radiator", "ENGINE COOLING SYSTEM").

Changing Arr Fluid

1. Warm up AfT fluid.
2. Stop engine. 'i?C2
I''
3. Drain AfT fluid from drain plug and refill with new AfT fluid.
Measure amount of fluid drained and refill with equal amount
of new fluid.
Fluid grade and viscosity:
Nissan Matic "D" (Continental U.S. and Alaska) or
Genuine Nissan Automatic Transmission Fluid
Check fluid for contamination.
(Canada). Refer to "RECOMMENDED FLUIDS AND
SMA853B LUBRICANTS", MA-8.
Fluid capacity (With torque converter):
7.9 r (8-3/8 US qt, 7 Imp qt)
Drain plug:
~: 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb)
4. Run engine at idle speed for five minutes.
5. Check fluid level and condition. Refer to "Checking AfT Fluid".
If fluid is still dirty, repeat steps 2 through 5, MA· 16.

•
Drain plug

SMA5l5C

Checking Transfer Fluid

Rear view
Check for fluid leakage and fluid level.
Automatic Transmission Fluid is used for the transfer in the ~i0.
factory.
Never start engine while checking fluid level.
Filler plug: ~L~
~: 25 - 34 N·m (2.5- 3.5 kg-m, 18- 25 ft-lb)

SMA439B

MA-17 69
 CHASSIS AND BODY MAINTENANCE

Changing Transfer Fluid

When changing transfer fluid completely, use the following fluid.
Vehicle. Fluid grade:
front Type DEXRON™. Refer to "RECOMMENDED
FLUIDS AND LUBRICANTS", MA-8.
Fluid capacity:
2.2 I' (2-3/8 US qt, 2 Imp qt)
Drain plug:
1:C:J: 25 • 34 N·m (2.5 - 3.5 kg-m, 18 - 25 fl-lb)
SMA444B

Rear Check journals for Checking Propeller Shaft

wear or damage.
Check propeller shaft for damage, looseness and grease leakage.
Tightening torque: Refer to PD section.

Check center bearing

for noise or damage.

Check tube surfaces

for dents or cracks .

. . : Check tightening torque.

SMA231

Front
Check journals for

wear or dama~e/ ~k;;(b1i:l

• •
dents or cracks .

: Check tightening torque.

<) : Greasing point SMA566

Checking Differential Gear Oil

Check for oil leakage and oil level.
Filler plug:
Front
1:C:J: 39 - 59 N·m (4 - 6 kg-m, 29 - 43 fl-lb)
Rear
H190A, H233B
1:C:J: 59 - 98 N·m (6 - 10 kg-m, 43 - 72 fl-lb)
C200
1:C:J: 39 - 59 N·m (4 - 6 kg-m, 29 - 43 fl-lb)
SMA440B

70 MA-18
 CHASSIS AND BODY MAINTENANCE

Changing Differential Gear Oil

•
1. Drain oil from drain plug and refill with new gear oil.
2. Check oil level.
Oil grade and viscosity:
See "RECOMMENDED FLUIDS AND
LUBRICANTS", MA-8.
Oil capacity:
Front
1.3 t (2-3/4 US pt, 2-1/4 Imp pi)
Rear
H190A
1.5 r (3-1/8 US pt, 2-5/8 Imp pt)
Rear C200
1.3 r (2-3/4 US pt, 2-1/4 Imp pt)
H233B
2.8 r (5-7/8 US pt, 4-7/8 Imp pt)
Drain plug:
~ Front
Filler plug
~: 39 - 59 N·m (4 - 6 kg-m, 29 - 43 ft-lb)
I~ Rear
~y---~ ~: 59 - 98 N·m (6 - 10 kg-m, 43 - 72 ft-lb)
Fill to this level.
SMA631C

Limited-slip differential gear

• Use only approved limited-slip differential gear oil.
• Limited-slip differential identification .
(1) Lift both rear wheels off the ground.
(2) Turn one rear wheel by hand.
(3) If both rear wheels turn in the same direction simultaneously, iS!':
vehicle is equipped with limited-slip differential.

Balancing Wheels
Adjust wheel balance using the road wheel center.
Wheel balance (Maximum allowable unbalance):
Refer to SDS, MA-24.

Tire Rotation
Front
• After rotating the tires, adjust the tire pressure .
• lli21

0 0
Retighten the wheel nuts after the aluminum wheel has
been run for the first 1,000 km (600 miles) or if a flat tire
occurs.
• Do not include the T-type spare tire and small size spare ~is
~ ~ tire when rotating the tires.
Wheel nuts:

0 0 ADI0656
~: 118- 147 N·m (12- 15 kg-m, 87- 108 ft-lb)

MA-19 71
 CHASSIS AND BODY MAINTENANCE

Checking Brake Fluid Level and Leaks

If fluid level is extremely low, check brake system for leaks.

Checking Brake System

Check brake fluid lines and parking brake cables for improper
attachment, leaks, chafing, abrasion, deterioration, etc.

SBR389C

Checking Disc Brake

ROTOR
Check condition and thickness.
Minimum thickness:
CL28VA 20 mm (0.79 in)
CL28VD 24 mm (0.94 in)

SMA260A

CALIPER
Check for leakage.

SMA922A

PAD
Measure wear and check for damage.
Minimum thickness: 2 mm (0.08 in)

SMA364A

Checking Drum Brake

Inner diameter
WHEEL CYLINDER
Check for leakage.
DRUM
Check condition and inner surface.
Check condition of
Drum repair limit (Maximum inner diameter):
inner surface of drum LT26B 261.5 mm (10.30 in)
LT30A 296.5 mm (11.67 in)

SMA139

72 MA-20
 CHASSIS AND BODY MAINTENANCE
Checking Drum Brake (Cont'd)
LINING
Measure wear and check for damage.
Lining wear limit (Minimum thickness):
1.5 mm (0.059 in)

Checking Steering Gear and Linkage

STEERING GEAR
~~
• Check gear housing and boots for looseness, damage and
grease leakage.
• Check connection with steering column for looseness .
STEERING LINKAGE
• Check ball joint, dust cover and other component parts for
looseness, wear, damage and grease leakage. 1,iil
SMA442B

Checking Power Steering Fluid and Lines

• Check fluid level with engine off.
• Check fluid level with dipstick on reservoir cap. Use "HOT" t:IP
range at fluid temperatures of 50 to sooc (122 to 176°F). Use
"COLD" range at fluid temperatures of 0 to 30°C (32 to 86°F).
CAUTION: [0~)
• Do not overfill.
• Recommended fluid is Automatic Transmission Fluid type
"DEXRON™ liE", "DEXRON™ Ill" or equivalent. :Pi!\
SST2808
lRlt~
• Check lines for improper attachment, leaks, cracks, damage,
loose connections, chafing and deterioration.

SMA488C

Filler plug opening Checking Steering Gear Oil Level and Leaks
• Check steering gear for oil level and leakage.
• Check oil level.
A
Oil level:
Distance "A"
20 mm (0.79 in) or less
Be careful not to overflow gear oil when filling up.

(On vehicle)
SMA660B

MA-21 73
 CHASSIS AND BODY MAINTENANCE

Lubricating Hood Latches, Locks and Hinges

l!i:i! : Grease-up points

SMA851C

74 MA-22
 CHASSIS AND BODY MAINTENANCE

Checking Seat Belts, Buckles, Retractors,

Anchors and Adjusters

Front separate
seat Jump seat
With ELR type (King cab)

Check anchors for

I loose mounting.
/1 i
til J__ Check belts for

!I I- damage.

I' .
r -
!3--~:-- -~

Check buckles and

tongues for function
when buckled and
released.

Q®~'
,u.~~
~ Check retractor for
Check anchors for loose mounting. Checking items are
the same as the
smooth operation. Check buckles and tongues for function front seat.
when buckled and released. Jf

Label For front seat belt, shock absorber

type belt has been used.
Replace the belt when loop has
Front bench seat been pulled out and "REPLACE
(Including split seat) BELT" is visible because this

~
seat belt has a loop of webbing
under the sleeve.

' CAUTION:
1. If the vehicle has collided or overturned, replace the entire belt
assembly, regardless of nature of accident.
2. If the condition of any component of a seat belt is questionable,
do not repair seat belt, but replace it as a belt assembly.
3. If webbing is cut, frayed, or damaged, replace belt assembly.
4. Do not spill drinks, oil, etc. on inner lap belt buckle.
Never oil tongue and buckle.
5. Use a NISSAN genuine seat belt assembly.
Anchor bolt:
Check buckles and tongues for function
~; 24- 31 N•m (2.4- 3.1 kg-m, 17- 23 ft-lb)
Check belts for damage.
when buckled and released.

AMA088

MA-23 75
 SERVICE DATA AND SPECIFICATIONS (SDS)

Engine Maintenance
INSPECTION AND ADJUSTMENT Spark plug
Drive belt deflection Standard type ZFASE-11
Unit· mm (in) Hot type ZFR4E-11

Used belt deflection Cold type ZFR6E-11

Deflection of
Deflection after new belt Plug gap 1.0 - 1.1 mm (0.039 - 0.043 in)
Limit
adjustment

10- 12 8- 10
Generator 17 (0.67)
(0.39- 0.47) (0.31 - 0.39)

Air conditioner 10- 12 8- 10

16 (0.63)
compressor (0.39- 0.47) (0.31 - 0.39)

Power steering 9- 11 7- 9
15 (0.59)
oil pump (0.35 - 0.43) (0.28 - 0.35)

Applied pushing
98 N (10 kg, 22 lb)
force

Chassis and Body Maintenance

INSPECTION AND ADJUSTMENT
Wheel balance
Dynamic
Maximum allowable (At rim flange) 10 (0.35) (one side)
unbalance 9 (oz)
Static g (oz) 20 (0.71)

76 MA-24
 ENGINE MECHANICAL ~[

SECTION EM
CONTENTS
PRECAUTIONS ..............................................................2 OIL SEAL REPLACEMENT .... .................................... 14
Supplemental Restraint System (SRS) "AIR Valve Oil Seal .......................................................... 14
BAG" ........................................................ . ....... 2 Front Oil Seal. .......................................................... 14 0L
Parts Requiring Angular Tightening ............................. 2 Rear Oil Seal ............................................................ 15
Liquid Gasket Application Procedure .......................... 2 CYLINDER HEAD .......................................................... 16
PREPARATION ................................................................ 3 Removal ..................................................................... 17 i~lit
Special Service Tools .................................................. 3 Disassembly ............................................................. 19
Commercial Service Tools ........................................... 5 Inspection.................. ............................ ........ 19
OUTER COMPONENT PARTS ....................................... 6 Assembly ...................................................................25 ~~~:u
COMPRESSION PRESSURE .......................................... 7 Installation ..................................................................26
Measurement of Compression Pressure ..................... 7 ENGINE REMOVAL ....................................................... 29 'YiP
OIL PAN ...........................................................................8 Removal ....................................................................30
Removal .............. . . ............................ ····· ........ 8 Installation ................................................................. 31
lnstallation .................................................................... S CYLINDER BLOCK........................ ............... ....... 32 ["['j
TIMING CHAIN .............................................................. 10 Disassembly ............................................................. 33
Removal ..................................................................... 10 Inspection .................................................................. 33
lnspection ................................................................... 11 Assembly .................................................................. 39
Installation .................................................................. 12 SERVICE DATA AND SPECIFICATIONS (SDS) ......... .42
General Specifications................. .42
. an d Ad"JUStmen t ....................................... .42
Inspect1on !Rli~\

77
 PRECAUTIONS

Supplemental Restraint System (SRS) "AIR

BAG"
The Supplemental Restraint System "Air Bag", used along with a seat belt, helps to reduce the risk or sever-
ity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of an air bag mod-
ule (located in the center of the steering wheel), a diagnosis sensor unit, warning lamp, wiring harness, a crash
zone sensor (4WD models) and spiral cable. Information necessary to service the system safely is included
in the RS section of this Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed
by an authorized NISSAN dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses are covered with yellow insulation either just before the
harness connectors or for the complete harness, for easy identification.
Parts Requiring Angular Tightening
• Use an angle wrench for the final tightening of the following
engine parts:
(1) Cylinder head bolts
(2) Connecting rod cap nuts
• Do not use a torque value for final tightening.
• The torque values for these parts are for a preliminary step.
• Ensure thread and seat surfaces are clean and coated with
engine oil.

Liquid Gasket Application Procedure

a. Use a scraper to remove all traces of old liquid gasket
from mating surfaces and grooves. Also, completely clean
any oil from these areas.
Inner
side
b. Apply a continuous bead of liquid gasket to mating sur-
faces. (Use Genuine Liquid Gasket or equivalent.)
• For oil pan, be sure liquid gasket diameter is 3.5 to 4.5
mm (0.138to 0.177 in).
Groove Bolt hole • For areas except oil pan, be sure liquid gasket diameter
is 2.0 to 3.0 mm (0.079to 0.118 in).
SEM164F

c. Apply liquid gasket around the inner side of boll holes

(unless otherwise specified).
d. Assembly should be done within 5 minutes after coating.
e. Wait at least 30 minutes before refilling engine oil and
engine coolant.

78 EM-2
 PREPARATION

Special Service Tools

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number
(Kent-Moore No.) Description

•
Tool name

ST0501SOOO Disassembling and assembling

( - )
Engine stand assembly
CD ST05011 000
( - )
Engine stand
@ ST050 12000
( - )
Base NT042

KV10105001
( - )
Engine attachment

NT031

KV10109250 1 ', Disassembling and assembling valve compo-

(J26336-B) nents
Valve spring compressor
CD KV10109210
( - )
Compressor
@ KV1 0109220
( - )
Adap1er NT021

KV109B0010 Installing valve oil seal

( - )
Valve oil seal drift

NT027

KV10110300 Disassembling and assembling piston with

( -) connecting rod
Piston pin press stand
assembly
CD KV10110310
( - )
Cap
@ KV10110330
( - )
Spacer
@ ST13030020
( - )
Press stand
@) ST13030030
( - )
Spring
@ KV10110340
( - )
Drift
@ KV10110320
( - )
Center shaft NT036

EM-3 79
 PREPARATION
Special Service Tools (Cont'd)
Tool number
(Kent-Moore No.) Description
Tool name

EM03470000 Installing piston assembly into cylinder bore

(J8037)
Piston ring compressor

NT044

(J36467) Displacement valve oil seal

Valve oil seal remover

NT034

ST16610001 Removing crankshaft pilot bushing

(J23907)
Pilot bushing puller

NT045

KV10111100 Removing oil pan

(J37228)
Seal cutter

NT046

WS39930000 Pressing the tube of liquid gasket

( - )
Tube presser

NT052

KV10105800 Holding the timing chain

(J25660-C)
Chain stopper

NT010

KV10112100 Tightening bolts for bearing cap, cylinder

(BT8653-A) head, etc.
Angle wrench

NT014

80 EM-4
 PREPARATION

Commercial Service Tools

Tool name Description

g
Spark plug wrench Removing and installing spark plug

NT047
16 mm
(0.63 in)
0
Pulley holder Holding camshaft pulley while tightening or
~
loosening camshaft bolt

NT035

Valve seat cutter set Finishing valve seat dimensions

NT048
~
Piston ring expander Removing and installing piston ring

NT030
~
Valve guide drift Removing and installing valve guide

mm(in)

·~
Diameter

Intake Exhaust

a 10.5 (0.413) 11.5 (0.453)

b 6.6 (0.260) 7.6 (0.299)

NT015

Valve guide reamer Reaming valve guide CD or hole for oversize

valve guide @

~~;
Intake:
d 1 ; 7.0 mm (0.276 in) dia.
d 2 = 11.2 mm (0.441 in) dia.
d
Exhaust:
2 d 1 ; 8.0 mm (0.315 in) dia.
NT016 d 2 ; 12.2 mm (0.480 in) dia.

EM-5 81
 OUTER COMPONENT PARTS

SEC. 120•140•147•150•163•164•21 0•220•221•230•231

~~1st: 9-11 (0.9-1.1,6.5-8.0)
~2.9-3.8 EGA temperature sensor
(0.30- 0.39, y ~ ~2nd: 18-22(1.8-2.2,13-16)
~15-25(1.5-2.5,11-18)
26.0- 33.9)
Throttle body r1
Fuel tube* n ,, ..
{~~
~ 1st: 9.3-10.8
{0.95-1.1,
6.9- 8.0)

~2nd: 21-26
(2.1- 2.7, to.: 16-21
15-20) (1.6- 2.1'
12- 15)

Oil filter
bracket

Exhaust
manifold
High-tension cable

Adjusting bar

"'-- C1rnn• pulley damper

~: N·m (kg-m, in-lb)

12 (1.0 -1.2, 87 -104) ~: N-m (kg-m, ft-lb)

[4 : Apply liquid gasket.
*For sub-fuel tube: ~ ~142 -152 (14.5 -15.5,105 -112) ~ : Lubricate with
new engine oil.
~1st: 3.1-4.2 (0.32- 0.43, 27.8- 37.3)
2nd: 6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)

AEM254

82 EM-6
 COMPRESSION PRESSURE

Measurement of Compression Pressure

1. Warm up engine.
2. Turn ignition switch OFF.
3. Release fuel pressure.
Refer to EC section ("Fuel Pressure Release", "BASIC SER-
VICE PROCEDURE").
4. Remove all spark plugs.
5. Disconnect distributor center cable.

6. Attach a compression tester to No. 1 cylinder.

7. Depress accelerator pedal fully to keep throttle valve wide
open.
8. Crank engine and record highest gauge indication.
9. Repeat the measurement on each cylinder.
• Always use a fully-charged battery to obtain specified
engine speed.
~r
1
c;c
Compression pressure:
kPa (kg/cm 2 , psi)/rpm
Standard
SEM113B
1 ,324 (13.5, 192)/300
Minimum
981 (1 0, 142)/300
Difference limit between cylinders
98 (1.0, 14)/300
10. If compression in one or more cylinders is low:
a. Pour a small amount of engine oil into cylinders through spark
plug holes.
b. Retest compression.
• If adding oil helps compression, piston rings may be worn
or damaged. If so, replace piston rings after checking pis-
::Fl~i
ton.
• If pressure stays low, a valve may be sticking or seating
improperly. Inspect and repair valve and valve seat. (Refer
to SDS.) If valve or valve seat is damaged excessively, ~i;i,
replace them.
• If compression stays low in two cylinders that are next to
each other: iBH'i
a. The cylinder head gasket may be leaking, or
b. Both cylinders may have valve component damage.
Inspect and repair as necessary. .\\)(

EM-7 83
 OIL PAN

Removal
1. Raise vehicle and support it with safety stands.
2. Drain engine oil.
G)o 3. Remove front stabilizer bar securing bolts and nuts from side
member.
4. Lift engine.
@o 5. Remove oil pan bolts.
0 0 0

@
<=:J® Loosen bolts in numerical order.
Front AEM298

6. Remove oil pan.

a. Insert Tool between cylinder block and oil pan.
• Be careful not to damage aluminum mating surface.
• Do not insert screwdriver, or oil pan flange will be dam-
KV10111100 aged.
(J37228)
b. Slide Tool by tapping on the side of the Tool with a hammer.
7. Pull out oil pan from front side.

Installation
1. Use a scraper to remove old liquid gasket from mating surface
of oil pan.
• Also remove traces of liquid gasket from mating surface
of cylinder block.

AEM299

2. Apply a continuous bead of liquid gasket to mating surface of

oil pan.
• Use Genuine Liquid Gasket or equivalent.
• Apply to groove on mating surface.
• Allow 7 mm (0.28 in) clearance around bolt hole.

Cut here.

7 mm (0.28 in)

-j f-
•
Liquid gasket

Inner
side

Groove Bolt hole

SEM015E

84 EM-8
 OIL PAN
Installation (Cont'd)
(~~
• Be sure liquid gasket diameter is 3.5 to 4.5 mm (0.138 to
I .I I I 0.177 in).
\:i ii i • Attaching should be done within 5 minutes after coating.

..d)o
~~
Re~ 0

0 AEM301

® @) 3. Install oil pan.

0 0
® ® • Tighten oil pan bolts in numerical order.
0
@o
\\@ •
4.
~: 6.3- 8.3 N·m (0.64- 0.85 kg-m, 55.6- 73.8 in-lb)
Wait at least 30 minutes before refilling engine oil.
Install parts in reverse order of removal.
@o
\. 0®
0 0 0 0
G) ® (i) ® 'j[u'[F
0Front
Tighten in numerical order
AEM259

EM-9 85
 TIMING CHAIN

SEC. 120•130•135

Timing chain

Crankshaft sprocket

Front cover

L-
Crankshaft
Crankshaft
AEM305
sprocket

CAUTION:
• After removing timing chain, do not turn crankshaft and
camshaft separately, or valves will strike piston heads.
• When installing rocker arms, camshafts, chain tensioner,
oil seals, or other sliding parts, lubricate contacting sur-
faces with new engine oil.
• Apply new engine oil to bolt threads and seat surfaces
when installing cylinder head, camshaft sprockets, crank-
shaft pulley, and camshaft brackets.

Removal
1. Disconnect battery terminal.
2. Drain coolant from radiator.
3. Remove radiator shroud and cooling fan.
4. Remove the following belts.
• Power steering drive belt
• Compressor drive belt
• Generator drive belt

86 EM-10
 TIMING CHAIN
Removal (Cont'd)
5. Remove all spark plugs.
6. Set No. 1 piston at TDC on its compression stroke.
CJ
Front

AEM261
•
7. Remove the following parts.
• Power steering pump, idler pulley and power steering pump
brackets
• Compressor idler pulley
• Crankshaft pulley with a suitable puller
• Oil pump with pump drive spindle
• Rocker cover

SEM200C

8. Remove oil pan. (Refer to OIL PAN, EM-9.)

9. Remove front cover.
• Inspect for oil leakage at front oil seal. Replace seal if oil leak
is present. 'JJ'

10. Remove the following parts.

• For retiming during cylinder head removal/installation,
apply paint mark to timing chain at mating mark of cam- ~lfu

~
shaft sprocket.

'(); •
•
•
•
Chain tensioner
Chain guides
Timing chain and camshaft sprocket
Oil thrower, oil pump drive gear and crankshaft sprocket
©1:'

Inspection
• Check for cracks and excessive wear at roller links.
Replace chain if necessary.

Wear

SEM204C

EM-11 87
 TIMING CHAIN

Installation
1. Install crankshaft sprocket, oil pump drive gear and oil thrower.
• Make sure that mating marks on crankshaft sprocket face
front of engine.

SEM205C

2. Install camshaft sprocket.

3. Confirm that No. 1 piston is set at TDC on its compression
stroke.
4. Install timing chain.
Paint • Set timing chain by aligning paint marks with mating
mark on marks of crankshaft sprocket and camshaft sprocket.
chain

Camshaft sprocket

~~sr--- Paint mark

on chain
e : Punchmark

5. Tighten camshaft sprocket bolt.

6. Install chain guide and chain tensioner.

7. Use a scraper to remove old liquid gasket from mating surface

of front cover.
• Also remove traces of liquid gasket from mating surface
of cylinder block.

88 EM-12
•
 TIMING CHAIN
Installation (Cont'd)
8. Apply a continuous bead of liquid gasket to front cover.
• Use Genuine Liquid Gasket or equivalent.
2.0 3.0 mm
M

• Be sure to install new front oil seal in the right direction.

(0.079 - 0.118 in) dia.
_,~ Refer to EM-14.
9. Apply lithium grease to sealing lip of crankshaft oil seal.

10. Install front cover.

• Be careful not to damage cylinder head gasket.
• Be careful not to damage front oil seal when installing
front cover.
!P~

11. Install new rubber plug. (Refer to "Installation", CYLINDER

HEAD, EM-27.)
12. Install oil pan. (Refer to OIL PAN, EM·9.)

13. Install oil pump and distributor driving spindle with new gasket fk'T
in front cover.
a. Assemble oil pump and driving spindle, aligning punch mark on 1i'IP
driving spindle with oil hole.
il!" Punchmark

SEM395E

b. Make sure that driving spindle is set as shown in figure.

Front <=:J

14. Install distributor.

15. Make sure that No. 1 piston is set at TDC and that distributor
CJ
Front
rotor is set at No. 1 cylinder spark position.

AEM261

EM-13 89
 OIL SEAL REPLACEMENT

Valve Oil Seal

1. Remove rocker cover.
2. Remove rocker shaft assembly. (Refer to "Disassembly",
CYLINDER HEAD, EM-19.)
3. Remove valve spring and valve oil seal with Tool or suitable
tool.
• Piston concerned should be set at TDC to prevent valve
from falling.

4. Apply engine oil to new valve oil seal and install it with Tool.
KV109B0010
• Before installing valve oil seal, install valve spring seat.
I ~ I

SEM396E

Valve
oil seal

15.6 - 16.2
Valve ll'!-+---t--T'-''(0.614 - 0.638)
spring seat

1.0 (0.039)

Unit: mm (in) SEM397E

Front Oil Seal

1. Remove radiator shroud and crankshaft pulley.
2. Remove front oil seal.
• Be careful not to scratch front cover.

3. Apply engine oil to new oil seal and install it using suitable tool.
• Install new oil seal in the direction shown.

Engine /'-, .......flr-4-~~ Engine

inside Y Y outside

Oil seal lip Dust seal Up

SEM715A

90 EM-14
 OIL SEAL REPLACEMENT

Rear Oil Seal

1. Remove flywheel or drive plate.
2. Remove rear oil seal retainer.
3. Remove rear oil seal from retainer.
• Be careful not to scratch rear oil seal retainer.

~,r;

4. Apply engine oil to new oil seal and install it using suitable tool. '~I©

• Install new oil seal in the direction shown .

["~

Engine
inside
<)-- Q Engine
outside ©11

uulr

&'1'

fiF

r[i)J

~~

~~~
5. Install rear oil seal retainer.
a. Before installing rear oil seal retainer, remove all traces ofliq-
uid gasket from mating surface using a scraper.
~tRl
• Also remove traces of liquid gasket from mating surface
of cylinder block.
~}11

i?li!i

IID'L
b. Apply a continuous bead of liquid gasket to mating surface of
Diameter of rear oil seal retainer.
liquid gasket:
2.0 • 3.0 mm • Use Genuine Liquid Gasket or equivalent. [r{]~
(0.079-
0.118 in)
• Apply around inner side of bolt holes .

0
l?:l

~[QI}Z

AEM30-3

EM-15 91
 CYLINDER HEAD

SEC. 111·130

~ ~ ~efer to step 8 in
Installation''
of CYLINDER HEA D.

Valve rock er cover _

Rocker cover gasket ~-

!
/
/I Valve rocker
and shaft

~ 37-41 N·m
I/ ' !
assembly
) I
(3.8 . 4.2 kg-m
,27->0i~

/ v
Valve and spring
l ~~
~---'
~ lth~~ Iff
Intake
~"""' ~~~

Cylinder head

head
gasket~

Head bolt
f]~ Refer to sl .
of CYL INDERep 2 m "I ~stallation"
HEAD

~ : Apply liqUid gaske

LJ Lubncate with :lewt engine Oil
Camshaft

SEM552EA

92 EM-16
 CYLINDER HEAD

OK CAUTION:
Oil Rocker arm with • When installing rocker arms, camshaft and oil seal, lubri-
cate contacting surtaces with new engine oil.
• When tightening cylinder head bolts and rocker shaft
bolts, lubricate bolt threads and seat surtaces with new
engineoil. •
• Hydraulic valve lifters are installed in each rocker arm. If
hydraulic valve lifter is kept on its side, even when
installed in rocker arm, there is a risk of air entering it.
When rocker arms are removed, stand them straight up or lCG~
SEM878BA
soak them in new engine oil.
• Do not disassemble hydraulic valve lifter.

NG
• Attach tags to valve lifters so as not to mix them up.

SEM868BA

Removal
1. Release fuel pressure. Refer to EC section ("Fuel Pressure
Release", "BASIC SERVICE PROCEDURE").
2. Drain coolant from radiator and drain plug of block.
3. Remove the following parts.
• Power steering drive belt
• Power steering pump, idler pulley and power steering brackets
• Vacuum hoses of swirl control valve and pressure control sole·
noid valve
•4. Accelerator wire bracket
Disconnect EGR tube from exhaust manifold.
5. Remove bolts which hold intake manifold collector to intake f:i/k
manifold.
6. Remove bolts which hold intake manifold to cylinder head
while raising collector upwards.
7. Remove rocker cover.
• When removing rocker cover, do not hit rocker cover
against rocker arm. §7

8. Set No. 1 piston at TDC on its compression stroke.

~ 0° 5" 10° 15" 20°

Red painted j
SEM216C

EM-17 93
 CYLINDER HEAD
Removal (Cont'd)
• Make sure No. 1 cylinder is at TDC by looking at the distribu-
tor rotor position.
<::::;
Fmnt

9. Loosen camshaft sprocket bolt

• Support timing chain by using Tool as shown in figure.

10. Remove camshaft sprocket

• For retiming during installation, apply paint marks to tim-
ing chain at mating marks of crankshaft sprocket and
camshaft sprocket.

\~
\ SEM219C

11. Remove front timing cover to cylinder head bolts.

SEM210B

12. Remove cylinder head.

• Loosen in numerical order.
• A warped or cracked cylinder head could result from
removing in incorrect order.
• Loosen cylinder head bolts in two or three steps.

SEM210E

94 EM-18
 CYLINDER HEAD

@I
Disassembly
1. Remove rocker shaft assembly.
0 ® @ ® ® a. When loosening bolts, evenly loosen as shown in figure at
IO 0 o o Of left.
b. Bolts should be loosened in two or three steps.
2. Remove camshaft.
IO 0 0 0 Ol • Before removing camshaft, measure camshaft end play.
(Refer to "Inspection".)
0 ® ® (i)

3. Remove valve components with Tool.

4. Remove valve oil seals. (Refer to OIL SEAL REPLACEMENT,
EM-14.)

Iill

Inspection
CYLINDER HEAD DISTORTION
• Clean surface of cylinder head.
• Use a reliable straightedge and feeler gauge to check the flat·
ness of cylinder head surface.
• Check along six positions shown in figure.
Head surface flatness:
Standard
Less than 0.03 mm (0.0012 in)
Limit
0.1 mm (0.004 in)
If beyond the specified limit, replace or resurface.
Resurfacing limit:
The limit for cylinder head resurfacing is determined by the
~~
cylinder block resurfacing.
Amount of cylinder head resurfacing is "A"
Amount of cylinder block resurfacing is "B"
The maximum limit is as follows:
A + B = 0.2 mm (0.008 in)
After resurfacing cylinder head, check that camshaft rotates freely
by hand. If resistance is felt, cylinder head must be replaced. ~:§!
Nominal cylinder head height:
98.8 - 99.0 mm (3.890 - 3.898 in)
CAMSHAFT VISUAL CHECK
Check camshaft for scratches, seizure and wear.

EM-19 95
 CYLINDER HEAD
Inspection (Cont'd)
CAMSHAFT RUNOUT
1. Measure camshaft runout at the center journal.
Runout (Total indicator reading):
0 - 0.02 mm (0 - 0.0008 in)
2. If it exceeds the limit, replace camshaft.

CAMSHAFT CAM HEIGHT

1. Measure camshaft cam height.
Standard cam height:
44.43- 44.58 mm (1.7492- 1.7551 in)
Cam height wear limit:
0.2 mm (0.008 in)
2. If wear is beyond the limit, replace camshaft.

CAMSHAFT JOURNAL CLEARANCE

1. Install camshaft bracket and rocker shaft and tighten bolts to
the specified torque.
2. Measure inner diameter of camshaft bearing.
Standard inner diameter:
33.000 - 33.025 mm (1.2992 - 1.3002 in)

3. Measure outer diameter of camshaft journal.

Standard outer diameter:
32.935- 32.955 mm (1.2967- 1.2974 in)
4. If clearance exceeds the limit, replace camshaft and/or cylin-
der head.
Camshaft journal clearance:
Standard
0.045 - 0.090 mm (0.0018 - 0.0035 in)
Limit
0.12 mm (0.0047 in)

CAMSHAFT END PLAY

1. Install camshaft in cylinder head.
2. Measure camshaft end play.
Camshaft end play:
Standard
0.07- 0.15 mm (0.0028- 0.0059 in)
Limit
0.2 mm (0.008 in)
3. If end play exceeds the limit, replace camshaft and remeasure
camshaft end play.
• If end play still exceeds the limit after replacing camshaft,
replace cylinder head.

96 EM-20
 CYLINDER HEAD
Inspection (Cont'd)
CAMSHAFT SPROCKET RUNOUT
1. Install sprocket on camshaft
2. Measure camshaft sprocket runout
Runout (Total indicator reading):
Limit 0.12 mm (0.0047 in)
3. If it exceeds the limit, replace camshaft sprocket.

VALVE GUIDE CLEARANCE

1. Measure valve deflection as shown in illustration. (Valve and
valve guide wear the most in this direction.) 1"11'
Valve deflection limit (Dial gauge reading):
Dial gauge 0.15 mm (0.0059 in)

lio11

2. If it exceeds the limit, check valve to valve guide clearance.

a. Measure valve stem diameter and valve guide inner diameter.
b. Check that clearance is within specification.
Valve to valve guide clearance = valve guide inner Jf
diameter - valve stem diameter:
Standard
Intake
0.020 - 0.053 mm (0.0008 - 0.0021 in)
Exhaust
lc'/,•.\
0.040 - 0.070 mm (0.0016 - 0.0028 in) .r . ,-\]
Limit 0.1 mm (0.004 in)
c. If it exceeds the limit, replace valve and remeasure clearance.
• If clearance still exceeds the limit alter replacing valve, replace
the valve guide.
J13;

13~i

EM-21 97
 CYLINDER HEAD
Inspection (Cont'd)
VALVE GUIDE REPLACEMENT
1. To remove valve guide, heat cylinder head to 150 to 160°C
(302 to 320°F).

SEMOOBA

2. Drive out valve guide using a hammer and suitable tool or a

press [under a 20 kN (2 ton, 2.2 US ton, 2.0 Imp ton) pressure].

3. Ream cylinder head valve guide hole.

Valve guide hole diameter
(for service parts):
Intake
11.175- 11.196 mm (0.4400- 0.4408 in)
Exhaust
12.175- 12.196 mm (0.4793- 0.4802 in)

0
0

4. Heat cylinder head to 150 to 160°C (302 to 320°F) and press

service valve guide onto cylinder head.
Projection "L":
14.9 - 15.1 mm (0.587 - 0.594 in)
5. Ream valve guide.
Finished size:
Intake
7.000-7.018 mm (0.2756- 0.2763 in)
Exhaust
8.000- 8.018 mm (0.3150- 0.3157 in)
SEM225C

VALVE SEATS
Check valve seats for pitting at contact surface. Resurface or
replace if excessively worn.
• Before repairing valve seats, check valve and valve guide
for wear. If they have worn, replace them. Then correct
valve seat.
• Use both hands to cut uniformly.

98 EM-22
 CYLINDER HEAD
Inspection (Cont'd)
REPLACING VALVE SEAT FOR SERVICE PARTS
Recess ' diameter
1. Bore out old seat until it collapses. Set machine depth stop so

It[1 ---1
I that boring cannot contact bottom face of seat recess in cylin-
der head.
2. Ream cylinder head recess.
Reaming bore for service valve seat
Oversize [0.5 mm (0.020 in)]:
lI Intake 36.500 - 36.516 mm (1.4370 - 1.4376 in)
Exhaust 42.500 - 42.516 mm (1.6732 - 1.6739 in)
Use the valve guide center for reaming to ensure valve seat ~(;';
SEM795A will have the correct fit.

3. Heat cylinder head to 150 to 160'C (302 to 320'F).

4. Press fit valve seat until it seats on the bottom.

li!lT
SEM008A

5. Cut or grind valve seat using suitable tool of the specified

dimensions. Refer to SDS, EM-43.
6. After cutting, lap valve seat with abrasive compound.
7. Check valve seating condition.
Seat face angle ''c,":
45 deg.
Contacting width "W":
Intake
1.6 - 1.7 mm (0.063 - 0.067 in)
)
Exhaust
1.7- 2.1 mm (0.067- 0.083 in)
SEM892B

T (Margin thickness) VALVE DIMENSIONS

-1 '-- Check dimensions of each valve. Refer to SDS, EM-44.
,--1 When valve head has been worn down to 0.5 mm (0.020 in) in ~fil
margin thickness, replace valve.
II'~", Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or
less. iSu

-- L-----1
SEM188A

EM-23 99
 CYLINDER HEAD
Inspection {Cont'd)
~ r-- S (Ou1-o1-squace)
VALVE SPRING
Squareness
1. Measure dimension "S".
Out-of-square "S":
Outer
Intake Less than 2.5 mm (0.098 in)
Exhaust Less than 2.3 mm (0.091 in)
Inner
Intake Less than 2.3 mm (0.091 in)
Exhaust Less than 2.1 mm (0.083 in)
SEM288A
2. If it exceeds the limit, replace spring.

Pressure
Check valve spring pressure at specified spring height.
Pressure: N (kg, lb) at height mm (in)
Standard
Outer
Intake 604.1 (61.6, 135.8) at 37.6 (1.480)
Exhaust 640.4 (65.3, 144.0) at 34.1 (1.343)
Inner
Intake 284.4 (29.0, 63.9) at 32.6 (1.283)
Exhaust 328.5 (33.5, 73.9) at 29.1 (1.146)
EM1
Limit
Outer
Intake 567.8 (57.9, 127.7) at 37.6 (1.480)
Exhaust 620.8 (63.3, 139.6) at 34.1 (1.343)
Inner
Intake 266.8 (27.2, 60.0) at 32.6 (1.283)
Exhaust 318.7 (32.5, 71.7) at 29.1 (1.146)
If it exceeds the limit, replace spring.

ROCKER SHAFT AND ROCKER ARM

1. Check rocker shafts for scratches, seizure and wear.
2. Check outer diameter of rocker shaft.
Diameter:
21.979 - 22.000 mm (0.8653 - 0.8661 in)

3. Check inner diameter of rocker arm.

Diameter:
22.012 - 22.029 mm (0.8666 - 0.8673 in)
Rocker arm to shaft clearance:
0.012 - 0.050 mm (0.0005 - 0.0020 in)
• Keep rocker arm with hydraulic valve lifter standing to
prevent air from entering hydraulic valve lifter when
checking.

100 EM-24
 CYLINDER HEAD

@I
Assembly
Install valve component parts.
Always use new valve oil seal. Refer to OIL SEAL
REPLACEMENT.
Before installing valve oil seal, install inner valve spring
seat.
Install outer valve spring (uneven pitch type) with its nar-
row pitch side toward cylinder head side.
0 After installing valve component parts, use plastic ham- 1}~
Cylinder head side
mer to lightly tap valve stem tip to assure a proper fit.

Install camshaft, placing knock pin towards front of engine and ~©

Place in the top position.
upside.
Apply engine oil to camshaft when mounting onto cylinder f[g
head.

Install camshaft brackets.

Front mark is punched on the camshaft brackets.

4. Install rocker shaft with rocker arms.

~Front
Intake

@11
• Install retainer with cutout facing direction shown in figure at
left.

SEM274C

EM-25 101
 CYLINDER HEAD
Assembly (Cont'd)
5. Tighten bolts as shown in figure at left.

(j) 0 G) ® ®
IO 0 0 0 OJ

IO 0 0 0 OJ
® 0 0 ® ®>
Q Front
AEM105

Installation
1. Set No. 1 piston at TDC on its compression stroke as follows:
a. Align mark on crankshaft pulley with "0"' position and confirm
that distributor rotor head is set as shown in figure.

CJ
Front

AEM261

b. Confirm that knock pin on camshaft is set at the top.

Knock pin

SEM442C

2. Install cylinder head with new gasket and tighten cylinder head
@ @ bolts in numerical order.
• Do not rotate crankshaft and camshaft separately, or
valves will hit piston heads.
• Tightening procedure
a. Tighten all bolts to 29 N·m (3.0 kg-m, 22 ft-lb).
b. Tighten all bolts to 78 N·m (8.0 kg-m, 58 ft-lb).
c. Loosen all bolts completely.
d. Tighten all bolts to 29 N·m (3.0 kg-m, 22 ft-lb).
e. Turn all bolts 80~~ degrees clockwise with an angle
® ® CD ® ® wrench. If an angle wrench is not available, tighten all
AEM106 bolts to 74 to 83 N·m (7.5 to 8.5 kg-m, 54 to 61 ft-lb).

102 EM-26
 CYLINDER HEAD
Installation (Cont'd)
~~
3. Set chain on camshaft sprocket by aligning each mating mark.
Then install camshaft sprocket to camshaft.

SEM242C
•
4. Tighten camshaft sprocket bolt.

5. Install rubber plugs as follows:

a. Apply liquid gasket to rubber plugs.
• Rubber plugs should be replaced with new ones .
Liquid gasket
• Rubber plugs should be installed within 5 minutes of '{?
applying liquid gasket.

3 mm (0.12 in) diameter

(liquid gasket) SEM 931 8

b. Install rubber plugs, then move them with your lingers to uni-
formly spread the gasket on cylinder head surface.
• Rubber plugs should be installed flush with the surface. ~IFl
• Do not start the engine for 30 minutes after installing
rocker cover.
• Wipe away excessive liquid gasket from cylinder head top
surface.
illf

lliif

NG
- Good

SEM933BA

EM-27 103
 CYLINDER HEAD
Installation (Cont'd)
, Rocker arm 6. Check hydraulic valve lifter.
a. Push hydraulic valve lifter forcefully with your finger.
• Be sure to check it with rocker arm in its free position.
b. If valve lifter moves more than 1 mm (0.04 in), air may be
inside of it.
c. Bleed air off by running engine at 1,000 rpm under no load for
about 20 minutes.
d. If hydraulic valve lifters are still noisy, replace them and bleed
air off again in the same manner as in step c.

SEM275C

7. Install rocker cover.

• Be sure to avoid interference between rocker cover and
rocker arm.
8. Tighten bolts as follows:
a. Tighten two bolts to 3 N·m (0.3 kg·m, 26 in-lb) temporarily in
order shown in figure.

SEM546C

b. Then tighten bolts to 7 to 11 N·m (0. 7 to 1.1 kg-m, 61 to 95

~
@ in-lb) in order shown in figure.
® 9. Install any parts removed.
® 0
0
® ~ ®
"' 0
®
®
@
SEM547C

104 EM-28
 ENGINE REMOVAL

SEC. 112

.
I /
~ 41 . 52 (4.2 . 5.3, 30 . 38)

~1 - 42
I
(3.~ - 4.3, 23 - 31) ~31 - 42 z:
~ 41 - 52 (4.2 - 5.3, 30 - 38)
/
4.3, 2 3 ; )

>"~J I~ -

~~
®' ~- ~
\.- \_~ 31 - 42 (3.2 - 4.3, 23 - 31)
~
AfT model: :
~41 - 52 (4.2 - 5.3, 30 - 38)

MIT model:
~ 68 _ 87 (6.9 . 8.9. 50 _ 64) TI
r-~
l

~ 41 . 52 (4.2 . 5.3, 30 ' 38) __j

~ ' N·m (kg-m, ft-lb)
~ 41 - 52 (4.2 - 5.3, 30 . 38) J
MEM195A

EM-29 105
 ENGINE REMOVAL

WARNING:
• Position vehicle on a flat and solid surface.
• Place chocks at front and back of rear wheels.
• Do not remove engine until exhaust system has com-
pletely cooled off.
Otherwise, you may burn yourself and/or fire may break
out in fuel line.
• Before disconnecting fuel hose, release fuel pressure.
Refer to EC section ("Fuel Pressure Release", "BASIC
SERVICE PROCEDURE").
• Be SIJre to hoist engine and transmission in a safe man-
ner.
• For engines not equipped with engine slingers, attach
proper slingers and bolts described in PARTS CATALOG.
CAUTION:
• When lifting engine, be sure to clear surrounding parts.
Take special care near accelerator wire casing, brake lines
and brake master cylinder.
• In hoisting the engine, always use engine slingers in a
safe manner.
• Before separating engine and transmission, remove the
crankshaft position sensor (OBD) from the assembly.
• Always take extra care not to damage edge of crankshaft
position sensor (OBD) or ring gear teeth.
Removal
1. Drain coolant from engine block and radiator. Refer to MA
section ("Changing Engine Coolant", "ENGINE MAINTE-
NANCE").
2. Release fuel pressure. Refer to EC section ("Fuel Pressure
Release", "BASIC SERVICE PROCEDURE").
3. Remove negative battery cable.
4. Remove hood. Refer to BT section.
5. Remove power steering drive belt, generator drive belt and
NC compressor drive belt
6. Remove radiator. Refer to LC section ("Radiator", "ENGINE
COOLING SYSTEM").
7. Remove exhaust manifold heat shield.
8. Disconnect exhaust system from exhaust manifold.
9. Discharge refrigerant. Refer to HA section ("R-134a Service
Procedure", "SERVICE PROCEDURES").
10. Disconnect refrigerant lines. Refer to HA section ("Refrigerant
Lines", "SERVICE PROCEDURES").
11 . Disconnect accelerator wire, vacuum hoses, electrical
connectors, heater hoses and vacuum booster hose.

106 EM-30
ENGINE REMOVAL
Removal (Cont'd)
12. Remove four power steering pump bolts.
13. Disconnect NT dipstick tube and NT throttle wire. (NT mod-
els only)
14. Remove transmission Refer to MT or AT section ("Removal",
"REMOVAL AND INSTALLATION").

•
15. Remove LH and RH engine mounts.

AEM264

Installation
• Install in reverse order of removal.

EM-31 107
 CYLINDER BLOCK

SEC. 11 0•120•135•150•21 0

Oil filter bracket

Cylinder block
Rear oil seal retainer

-jJjjl] 6.3 - 8.3

(0.64 - 0.85,
55.6 - 73.8)
fl ~ 142- 152 (14.5 . 15.5, 105 . 7112)

Dnve plate _retnforcem~t

Front cover
Otl stratner ...--:-~

.~
-:v•
·~ 0

Drive plate (AfT)

Main bearing

[l ~ 142 - 152
(14.5 - 15.5,
0 105 -]112)
Flywheel
(MIT)

'o ~

~ ~~~ ~
~lii!J6.3
o
- 8.3
0 0
(MIT)
Rear plate

(0.64 - 0.85, 55.6 - 73.8)

f] : Lubricate with new engine oil.

~D•alnplug
~ : Apply liquid gasket.
~ : N•m (kg-m, in-lb)
~ 29 - 39 (3.0 - 4.0, 22 - 29)
~ : N•m (kg-m, ft-lb)

AEM256

108 EM-32
 CYLINDER BLOCK

CAUTION:
• When installing sliding parts (bearings, pistons, etc.),
lubricate contacting surfaces with new engine oil.
• Place removed parts such as bearings and bearing caps
in their proper order and direction.
• When installing connecting rod nuts and main bearing cap
bolts, apply new engine oil to threads and seating sur·
faces.
• Do not allow any magnetic materials to contact the ring
gear teeth of flywheel or drive plate. rse

Disassembly
PISTON AND CRANKSHAFT
1. Place engine on a work stand.
2. Drain coolant and oil.
3. Remove oil pan.
4. Remove timing chain.
5. Remove water pump.
6. Remove cylinder head.
7. Remove pistons with connecting rod.
SEM744

3 B. Remove bearing caps and crankshaft.

~ -.-•< -....._ ~
• Before removing bearing caps, measure crankshaft end
play. Refer to EM-40.
•
• 0
- . 0.
0 Bolts should be loosened in two or three steps .
0 0 0 0 0

0 0 0 0 0

2 Loosen in numerical order. EEM118

Inspection
PISTON AND PISTON PIN CLEARANCE
1. Measure inner diameter of piston pin hole "dp".
Standard diameter "dp":
21.002 - 21.008 mm (0.8268 - 0.8271 in)

AEM023

2. Measure outer diameter of piston pin "Dp".

Standard diameter "Dp":
20.994 - 20.996 mm (0.8265 - 0.8266 in)
3. Calculate piston pin clearance.
dp- Dp = 0.008- 0.012 mm (0.0003- 0.0005 in)
If it exceeds the above value, replace piston assembly with pin. ~IL

Micrometer

AEM024

EM-33 109
 CYLINDER BLOCK
Inspection {Cont'd)
PISTON RING SIDE CLEARANCE
NG Side clearance:
Top ring 0.04- 0.08 mm (0.0016 - 0.0031 in)
2nd ring 0.03 - 0.07 mm (0.0012 - 0.0028 In)
Oil ring 0.065 - 0.135 mm (0.0026 - 0.0053 in)
Max. limit of side clearance:
0.1 mm (0.004 in)
If out of specification, replace piston ring.
If clearance exceeds maximum limit with new ring, replace piston.

SEM249CA

PISTON RING END GAP

End gap:
Top ring
0.28- 0.52 mm (0.0110- 0.0205 in)
2nd ring
0.45 - 0.69 mm (0.0177 - 0.0272 in)
(R or T Is punched on the ring.)
0.55 - 0.70 mm (0.0217- 0.0276 In)
(N is punched on the ring.)
011 ring
0.20 - 0.69 mm (0.0079 - 0.0272 in)
Max. limit of ring gap:
0.5 mm (0.020 In)
If out of specification, replace piston ring. If gap exceeds maximum
limit with a new ring, rebore cylinder and use oversized piston and
piston rings. Refer to SDS, EM-46.
a When replacing the piston, check cylinder block surface for
scratches or seizure. If scratches or seizure are found, hone
or replace the cylinder block.

CONNECTING ROD BEND AND TORSION

Bend:
Limit 0.15 mm (0.0059 in)
per 100 mm (3.94 in) length
Torsion:
limit 0.3 mm (0.012 in)
per 100 mm (3.94 In) length
If it exceeds the limit, replace connecting rod assembly.

SEM003

110 EM-34
 CYLINDER BLOCK
Inspection (Cont'd)
Measuring points CYLINDER BLOCK DISTORTION AND WEAR
1. Clean upper face of cylinder block.
Use a reliable straightedge and feeler gauge to check the flat-
ness of cylinder block surface. Check along six positions
shown in figure.
Limit:
0.1 mm (0.004 in)
2. If out of specification, resurface it.
The limit for cylinder block resurfacing is determined by cylin-
der head resurfacing. ls•Zi
Amount of cylinder head resurfacing is "A"
Amount of cylinder block resurfacing is "B"
The maximum limit is as follows:
A + B = 0.2 mm (0.008 in)
Nominal cylinder block height
from crankshaft center:
246.95- 247.05 mm (9.7224- 9.7264 in)
3. If necessary, replace cylinder block.

PISTON-TO-BORE CLEARANCE
1. Using a bore gauge, measure cylinder bore for wear, out-of-
round and taper. Tl"

tt
Standard inner diameter:
' '
! Refer to SDS, EM-42.
f-A- Wear limit: 0.2 mm (0.008 in) ~'[)
'-XY Out-of-round (X-V) standard: 0.015 mm (0.0006 in)
I Taper (A- B) standard: O.o15 mm (0.0006 in)
--s
If it exceeds the limit, rebore all cylinders. Replace cylinder :")\
Unit: mm (in) block if necessary.
SEM040 2. Check for scratches and seizure. If seizure is found, hone it.

Piston grade number

• If cylinder block and piston are replaced, match piston
grade with grade number on cylinder block upper surface.
I
I I\
,-------,L\,"-'r'c--------.

Front
cbcov
X X X

SEM257C

3. Measure piston skirt diameter.

Piston diameter "A":
Refer to SDS, EM-46.
Measuring point "a" (Distance from the top):
Approximately 52 mm (2.05 in)
4. Check that piston-to-bore clearance is within specification.
Piston-to-bore clearance "B":
0.020 - 0.040 mm (0.0008 - 0.0016 in)
' 5. Determine piston oversize according to amount of cylinder
wear.
Oversize pistons are available for service. Refer to SDS,
EM-46.
EM-35 111
 CYLINDER BLOCK
Inspection (Cont'd)
6.
Cylinder bore size is determined by adding piston-to-bore
clearance to piston diameter "A".
Rebored size calculation:
D=A+B-C
where,
D: Bored diameter
A: Piston diameter as measured
B: Piston-to-bore clearance
C: Honing allowance 0.02 mm (0.0008 in)
7. Install main bearing caps and tighten bolts to the specified
torque. This will prevent distortion of cylinder bores.
8. Cut cylinder bores.
• When any cylinder needs boring, all other cylinders must
also be bored.
• Do not cut too much out of cylinder bore at a time. Cut
only 0.05 mm (0.0020 in) or so at a time.
9. Hone cylinders to obtain specified piston-to-bore clearance.
10. Measure finished cylinder bore for out-of-round and taper.
• Measurement should be done after cylinder bore cools
down.

A B CRANKSHAFT
1. Check crankshaft main and pin journals for score, wear or
cracks.
x 2. With a micrometer, measure journals for taper and out-of-
round.
Out-of-round (X - Y):
y Main journal Less than 0.01 mm (0.0004 in)
Crank pin Less than 0.005 mm (0.0002 in)
Taper: A- B Taper (A - B):
Out-of-round: X- Y Main journal Less than 0.01 mm (0.0004 in)
SEM 316 A Crank pin Less than 0.005 mm (0.0002 in)
~=========~~ 3. Measure crankshaft runout.
Runout (Total indicator reading):
Less than 0.10 mm (0.0039 in)

cf';\ BEARING CLEARANCE

~~
• Use Method A or Method B. Method A is preferred because it
is more accurate.
~,~No.5 Method A (Using bore gauge and micrometer)
~~No4 Main bearing
1. Set main bearings in their proper positions on cylinder block
~~No.3 and main bearing cap.
c2 ~ No.2

Front No. 1
SEM448C

112 EM-36
 CYLINDER BLOCK
Inspection (Cont'd)
2. Install main bearing cap to cylinder block.
• Tighten all bolts in correct order in two or three stages.
3. Measure inner diameter "A" of each main bearing .

•
4. Measure outer diameter "Dm" of each crankshaft main journal. !'i©
5. Calculate main bearing clearance.
Main bearing clearance = A - Dm
Standard: f'l'
0.020 - 0.047 mm (0.0008 - 0.0019 in)
Limit:
0.1 mm {0.004 in) ©r~
6. If it exceeds the limit, replace bearing.
7. If clearance cannot be adjusted within the standard of any
bearing, grind crankshaft journal and use undersized bearing. lit1i'

J\1]'
a. When grinding crankshaft journal, confirm that "L" dimen-
sion in fillet roll is more than the specified limit.
"L": 0.1 mm (0.004 in)
11!'
b. Refer to SDS for grinding crankshaft and available service

"//117'
II 1m
,
parts.

(~Tk"U
U)
~r'v
\\
1
OJ
"' 1)
\

SEM964

8. If crankshaft is reused, measure main bearing clearance and ll'P~

select thickness of main bearing.
0
0
If crankshaft or cylinder block is replaced, select thickness of '~''''
0
main bearings as follows: p,c,
0 0 0 a. Grade number of each cylinder block main journal is punched
¢::1 on the respective cylinder block. These numbers are punched il!l,"
Front 0 0 in either Arabic or Roman numerals. ~
0

Journal grade number EEM120

[~7
Crank mam\ b. Grade number of each crankshaft main journal is punched on
JOurnal grade \ __ crankshaft. These numbers are punched in either Arabic or
numbec (\:~~ Rornan numerals.
11ii\
c. Select main bearing with suitable thickness according to the

No
-v!r«f&\?
1_/~\~)~No 5
following example or table.
For example:
Main journal grade number: 1
Crankshaft journal grade number: 2
(-1
1-\
L:::i:P-j
if J
r Main bearing grade number = 1 + 2
= 3 (Yellow)
"~~- 10 SEM272C

EM-37 113
 CYLINDER BLOCK
Inspection (Cont'd)
Main bearing grade number and identification color:
Main journal grade number

0 1 2

0 0 (Black) 1 (Brown) 2 (Green)

Crankshaft
journal grade 1 or I 1 (Brown) 2 (Green) 3 (Yellow)
number
2 or II 2 (Green) 3 (Yellow) 4 (Blue)

Connecting rod bearing (Big end)

1. Install connecting rod bearing to connecting rod and cap.
2. Install connecting rod cap to connecting rod.
• Tighten bolts to the specified torque.
3. Measure inner diameter "C" of each bearing.

AEM027

4. Measure outer diameter "Dp"' of each crankshaft pin journal.

5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance = C - Dp:
Standard
0.010- 0.035 mm (0.0004- 0.0014 in)
limit
0.09 mm (0.0035 in)
6. If it exceeds the limit, replace bearing.
7. If clearance cannot be adjusted within the standard of any
bearing, grind crankshaft journal and use undersized bearing.
Refer to step 7 of "BEARING CLEARANCE- Main bearing".

8. If crankshaft is replaced, select connecting rod bearing accord-

ing to the following table.
Connecting rod bearing grade number:
These numbers are punched in either Arabic or Roman numerals.
Connecting rod bearing
Crank pin grade number
grade number
0 0
1 or I
2 or II 2

Method B (Using plastigage)

CAUTION:
• Do not turn crankshaft or connecting rod while plastigage
is being inserted.
• When bearing clearance exceeds the specified limit,
ensure that the proper bearing has been installed. Then if
excessive bearing clearance exists, use a thicker main
bearing or undersized bearing so that the specified bear-
ing clearance is obtained.

114 EM-38
 CYLINDER BLOCK
Inspection (Cont'd)
CONNECTING ROD BUSHING CLEARANCE (Small end)
1. Measure inner diameter "C" of bushing.
2. Measure outer diameter "Dp" of piston pin.
3. Calculate connecting rod bushing clearance.
C-Dp= •
-0.015 to -0.033 mm (-0.0006 to -0.0013 in) (Stan-
dard)
If out of specification, replace connecting rod assembly and/or
piston set with pin.
Micr~meter
SEM245E

FLYWHEELJDRIVE PLATE RUNOUT

Runout (Total indicator reading):
Dial gauge Flywheel (MIT model)
Less than 0.1 mm (0.004 in)
Drive plate (AfT model)
Less than 0.1 mm (0.004 in)
CAUTION:
• Be careful not to damage the ring gear teeth.
• Check the drive plate for deformation and cracks.
• Do not allow any magnetic materials to contact the ring liu'J'
gear teeth.
AEM100
• Do not resurface the flywheel. Replace as necessary.
Assembly
Front mark PISTON
Piston grade number 'j I~
1. Heat piston to 60 to 70°C (140 to 158°F) and assemble piston,
piston pin and connecting rod.
• Align the direction of piston and connecting rod. y;,Lj
• Numbers stamped on connecting rod and cap correspond
to each cylinder.
• After assembly, make sure connecting rod swings
smoothly.
Cylinder number
SEM262C

KV10110300
I - I

SEM21SE

Punchmark side 2. Set piston rings as shown.

up if present CAUTION:
• When piston rings are not replaced, make sure that piston
rings are mounted in their original positions.
• When piston rings are being replaced and no punchmark
is present, piston rings can be mounted with either side l~[b
up.

SEM264C

EM-39 115
 CYLINDER BLOCK
Assembly (Cont'd)
Oil ring
• Top ring 3. Align piston rings so that end gaps are positioned as shown.
expander ~ ~ • Oil ring
If'
1/ ------~
upper rail

Engine
front

¢::J
\; II
2ndringfl~
./') Oil ring
/ ... lower rail
SEM160B

CRANKSHAFT
1. Set main bearings in their proper positions on cylinder block
and main bearing beam.
• Confirm that correct main bearings are used. Refer to
EM-36.
• Apply new engine oil to bearing surfaces.

2. Install crankshaft and main bearing beam and tighten bolts to

the specified torque.
• Apply new engine oil to the bolt threads and seat surface.
• Prior to tightening bearing cap bolts, place bearing cap in
its proper position by shifting crankshaft in the axial direc-
tion.
• Tighten bearing cap bolts gradually in two or three stages.
Start with center bearing and move outward as shown in
figure.
• After securing bearing cap bolts, make sure crankshaft
turns smoothly by hand.

3. Measure crankshaft end play.

Crankshaft end play:
Standard
0.05 · 0.18 mm (0.0020- 0.0071 in)
Limit
0.3 mm (0.012 in)
If beyond the limit, replace bearing with a new one.

4. Install connecting rod bearings in connecting rods and con·

necting rod caps.
• Confirm that correct bearings are used .
Refer to EM-38.
• Install bearings so that oil hole in connecting rod aligns
with oil hole of bearing.
• Apply new engine oil to bearing surfaces, bolt threads and
seating surfaces.

116 EM-40
 CYLINDER BLOCK
Assembly (Cont'd)
5. Install pistons with connecting rods.
a. Install them into corresponding cylinders with Tool.
• Arrange so that front mark on piston head faces toward
front of engine.
• Make sure connecting rod does not scratch cylinder wall.
• Make sure connecting rod bolts do not scratch crankshaft
journals.
• Apply new engine oil to piston rings and sliding surface
of piston.

b. Install connecting rod bearing caps.

Tighten connecting rod bearing cap nuts using the following
procedure.
Connecting rod bearing nut:
(1) Tighten to 14 to 16 N·m
(1.4 to 1.6 kg-m, 10 to 12 11-lb).
(2) Tighten bolts so:~ degrees clockwise
with an angle wrench.
If an angle wrench is not available, tighten
them to 38 to 44 N·m (3.9 to 4.5 kg-m, 28 to 33
fl-lb).

6. Measure connecting rod side clearance.

Connecting rod side clearance:
Standard
0.2- 0.4 mm (0.008- 0.016 in)
Limit
0.6 mm (0.024 in)
If beyond the limit, replace connecting rod and/or crankshaft.

EEM124

REPLACING PILOT BUSHING

ST16610001 1. Remove pilot bushing (MIT) or pilot convertor (A/T).
(J23907)
or suitable tool

2. Install pilot bushing (MIT) or pilot convertor (A/T).

Crankshaft side

MIT AfT
SEM163B

EM-41 117
 SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications
Unit· kPa (kg/cm 2 psi)/rpm
Cylinder arrangement 4, in-line
Compression pressure
Displacement cm 3 (cu in) 2,389 (145.78)
Standard 1,324 {13.5, 192)/300
Bore x stroke mm (in) 89 X 96 (3.50 X 3.78)
Minimum 981 (10, 142)/300
Valve arrangement OHC
Differential limit between cylin-
Firing order 1-3-4-2 98 (1.0, 14)/300
ders
Number of piston rings

Compression 2

Oil 1

Number of main bearings 5

Compression ratio 8.6

Inspection and Adjustment

CYLINDER BLOCK

60 (2.36)

120 (4.72)[

I IH
~\I
SEM400E

Unit: mm (in)

Standard Limit

Distortion - 0.1 (0.004)

Grade 1 89.000- 89.010 (3.5039- 3.5043)

Inner diameter Grade 2 89.010-89.020 (3.5043- 3.5047) 0.2 (0.008)'

Cylinder bore Grade 3 89.020-89.030 (3.5047- 3.5051)

Out-of-round (X- Y) Less than 0.015 (0.0006) -

Taper (A- B) Less than 0.015 (0.0006) -

Difference in inner diameter between cylinders Less than 0.05 (0.0020) 0.2 (0.008)

Piston-to-cylinder clearance 0.020- 0.040 (0.0008- 0.0016) -

Cylinder block height

246.95- 247.05 (9.7224- 9.7264) 0.2 (0.008) ..
(From crankshaft center)
. Wear hm1t
** Total amount of cylinder head resurfacing and cylinder block resurfacing

CYLINDER HEAD
Unit· mm (in)

Standard Limit

98.8- 99.0
Height (H) 0.2 (0.008)"
(3.890 - 3.898)

Surface distortion 0.03 (0.0012) 0.1 (0.004)

. Total amount of cylinder head resurfacing and cylinder block resurfac
ing

118 EM-42
 SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont'd)
VALVE GUIDE

f--- --
~ D

SEM401E

Unit· mm (in)

Standard Service Limit

Intake Exhaust Intake Exhaust -

Length (L) 52.6 (2.071 1 56.0 (2.2051 52.6 (2.071 1 56.0 (2.2051 -
11.023. 11.034 12.023- 12.034 11 .223 - 11.234 12.223- 12.234
Outer diameter {D) -
(0.4340- 0.43441 (0.4733- 0.47381 (0.4418- 0.44231 (0.4812- 0.48171
Inner diameter (d) 7.000- 7.018 8.000 - 8.018 7.000- 7.018 8.000- 8.018
-
(Finished size) (0.2756 - 0.2763) {0.3150- 0.3157) (0.2756 - 0.2763) (0.3150- 0.3157)
10.975 - 10.996 11.975-11.996 11.175- 11.196 12.175-12.196
Cylinder head hole diameter -
(0.4321 - 0.4329) (0.4715- 0.4723) (0.4400 - 0.4408) (0.4793 - 0.4802)

Interference fit 0.027- 0.059 {0.0011 - 0.0023) -

0.020 - 0.053 0.040 - 0.070 0.020 - 0.053 0.040 - 0.070
Stem to guide clearance 0.1 (0.0041
(0.0008 - 0.0021) (0.0016 - 0.0028) (0.0008 - 0.0021) (0.0016 - 0.0028)

Tapping length ( f') 14.9- 15.1 (0.587- 0.594)

VALVE SEAT

Standard Service

!
~~" "
I f---------0, - - - - - - j
o,
SEM402E
Unit mm (in)

Standard Service

Intake Exhaust Intake Exhaust

Cylinder head seat recess 36.000- 36.016 42.000 - 42.016 36.500- 36.516 42.500- 42.516
diameter (1.4173- 1.4179) (1.6535 - 1.65421 (1.4370- 1.43761 (1.6732 - 1.67391
Valve seat outer diameter 36.080 - 36.096 42.080 - 42.096 36.580 - 36.596 42.580 - 42.596
(D,I (1.4205 - 1.4211) (1.6567 - 1.6573) (1.4402 - 1.4408) (1.6764 - 1.6770)
Face angle (a) 45" 45" 45" 45"
Contacting width (W) 1.6 - 1.7 (0.063 - 0.0671 1.7-2.1 (0.067- 0.083) 1.6- 1.7 (0.063- 0.067) 1.7-2.1 (0.067- 0.083)

EM-43 119
 SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont'd)
VALVE

T (Margin thickness)

--rt
r~\. D :=c:=fJctC::=r:::I:j
i------L----1
SEM188A

Unit mm (in)

Standard Limit

33.95 • 34.25
ln. -
(1.3366 - 1.3484)
Valve head diameter (D)
40.0-40.2
Ex.
(1.575 - 1.583)
-

119.9- 120.2
ln.
(4.720- 4.732)
-
Valve length (L)
120.67 - 120.97
Ex.
(4.7508- 4.7626) -
6.965 - 6.980
ln.
(0.2742- 0.2748)
-
Valve stem diameter (d)
7.948- 7.960
Ex.
(0.3129- 0.3134)
-

ln. 45°30' -
Valve face angle (u)
Ex. 45°30' -
1.15- 1.45
ln.
(0.0453- 0.0571)
Valve head margin (T) 0.5 (0.020)
1.35- 1.65
Ex.
(0.0531 - 0.0650)
Valve clearance 0 (0)

VALVE SPRING
Unit mm (in)

Standard Limit

Intake Exhaust Intake Exhaust

Outer 57.44 (2.2614) 53.21 (2.0949) - -

Free height (H)
Inner 53.34 (2. 1000) 47.95 (1.8878) - -
604.1 (61.6, 135.8) 640.4 (65.3, 144.0) 567.8 (57.9, 127.7) 620.8 (63.3, 139.6)
Outer
Pressure a1 37.6 (1.480) at 34.1 {1.343) at 37.6 {1.480) at 34.1 (1.343)
N (kg, lb) at height 284.4 (29.0, 63.9) 328.5 (33.5, 73.9) 266.8 (27.2, 60.0) 318.7 (32.5, 71.7)
Inner
at 32.6 (1.283) at 29.1 (1.146) at 32.6 (1.283) at 29.1 (1.146)
Outer - - 2.5 (0.098) 2.3 (0.091)
Out-of-square
Inner - - 2.3 (0.091) 2.1 (0.083)

120 EM-44
 SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont'd)
CAMSHAFT AND CAMSHAFT BEARING

A/\
\IJ Q
I
r-
~

~
r-
'---..,

-
r---'
D
•
IL©

BDC

SEM568A EM120

Unit mm (in) ©b
Standard Limit

Cam height (A) 44.43-44.58 (1.7492- 1.7551) -

Valve lift (h) 9.7 (0.382) -
Wear limit of cam height - 0.2 (0.008)

Camshaft journal to bearing clearance 0.045- 0.090 {0.0018- 0.0035) 0.12 (0.0047)
Inner diameter of camshaft bearing 33.000 - 33.025 (1.2992 - 1.3002) -
Outer diameter of camshaft journal (D) 32.935 - 32.955 {1.2967 - 1.2974) -
Camshaft runout 0 - 0.02 (0 - 0.0008) -
Camshaft end play 0.07-0.15 (0.0028- 0.0059) 0.2 (0.008)
a 232 -
b 232 -

Valve timing (Degree on crankshaft)

c -5 -
d 57 -

e 11 -
f 41 -

ROCKER ARM AND ROCKER SHAFT

Unit· mm (in)

Rocker arm to shaft clearance 0.012- 0.050 {0.0005- 0.0020)

21.979 - 22.000
Rocker shaft diameter
(0.8653 - 0.8661 I
Rocker arm rocker shaft hole 22.012- 22.029
diameter (0.8666 - 0.8673)

EM-45 121
 SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont'd)
PISTON, PISTON RING AND PISTON PIN Piston ring
Unit mm (in)
Piston
Standard Limit

0.040 - 0.080
Top 0,1 (0,004)
(0,0016- 0,0031)

Side clear- 0.030 - 0.070

2nd 0_1 (0,004)
d
1 a nee (0.0012 - 0.0028)
I f
0.065 - 0.135
Oil 0,1 (0,004)
(0,0026 - 0_0053)'
a '/ t1\ Top
0.28- 0.52
0-5 (0,020)
--- (0,011 0 - 0_0205)

0.45 - 0.69
~ ~ Ring gap 2nd
(0.0177- 0.0272)
0-5 (0,020)
A
Oil 0.20 - 0.69
0-5 (0,020)
(rail ring) (0.0079 - 0.0272)
SEM444C
*: R1ken-make
Unit· mm (in)

Grade No. 1
88.970 - 88.980 CONNECTING ROD
(35027' 3_5031)

88.980 - 88.990
Standard Grade No.2
(3.5031 - 3.5035)
Piston skirt 88.990 - 89.000
Grade No.3
diameter (A) (35035 - 3,5039)

89.470 - 89.500
05 (0,020)
Service (3,5224 - 35236)
{Oversize) 89.970 - 90.000
1,0 (0,039)
(35421 - 3,5433)

Dimension (a) Approximately 52 (2.05)

Piston pin hole diameter (d)

21.002 - 21.008
(0,8268 - 0_8271 I
~-----5----~~~
Piston-to-cylinder bore clearance 0.020 - 0,040 (0,0008 - 0,0016)

SEM216E
Piston pin Unit· mm (in)
Unit· mm (in)
Standard Limit
Standard
164.95- 165.05
20.994 - 20.996 Center distance (S) -
(6_4941 - 6-4980)
Piston pin outer diameter
(0,8265 - 0_8266)
Bend
0,008 - 0,012 [per 100 mm (3.94 in)]
- 0.15 (0.0059)
Pin to piston pin hole clearance
(0.0003 - 0.0005)
Torsion
Piston pin to connecting rod -0.015 to -0.033
- 0,3 (0,012)
[per 100 mm (3.94 in)]
clearance (-0.0006 to -0.0013)
20.948 - 20.978
Small end inner diameter (d) -
(0,8247 - 0,8259)

Connecting rod big end inner 53.000 - 53.013

-
diameter {D) (2.0866 - 2.0871)

0.2- 0.4
Side clearance 0_6 (0,024)
(0,008 - 0,016)

122 EM-46
 SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont'd)
~~u
CRANKSHAFT

out-of-cound (x)- (J)

Tapec @-@
® ®

~
Dp
~
SEM394
EM715

Unit: mm (in) ©\L

No.O 59.967 - 59.975 (2.3609 - 2.3612)
Main journal diameter (Om) Grade No. 1 59.959 - 59.967 (2.3606 - 2.3609)

No.2 59.951 - 59.959 (2.3603 - 2.3606)

No. 0 49.968 - 49.974 (1.9672 - 1.9675)

Pin journal diameter (Dp) Grade No.1 49.962 - 49.968 (1.9670 - 1.9672)

No.2 49.956 - 49 962 (1.9668 - 1.9670)

Center distance (r) 47.95 - 48.05 (1.8878 - 1.8917}

Standard Limit

Journal - 0.01 (0.0004)

Taper of journal and pin [@ - @J
Pin - 0.005 (0.0002)

Out-of-round of journal and pin Journal - 0.01 (0.0004)

I@- ®1 Pin - 0.005 (0.0002)

Runout [TIR]* - 0.10 (0.0039)

Free end play 0.05-0.18 {0.0020- 0.0071) 0.3 (0.012)

Fillet roil More than 0.1 (0.004)

.Total 1nd1cator reading
BEARING CLEARANCE
Unit· mm (in)

Standard Limit

0.020 - 0.047
Main bearing clearance 0.1 (0.004)
(0.0008 - 0.0019)

Connecting rod bearing 0.010 - 0.035

0.09 (0.0035)
clearance (0.0004 - 0.0014)

EM-47 123
 SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont'd)
AVAILABLE MAIN BEARING AVAILABLE CONNECTING ROD BEARING
Standard Standard
Grade Thickness Identification Grade Thickness Identification
number mm (in) color number mm {in) color

1.821 - 1.825 1.505 - 1.508

0 Black 0
(0.0717 - 0.0719) (0.0593- 0.0594)
1.825 • 1.829 1.508-1.511
Brown Brown
(0.0719 - 0.0720) {0.0594 - 0.0595)

1.829 - 1.833 1.511-1.514

2 Green 2 Green
(0.0720 - 0.0722) (0.0595 - 0.0596)
1.833 - 1.837
3 Yellow
(0.0722 - 0.0723)
1.837- 1.841
4
(0.0723 - 0.0725)
Blue Undersize (service)
Unit· mm (in)

Crank pin journal

Thickness
diameter "Dp"
Undersize (service) 1.540 - 1.548
Unit' mm (in)
o.o8 [o.oo31 1
(0.0606 - 0.0609)
Grind so that bearing
Main journal 1 .560 - 1.568
Thickness 0.12 (0.0047) clearance is the
diameter "Dm" {0.0614- 0.0617)
specified value.
Grind so that bearing 1.625 - 1.633
0.25 1.952 - 1.960 0.25 (0.0098)
clearance is the (0.0640 - 0.0643)
(0.0098) (0.0769 - 0.0772)
specified value.

MISCELLANEOUS COMPONENTS
Unit· mm (in)

Camshaft sprocket runout

Less than 0.12 (0.0047)
[TIR]'

Flywheel runout [TIR]• Less than 0.1 (0.004)

Drive plate runout [TIR]* Less than 0.1 (0.004)

*Total 1nd1cator read1ng

124 EM-48
 GENERAL INFORMATION

SECTION Gl
CONTENTS
PRECAUTIONS ............................................................ 2 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR
Precautions for Supplemental Restraint System AN ELECTRICAL INCIDENT ................................... ..... 18
(SRS) "AIR BAG" ........................................................ 2 Work Flow .............................. .. ............. 18 !;IL,
General Precautions ................ ................. ................. 3 Incident Simulation Tests ........................................... 19
Precautions lor Engine Oils ......................................... 5 Circuit Inspection ....................................................... 23
Precautions for Multipart Fuel Injection System lntroduction ............................................................23
or ECCS Engine ..........................................................6 Testing For "Opens" In The Circuit.. .................... 24
Precautions for Three Way Catalyst......... .......... 6 Testing For "Shorts" In The Circuit.. .................... 25
Precautions for Fuel ........ ........................ ................. 6 Ground Inspection.................. .............. 26 ~1
Precautions for Air Conditioning .................................. 6 Voltage Drop Tests ................................................ 27
HOW TO USE THIS MANUAL ...................................... ? HOW TO FOLLOW FLOW CHART IN TROUBLE
1~
HOW TO READ WIRING DIAGRAMS ............................ 9 DIAGNOSES .................................................................. 30
Sample/Wiring Diagram - EXAMPL - ..................... 9 CONSULT CHECKING SYSTEM .................................. 33
Description ................................................................. 11 IDENTIFICATION INFORMATION ................................. 34 [Cl!J
Connector Symbols........... . ......................... 13 Model Variation .........................................................34
Switch Positions .................................................... 14 Identification Number ................................................. 36
Detectable Lines And Non-Detectable Lines ........ 15 Dimensions ................................................................38 (F~
Multiple Switch ...................................................... 15 Wheels & Tires ..........................................................38
Foldout Page ....................................................... 16 LIFTING POINTS AND TOW TRUCK TOWING ........... 39
Wiring Diagram Codes (Cell Codes) ........................ 17 P I
M~~ hJk OC .................................... . 39 [W,\
Screw Jack ................................................................ 39
Garage Jack and Safety Stand ............................... ..40
2-pole Lift ................................................................. .A 1
Tow Truck Towing .................................................... ..42
Towing Point ............................................................. .43 'il11'
TIGHTENING TORQUE OF STANDARD BOLTS ..... ..44
SAE J1930 TERMINOLOGY LIST ............................ .. ..45

5
 PRECAUTIONS

Observe the following precautions to ensure safe and proper

servicing.

Precautions for Supplemental Restraint System

(SRS) "AIR BAG"
The Supplemental Restraint System "Air Bag", used along with a
seat belt, helps to reduce the risk or severity of injury to the driver
in a frontal collision. The Supplemental Restraint System consists
of an air bag module (located in the center of the steering wheel),
a diagnosis sensor unit, warning larnp, wiring harness, a crash
zone sensor (4WD rnodels) and spiral cable. Information necessary
to service the system safely is included in the RS section of this
Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could
increase the risk of personal injury or death in the event
of a collision which would result in air bag inflation, all
maintenance must be performed by an authorized NISSAN
dealer.
• Improper maintenance, including incorrect removal and
installation of the SRS, can lead to personal injury caused
by unintentional activation of the system.
• Do not use electrical test equipment on any circuit related
to the SRS unless instructed to in this Service Manual.
SRS wiring harnesses are covered with yellow insulation
either just before the harness connectors or for the com-
plete harness, for easy identification.

6 Gl-2
 PRECAUTIONS

General Precautions
• Do not operate the engine for an extended period of time
without proper exhaust ventilation.
Keep the work area well ventilated and free of any inflammable
materials. Special care should be taken when handling any
inflammable or poisonous materials, such as gasoline, refrig- if'il!~
erant gas, etc. When working in a pit or other enclosed area,
be sure to properly ventilate the area before working with haz-
ardous materials.
Do not smoke while working on the vehicle.
SGI285

• Before jacking up the vehicle, apply wheel chocks or other tire ~·:;;
blocks to the wheels to prevent the vehicle from moving. After
jacking up the vehicle, support the vehicle weight with safety
stands at the points designated for proper lilting before work- .P~
ing on the vehicle.
These operations should be done on a level surface.
• When removing a heavy component such as the engine or !;~
transaxle/transmission, be careful not to lose your balance and
drop them. Also, do not allow them to strike adjacent parts,
especially the brake tubes and master cylinder. IT~~T

• Before starting repairs which do not require battery power:

Turn off ignition switch.
Disconnect the negative battery terminal.

SEF289H

• To prevent serious burns:

Avoid contact with hot metal parts.
Do not remove the radiator cap when the engine is hot.

SGI233

• Before servicing the vehicle:

Protect fenders, upholstery and carpeting with appropriate cov-
ers. ~ffii
Take caution that keys, buckles or buttons do not scratch paint.

SGI234

Gl-3 7
 PRECAUTIONS
General Precautions (Cont'd)
• Clean all disassembled parts in the designated liquid or solvent
prior to inspection or assembly.
• Replace oil seals, gaskets, packings, 0-rings, locking washers,
cotter pins, self-locking nuts, etc. with new ones.
• Replace inner and outer races of tapered roller bearings and
needle bearings as a set.
• Arrange the disassembled parts in accordance with their
assembled locations and sequence.
• Do not touch the terminals of electrical components which use
microcomputers (such as ECMs).
Static electricity may damage internal electronic components.
• After disconnecting vacuum or air hoses, attach a tag to indi-
cate the proper connection.
• Use only the fluids and lubricants specified in this manual.
• Use approved bonding agent, sealants or their equivalents
when required.
• Use tools and recommended special tools where specified for
safe and efficient service repairs.
• When repairing the fuel, oil, water, vacuum or exhaust
systems, check all affected lines for leaks.
• Dispose of drained oil or the solvent used for cleaning parts in
an appropriate manner.
WARNING:
To prevent ECM from storing the diagnostic trouble codes, do
not carelessly disconnect the harness connectors which are
related to the ECCS and AfT control system. The connectors
should be disconnected only when working according to the
WORK FLOW of TROUBLE DIAGNOSES in EC and AT sec-
tions.

8 Gl-4
 PRECAUTIONS

Precautions for Engine Oils

Prolonged and repeated contact with used engine oil may cause
skin cancer. Try to avoid direct skin contact with used oil.
If skin contact is made, wash thoroughly with soap or hand cleaner
as soon as possible.

HEALTH PROTECTION PRECAUTIONS

• Avoid prolonged and repeated contact with oils, particularly
used engine oils. lb©
• Wear protective clothing, including impervious gloves where
practicable.
• Do not put oily rags in pockets. ~©
• Avoid contaminating clothes, particularly underclothing, with
oil.
• Heavily soiled clothing and oil-impregnated footwear should :p~
not be worn. Overalls must be cleaned regularly.
• First Aid treatment should be obtained immediately for open
cuts and wounds. !;;[b
• Use barrier creams, applying them before each work period, to
help the removal of oil from the skin.
• Wash with soap and water to ensure all oil is removed (skin I:TI!i'
cleansers and nail brushes will help). Preparations containing
lanolin replace the natural skin oils which have been removed.
• Do not use gasoline, kerosene, diesel fuel, gas oil, thinners or lkl
solvents for cleaning skin.
• If skin disorders develop, obtain medical advice without delay.
• Where practicable, degrease components prior to handling. lilP
• Where there is a risk of eye contact, eye protection should be
worn, for example, chemical goggles or face shields; in
addition, an eye wash facility should be provided. [~[ij:

ENVIRONMENTAL PROTECTION PRECAUTIONS

Burning used engine oil in small space heaters or boilers can be 1'5',
recommended only for units of approved design. The heating sys-
tem must meet the requirements of HM Inspectorate of Pollution for
small burners of less than 0.4 MW. If in doubt, check with the ~~.i~c
appropriate local authority and/or manufacturer of the approved
appliance.
Dispose of used oil and used oil filters through authorized waste ~~~~
disposal contractors to licensed waste disposal sites, or to the
waste oil reclamation trade. If in doubt, contact the local authority
for advice on disposal facilities. @]
It is illegal to pour used oil on the ground, down sewers or drains,
or into water courses.
The regulations concerning the pollution of the environment l"!!l
will vary between regions.

Gl-5 9
 PRECAUTIONS

Precautions for Multiport Fuel Injection System

or ECCS Engine
• Before connecting or disconnecting any harness connector for
the multi port fuel injection system or ECM (ECCS control mod-
ule):
Turn ignition switch to OFF position.
Disconnect negative battery terminal.
Otherwise, there may be damage to ECM.
• Before disconnecting pressurized fuel line from fuel pump to
injectors, be sure to release fuel pressure.
• Be careful not to jar components such as ECM and mass air
flow sensor.

Precautions for Three Way Catalyst

If a large amount of unburned fuel flows into the catalyst, the cata-
lyst temperature will be excessively high. To prevent this, follow the
instructions below:
• Use unleaded gasoline only. Leaded gasoline will seriously
damage the three way catalyst.
• When checking for ignition spark or measuring engine
compression, make tests quickly and only when necessary.
• Do not run engine when the fuel tank level is low, otherwise the
engine may misfire, causing damage to the catalyst.

Do not place the vehicle on inflammable material. Keep inflam-

mable material off the exhaust pipe and the three way catalyst.

Precautions for Fuel

Use unleaded gasoline with an octane rating of at least 87 AKI
(Anti-Knock Index) number (research octane number 91 ).
CAUTION:
Do not use leaded gasoline. Using leaded gasoline will dam-
age the three way catalyst.
Using a fuel other than that specified could adversely affect
the emission control devices and systems, and could also
affect warranty coverage.

Precautions for Air Conditioning

Use an approved refrigerant recovery unit any time the air condi-
tioning system must be discharged. Refer to HA section ("R-134a
Service Procedure", "SERVICE PROCEDURES") for specific
instructions.

10 Gl-6
 HOW TO USE THIS MANUAL

• AN ALPHABETICAL INDEX is provided at the end of this manual so that you can rapidly find the item
and page you are searching for.
• A QUICK REFERENCE INDEX, a black tab (e.g., 1:1;1 ) is provided on the first page. You can quickly find
the first page of each section by mating it to the section's black tab. i!iiffi1
• THE CONTENTS are listed on the first page of each section.
• THE TITLE is indicated on the upper portion of each page and shows the part or system.
• THE PAGE NUMBER of each section consists of two letters which designate the particular section and a ll!ml
number (e.g., "BR-5"').
• THE LARGE ILLUSTRATIONS are exploded views (see below) and contain tightening torques, lubrica-
tion points, section number of the PARTS CATALOG (e.g., SEC.440) and other information necessary to ~©
perform repairs.
The illustrations should be used in reference to service matters only. When ordering parts, refer to the
appropriate PARTS CATALOG. ~©

"Example"
SEC. 440
Pad retainer
(Upper side) [11,

Torque
member

SBR364AC

• THE SMALL ILLUSTRATIONS show the important steps such as inspection, use of special tools, knacks ©11
of work and hidden or tricky steps which are not shown in the previous large illustrations.
Assembly, inspection and adjustment procedures for the complicated units such as the automatic transaxle
or transmission, etc. are presented in a step-by-step format where necessary.

Gl-7 11
 HOW TO USE THIS MANUAL

• The following SYMBOLS AND ABBREVIATIONS are used:

• The UNITS given in this manual are primarily expressed as the Sl UNIT (International System of Unit),
and alternatively expressed in the metric system and in the yard/pound system.
"Example"
Tightening torque:
59 - 78 N·m (6.0 - 8.0 kg-m, 43 - 58 ft-lb)
• TROUBLE DIAGNOSES are included in sections dealing with complicated components.
• SERVICE DATA AND SPECIFICATIONS are contained at the end of each section for quick reference of
data.
• The captions WARNING and CAUTION warn you of steps that must be followed to prevent personal injury
and/or damage to some part of the vehicle.
WARNING indicates the possibility of personal injury if instructions are not followed.
CAUTION indicates the possibility of component damage if instructions are not followed.
BOLD TYPED STATEMENTS except WARNING and CAUTION give you helpful information.

12 Gl-8
 HOW TO READ WIRING DIAGRAMS

Sample/Wiring Diagram - EXAMPL -

• For Description, refer to Gl-11.

POWER POSITION POSITION SIGNAL

A B

A GND GND
ffi ~~!did~
MOTOR
CONTROL

I•· I•ji9•·
MODULE @TI)

~A5
<k> : ~----------------· ·~~------·•
@
AfT models
: MIT models
._.
B B B

r-,-~-.-~--;~;-~-v
Refer to last page (Foldout page).
@).@)
i~-~;----ru--~-~------: Ci:ID
: 23 r=:t._ I
1 5678 B 23 B Lf...l.l.J @])
I

L--------------------! : 25
I I 24
:<W
I

dnJ @) <:fib Ci:ID G!D @9) 1------- D-!QIQJ-0

I
I •·-a -J; --------' I
:
B GY

crmv@ID GY

AGI064

Gl-9 13
 HOW TO READ WIRING DIAGRAMS
Sample/Wiring Diagram - EXAMPL - (Cont'd)
OPTIONAL SPLICE

Optional splice

Mrr models AfT models

10A 10A
~ ~
L G/R

L-·I
L

I I
~ ·-GIR~ ~L-·I
I I CID
L @ GIR L
~@
1rh-~~-1rtu 1~1@
'-r'@'io-'
L GIA L

0 ~l ~
RELAY

aiD
lbjdl
SGI858

14 Gl-10
 HOW TO READ WIRING DIAGRAMS

Description
Number Item Description
• This shows the condition when the system receives battery positive voltage (can
(j) Power condition
be operated).

• The double line shows that this is a fusible link .

® Fusible link • out. circle shows current flow in, and the shaded circle shows current flow
The open

• This shows the location of the fusible link or fuse in the fusible link or fuse box.
® Fusible link/fuse location
For arrangement, refer to EL section ("POWER SUPPLY ROUTING").

• The single line shows that this is a fuse.

0 Fuse • The open circle shows current flow in, and the shaded circle shows current flow
out.

® Current rating • This shows the current rating of the fusible link or fuse.

• This shows that connector @ is female and connector @) is male.

• The G/R wire is located in the A 1 terminal of both connectors.
® Connectors
• Alphabetic letters with terminal numbers (A 1, BS, etc.) indicate that the connector is
SMJ connector. Refer to Gl-16.

IJ) Optional splice • The open circle shows that the splice is optional depending on vehicle application.

® Splice • The shaded circle shows that the splice is always on the vehicle.

• This arrow shows that the circuit continues to an adjacent page.

® Page crossing
• The A will match with the A on the preceding or next page.
• The dotted lines between terminals show that these terminals are part of the same
@ Common connector
connector.

@ Option abbreviation • This shows that the circuit is optional depending on vehicle application.

• This shows an internal representation of the relay. For details, refer to EL section
@ Relay
("STANDARDIZED RELAY").
• This shows that the connector is connected to the body or a terminal with bolt or
@ Connectors
nut.

• This shows a code for the color of the wire .

B =Black BR =Brown
W =White OR= Orange
R =Red P =Pink
G =Green PU = Purple
L =Blue GY =Gray
@ Wire color
Y =Yellow SB =Sky Blue
LG = Light Green CH = Dark Brown
DG = Dark Green
When the wire color is striped, the base color is given first, followed by the stripe
color as shown below:
Example: UW = Blue with White Stripe

@ Option description • This shows a description of the option abbreviation used on the page.

@ Switch
• This shows that continuity exists between terminals 1 and 2 when the switch is in
the A position. Continuity exists between terminals 1 and 3 when the switch is in
the B position.

@ Assembly parts • Connector terminal in component shows that it is a harness incorporated assem-
bly.

@ Cell code • gram

This identifies each page of the wiring diagram by section, system and wiring dia-
page number.

Gl-11 15
 HOW TO READ WIRING DIAGRAMS
Description (Cont'd)
Number Item Description
• Arrow indicates electric current flow, especially where the direction of standard
flow (vertically downward or horizontally from left to right) is difficult to follow.
@ Current flow arrow
• A double arrow .. .....,., shows that current can flow in either direction depending
on circuit operation.
• This shows that the system branches to another system identified by cell code
@> System branch
(section and system).
• This arrow shows that the circuit continues to another page identified by cell code.
@ Page crossing • The C will match with C on any other page within the system except the next or
preceding page.

@ Shielded line • The line enclosed by broken line circle shows shield wire.

Component box in wave • This shows that another part of the component is also shown on another page
@ line (indicated by wave line) within the system.

@ Component name • This shows the name of a component.

• This shows the connector number.

• The letter shows which harness the connector is located in.
@ Connector number Example: M: main harness. For detail and to locate the connector, refer to EL sec-
tion ("Main Harness", "HARNESS LAYOUT"). A coordinate grid is included for
complex harnesses to aid in locating connectors.
• The line spliced and grounded under wire color shows that ground line is spliced
@ Ground (GND)
at the grounded connector.

@ Ground (GND) • This shows the ground connection .

@ Connector views • This area shows the connector faces of the components in the wiring diagram on
the page.

@ Common component • Connectors enclosed in broken lines show that these connectors belong to the
same component.
• This shows a code for the color of the connector. For code meaning, refer to wire
@ Connector color
color codes, Number @ of this chart.
• This shows the arrangement of fusible link(s) and fuse(s), used for connector
views of "POWER SUPPLY ROUTING" in EL section.
@ Fusible link and fuse box
The open square shows current flow in, and the shaded square shows current
flow out.
• This shows that more information on the Super Multiple Junction (SMJ) and Joint
@ Reference area
Connectors (J/C) exists on the foldout page. Refer to Gl-16 for details.

16 Gl-12
 HOW TO READ WIRING DIAGRAMS
Description (Cont'd)
Example CONNECTOR SYMBOLS
View from terminal side Most of connector symbols in wiring diagrams are shown from the
Connector symbol
terminal side.

js;~DI;n~ I
• Connector symbols shown from the terminal side are enclosed
by a single line and followed by the direction mark ~ .

Direction mark

~
• Connector symbols shown from the harness side are enclosed
by a double line and followed by the direction mark ~ .
l..m !,([;

View from harness side

Connector symbol

Double hne

Direction mark

~
Connector

SG/364

Example
Male terminal #' •
•
Connector guides for male terminals are shown in black .
Connector guides for female terminals are shown in white .

•
'""V
Connector symbol
Connector

Female terminal

Guide

Connector
Connector symbol
SG/363

Gl-13 17
 HOW TO READ WIRING DIAGRAMS
Description (Cont'd)
Example • Connector numbers that indicate harness are enclosed by a
Harness indication single line.

~i)~
• Connector numbers that indicate components are enclosed by
a double line.
BCM connector @.......,_Single
II C/UNIT ]OfCONNECTOR!! Une
109

h•JJ 1
Component indication

~IV
NC mode switch
connector~ +- Double

r;::~~- Une

-
AGI067

SWITCH POSITIONS
Normally open Switches are shown in wiring diagrams as if the vehicle is in the
"normal" condition.

~j
A vehicle is in the "normal" condition when:

-1 •
•
•
ignition switch is "OFF",
doors, hood and trunk lid/back door are closed,
pedals are not depressed, and
• parking brake is released.

) 1
Normally closed

SGI860

18 Gl-14
 HOW TO READ WIRING DIAGRAMS
Description (Cont'd)
DETECTABLE LINES AND NON-DETECTABLE LINES
In some wiring diagrams, two kinds of lines with different thick-
nesses are used to represent wires.
• A line with regular thickness (wider line) represents a "detect-
able line for DTC (Diagnostic Trouble Code)". A "detectable
line for DTC" is a circuit in which ECM (ECCS control module)
can detect malfunctions with the on-board diagnostic system.
y VEHICLE
SPEED • A line with less thickness (thinner line) represents a "non-de-
~
SENSOR
@ tectable line for DTC". A "non-detectable line for DTC" is a
circuit in which ECM cannot detect malfunctions with the on- 1C~
f®oG-Gojgu board diagnostic system.

~G-R-\Q
L...;lr,0;,-1S.,jPEED
OMETER
YIG@ - : Detectable line

I
Y/G
for DTC
: Non-detectable
line for DTC

[J p
ECM
(EGGS CONTROL MODULE)
@)
SG/862

MULTIPLE SWITCH
The continuity of multiple switch is described in two ways as shown
below. li'U"'
• The switch chart is used in schematic diagrams.
• The switch diagram is used in wiring diagrams.

Example

(SWITCH CHART) (SWITCH DIAGRAM)

WIPER SWITCH ~~Jn~

...
OFF INT LO HI WASH

""'
1
2
0 LO .... HI
.WASH OFF
WIPER
SWITCH

3 0 0

~'f'
4 0 0
5 )
c)
6 0
Both sw1tches are turned 1n
combination.
'f
Cont1nu1ty Circuit of wiper switch

SWITCH POSITION CONTINUITY CIRCUIT

OFF 3-4
INT 3-4,5-6
LO 3-6
HI 2-6
WASH 1-6

AG/033

Gl-15 19
 HOW TO READ WIRING DIAGRAMS
Description (Cont'd)
FOLDOUT PAGE
The foldout page should be opened when reading wiring diagram.
Super multiple junction (SMJ)
In wiring diagram, SMJ connectors include a letter of the alphabet with the terminal number for each terminal.
SMJ connector numbers are shown in the Reference Area. Terminal arrangement can be found on the fold-
out page.
If connector numbers are shown in Reference Area, these connector symbols are not shown in Connector
Area. For terminal arrangement of these connectors, refer to the foldout page at the end of this manual.
Joint connector
Joint connector symbols are shown in Connector Area of the wiring diagram. Inside wiring layout and joint
connector terminal arrangement can be found on the foldout page
Example
Super Multiple Junction
(SMJ)
~R--~l
A181C1 01 El F1G1 G1 Ft El 01 Cl 81 Al

I (Main 1
R harness)
A282 C2
02
E2 F2 G2
A3 83 C J - EJ FJ GJ
G2F2E2
02
C2B2A2
GJ F3 EJf.-- C3 83 AJ
@ BR
l~f- ~ - -ir£,1 ~~@]~~
5

........ <illl) ........ ~~ .'2§ ~~c~~

~t.S ~~
L (Engine BR
I mom I -:-::.- 0
~~
c-.-
~~
fe-r-
~~
;--;--
~~
harness) A787 F7k37 G7F7 87A7
A888 CBf-- EB F8 GB GBFB EB~ C8 88 AB
09 09
A9 89 C9f-- E9 F9 G9 G9F9E9 C989A9
lAD 80 CO DO EO FOGO GO FO EO Dj) CO 80 AO
lc_,___ BR---'(
r---sR----_j/
(Main harness) (Engine room harness)

t
STARTI GSYSTEM ~ ---~s3irr;;A:iiRrrTiiNNiGGi:s3iviisrrTEEMM-fiiJt-------~L=cc--:::-:,--:----,==-====---,

1r/ T
Wirin

'f [ T"'
~~/-__:..::_::.::_::.::::_.::.:_:::.:.::::::___ SUPER MULTIPLE UNCTION (SMJ)

•"- '"·;-~
JOINT CONNECTOR

:-· .......

I
i @I ml
-=~
Itt,:M51
I@jl 0
[J[J Check @n@IDI
*
Bi~
@)
= @
9:1:1:1:i:P (ill)
@§)

~I''',,',,',,,,," ',',»J ~

Connector Area

Reference Area:
Refer to the foldout page for the terminal arrangement
of the connectors shown here in the "Reference Area".

SGI859-A

20 Gl-16
 HOW TO READ WIRING DIAGRAMS

Wiring Diagram Codes (Cell Codes)

• Use the chart below to find out what each wiring diagram code stands for.
• Refer to the wiring diagram code in the Alphabetical Index to find the location (page number) of each wiring
diagram.

Code Section Wiring Diagram Name Code Section Wiring Diagram Name
AACIV EC IACV·AAC Valve MAFS EC Mass Air Flow Sensor
ABS BR Anti-lock Brake System Main Power Supply and Ground
MAIN EC
A/C HA Air Conditioner Circuit

AP/SEN EC Absolute Pressure Sensor Speedometer, Tachometer, Temp.

METER EL
and Fuel Gauges
Automatic Speed Control Device
ASCD EL MIUDL EC MIL & Data Link Connectors
(ASCD)
AfT AT Automatic Transmission MIRROR EL Door Mirror

AUDIO EL Audio EVAP Canister Purge Control Sole-

PGCIV EC
noid Valve
BACKJL EL Back-up Lamp
PNP/SW EC Park/Neutral Position Switch
BYPSIV EC Vacuum Cut Valve Bypass Valve
POWER EL Power Supply Routing
EVAP Canister Purge Control Valve/
CANIIV EC EVAP Control System Pressure Sen-
Solenoid Valve PRE/SE EC
sor
CHARGE EL Charging System
PST/SW EC Power Steering Oil Pressure Switch
CHIME EL Warning Chime
RR02 EC Rear Heated Oxygen Sensor
CKPS EC Crankshaft Position Sensor (OBD)
RR02/H EC Rear Heated Oxygen Sensor Heater
CMPS EC Camshaft Position Sensor
SHIFT AT AfT Shift Lock System
0/LOCK EL Power Door Lock
SRS RS Supplemental Restraint System
Headlamp - With Daytime Light Sys-
DTRL EL S/SIG EC Start Signal
tem
Engine Coolant Temperature START EL Starting System
ECTS EC
Sensor Swirl Control Valve Control Vacuum
SIVCSW EC
EGRCIV EC EGRC-Solenoid Valve Check Switch

EGRCt EC Swirl Control Valve Control Solenoid

EGA System Function SWLN EC
Valve
EGR/TS EC EGA Temperature Sensor
SWIV EC MAP/BARO Switch Solenoid Valve
FICO EC IACV-FICD Solenoid Valve
Clearance, License, Tail and Stop
F/PUMP EC Fuel Pump Control TAIUL EL
Lamps
FR02 EC Front Heated Oxygen Sensor TFTS EC Tank Fuel Temperature Sensor
FR02/H EC Front Heated Oxygen Sensor Heater TPS EC Throttle Position Sensor
FUEL EC Fuel Injection System Function TP/SW EC Throttle Position Switch
HEATER HA Heater System Turn Signal and Hazard Warning
TURN EL
Headlamp - Without Daytime Light Lamps
H/LAMP EL
System VENTIV EC EVAP Canister Vent Control Valve
HORN EL Horn, Lighter and Clock vss EC Vehicle Speed Sensor
IATS EC Intake Air Temperature Sensor WARN Warning Lamps
EL
IGN/SG EC Ignition Signal WINDOW EL Power Window
ILL EL Illumination WIPER EL Front Wiper and Washer
INJECT EC Injector
INT/L EL Interior and Map Lamps

Gl-17 21
 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT

Work Flow

-------------------STEP 1

----------------------------SITP4

------------------------STEP 6

SGl838

STEP DESCRIPTION
STEP 1 Get detailed information about the conditions and the environment when the incident occurred.
The following are key pieces of information required to make a good analysis:
WHAT Vehicle Model, Engine, Transmission and the System (i.e., Radio).
WHEN Date, Time of Day, Weather Conditions, Frequency.
WHERE Road Conditions, Altitude and Traffic Situation.
HOW System Symptoms, Operating Conditions (Other Components Interaction).
Service History and if any After Market Accessories have been installed.
STEP 2 Operate the system, road test if necessary.
Verify the parameter of the incident.
If the problem can not be duplicated, refer to "Incident Simulation Tests" next page.
STEP3 Get the proper diagnosis materials together, including:
POWER SUPPLY ROUTING
System Operation Descriptions
Applicable Service Manual Sections
Check for Any Service Bulletins
Identify where to begin diagnosis based upon your knowledge of the system operation and the customer comments.
STEP 4 Inspect the system for mechanical binding, loose connectors or wiring damage.
Determine which circuits and components are involved and diagnose using the Power Supply Routing and Harness
Layouts.
STEP 5 Repair or replace the incident circuit or component.
STEP 6 Operate the system in all modes. Verify that the system works properly under all conditions. Make sure you have not
inadvertently created a new incident during your diagnosis or repair steps.

22 Gl-18
 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT

Incident Simulation Tests

INTRODUCTION
Sometimes the symptom is not present when the vehicle is brought in for service. If possible, recreate the
conditions present at the time of the incident. Doing so may help avoid a No Trouble Found Diagnosis. The
following section illustrates ways to simulate the conditions/environment under which the owner experiences
an electrical incident. ~i 1l

The section is broken into the six following topics:

• Vehicle vibration 1CC::
• Heat sensitive
• Freezing
• Water intrusion ~i'i
• Electrical load
• Cold or hot start up

Get a thorough description of the incident from the customer. It is important for simulating the conditions of
the problem.

VEHICLE VIBRATION
The problem may occur or become worse while driving on a rough road or when engine is vibrating (idle with
A/Con). In such a case, you will want to check for a vibration related condition. Refer to the illustration below. fill

Connectors & harness

},1]'
Determine which connectors and wiring harnesses would affect the electrical system you are inspecting.
Gently shake each connector and harness while monitoring the system for the incident you are trying to
duplicate. This test may indicate a loose or poor electrical connection.

Hint
Connectors can be exposed to moisture. It is possible for a thin film of corrosion to build up on the connec- ~D)
tor terminals. A visual inspection may not reveal this without disconnecting the connector. If the problem occurs
intermittently, perhaps the problem is caused by corrosion. It is a good idea to disconnect, inspect and clean
the terminals on related connectors in the system. !"ii\

Sensors & relays

Gently apply a slight vibration to sensors and relays in the system you are inspecting.
This test may indicate a loose or poorly mounted sensor or relay.
Vibration test Tap gently.

Bend gently.

Gl-19 23
 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT
Incident Simulation Tests (Cont'd)
Possible cause
Any probe entering the
terminal may enlarge
,, the contact spring
"o opening creating an
"
II
l~
intermittent signal.

Intermittent
signals
through
pierced
insulation

Enlarged Normal Proper crimp Insulation not Wire strands

removed missing
DEFORMED (ENLARGED) FEMALE TERMINALS
DEFECTIVE INSULATION STRIPPING

Female half
Locked terminal Seal
Loose

Check for unlocked terminals by

pulling each wire at the end of
Intermittent
the connector.
contact
TERMINAL NOT PROPERLY SEATED SGI840

Tester probe
When probing a connector it is possible to enlarge the contact
spring opening. If this occurs it may create an intermittent signal in
the circuit. When probing a connector, use care not to enlarge the
opening. The probe of the Digital Multimeter (DMM) may not fit into
the connector cavity. In such cases make an extension of a "T" pin
and probe it from the harness side of the connector. Most DMMs
have accessory alligator clips. Slide these over the probe to allow
Alligator clip DMM clipping the "T" pin for a better contact. If you have any difficulty
"T" pin
probing a terminal, inspect the terminal. Ensure that you have not
SGI841 accidentally opened the contact spring or pulled a wire loose.

24 Gl-20
HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT
Incident Simulation Tests (Cont'd)
Engine compartment
There are several reasons why a vehicle or engine vibration could
cause an electrical complaint. Some of the things to check for are:

• Connectors not fully seated .

• Wiring harness not long enough and stressed due to engine
vibrations or rocking.
• Wires laying across brackets or moving components .
• Loose, dirty or corroded ground wires .
• Wires routed too close to hot components .

To inspect components under the hood, start by verifying the integ-

rity of ground connections. (Refer to GROUND INSPECTION '§:i"i
described later.) First check that the system is properly grounded.
Then check for loose connection by gently shaking the wiring or
components as previously explained. Using the wiring diagrams f'!':
inspect the wiring for continuity.

Behind the instrument panel

An improperly routed or improperly clamped harness can become
pinched during accessory installation. Vehicle vibration can aggra-
vate a harness which is routed along a bracket or near a screw.

Under seating areas

An unclamped or loose harness can cause wiring to be pinched by
seat components (such as slide guides) during vehicle vibration. If
the wiring runs under seating areas, inspect wire routing for pos- 1T'f
sible damage or pinching.

Heating test
HEAT SENSITIVE
The owner's problem may occur during hot weather or after car has
sat for a short tirne. In such cases you will want to check for a heat ~1q
sensitive condition.
To determine if an electrical component is heat sensitive, heat the
component with a heat gun or equivalent. ~r
Do not heat components above sooc (140°F). If incident occurs
while heating the unit, either replace or properly insulate the com-
ponent. ~i!:l

Do not heat above 60°C (140°F).

SGI842

Gl-21 25
 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT
Incident Simulation Tests (Cont'd)
FREEZING
Freezing test
The customer may indicate that the incident goes away after the
Water in
car warms up (winter time). The cause could be related to water
connector freezing somewhere in the wiring/electrical system.
There are two methods to check for this. The first is to arrange for
the owner to leave his car overnight. Make sure it will get cold
enough to demonstrate his complaint. Leave the car parked out-
side overnight. In the morning, do a quick and thorough diagnosis
of those electrical components which could be affected.
Solenoid
The second method is to put the suspect component into a freezer
SGI843 long enough for any water to freeze. Reinstall the part into the car
and check for reoccurrence of the incident. If it occurs, repair or
replace the component.

WATER INTRUSION
Water Intrusion test
The incident may occur only during high humidity or in rainy/snowy
weather. In such cases the incident could be caused by water
intrusion on an electrical part. This can be simulated by soaking the
car or running it through a car wash.
Do not spray water directly on any electrical components.

SGI844

Electrical load test

ELECTRICAL LOAD
The incident may be electrical load sensitive. Perform diagnosis
with all accessories (including A/C, rear window defogger, radio,
fog lamps) turned on.
"ON"
COLD OR HOT START UP
A/C
Rear ~l"j On some occasions an electrical incident may occur only when the
window..,. \) Light switch car is started cold. Or it may occur when the car is restarted hot
defogger shortly after being turned off. In these cases you may have to keep
the car overnight to make a proper diagnosis.
SGI845

26 Gl-22
 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT

Circuit Inspection
CONNECTOR AND TERMINAL PIN KIT
Use the connector and terminal pin kit listed below when replacing connectors or terminals.
The connector and terminal pin kit contains some of the most commonly used NISSAN connectors and ter-
minals.

Tool number
(Kent-Moore No.) Description
Tool name

(J38751-95NI)
Connector and terminal pin
kit

©I~

AGI063

INTRODUCTION
In general, testing electrical circuits is an easy task if approached logically. Before beginning, it is important
to have all available information on the system to be tested. Also, get a thorough understanding of system ur"
operation. Then you will be able to use the appropriate equipment and follow the correct test procedure.
You may have to simulate vehicle vibrations while testing electrical components. Gently shake the wiring
harness or electrical component to do this. r!il
OPEN A circuit is open when there is no continuity through a section of the circuit.
SHORT There are two types of shorts.
When a circuit contacts another circuit and causes the
• SHORT CIRCUIT
normal resistance to change.
When a circuit contacts a ground source and grounds the
• SHORT TO GROUND
circuit.

Gl-23 27
 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT
Circuit Inspection (Cont'd)
TESTING FOR "OPENS" IN THE CIRCUIT
Before you begin to diagnose and test the system, you should rough sketch a schematic of the system. This
will help you to logically walk through the diagnosis process. Drawing the sketch will also reinforce your work-
ing knowledge of the system.

Inspection for opens

AGI034

Continuity check method

The continuity check is used to find an open in the circuit. The Digital Multimeter (DMM) set on the resistance
function will indicate an open circuit as over limit (OL, no beep tone or no ohms symbol). Make sure no power
is supplied to the checked component. Always start with the DMM at the highest resistance level.
To help in understanding the diagnosis of open circuits please refer to the schematic above.

1. Disconnect the battery negative cable.

2. Start at one end of the circuit and work your way to the other end (At the fuse block in this example).
3. Connect one probe of the DMM to the fuse block terminal on the load side.
4. Connect the other probe to the fuse block (power) side of SW1. Little or no resistance will indicate that
portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an
over limit or infinite resistance condition (point A).
5. Connect the probes between SW1 and the relay. Little or no resistance will indicate that portion of the cir-
cuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infi-
nite resistance condition (point B).
6. Connect the probes between the relay and the solenoid. Little or no resistance will indicate that portion of
the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit
or infinite resistance condition (point C).
Any circuit can be diagnosed using the approach in the above example.

Voltage check method

To help in understanding the diagnosis of open circuits please refer to the previous schematic.
In any powered circuit, an open can be found by methodically checking the system for voltage. This is done
by switching the DMM to the voltage function.
1. Connect one probe of the DMM to a known good ground.
2. Begin probing at one end of the circuit and work your way to the other end.
3. With SW1 open, probe at SW1 to check for voltage.
Voltage: Open is further down the circuit than SW1.
No voltage: Open is between fuse block and SW1 (point A).
4. Close SW1 and probe at relay.
Voltage: Open is further down the circuit than the relay.
No voltage: Open is between SW1 and relay {point B).
5. Close the relay and probe at the solenoid.
Voltage: Open is further down the circuit than the solenoid.
No voltage: Open is between relay and solenoid (point C).
Any powered circuit can be diagnosed using the approach in the above example.

28 Gl-24
 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT
Circuit Inspection (Cont'd)
TESTING FOR "SHORTS" IN THE CIRCUIT
To simplify the discussion of shorts in the system please refer to the schematic below.
Inspection for shorts

l ~
{Resistance check)
IGN "ON"
OR "ST:R~" ~~SE BLOCK RELAY

-osw~--1...------.-tU- l s~
B+ SIDE l ~~~~ I
SHORT SHORT ~I SHORT
8 SW2 C
CSZJ DMM A _r
+ - (Voltage check) AGI035

Resistance check method IP'f'

1. Disconnect the battery negative cable and remove the blown fuse.
2. Disconnect all loads (SW1 open, relay disconnected and solenoid disconnected) powered through the
~. m
3. Connect one probe of the ohmmeter to the load side of the fuse terminal. Connect the other probe to a
known good ground.
4. With SW1 open, check lor continuity. u'j'ji'
Continuity: Short is between fuse terminal and SW1 (point A).
No continuity: Short is further down the circuit than SW1.
5. Close SW1 and disconnect the relay. Put probes at the load side of fuse terminal and a known good ~~'u"
ground. Then, check lor continuity.
Continuity: Short is between SW1 and the relay (point B).
No continuity: Short is further down the circuit than the relay. lll'
6. Close SW1 and jump the relay contacts with jumper wire. Put probes at the load side of fuse terminal and
a known good ground. Then, check lor continuity.
Continuity: Short is between relay and solenoid (point C). ~Q!
No continuity: Check solenoid, retrace steps.

Voltage check method

1. Remove the blown fuse and disconnect all loads (i.e., SW1 open, relay disconnected and solenoid dis-
connected) powered through the fuse.
rn·;;~~
2. Turn the ignition key to the ON or START position. Verily battery voltage at the B+ side of the fuse termi-
nal (one lead on the B+ terminal side of the fuse block and one lead on a known good ground).
3. With SW1 open and the DMM leads across both fuse terminals, check lor voltage.
Voltage: Short is between fuse block and SW1 (point A).
No voltage: Short is further down the circuit than SW1.
4. With SW1 closed, relay and solenoid disconnected and the DMM leads across both fuse terminals, check
lor voltage. ~r
Voltage: Short is between SW1 and the relay (point B).
No voltage: Short is further down the circuit than the relay.
5. With SW1 closed, relay contacts jumped with fused jumper wire check lor voltage.
Voltage: Short is down the circuit of the relay or between the relay and the disconnected sole-
noid (point C).
No voltage: Retrace steps and check power to fuse block.

Gl-25 29
 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT
Circuit Inspection (Cont'd)
GROUND INSPECTION
Ground connections are very important to the proper operation of electrical and electronic circuits. Ground
connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can become
an unwanted resistance. This unwanted resistance can change the way a circuit works.
Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can dras-
tically affect an electronically controlled circuit. A poor or corroded ground can easily affect the circuit. Even
when the ground connection looks clean, there can be a thin film of rust on the surface.
When inspecting a ground connection follow these rules:
1. Remove the ground bolt screw or clip.
2. Inspect all mating surfaces for tarnish, dirt, rust, etc.
3. Clean as required to assure good contact.
4. Reinstall bolt or screw securely.
5. Inspect for "add-on" accessories which may be interfering with the ground circuit.
6. If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the
wires are clean, securely fastened and providing a good ground path. If multiple wires are cased in one
eyelet make sure no ground wires have excess wire insulation.

Ground Inspection

• • •
Remove bolt (screw). Inspect mating surtaces Reinstall bolt (screw)
for tarnish, dirt, rust, etc. securely.
Clean as required to
assure good contact.

SGI853

30 Gl-26
 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT
Circuit Inspection (Cont'd)
VOLTAGE DROP TESTS
Voltage drop tests are often used to find components or circuits which have excessive resistance. A voltage
drop in a circuit is caused by a resistance when the circuit is in operation.
Check the wire in the illustration. When measuring resistance with ohmmeter, contact by a single strand of
wire will give reading of 0 ohms. This would indicate a good circuit. When the circuit operates, this single strand
of wire is not able to carry the current. The single strand will have a high resistance to the current. This will
be picked up as a slight voltage drop.
Unwanted resistance can be caused by many situations:
Undersized wiring (single strand example)
Corrosion on switch contacts
Loose wire connections or splices.
If repairs are needed, always use wire that is of the same or larger gauge.

Measuring voltage drop - Accumulated method

1. Connect the voltmeter across the connector or part of the circuit you want to check. The positive lead of [sl~
the voltmeter should be closer to power and negative lead closer to ground.
2. Operate the circuit.
3. The voltmeter will indicate how many volts are being used to "push'" current through that part of the cir- 1\'l
cuit.
Note in the illustration that there is an excessive 4.1 volt drop between the battery and the bulb.
!Iff
Symptom: Dim bulb or no operation

0 (zero) ohm
resistance
between switch
and bulb
DMMci:::;;:.::-:.:-::-:::::~-~-:-_-:...::-::.:::-.:_-:..::- - - - - - -- - ~
---, OV I
12V 11.9V: 7.9V :

I Lo~)
Connection with
high resistance

Ground Battery

t
- _ Ground

SGI848 ~L

Gl-27 31
 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT
Circuit Inspection (Cont'd)
Measuring voltage drop - Step by step
The step by step method is most useful for isolating excessive drops in low voltage systems (such as com-
puter controlled systems).
Circuits in the computer controlled system operate on very low amperage.
Computer controlled operations can be adversely affected by any variation in resistance in the system. Such
resistance variation may be caused by poor connection, improper installation, improper wire gauge or corro-
sion.
The step by step voltage drop test can identify a component or wire with too much resistance.

1. Connect the voltmeter as shown, starting at the battery and

working your way around the circuit.

Switch _,..JVL
- - .
-
-
2. An unusually large voltage drop will indicate a component or
wire that needs to be repaired. In the illustration, the poor
connection causes a 4 volt drop.

'cj_ -~
~I l
1\E 12V
-\Batte~~~
,_, Connection

L ' -

-
with high
resistance

The chart that follows illustrates some maximum allowable voltage drops. These values are given as a guideline, the exact value for each
component may vary.

COMPONENT VOLTAGE DROP

Wire negligible <.001 volts
Ground Connections Approx. 0.1 volts
Switch Contacts Approx. 0.3 volts
AGI055

32 Gl-28
 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT
Circuit Inspection (Cont'd)
CONTROL UNIT CIRCUIT TEST
System Description: When the switch is ON, the ECM lights up the lamp.

Case 1 TERMINAL: 1 TERMINAL: 2

Monitoring Power supply Lamo
of the switch to light up
operation (ON/OFF) the lamp
Battery 2~~~~~~~~~~~~~

0
'--v---' ~
ECM
Short: FUSE blows. Short: FUSE blows Short & Open: Short: No problem
Open: Inoperative lamp when switch is ON. Inoperative lamp Open: Inoperative lamp
Open Inoperative lamp
High resistance:
(Single strand) See below. •

Input-output voltage chart

-
Pin litem Condition Voltage In case of high resistance
No. value [V] such as single strand [V] *

~~tch Switch
ON
Battery
voltage
Lower than battery voltage
Approx. 8 (Example)
·-
OFF I Approx. 0 Approx. 0

2 Lamp Switch Battery Approx. 0

ON voltage (Inoperative lamp)

OFF Approx. 0 Approx. 0

The voltage value 1s based on the body ground

: If high resistance exists in the switcl""r side circuit (caused by a single strand), terminal 1 does not detect battery voltage. ECM
does not detect the switch is ON even if the switch does turn ON. Therefore, the ECM does not supply power to light up the lamp.

Case 2 TERMINAL: 2
TERMINAL: 1 Monitoring
Lamp
Ground control of the switch
to light up the lamp operation (ON/OFF)
Battery

'-v-' ECM '---y--'

Short: FUSE blows. Short: Lamp stays ON. Short: Lamp stays ON. Short: No problem
Open: Inoperative lamp Open· Inoperative lamp (Same as the switch ON) Open· Inoperative lamp
Open: Inoperative lamp

High resistance See below.

(Single strand)·
Input-output voltage chart
Pin Item I Condition Voltage In case of high resistance
No.

1 Lamp
~~ , .ON
value [V]

Approx. 0
such as single strand [V} •

Battery voltage
(Inoperative lamp)
-

I OFF Battery Battery voltage

voltage
2 Switch Switch Approx. 0 Higher than 0
ON Approx. 4 (Example)
OFF Approx. 5 Approx. 5
The voltage value 1s based on the body ground.

: If high resistance exists in the switch side circuit (caused by a single strand), terminal 2 does not detect approx. OV. ECM does
not detect the switch is ON even if the switch does turn ON. Therefore, the ECM does not control ground to light up the lamp.

SGI849-A

Gl-29 33
 HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES

The flow chart indicates work procedures required to diagnose problems effectively. Observe the following
instructions before diagnosing.
1) Use the flow chart after locating probable causes of a problem following the "Preliminary Check",
the "Symptom Chart" or the "Work Flow".
2) After repairs, recheck that the problem has been completely eliminated.
3) Refer to Component Parts and Harness Connector Location for the systems described in each
section for identification/location of components and harness connectors.
4) Refer to the Circuit Diagram for Quick Pinpoint Check.
If you must check circuit continuity between harness connectors in more detail, such as when a
sub-harness is used, refer to Wiring Diagram in each individual section and Harness Layout in EL
section for identification of harness connectors.
5) When checking circuit continuity, ignition switch should be OFF.
6) Before checking voltage at connectors, check battery voltage.
7) After accomplishing the Diagnostic Procedures and Electrical Components Inspection, make sure
that all harness connectors are reconnected properly.

m·- &,

lAt iv~
G5£ ~@-----~
ro~
\m
INSPECTION START
I
..----{1]
B•B Check the following.
~
CHECK POWER SUPPLY.
[YJ 1. Stop engine. • Harness connectors
+ 2. Disconnect IACV-FICD solenoid valve @]),@j)
harness connector. • Harness connectors
3. Start engine, then turn air conditioner @§),(@
~ AEC765
switch and blower fan "ON". • Harness continuity
4. Check voltage between terminal G) between IACV-FICD
and ground with CONSULT or tester. solenoid valve harness
rn I r+ Voltage: Battery voltage connector and air

~ IV ~
DISCUNNEC~

conditioner relay
OK

@)
Lm If NG, repair harness or
connectors.

[ill
m
CHECK GROUND CIRCUIT. NG Repair harness or
~
1. Turn ignition switch "OFF". r--- connectors.
2. Check harness continuity between
~ AEC766
terminal 0 and body ground.
Continuity should exist.

lOK

AGI056

34 Gl-30
HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES

HOW TO FOLLOW THIS FLOWCHART

'!' Work and diagnostic procedure
Start to diagnose a problem using procedures indicated in lcilJ,
enclosed blocks, as shown in the following example.

fa
~"c~HccE=-c::cK=P-c-Occw=E=R--:Sccu=P=P-:-LY=.------,.._ Check item being
1. stop engine. performed.
2. Disconnect IACV-FICD solenoid valve
harness connector.
3. Start engine, then turn air conditioner Procedure, steps or
switch and blower fan "ON".
4. Check voltage between terminal CD and measurement results
ground with CONSULT or tester.
Voltage: Battery voltage

I2J Measurement results

Required results are indicated in bold type in the correspond-
ing block, as shown below.
These have the following meanings:
Battery voltage --> 11 - 14V or approximately 12V
Voltage: Approximately OV --> Less than 1V
Resistance: Continuity should exist --> Approximately
on
~ Cross reference of work symbols in the text and
illustrations
Illustrations are provided as visual aids for work procedures. 'f1 5
For example, symbol fa indicated in the left upper portion of
each illustration corresponds with the symbol in the flowchart
for easy identification. More precisely, the procedure under the 11''!2
"CHECK POWER SUPPLY" outlined previously is indicated by
an illustration fa .

-~ Symbols used in illustrations

Symbols included in illustrations refer to measurements or pro-
cedures. Before diagnosing a problem, familiarize yourself with
each symbol.
For connector symbols, refer to "HOW TO READ WIRING
DIAGRAMS" on Gl-13. ]![2
Direction mark
Refer to "CONNECTOR SYMBOLS" on Gl-13.

Gl-31 35
 HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES

Key to symbols signifying measurements or procedures

Symbol Symbol explanation Symbol Symbol explanation
OISCONNECT
Check after disconnecting the connector
EO
CO~NECT
to be measured. ® Procedure with CONSULT

£)
Check after connecting the connector to
be measured. ® Procedure without CONSULT

«f..~ Insert key into ignition switch.

~
Procedure with Generic Scan Tool (GST,
OBD-11 scan tool)

«f..~ Remove key from ignition switch. @s Procedure without CONSULT or GST

~ Turn ignition switch to "OFF" position.

~ AJC switch is "OFF".

~ Turn ignition switch to "ON" position. § AJC switch is "ON".

~
)C'OFF1234 Fan switch is "ON". (At any position
Turn ignition switch to "START" position. =o= except for "OFF" position)

~~
Turn ignition switch from "OFF" to "ACC" _xOFF1234

position. <0 Fan switch is "OFF".

~~F ~
Turn ignition switch from "ACC" to "OFF" Apply positive voltage from battery with
position. l fuse directly to components.

~~ !~
Turn ignition switch from "OFF" to "ON"
Drive vehicle.
position.

~F ~·
Turn ignition switch from "ON" to "OFF"
Disconnect battery negative cable.
position.

l0 Do not start engine, or check with engine

stopped. ~ Depress brake pedal.

ID Start engine, or check with engine run-

ning. ~ Release brake pedal.

~
~
cf~H
Apply parking brake.

Release parking brake.

Check after engine is warmed up suffi-

ciently. ~
•
i!J
Depress accelerator pedal.

Release accelerator pedal.

Pin terminal check for SMJ type ECM

and AfT control unit connectors.

leJ Voltage should be measured with a volt-

meter.
"
II 'eM
8
flco~NEocToRII For details regarding the terminal
arrangement, refer to the foldout page.

l!9J Circuit resistance should be measured ~io 1~1~

7 8.
0
' "'

leJ with an ohmmeter.

~ ~i5
LeJ Current should be measured with an
ammeter.
1 1

36 Gl-32
 CONSULT CHECKING SYSTEM

Function and System Application

Diagnostic
Function ECCS Air bag
test mode
This mode enables a technician to adjust some
Work support devices faster and more accurately by following X -
the indications on CONSULT.
Self-diagnostic results can be read and erased
Self-diagnostic results X X
quickly.
Trouble diagnostic Current self-diagnostic results and all trouble diag-
- X
record nostic records previously stored can be read.
Classification number of a replacement ECU can
ECU discriminated No. be read to prevent an incorrect ECU from being - X
installed.
Data monitor Input/Output data in the ECM can be read. X -
Diagnostic Test Mode in which CONSULT drives
Active test some actuators apart from the ECMs and also X -
shifts some parameters in a speci1ied range.
ECM part number ECM part number can be read. X -
Conducted by CONSULT instead of a technician
Function test to determine whether each system is "OK" or X -
"NG".

x. Applicable

Lithium Battery Replacement

CONSULT contains a lithium battery. When replacing the battery obey the following:
WARNING:
Replace the lithium battery with SANYO Electric Co., Ltd., CR2032 only. Use of another battery may
present a risk of fire or explosion. The battery may present a fire or chemical burn hazard if mistreated.
Do not recharge, disassemble of dispose of in fire.
Keep the battery out of reach of children and discard used battery conforming to the local regulations.

Checking Equipment
When ordering the equipment below, contact your NISSAN distributor.

Tool name Description

NISSAN CONSULT
CD CONSULT unit
and accessories
® Program card
UE950

NT004

Gl-33 37
 IDENTIFICATION INFORMATION

Model Variation
2-WHEEL DRIVE
Engine KA24E

RL4R01A
Destination Transmission FS5W71C FSSW71C
(Floor shift)

Body Differential carrier H190A C200 H190A

STD ABFALCFD21 EUN - -

Regular Cab Standard wheelbase
Non-California, "XE ABFALEFD21 EUN - ABFALEAD21 EUN
U.S.A. XE BBFGLEAD21 EUN
BBFGLEFD21 EUN BBFGLEFD21 EUN*
King Cab f-- Long wheelbase
SE - BBFGLFFD21 EUN BBFGLFAD21 EUN

STD ABFALCFD21 EVN - -

Regular Cab f-- Standard wheelbase
California, XE ABFALEFD21 EVN - ABFALEAD21 EVN
U.S.A. XE BBFGLEFD21 EVN BBFGLEFD21 EVN* BBFGLEAD21 EVN
King Cab f-- Long wheelbase
SE - BBFGLFFD21 EVN BBFGLFAD21 EVN

STD ABFALCFD21ENN - -
Regular Cab '----- Standard wheelbase
XE ABFALEFD21 ENN - ABFALEAD21 ENN
Canada
XE BBFGLEFD21 ENN BBFGLEFD21 ENN' BBFGLEAD21 ENN
King Cab - Long wheelbase
SE - BBFGLFFD21ENN BBFGLFAD21 ENN
..
. Opt1on

4-WHEEL DRIVE
Engine KA24E

Transmission FS5W71C
Destination Transfer TX10

Front Rear
Body Differential carrier
R180A
I H233B

Regular Cab XE Standard wheelbase ABFNLEFD21 EUN

Non-California,
U.S.A.
XE BBFULEFD21 EUN
King Cab
fsE Long wheelbase
BBFULFFD21 EUN

Regular Cab XE Standard wheelbase ABFNLEFD21 EVN

California,
U.S.A.
XE BBFULEFD21 EVN
King Cab Long wheelbase
8E BBFULFFD21 EVN

Regular Cab XE Standard wheelbase ABFNLEFD21 ENN

Canada XE BBFULEFD21ENN
King Cab Long wheelbase
8E BBFULFFD21 ENN

38 Gl-34
 IDENTIFICATION INFORMATION
Model Variation (Cont'd)
Prefix and suffix designations:
A BF A L c F 021 E u N

N : Standard cargo bed

U : Non-California, U.S.A.
V : California, U.S.A.
N: Canada
E : Multipart fuel injection system engine
Model
F : 5-speed manual transmission
A : 4-speed automatic transmission
C : Standard
E: XE
F: SE
L : Left-hand drive
A : Regular Cab (2WD) G : King Cab (2WD)
N : Regular Cab (4WD) U : King Cab (4WD)
BF : KA24E engine
A : Regular Cab
B: King Cab

Gl-35 39
 IDENTIFICATION INFORMATION

Identification Number

Emission control information label

FMVSS certification label

FMVSS certification
label

Vehicle identification
number (Chassis number)
Type A Type B

SGI924

VEHICLE IDENTIFICATION NUMBER ARRANGEMENT

1N6 S D s v c 300001

I
Vehicle serial number

Manufacturing plant
C : Smyrna, Tennessee
Model year
V : 1997 model year
Check digit (0 to 9 or X)
The code for the check digit is determined by mathematical computation.
Gross vehicle weight rating
S : Standard (2-wheel drive)
Y : Standard (4-wheel drive)
Body type
1 : Standard body
6: King Cab
Model change (0-9)
Vehicle line
D : Nissan Truck
Engine type
S: KA24E
Manufacturer
1N6 : U.S.A. produced truck

40 Gl-36
 IDENTIFICATION INFORMATION
Identification Number (Cont'd)
ENGINE SERIAL NUMBER TRANSMISSION SERIAL NUMBER

UillLk

[gJ~t

~©

~©
Manual transmission number

[f~
SGI925 SGI758-A

TRANSMISSION SERIAL NUMBER TRANSFER SERIAL NUMBER (':[s

RL4R01A

ioTI'l'

~1

'IT'!'

~[Ql

Automatic transmission number

ifL~\
SGI759-A SGI761-A

Iii"'
~l

~]'~

1llr

'Iii~

~li

~ril~

~~

~\Q~iz

Gl-37 41
 IDENTIFICATION INFORMATION

Dimensions
Unit mm (in)

2-wheel drive

Regular Cab King Cab Regular Cab King Cab

Standard wheelbase Long wheelbase Standard wheelbase Long wheelbase

Overalllength*1 4.435 (174.6) 4,825 (190.0) 4,435 (174.6) 4,825 (190.0)

Overall width 1,650 (65 0) 1,650 (650) 1,690 (66 5) 1,690 (66.5)

Overall height 1 ,575 (62.0) 1,575 (62.0) 1,705 (671) 1,705 {67.1)
Front tread*2 1,395 (54.9) 1,395 (54.9) 1,455 (57.3) 1,455 (57.3)

Rear tread*2 1,385 (54.5) 1,385 (54.5) 1,440 (56.7) 1,440 (56.7)

Wheelbase 2,650 (1 04.3) 2,950 (116.1) 2,650 (104.3) 2.950 (116.1)

Cargo space Length 1 ,875 (73.8) 1 ,895 (74.6) 1,875 (73.8) 1,895 (74.6)

Width 1,520 (59.8) 1,520 (59.8) 1,520 (59.8) 1,520 (59.8)

Height 435 (17.1) 435 (17.1) 435 (17.1) 435 (17.1)

Minimum ground clearance 211 (8.3) 211 (8.3) 236 (9.3) 236 (9.3)
*1: On step bumper equipped models, the bumper adds 140 mm (5.5 in) to the overall length.
*2: On 14x6JJ road wheel equipped models, adds 20 mm {0.79 in) to the tread.

Wheels & Tires

Cab type Grade Road wheel/offset mm (in) Tire Spare tire size

T135/70D16
Regular STD 14x5J/40 (1.57) P195/75R14
P195/75Ri4*

Regular T135/70Di6
4x2 14x5J/40 (1.57) P195/75R14
& XE P195/75R14*
14x6JJ Aluminum/3D (1.18)* P215/70R14•
King P215/70R14*

King SE 14x6JJ Aluminum/30 (1.18) P215/70R14 T135/70016

15x6JJ/25 (0.98) P215/75R15*

Regular XE P235/75R15
15x7JJ Aluminum/25 (0.98} P235/75R15

4x4 15x6JJ/25 (0.98)

King XE P235/75R15 P235/75R15
15x7JJ Aluminum/25 (0.98)

King SE 15x7JJ Aluminum/25 (0.98) P235/75R15 P235/75R15

*: Option

42 Gl-38
 LIFTING POINTS AND TOW TRUCK TOWING

WARNING:
a. Never get under the vehicle while it is supported only by the jack. Always use safety stands to
support the frame when you have to get under the vehicle.
b. Place wheel chocks at both front and back of the wheels on the ground.

Pantograph Jack

Front~ Front~

AGI038

Screw Jack
Front (2-wheel drive model) Front (4-wheel drive model) Rear

SGI762

Gl-39 43
 LIFTING POINTS AND TOW TRUCK TOWING

Garage Jack and Safety Stand

CAUTION:
Place a wooden or rubber block between safety stand and vehicle body when the supporting body is
flat.

2-WHEEL DRIVE

4-WHEEL DRIVE SGI416

44 Gl-40
 LIFTING POINTS AND TOW TRUCK TOWING

2-pole Lift
WARNING:
When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear of ilui!l
the vehicle are well balanced.
When setting the lift arm, do not allow the arm to contact the brake tubes, brake cable or fuel lines.

©l

ul:llli'

1r!F
SG1718

~~

~i!l

~jffi)

~liil

©iF

~~

11!11

\}j)L~

~lb

mQ)JZ

Gl-41 45
 LIFTING POINTS AND TOW TRUCK TOWING

Tow Truck Towing

CAUTION:
• All applicable state or provincial (in Canada) laws and local laws regarding the towing operation
must be obeyed.
• It is necessary to use proper towing equipment to avoid possible damage to the vehicle during
towing operation.
Towing is in accordance with Towing Procedure Manual at dealer.
• Attach safety chains for all towing.
• When towing, make sure that the transmission, steering system and powertrain are in good order.
If any unit is damaged, a dolly must be used.
• When towing with the front wheels on the ground:
Turn the ignition key to the "OFF" position and secure the steering wheel in a straight ahead posi-
tion with a rope or similar device. Never place the ignition key in the "LOCK" position. This will
result in damage to the steering lock mechanism.
• When towing manual transmission models with the rear wheels on the ground, release the park-
ing brake and move the gearshift lever to neutral position ("N" position).
• Never tow vehicle from the rear (i.e., backward) with four wheels on the ground as this may cause
serious and expensive damage to the transmission.
• For 4-wheel drive model:
Set the free-running hubs to the free position. Move the transfer case shift lever into the "2H"
position and the transmission shift lever into the neutral ("N") position.

2-WHEEL DRIVE MODELS

NISSAN recommends that vehicle be towed with the driving (rear)
wheels oft the ground as illustrated.

SGI406

Towing with four wheels on ground or towing with front wheels raised (With rear wheels on
ground)
Observe the following restricted towing speeds and distances.
Automatic transmission model:
Speed: Below 50 km/h {30 MPH)
Distance: Less than 65 km (40 miles)
Manual transmission model:
Speed: Below 95 km/h (60 MPH)
Distance: Less than 800 km (500 miles)
If the speed or distance must necessarily be greater, remove the propeller shaft beforehand to prevent dam-
age to the transmission.

46 Gl-42
 LIFTING POINTS AND TOW TRUCK TOWING
Tow Truck Towing (Cont'd)
4-WHEEL DRIVE MODELS
N ISSAN recommends that a dolly be used as illustrated when
towing 4-speed drive models.

Towing with four wheels on ground or towing with front or rear wheels raised
Observe the following restricted towing speeds and distances.
Automatic transmission model:
Speed: Below 50 km/h (30 MPH)
Distance: Less than 65 km (40 miles)
Manual transmission model:
Speed: Below 95 km/h (60 MPH)
Distance: Less than 800 km (500 miles)
If the speed or distance must necessarily be greater, remove the front and rear propeller shafts beforehand
to prevent damage to the transmission.

Towing Point
• Never tow the vehicle using only the towing hooks. To avoid damaging the vehicle body, use proper
towing equipment when towing.
• Always pull the cable straight out from the vehicle. Never pull on the hook at a sideways angle .
Front (4x2 TRUCK) Front (If so equipped)
I{4x4 TRUCK)
Rear

--~
'~·w~.Pf~~,
~GJ
AGI060 SG1926

VEHICLE RECOVERY (Freeing a stuck vehicle)

• Tow chains or cables must be attached only to the main struc-
tural members of the vehicle.
~T

• Pulling devices should be routed so they do not touch any part

of the suspension, steering. brake or cooling systems.
~.~~£~·
• Always pull the cable straight out from the front or rear of the
vehicle. Never pull the vehicle at a sideways angle.
• Pulling devices such as ropes or canvas straps are not recom-
mended for use for vehicle towing or recovery.
lcl
sco

Gl-43 47
 TIGHTENING TORQUE OF STANDARD BOLTS

Tightening torque (Without lubricant)

Bolt
Pitch
Grade Bolt size diameter* Hexagon head bolt Hexagon flange bolt
mm
mm
N·m kg-m ft-lb in-lb N·m kg-m ft-lb in-lb

M6 6.0 1.0 5.1 0.52 3.8 45.1 6.1 0.62 4.5 53.8

1.25 13 1.3 9 - 15 1.5 11 -

M8 8.0
1.0 13 1.3 9 - 16 1.6 12 -
1.5 25 2.5 18 - 29 3.0 22 -
4T M10 10.0
1.25 25 2.6 19 - 30 3.1 22 -
1.75 42 4.3 31 - 51 5.2 38 -
M12 12.0
1.25 46 4.7 34 - 56 5.7 41 -
M14 14.0 1.5 74 7.5 54 - 88 9.0 65 -
M6 6.0 1.0 8.4 0.86 6.2 74.6 10 1.0 7 87

1.25 21 2.1 15 - 25 2.5 18 -

M8 8.0
1.0 22 2.2 16 - 26 2.7 20 -
1.5 41 4.2 30 - 48 4.9 35 -
7T M10 10.0
1.25 43 4.4 32 - 51 5.2 38 -
1.75 71 7.2 52 - 84 8.6 62 -
M12 12.0
1.25 77 7.9 57 - 92 9.4 68 -

M14 14.0 1.5 127 13.0 94 - 147 15.0 108 -

M6 6.0 1.0 12 1.2 9 - 15 15 11 -
i.25 29 3.0 22 - 35 3.6 26 -
M8 8.0
1.0 31 3.2 23 - 37 3.8 27 -
1.5 59 6.0 43 - 70 7.1 51 -
9T M10 10.0
1.25 62 6.3 46 - 74 7.5 54 -
1.75 98 10.0 72 - 118 12.0 87 -
M12 12.0
1.25 108 11.0 80 - 137 14.0 101 -
M14 14.0 1.5 177 18.0 130 - 206 21.0 152 -

1. Special parts are excluded.

2. This standard is applicable to bolts having the following
marks embossed on the bolt head. *: Nominal diameter

Grade Mark
M 6
4T 4
T
7T

9T
7

9
T Nominal diameter of bolt threads (Unit: mm)
Metric screw threads

48 Gl-44
 SAE J1930 TERMINOLOGY LIST

SAE J1930 Terminology List

All emission related terms used in this publication in accordance with SAE J1930 are listed. Accordingly, new
terms, new acronyms/abbreviations and old terms are listed in the following chart. cab\
***· Not applicable

NEW ACRONYM I
NEW TERM OLD TERM
ABBREVIATION

Air cleaner ACL Air cleaner

Barometric pressure BARO ...
Barometric pressure sensor-BCDD BAROS-BCDD BCDD

Camshaft position CMP

...
Camshaft position sensor CMPS Crank angle sensor
Carburetor CARS Carburetor
Charge air cooler CAC Intercooler
Closed loop CL Closed loop
Closed throttle position switch CTP switch Idle switch
Clutch pedal position switch CPP switch
Continuous fuel injection system CFI system ...
Clutch switch

Continuous trap oxidizer system CTOX system

...
Crankshaft position CKP ...
Crankshaft position sensor ...
Data link connector
CKPS

DLC ...
Data link connector for CONSULT DLC for CONSULT Diagnostic connector for CONSULT
Diagnostic test mode DTM Diagnostic mode
Diagnostic test mode selector DTM selector Diagnostic mode selector
Diagnostic test mode I DTM I Mode I
Diagnostic test mode II DTM II Mode II

Diagnostic trouble code DTC Malfunction code

Direct fuel injection system DFI system ...
Distributor ignition system Dl system Ignition timing control
Early fuel evaporation-mixture heater EFE-mixture heater Mixture heater
Early fuel evaporation system EFE system Mixture heater control
Electrically erasable programmable read only
memory
EEPROM
...
Electronic ignition system El system Ignition timing control
Engine control EC
...
Engine control module ECM ECCS control unit
Engine coolant temperature ECT Engine temperature
Engine coolant temperature sensor
Engine modification
ECTS

EM
Engine temperature sensor
...
Engine speed RPM Engine speed
Erasable programmable read only memory EPROM ...
Evaporative emission canister EVAP canister or Canister Canister

Gl-45 49
 SAE J1930 TERMINOLOGY LIST
SAE J1930 Terminology List (Cont'd)
***: Not applicable

NEW ACRONYM I
NEW TERM OLD TERM
ABBREVIATION
Evaporative emission system EVAP system Evaporative emission control system
Exhaust gas recirculation valve EGR valve EGR valve
Exhaust gas recirculation controi-BPT valve EGRC-BPT valve BPT valve
Exhaust gas recirculation control-solenoid valve EGRC-solenoid valve EGA control solenoid valve
Exhaust gas recirculation temperature sensor
EGRT sensor Exhaust gas temperature sensor
EGR temperature sensor
Flash electrically erasable programmable read
only memory
FEEPROM ...
Flash erasable programmable read only memory FEPROM ...
Flexible fuel sensor FFS ...
Flexible fuel system FF system ...
Fuel pressure regulator ... Pressure regulator
Fuel pressure regulator control solenoid valve ... PRVR control solenoid valve
Fuel trim FT ...
Heated oxygen sensor H02S Exhaust gas sensor
Idle air control system lAC system Idle speed control
Idle air control valve-air regulator IACV-air regulator Air regulator
Idle air control valve-auxiliary air control valve IACV-AAC valve Auxiliary air control (AAC) valve
Idle air control valve-FICO solenoid valve IACV-FICD solenoid valve FICO solenoid valve
Idle air control valve-idle up control solenoid IACV-idle up control solenoid
Idle up control solenoid valve
valve valve
Idle speed controi-FI pot ISC-FI pot Fl pot
...
Idle speed control system
Ignition control
ISC system
IC
...
Ignition control module ICM ...
Indirect fuel injection system IFI system ...
Intake air lA Air
Intake air temperature sensor IAT sensor Air temperature sensor
Knock ... Detonation
Knock sensor KS Detonation sensor
Malfunction indicator lamp
Manifold absolute pressure
MIL
MAP ...
Check engine light

Manifold absolute pressure sensor MAPS ...

Manifold differential pressure MDP ...
Manifold differential pressure sensor MDPS ...

50 Gl-46
 SAE J1930 TERMINOLOGY LIST
SAE J1930 Terminology List (Cont'd)
Not applicable

NEW ACRONYM I
NEW TERM OLD TERM
ABBREVIATION

Manifold surface temperature MST ...

Manifold surface temperature sensor MSTS ...
Manifold vacuum zone MVZ ...
Manifold vacuum zone sensor MVZS ...
Mass air flow sensor MAFS Air flow meter

Mixture control solenoid valve MC solenoid valve Air-fuel ratio control solenoid valve

Multipart fuel injection System MFI system Fuel injection control

Neutral position switch ... Neutral switch

Nonvolatile random access memory NV RAM

...
On board diagnostic system OBD system Self-diagnosis

Open loop OL Open loop

Oxidation catalyst oc Catalyst

Oxidation catalytic converter system OC system ...

Oxygen sensor 02S Exhaust gas sensor
Park position switch ... Park switch

Park/neutral position switch PNP switch Park/neutral switch

Periodic trap oxidizer system PTOX system ...
Positive crankcase ventilation PCV Positive crankcase ventilation
Positive crankcase ventilation valve PCV valve PCV valve
Powertrain control module PCM
...
Programmable read only memory PROM
...
Pulsed secondary air injection control solenoid valve PAIRC solenoid valve AIV control solenoid valve
Pulsed secondary air injection system PAIR system Air induction valve (AIV) control
Pulsed secondary air injection valve PAIR valve Air induction valve
Random access memory RAM
...
Read only memory ROM
...
Scan tool ST
...
Secondary air injection pump AIR pump ...
Secondary air injection system AIR system ...
Sequential multipart fuel injection system SFJ system Sequential fuel injection
Service reminder indicator SRI
...
Simultaneous multipart fuel injection system ... Simultaneous fuel injection
Smoke puff limiter system SPL system ...
Supercharger sc ...
Supercharger bypass SCB
...
System readiness test SAT ...
Thermal vacuum valve TVV Thermal vacuum valve
Three way catalyst TWC Catalyst
Three way catalytic converter system TWC system ...
Three way+oxidation catalyst TWC+OC Catalyst

Gl-47 51
 SAE J1930 TERMINOLOGY LIST
SAE J1930 Terminology List (Cont'd)
Not applicable

NEW ACRONYM I
NEW TERM OLD TERM
ABBREVIATION
Three way+oxidation catalytic converter system TWC+OC system ...
Throttle body TB Throttle chamber
SPI body
Throttle body fuel injection system TBI system Fuel injection control
Th rattle position TP Throttle position
Throttle position sensor TPS Throttle sensor
Throttle position switch TP switch Th rattle switch
Torque converter clutch solenoid valve TCC solenoid valve Lock-up cancel solenoid
Lock-up solenoid
Turbocharger TC Turbocharger
Vehicle speed sensor vss Vehicle speed sensor
Volume air flow sensor VAFS Air flow meter
Warm up oxidation catalyst WU-OC Catalyst
Warm up oxidation catalytic converter system WU-OC system ...
Warm up three way catalyst WU-TWC Catalyst
Warm up three way catalytic converter system WU-TWC system ...
Wide open throttle position switch WOTP switch Full switch

52 Gl-48
 ENGINE LUBRICATION & COOLING SYSTEMS ®u

SECTION LC
CONTENTS
PRECAUTIONS AND PREPARATION ............................ 2 ENGINE COOLING SYSTEM .......................................... ?
Supplemental Restraint System (SRS) "AIR Cooling Circuit .............................................................7
BAG" ............................................................................2 System Check ..............................................................? ©b
Liquid Gasket Application Procedure .......................... 2 Water Pump .................................................................8
Special Service Tools ..................................................3 Thermostat ...................................................................9
ENGINE LUBRICATION SYSTEM ................................. .4 Radiator ..................................................................... 11 iiUV
Lubrication Circuit ....................................................... .4 Cooling Fan ............................................................... 12
Oil Pressure Check ......................................................5 Overheating Cause Analysis ..................................... 13
Oil Pump ......................................................................5 SERVICE DATA AND SPECIFICATION S (SDS) .......... 14 ~l
Engine Lubrication System ........................................ 14
Engine Cooling System ............................................. 14 I!~

125
 PRECAUTIONS AND PREPARATION

Supplemental Restraint System (SRS) "AIR

BAG"
The Supplemental Restraint System "Air Bag", used along with a seat belt, helps to reduce the risk or sever-
ity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of an air bag mod-
ule (located in the center of the steering wheel), a diagnosis sensor unit, warning lamp, wiring harness, a crash
zone sensor (4WD models) and spiral cable. Information necessary to service the system safely is included
in the RS section of this Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed
by an authorized NISSAN dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses are covered with yellow insulation either just before the
harness connectors or for the complete harness, for easy identification.

Liquid Gasket Application Procedure

a. Use a scraper to remove all traces of old liquid gasket from
mating surfaces and grooves. Also, completely clean any oil
from these areas.
Inner
side
b. Apply a continuous bead of liquid gasket to mating surfaces.
(Use Genuine Liquid Gasket or equivalent.)
• For oil pan, be sure liquid gasket diameter is 3.5 to 4.5 rnm
(0.138 to 0.177 in).
Groove Bolt hole • For areas except oil pan, be sure liquid gasket diameter is
2.0 to 3.0 rnm (0.079 to 0.118 in).
SEM164F c. Apply liquid gasket around the inner side of bolt holes (unless
otherwise specified).
d. Assembly should be done within 5 minutes after coating.
e. Wait at least 30 minutes before refilling engine oil and engine
coolant.

126 LC-2
 PRECAUTIONS AND PREPARATION

Special Service Tools

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number
(Kent-Moore No.) Description
Tool name

(J34301-C) Measuring oil pressure

Oil pressure gauge set
G) (J34301-1)
~
Oil pressure gauge
® (J3430t-2)
Hoses ~
® (J34298)
Adapter
@) (J34282-1)
~
Adapter
@ (790-301-1230-A)
60° adapter
CD---0
® (J34301-15) Maximum measurin§ range:
Square socket AAT546 1,379 kPa (14 kg/em , 200 psi)

EG17650301 Adapting radiator cap tester to radiator filler T~~U

(J33984-A)
~ cf=~Hb
neck
Radiator cap tester adapter
§ •tc0===4t•
W$39930000
( ~

)
Tube presser
NT564
' a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)

Pressing the tube of liquid gasket

NT052

LC-3 127
128

Oil pan
l

. Oil gallery in
cylinder block I Oil strainer
j.~ ~~ ~~ -~~ ~~
I

-..- -- -- By-pass passage

....,..____________ Intermittently
I Oil pump j Relief valve

~
oiling portion

Oil passage

l
L~ ~ ~ ~
....
Oil filter
~ ~ ~

J
~ ~
--l
I

~ ~-
-. -

~ ~ ~'
J

Regulator valve j
I
~

v _
1
Pump drive gear
m
z
c;)
·--·--·-- ........ --·-- z
r- m
1 s::: r-
'r lr C" c
l :::!. m
-
Main bearing 0
r- j
Cylinder head
Ill ::0
(') 011 gallery
I 0
•
"" I Connecting
0 'r J l ' r
Cha~n and chainj
v c;·
~ ~
I bearing
rod I
l Oil jet
tens1oner I
(')
... 0
: Center cam bracket
z
-~ ' Jl v 0
s:::
::;:
en
-<
en
j Connecting rod j

I Timing chain j j Rocker shaft j

l Camshaft
J -1
m
A s:
'
Piston pin~;J
I ton and cylinder
I Rocker arm I= "~I Hydcaulic
valve lifter
I I Camshaft bearing I

! Cam •
surface j
7

I Timing chain
front cover
and I

"[)
~
 ENGINE LUBRICATION SYSTEM

Oil Pressure Check

WARNING:
• Be careful not to burn yourself, as the engine and oil may
be hot.
(J34301-1) • For MIT models, put gearshift lever in Neutral "N" position.
For AfT models, put selector lever in Park "P" position. ~r!u
1. Check oil level.
2. Remove oil pressure switch.
3. Install pressure gauge.
4. Start engine and warm it up to normal operating temperature.
5. Check oil pressure with engine running under no-load.
Engine speed Approximate discharge pressure
rpm kPa (kg/cm 2 , psi)

Idle speed More than 78 (0.8, 11)

3,000 412. 481 (4.2. 4.9, 60- 70)

• If difference is extreme, check oil passage and oil pump

for oil leaks. ril
6. Install oil pressure switch with sealant.

ALC059

Oil Pump
SEC. 150 Drive spindle

Gasket~

Outer rotor
Rotor

m3• _49
1 (4.o- s.o.
Outer Pump cover I 29 -36)

C@~f," ~--~ ~~0~

Pump
cover
v
Chamfer
'rft~
I :-c~
'P------- ~'9.~&:or,.~ q>8..,
~...
-" {..- &,9; '.9
-b.~tr
l_., q/v.lSJ "~~'a,...
Regulator

~ 6- 10 (0.6- 1.0. 52- 87) -"~ valve set

:!J.l11 -15 (1.1 -1.5. 8 -11)/~ ~ · N·m (kg-m. in-lbl

~ : N·m (kg-m. ft-lb)

SLC945-A

LC-5 129
 ENGINE LUBRICATION SYSTEM
Oil Pump (Cont'd)
• Always replace with new oil seal and gasket.
• When removing oil pump, turn crankshaft so that No. 1
piston is at TDC on its compression stroke.
• When installing oil pump, apply engine oil to gears, then
align punchmark on drive spindle and oil hole on oil
• Punch mark pump.
• • Oil hole

REGULATOR VALVE INSPECTION

1. Visually inspect components for wear and damage.
2. Check oil pressure regulator valve sliding surface and valve
spring.
3. Coat regulator valve with engine oil. Check that it falls
smoothly into the valve hole by its own weight.
• Replace regulator valve set or oil pump assembly if dam-
aged.

ALC058

OIL PRESSURE RELIEF VALVE INSPECTION

Inspect oil pressure relief valve for movement, cracks and breaks
by pushing the ball. If replacement is necessary, remove valve by
prying it out with a suitable tool.
Install a new valve by tapping it in place.

OIL PUMP INSPECTION

Use a feeler gauge to check the following clearances.

Standard clearance:
Unit: mm (in)

Rotor tip clearance Q) Less than 0.12 (0.0047)

Outer rotor to body clearance ® 0.15. 0.21 (0.0059. 0.0083)

Side clearance (with gasket) @ 0.04. 0.08 (0.0016. 0.0031)

• If the tip clearance ( 1 ) exceeds the limit, replace gear set .

• If body to gear clearances (@, @) exceed the limit,
replace oil pump assembly.

SLC732

130 LC-6
 ENGINE COOLING SYSTEM

Cooling Circuit Ciil

........ Thermostat: Open

~ Thermostat: Closed

Throttle body
Radiator ==~ Reservoir tank

~©

i)'~
Intake manifold Thermostat

©l
Heater
i~'i"

~'jj'

'['["

~rg,

[p~

ALC055
lPJL~

System Check
WARNING: ~l~l
Never remove the radiator cap when the engine is hot. Serious
burns could occur from high pressure coolant escaping from
the radiator.
Wrap a thick cloth around the radiator cap. Slowly turn it a
quarter turn to allow built up pressure to escape. Carefully
remove the radiator cap by turning it all the way.

CHECKING COOLING SYSTEM HOSES

Check hoses tor the following:
• Improper attachment
• Leaks
• Cracks
• Damage
• Chafing
• Deterioration

LC-7 131
 ENGINE COOLING SYSTEM
System Check (Cont'd)
CHECKING COOLING SYSTEM FOR LEAKS
Hose adapter To check for leakage, apply pressure to the cooling system with a
radiator cap tester.
Testing pressure:
157 kPa (1.6 kg/cm 2 , 23 psi)
CAUTION:
Higher pressure than specified may cause radiator damage.

SLC756A

CHECKING RADIATOR CAP

To check radiator cap, apply pressure to radiator cap with a radia-
tor cap tester.
Radiator cap relief pressure:
Standard
78- 98 kPa (0.8- 1.0 kg/cm 2 , 11 - 14 psi)
Limit
59 - 98 kPa (0.6 - 1.0 kg/cm 2 , 9 - 14 psi)

EG17650301
(J33984-A) SLC755A

Pull the negative pressure valve to open it.

Check that it closes completely when released.

SMA967B

SEC. 210A Water Pump

D Liquid gasket CAUTION:
• When removing water pump assembly, be careful not to
get coolant on drive belts.
• Water pump cannot be disassembled and should be
replaced as a unit.
• After installing water pump, connect hose and clamp
securely, then check for leaks using radiator cap tester.

REMOVAL
1. Drain coolant from engine.
Refer to MA section ("Changing Engine Coolant", "ENGINE
MAINTENANCE").
2. Remove fan coupling with fan.
3. Remove power steering pump drive belt, generator drive belt
and AIC compressor drive belt.
4. Remove water pump.

132 LC-8
 ENGINE COOLING SYSTEM
Water Pump (Cont'd)
INSPECTION
• Check body assembly for rust or corrosion.
• Check for rough operation due to excessive end play.

INSTALLATION
1. Use a scraper to remove liquid gasket from water pump.
• Also remove traces of liquid gasket from mating surface IP~
of cylinder block.

Scraper
u1Jj'
SLC188A

2. Apply a continuous bead of liquid gasket to mating surface of l2J'f

rJ Liquid gasket: water pump.
-- 2.0- 3.0 mm {0.079- 0.118 in)
• Use Genuine Liquid Gasket or equivalent.

When filling radiator with coolant, refer to MA section

("Changing Engine Coolant", "ENGINE MAINTENANCE"). ~~~
When installing drive belts, refer to MA section ("Checking
Drive Belts").

SLC391AA

SEC. 210A Thermostat

~~ Thecmostat
• Be careful not to spill coolant over engine compartment.

{~~~r.!~~.s~~t
0 Use a rag to absorb coolant. l~J~

- ltl.~ . . REMOVAL
~· .·~. 1. Drain coolant from engine. Refer to MA section ("Changing .I)J
Engine Coolant", "ENGINE MAINTENANCE").
\./ '~ 2. Remove air cleaner and air duct assembly.
\ / "'\/
~~ I 3. Remove water hose from water inlet housing.
I '
_j ~6.3 - 8.3 N·m (0.64 - 0.85 kg-m. 4. Remove water inlet housing, then take out thermostat.
Water inlet 55 6 - 73.8 in - lb)
. ALC061

LC-9 133
 ENGINE COOLING SYSTEM
Thermostat (Cont'd)
INSPECTION
1. Check valve seating condition at normal room temperature. It
should seat tightly.
2. Check valve opening temperature and valve lift.
Valve opening temperature 76.5 (170)
Valve lift mm/"C (in/"F) More than 8/90 (0.31/194)

3. Then check if valve closes at 5"C (9"F) below valve opening

temperature.
SLC343

INSTALLATION
1. Use a scraper to remove old liquid gasket from water inlet.
• Also remove traces of liquid gasket from mating surface
of front cover.
2. Apply a continuous bead of liquid gasket to mating surface of
water inlet.
• Use Genuine Liquid Gasket or equivalent.

3. Install thermostat with jiggle valve or air bleeder at upper side.

4. Install water inlet housing.
5. Install water hose to water inlet housing.
6. Install air cleaner and air duct assembly.
7. Refill engine coolant. Refer to MA section ("Changing Engine
Coolant", "ENGINE MAINTENANCE").
• After installation, run engine for a few minutes, and check
for leaks.

SLC097

134 LC-10
 ENGINE COOLING SYSTEM

Radiator
REMOVAL AND INSTALLATION
1. Drain coolant from radiator. Refer to MA section ("Changing
Engine Coolant", "ENGINE MAINTENANCE").
2. Disconnect upper and lower radiator hoses.
3. Remove air cleaner and air duct assembly. ~ITfu
4. Remove fan coupling with fan.
5. Remove lower radiator shroud.
6. Remove radiator shroud.
7. Remove Aff oil cooler hoses (Aff models only).
8. Disconnect coolant reservoir hose.
9. Remove radiator. I~©
10. After replacing radiator, install all parts in reverse order of
removal.
11. Refill engine coolant. Refer to MA section ("Changing Engine IS~
Coolant", "ENGINE MAINTENANCE").
• After installation, run engine for a few minutes, and check
for leaks. ~~6
Reservoir tank AfT model only
transmission
oil cooler hose

mounting

-~\.
~ 3.2 - 4.2 {0.33 . 0.43, 28.6 - 37 .3)

Radiator shroud

~: N·m (kg-m, in-lb)

ALC053

LC-11 135
 ENGINE COOLING SYSTEM

SEC. 210 ~s . 10 co.s - 1.0, 52 - 87) Cooling Fan

\)''',
DISASSEMBLY AND ASSEMBLY

Fan coupling

~: N·m (kg-m, in-lb} ALC057

INSPECTION
Check fan coupling for rough operation, oil leakage and bent
bimetal.

SLC072

136 LC-12
 ENGINE COOLING SYSTEM

Overheating Cause Analysis

Symptom Check items

Water pump malfunction Worn or loose drive belt

Thermostat stuck closed -

Dust contamination or paper
Poor heat transfer Damaged fins clogging -
Mechanical damage

Excess foreign material (rust,

Clogged radiator cooling tube
dirt, sand, etc.)

Cooling fan does not operate

Fan coupling does not operate

Reduced air flow - -
High resistance to fan rotation

Damaged fan blades

Damaged radiator shroud - - -

Improper coolant mixture ratio - - -
Cooling
system parts Poor coolant quality - - -
malfunctiOn
Loose clamp
Cooling hose
Cracked hose

Water pump Poor sealing

Loose
Radiator cap
Poor sealing
Coolant leaks
0-ring for damage, deteriora-
Insufficient coolant lion or improper fitting
Radiator
Cracked radiator tank

Cracked radiator core

Reservoir tank Cracked reservoir tank

Cylinder head deterioration

Exhaust gas leaks into cooling
Overflowing reservoir tank Cylinder head gasket deteriora-
system
lion

High engine rpm under no load

Driving in low gear for extended

Abusive driving
time

Driving at extremely high speed

- Overload on engine Powertrain system malfunction

Installed improper size wheels

and tires -
Except
Dragging brakes
cooling
system parts Improper ignition timing
malfunction
Blocked bumper -
Installed truck brassiere
Blocked radiator grille Mud contamination or paper
Blocked or restricted air flow clogging -
Blocked radiator -
Blocked condenser
-
Installed large fog tamp

LC-13 137
 SERVICE DATA AND SPECIFICATIONS (SDS)

Engine Lubrication System

Oil pressure check Oil pump
Unit: mm (in)
Engine speed Approximate discharge pressure
rpm kPa (kg/cm 2 , psi) Rotor tip clearance Less than 0.12 (0.0047)

Idle speed More than 78 (0.8, 11) Outer rotor to body clearance 0.15. 0.21 (0.0059. 0.0083)
3,000 412.481 (4.2. 4.9, 60. 70) Side clearance (with gasket) 0.04- 0.08 (0.0016 - 0.0031)

Engine Cooling System

Thermostat Radiator
Unit· kPa (kg/cm 2 , psi)
Valve opening temperature "C ("F) 76.5 (170)
Cap relief Standard 78.98 (0.8 ·1.0, 11 -14)
Valve lift mm/°C {infOF) More than 8/90 (0.31/194)
pressure Limit 59.98 (0.6 ·1.0, 9 ·14)
Leakage test pressure 157 (1.6, 23)

138 LC-14
 ENGINE CONTROL SYSTEM

SECTION EC
CONTENTS
DIAGNOSTIC TROUBLE CODE INDEX ... ...... 2 TROUBLE DIAGNOSIS -Introduction ..... . ........ 68
Alphabetical & P No. Index for DTC .......................... 2 Introduction ... ······························· ................. 68
PRECAUTIONS AND PREPARATION .......................... .4 Diagnostic Worksheet......................... ............. ..... 68
ENGINE AND EMISSION CONTROL OVERALL TROUBLE DIAGNOSIS- Work Flow...... ..... 70
SYSTEM ................. . .............. 9 Work Flow ...................... . ...... 70
Circuit Diagram .......................................................... 9 Description for Work Flow ... ....... .......... . ..... 71
System Diagram ........ .... .... .. .. .. .......... ........ 10 TROUBLE DIAGNOSIS- Basic Inspection ............. 72
ECCS Component Parts Location........ ............ 11 Basic Inspection........ ................... .. ........... 72
Vacuum Hose Drawing ............................................. 13 TROUBLE DIAGNOSIS- General Description ........ 75
System Chart .. ....... 14 Diagnostic Trouble Code (DTC) Inspection
ENGINE AND EMISSION BASIC CONTROL Priority Chart .......................... . ........... 75
SYSTEM DESCRIPTION .................... . ............... 15 Fail-Safe Chart ........................................................ 76
Multipart Fuel Injection (MFI) System ...................... 15 Symptom Matrix Chart..... ............... . .......... 77
Distributor Ignition (DI) System ...... ........... 17 CONSULT Reference Value in Data Monitor
Air Conditioning Cut Control.............................. ... 18 M~e...................... .................................... N
Fuel Cut Control (at no load & high engine Major Sensor Reference Graph in Data Monitor
speed) .................................................................... 19 Mode ............. ............. .................. 81
EVAPORATIVE EMISSION SYSTEM .......... ....... 20 ECM Terminals and Reference Value ...................... 83
Description............. ........................ .20 TROUBLE DIAGNOSIS FOR POWER SUPPLY ......... 89
Inspection ............................................................... 20 Main Power Supply and Ground Circuit .................. 89
Evaporative Emission Line Drawing ......................... 22 TROUBLE DIAGNOSIS FOR DTC P0100.... ..... 93
POSITIVE CRANKCASE VENTILATION ..................... 24 Mass Air Flow Sensor (MAFS) ............ . ......... 93
Description.. . .......... 24 TROUBLE DIAGNOSIS FOR DTC P0105 ........ 100
Inspection............. ......................... ........ 24 Absolute Pressure Sensor ............................ 100
BASIC SERVICE PROCEDURE ... .... ... 25 TROUBLE DIAGNOSIS FOR DTC P0110 ................. 107
Fuel Pressure Release ....... . ................ 25 Intake Air Temperature Sensor ................................ 107
Fuel Pressure Check .................. . ...... 25 TROUBLE DIAGNOSIS FOR DTC P0115 .................. 113
Injector Removal and Installation. ................. .26 Engine Coolant Temperature Sensor (ECTS) ........ 113
Fast Idle Cam (FIC) Inspection and Adjustment.. ..... 27 TROUBLE DIAGNOSIS FOR DTC P0120.... ....... 118
Idle Speed/Ignition Timing/Idle Mixture Ratio Throttle Position Sensor ... ...... 118
Adjustment....... .............................. ............. 28 TROUBLE DIAGNOSIS FOR DTC P0125 .. .... 124
ON BOARD DIAGNOSTIC SYSTEM Engine Coolant Temperature (ECT) Sensor ........... 124
DESCRIPTION ....................................... . ......... 34 TROUBLE DIAGNOSIS FOR DTC P0130 ................. 129
Introduction ......... . .......... 34 Front Heated Oxygen Sensor (Front H02S) .......... 129
Two Trip Detection Logic ...................... . .......... 34 TROUBLE DIAGNOSIS FOR DTC P0130 ................ 134
Emission·related Diagnostic Information ......... 35 Closed Loop Control....... .. ........... ..... . ......... 134
Malfunction Indicator Lamp (MIL) .. ........ .45 TROUBLE DIAGNOSIS FOR DTC P0135 .................. 135
OBD System Operation Chart ... ........ .48 Front Heated Oxygen Sensor Heater ...................... 135
CONSULT ........................ . ......... 53 TROUBLE DIAGNOSIS FOR DTC P0136 .................. 139
Generic Scan Tool (GST) ..................... . ......... 66 Rear Heated Oxygen Sensor (Rear H02S) ............ 139

140
 CONTENTS <cont'd.)
TROUBLE DIAGNOSIS FOR DTC P0141.. ................ 143 TROUBLE DIAGNOSIS FOR DTC P0705 ..................232
Rear Heated Oxygen Sensor Heater ...................... 143 Park/Neutral Position Switch .................................. 232
TROUBLE DIAGNOSIS FOR DTC P0171 .................. 148 TROUBLE DIAGNOSIS FOR DTC P1105 .................. 237
Fuel Injection System Function (Lean side) .......... 148 Manifold Absolute Pressure (MAP)/Barometric
~u:!i
TROUBLE DIAGNOSIS FOR DTC P0172 .................. 153 Pressure (BAAO) Switch Solenoid Valve ............... 237
Fuel Injection System Function (Rich side) ............. 153 TROUBLE DIAGNOSIS FOR DTC P1130 ................. 243
TROUBLE DIAGNOSIS FOR DTC P0180 .................. 158 Swirl Control Valve Control Solenoid Valve ............ 243 1"1!;:
Tank Fuel Temperature Sensor ............................... 158 TROUBLE DIAGNOSIS FOR DTC P1165 ................. 251
TROUBLE DIAGNOSIS FOR DTC P0300 • P0304 .... 162 Swirl Control Valve Control Vacuum Check
No. 4 - 1 Cylinder Misfire, Multiple Cylinder Switch ..................................................................251
M~re ...................................................................... 1~ TROUBLE DIAGNOSIS FOR DTC P1320 ................. 256
TROUBLE DIAGNOSIS FOR DTC P0335 .................. 166 Ignition Signal ..........................................................256
Crankshaft Position Sensor (CKPS) (OBD) ............ 166 TROUBLE DIAGNOSIS FOR DTC P1336 .................. 262 .)"~
TROUBLE DIAGNOSIS FOR DTC P0340 .................. 171 Crankshaft Position Sensor (CKPS) (OBD)
Camshaft Position Sensor (CMPS) ......................... 171 (COG) .....................................................................262
TROUBLE DIAGNOSIS FOR DTC P0400 .................. 176 TROUBLE DIAGNOSIS FOR DTC P1400 ................. 267 ©l.
EGA Function .......................................................... 176 EGAC-Solenoid Valve ........................................... 267
TROUBLE DIAGNOSIS FOR DTC P0402 .................. 184 TROUBLE DIAGNOSIS FOR DTC P1401 .................. 271
EGAC-BPT Valve Function ..................................... 184 EGA Temperature Sensor ...................................... 271
TROUBLE DIAGNOSIS FOR DTC P0420 .................. 186 TROUBLE DIAGNOSIS FOR DTC P1441 ................. 276
Three Way Catalyst Function .. ........... ........... 186 Vacuum Cut Valve Bypass Valve............... .276
1
1,1
TROUBLE DIAGNOSIS FOR DTC P0440 .................. 189 TROUBLE DIAGNOSIS FOR DTC P1445 ................. 281
Evaporative Emission (EVAP) Control System Evaporative Emission (EVAP) Canister Purge
(Small Leak) ............................................................. 189 Volume Control Valve .............................................. 281 ·.r~c·
TROUBLE DIAGNOSIS FOR DTC P0443 .................. 199 TROUBLE DIAGNOSIS FOR DTC P1447 .................. 288
Evaporative Emission (EVAP) Canister Purge Evaporative Emission (EVAP) Control System
Control Valve/Solenoid Valve ................................ 199 Purge Flow Monitoring ............................................. 288 [~liT!
TROUBLE DIAGNOSIS FOR DTC P0446....... .207 TROUBLE DIAGNOSIS FOR DTC P1550 ................. 295
Evaporative Emission (EVAP) Canister Vent Torque Converter Clutch Solenoid Valve ............... 295
Control Valve ........................................................... 207 TROUBLE DIAGNOSIS FOR DTC P1900 .................. 300 J'i\\
TROUBLE DIAGNOSIS FOR DTC P0450 .................. 212 Overheat ..................................................................300
Evaporative Emission (EVAP) Control System TROUBLE DIAGNOSIS FOR NON-DETECTABLE
[qi~\
Pressure Sensor ...................................................... 212 ITEMS ........................................................................... 303
TROUBLE DIAGNOSIS FOR DTC P0500 .................. 217 Injector .................................................................. 303
Vehicle Speed Sensor (VSS) ................................ 217 Start Signal ............................................................. 306 11)!!]
TROUBLE DIAGNOSIS FOR DTC P0505 .................. 221 Fuel Pump............................................... ............ 309
Idle Air Control Valve (IACV) - Auxiliary Air Power Steering Oil Pressure Switch ....................... 313
Control (AAC) Valve ................................................ 221 IACV-FICD Solenoid Valve ..................................... 317 ~'V
TROUBLE DIAGNOSIS FOR DTC P0510..... ... 226 MIL & Data Link Connectors .................................. 321
Closed Throttle Position Switch .............................. 226 SERVICE DATA AND SPECIFICATIONS (SDS) ........ 323
TROUBLE DIAGNOSIS FOR DTC P0605 ..... 230 General Specifications ............................................ 323 1'1~
Engine Control Module (ECM)-ECCS Control Inspection and Adjustment ...................................... 323
Module ....................................................................230

When you read wiring diagrams:

• Read Gl section, "HOW TO READ WIRING DIAGRAMS".
• See EL section, "POWER SUPPLY ROUTING" for power distribution circuit.
When you perform trouble diagnoses, read Gl section, "HOW TO FOLLOW FLOW
CHART IN TROUBLE DIAGNOSES" and "HOW TO PERFORM EFFICIENT DIAGNOSIS
FOR AN ELECTRICAL INCIDENT".

141
 DIAGNOSTIC TROUBLE CODE INDEX

Alphabetical & P No. Index for DTC

ALPHABETICAL INDEX FOR DTC

DTC"3 DTC"3
Items Reference Items Reference
(CONSULT screen terms) CONSULT page (CONSULT screen terms) CONSULT page
ECM*1 ECM•1
GST*2 GST"2

Unable to access ECCS - - EC-76 FUEL SYS DIAG-RICH 0114 P0172 EC-153

"COOLANT TEMP SEN 0908 P0125 EC-124 IACV-AAC VALVE 0205 P0505 EC-221

ABSOL PRESS SEN- IGN SIGNAL-PRIMARY 0201 P1320 EC-256

0803 P0105 EC-100
SOR
INT AIR TEMP SEN 0401 P0110 EC-107
CAMSHAFT POSI SEN 0101 P0340 EC-171
MAP/BARO SW SOUV 1302 P1105 EC-237
CLOSED LOOP 0307 P0130 EC-134
MASS AIR FLOW SEN"4 0102 P0100 EC-93
CLOSED THRL POS SW 0203 POSID EC-226
MULTI CYL MISFIRE 0701 P0300 EC-162
COOLANT TEMP SEN*4 0103 P0115 EC-113
NO SELF DIAGNOSTIC
Flashing·s No DTC EC-45
CRANK PIS (OBD) COG 0905 P1336 EC-262 FAILURE INDICATED

CRANK POS SEN (OBD) 0802 P0335 EC-166 NO SELF DIAGNOSTIC

0505 POOOO -
FAILURE INDICATED
CYL 1 MISFIRE 0608 P0301 EC-162
OVER HEAT 0208 P1900*6 EC-300
CYL 2 MISFIRE 0607 P0302 EC-162
PARK/NEUT POSI SW 1003 P0705 EC-232
CYL 3 MISFIRE 0606 P0303 EC-162
PURG CONT/V & SN 0807 P0443 EC-199
CYL 4 MISFIRE 0605 P0304 EC-162
PURG VOLUME
ECM 0301 P0605 EC-230 1008 P1445 EC-281
CONTN
EGR SYSTEM 0302 P0400 EC-176
EC-139
REAR 02 SENSOR 0707 P0136
EGR TEMP SENSOR 0305 P1401 EC-271
RR 02 SEN HEATER 0902 P0141 EC-143
EGRC SOLENOIDN 1005 P1400 EC-267
SWIRUV CONT VC SW 0112 P1165 EC-251
EGRC-BPT VALVE 0306 P0402 EC-184
EC-243
SWIRL CONT S/V 1004 P1i30
EVAP PURG FLOW/
0111 P1447 EC-288 TANK FUEL TEMP SEN 0402 P0180 EC-158
MON
THROITLE POSI SEN*4 0403 P0120 EC-118
EVAP SYS PRES SEN 0704 P0450 EC-212
TOR CONV CLUTCH SN 0904 P1550 EC-295
EVAP (SMALL LEAK) 0705 P0440 EC-189
TW CATALYST
FRONT 02 SENSOR 0303 P0130 EC-129 0702 P0420 EC-186
SYSTEM
FA 02 SEN HEATER 0901 P0135 EC-135
VC/V BYPASS/V 0801 P1441 EC-276
FUEL SYS DIAG-LEAN 0115 P0171 EC-148
VEHICLE SPEED SEN 0104 P0500 EC-217

VENT CONTROL VALVE 0903 P0446 EC-207

.1: In D1agnost1c Test Mode II (Self-d1agnost1c results). These
numbers are controlled by NISSAN.
*2: These numbers are prescribed by SAE J2012.
*3: 1st trip DTC No. is the same as DTC No.
*4: When the fail-safe operation occurs, the MIL illuminates.
*5: While engine is running.
*6: Since this diagnosis does not meet P1900 of SAE J2012, it
is indicated only by CONSULT.

142 EC-2
 DIAGNOSTIC TROUBLE CODE INDEX
Alphabetical & P No. Index for DTC (Cont'd)
P NO. INDEX FOR DTC

DTC~3 DTC*3
Items Reference Items Reference
CONSULT (CONSULT screen terms) page CONSULT (CONSULT screen terms) page
ECM*1 ECM*1
GST*2 GST'2

- - Unable to access ECCS EC-76 P0500 0104 VEHICLE SPEED SEN EC-217

NO SELF DIAGNOSTIC P0505 0205 IACV-AAC VALVE EC-221

No DTC Flashing*S EC-45
FAILURE INDICATED
P0510 0203 CLOSED THRL POS SW EC-226
NO SElF DIAGNOSTIC
POOOO 0505
FAILURE INDICATED
- P0605 0301 ECM EC-230

P0705 1003 PARK/NEUT POSI SW EC-232

P0100 0102 MASS AIR FLOW SEN*4 EC-93
P1105 1302 MAP/BARO SW SOUV EC-237
ABSOL PRESS SEN·
P0105 0803 EC-100
SOR P1130 1004 SWIRL CONT SIV EC-243
P0110 0401 INT AIR TEMP SEN EC-107 P1165 0112 SWI RLN CONT VC SW EC-251
P0115 0103 COOLANT TEMP SEN*4 EC-113 P1320 0201 IGN SIGNAL-PRIMARY EC-256
P0120 0403 THROTTLE POSI SEN*4 EC-118 P1336 0905 CRANK PIS (OBD) COG EC-262
P0125 0908 'COOLANT TEMP SEN EC-124 P1400 1005 EGRC SOLENOIDIV EC-267
P0130 0307 CLOSED LOOP EC-134 P1401 0305 EGA TEMP SENSOR EC-271
P0130 0303 FRONT 02 SENSOR EC-129 P1441 0801 VCIV BYPASSIV EC-276
P0135 0901 FR 02 SEN HEATER EC-135 PURG VOLUME
P1445 1008 EC-281
P0136 CONTIV
0707 REAR 02 SENSOR EC-139

P0141 EVAP PURG FLOW/

0902 RR 02 SEN HEATER EC-143 P1447 0111 EC-288
MON
P0171 0115 FUEL SYS DIAG-LEAN EC-148
TOR CONV CLUTCH
P1550 0904 EC-295
P0172 0114 FUEL SYS DIAG-R/CH EC-153 SIV

P0180 0402 TANK FUEL TEMP SEN EC-158 P1900*6 0208 OVER HEAT EC-300

P0300 0701 MULTI CYL MISFIRE EC-162 *1: In D1agnost1c Test Mode II (Self-d1agnost1c results). These l?~1
numbers are controlled by NISSAN.
P0301 0608 CYL 1 MISFIRE EC-162
*2: These numbers are prescribed by SAE J2012.
P0302 0607 CYL 2 MISFIRE EC-162 *3: 1st trip DTC No. is the same as DTC No. ~l~:·
*4: When the fail-safe operation occurs, the MIL illuminates.
P0303 0606 CYL 3 MISFIRE EC-162
*5: While engine is running.
P0304 0605 CYL 4 MISFIRE EC-162 *6: Since this diagnosis does not meet P1900 of SAE J2012, it
is indicated only by CONSULT.
P0335 0802 CRANK POS SEN (OBD) EC-166

P0340 0101 CAMSHAFT POSI SEN EC-171

P0400 0302 EGA SYSTEM EC-176

P0402 0306 EGRC-BPT VALVE EC-184

TW CATALYST
P0420 0702 EC-186
SYSTEM

P0440 0705 EVAP (SMALL LEAK) EC-189

P0443 0807 PURG CONT/V & SIV EC-199

P0446 0903 VENT CONTROL VALVE EC-207

P0450 0704 EVAP SYS PRES SEN EC-212

EC-3 143
 PRECAUTIONS AND PREPARATION

Special Service Tools

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number
(Kent-Moore No.) Description
Tool name
(J36471-A) Loosening or tightening front and rear heated
Heated oxygen sensor oxygen sensors
wrench

NT379

EG17650301 Adapting radiator cap tester to radiator filler

(J33984-A)
Radiator cap tester adapter ct~=tb neck

a±cG===[}J:j:a a: 28 (1.10) dia.

b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
NT564 Unit mm (in)

Commercial Service Tool

Tool name Description

Fuel filler cap adapter Checking fuel tank vacuum relief valve open-
ing pressure

NT653

Supplemental Restraint System (SRS) "AIR

BAG"
The Supplemental Restraint System "Air Bag", used along with a seat belt, helps to reduce the risk or sever-
ity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of an air bag mod-
ule (located in the center of the steering wheel), a diagnosis sensor unit, warning lamp, wiring harness, crash
zone sensor (4WD models) and spiral cable. Information necessary to service the system safely is included
in the RS section of this Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed
by an authorized NISSAN dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses are covered with yellow insulation either just before the
harness connectors or for the complete harness, for easy identification.

144 EC-4
 PRECAUTIONS AND PREPARATION

Precautions for On Board Diagnostic (OBD)

System of Engine
The ECM (ECCS control module) has an on board diagnostic system. It will light up the malfunction indica- uiifl,
tor lamp (MIL) to warn the driver of a malfunction causing emission deterioration.
CAUTION:
• Be sure to turn the ignition switch "OFF" and disconnect the negative battery terminal before any i~l:iL
repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc.,
will cause the MIL to light up.
• Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will !,·~
cause the MIL to light up due to the open circuit. (Be sure the connector is free from water, grease,
dirt, bent terminals, etc.)
• Be sure to route and secure the harnesses properly after work. The interference of the harness with
a bracket, etc., may cause the MIL to light up due to the short circuit.
• Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube
may cause the MIL to light up due to the malfunction of the EGR system or fuel injection system, [0~
etc.
• Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM before
returning the vehicle to the customer. Ci~.

EC-5 145
 PRECAUTIONS AND PREPARATION

Engine Fuel & Emission Control System

WIRELESS EQUIPMENT
e When installing CB ham radio or a
mobile phone, be sure to observe the
following as it may adversely affect
FUEL PUMP electronic control systems depending
e Do not operate fuel pump when there on its installation location.
is no fuel in lines. 1) Keep the antenna as far away as
• Tighten fuel hose clamps to the possible from the electronic control
specified torque. (Refer to MA units.
section.) 2) Keep the antenna feeder line more than
BAITERY 20 em (7.9 in) away from the harness
e Always use a 12 volt battery as power of electronic controls.
source Do not let them run parallel tor a long
• Do not attempt to disconnect battery distance.
cables while engine is running. 3) Adjust the antenna and feeder line so
that the standing-wave ratio can be
kept smaller.
4) Be sure to ground the radio to vehicle
body

ECCS PARTS HANDLING

• Handle mass air flow sensor carefully to
avoid damage
• Do not disassemble mass air flow
sensor
• Do not clean mass air flow sensor with
ECM WHEN STARTING any type ot detergent
e Do not disassemble ECCS control e Do not depress accelerator pedal when • Do not disassemble IACV-AAC valve
module (ECM). starting. • Even a slight leak in the air intake
e Do nat turn diagnosis mode selector • Immediately after starting, do not rev up system can cause serious problems.
forcibly. engine unnecessarily. • Do not shock or jar the camshaft
e If a battery terminal is disconnected, • Do not rev up engine just prior to position sensor.
the memory will return to the ECM shutdown.
value.
ECCS HARNESS HANDLING
The ECCS will now start to self-control
e Securely connect EGGS harness
at its initial value. Engine operation can
connectors.
vary slightly when the terminal is
A poor connection can cause an
disconnected. However, this is not an
extremely high (surge) voltage to
indication of a problem. Do not replace
develop in coil and condenser, thus
parts because of a slight variation.
resulting •in damage to ICs
e Keep ECCS harness at least 10 em (3.9
in) away from adjacent harnesses, to
prevent an ECCS system malfunction
due to receiving external noise,
• Keep ECM parts and harnesses dry
• Before removing parts, turn of ignition
switch and then disconnect battery
ground cable

SEF903MC

146 EC-6
 PRECAUTIONS AND PREPARATION

Precautions
• Before connecting or disconnecting the ECM harness
connector, turn ignition switch OFF and disconnect nega-
tive battery terminal. Failure to do so may damage the
ECM because battery voltage is applied to ECM even if
ignition switch is turned off. ':"!01

SEF289H

Tightened Loosened
• When connecting ECM harness connector, tighten secur-
ing bolt until the gap between orange indicators disap-
pears.
[II]: 3- 5 N·m (0.3- 0.5 kg-m, 26- 43 in-lb)

• When connecting or disconnecting pin connectors into or

from ECM, take care not to damage pin terminals (bend or
break). 1iT~

~
Make sure that there are not any bends or breaks on ECM
pin terminal when connecting pin connectors.

t/ f1 !::to
Bend Break
SEF291H

[R0:~
Perform ECM • Before replacing ECM, perform ECM Terminals and Refer-
Terminals and ence Value inspection and make sure ECM functions prop-
Reference Value erly. Refer to EC-83. !Bill

•
..__e/
After performing each TROUBLE DIAGNOSIS, perform
"OVERALL FUNCTION CHECK" or "DTC (Diagnostic
\ I Trouble Code) CONFIRMATION PROCEDURE" .
The DTC should not be displayed in the "DTC CONFIRMA-
TION PROCEDURE" if the repair is completed. The
- CHECK- "OVERALL FUNCTION CHECK" should be a good result if '!"I,
the repair is completed.
/ '
I I \
SEF051P

EC-7 147
 PRECAUTIONS AND PREPARATION
Precautions (Cont'd)
• When measuring ECM signals with a circuit tester, never
allow the two tester probes to contact.
Battery Accidental contact of probes will cause a short circuit and
voltage damage the ECM power transistor.

NG

Solenoid valve

~QJ)
~Kl
Ciccuit testec

SEF348N

148 EC-8
 r±l
l!J
~
TORQUE
CONVERTER
:LUTCH 8[~ DATA LINK
)OLENOID
VALVE
l[O CONNECT:JH
FOR CONSULT I Ill IGNITION
SVIITUI
ON or

:~II~
I~
I VACUUM
FUSIBLE IGNITION SWTTCH START
cur vALVE

~UEL
LINK 1 .

EFIAccl oN I sT , BYPASS

~ 1 VALVE z
2:
~
4

li[SJ
J II PUMP

~ELM
I~

I~ m
z
~ ~
~ !~~i~~ON
~ Ill I
-,;
f'USE 20 G)
~ loN
z
~
0

BATTE'RY
INJECTOR I 17n Fl_lfl
M) GAUGE
TANK
U'lll
I;=;
; ~ COMBINATION m
1 ~IND.l
102
(FUEL PUMf-')
!~ rM~E~T~E~R==~ )>
I r z
·~ c
;:r::: Ill
1m
i"
'"'· 1.
i ~0.4
•104

109
117
26
_j
I m
s:
(/)
(/)
I
4 21
UUAL-t'RESSURE
Q
56 115
pn"
~REAR HEATED
0 0C: 0
113
52
OXYGEN SENSOR
z
m I A ----------r
61
ECM (t:CCS 32
d \) 1 ..... 1 SWIKL CONTROL
VALVE CONTROL
VEH!r.l F
SPFFIJ
SENSOR
-•
... 0
0
' I MASSS:~sbi"" I CLmn(:) II II I47 control
module)
~
VACUUM CHECK

S~IITCH ~---~
c 0
z
~0
~~~~~~ g;·
CRONT
CD 48 ??
INHIBITOR I
HFATFD
(]XlGFN
SENSOR '~---------
I
l____.
42
"'I t-e--l
51
~
ENGINE COOLANT
TEMPERATURE
_:=:__jSENSnR
NEIJTRAI
POSITION
SWITCH@
SWITCH ~
iil
3
-1
JJ
0
46
f ~ Jn~~g~ATURC
EGR
r-
I, 62 _ _=c_ _jiNTAKE AIR 0
28 I~TEMPERATURE
I-+·+~-_:=-
_ _jSENSOR PARK AND
<
m
106

Em
ABSOLUTE NEUTRAL AIR
PRESSURE JJ
112 57 SENSOR
POSITION
RELAY 0 CONOJT!CNER
RELAY )>
39 r-
'•3
15
r-
++---f-'c---0 CRANKSHAFT
53 To

"i:::::__IIIQ_
38 L~ _______\..} ~~~g~o~OBO) compressor (/)

~~~~TION r-';ct-c~cc=c=c=o~-+i-+-i-~ 40
44,
t------1'=;-
__
THROTTLE
POSITION
-<
(/)
23 SENSOR -1
~ " 49 m
; r --1 POSITION
-=- 1 1 SFNSOR
CAMSHAFT
S
25
FUEL TANK GAUGE UNIT
(TANK FUEL TEMPERATURE SENSOR)
s:
Htt::::::::;=';-
~~ ~~
63
EVAP CONTROL SYSTEM
PRESSURF SFNSOR
® 6 67

=J ~E
16
17 27
)>
~
-=-=
SPARK
="='
PLUG EVAP CANISTER 118 10 19 110 ( } ; ) : with A/T
c.u PURGE VOLUMI::
I I I
I
o CONTROL VALVI:: POSITION @: with M/T
SWITCH
<;; _[
149

~I '~l c-' ['UiJ

coo ·~ ~
(()
~
'Nl ~ @2) 'E},'
~cJJ ~}
!r" ~!i"-:o ---{1 :.a ,~,
~" F llllil
150

I Mass air flow sensor (Hot wire type)

r=_-

1 ,J __ L

m
Air cleaner

:""-.
Intake air~
IN®i' ECM
(ECCS control m
z
~ ~-
module)
temperature sensor ----·-- G>
MAP/BARO switch~
solenoid valve II I I ,- z
I
'
EVAP canister
m
Absolute EGRC- Fast idle - ~- purge control )>
solenoid solenoid valve z
valve Fuel c
+---- valve
m
s:
CJ)
CJ) CJ)
'<
I tn 0
m I iD z
0 3 0
....' c 0
0 I =}_~~~valve EGRC- ~~ Ill
z
-1
~ ~~I ...
cc
Ill
::0
0
Swirl control valve '2 Ignition switch 3 r-
-1-uum~~ ~ 0
switch EGA temperature
sensor
1
I
.
<
m
Engme coolant
Swirl control
1empera1ure sensor
Fuel ::0
valve temperature )>
sensor r-
Rear heated oxygen sensor Gear position signal
r-
CJ)
Muff Ier
Three wa
catal st oxygen sensor
0 -<
CJ)
-1
canister vent
m
control valve
Vehicle speed sensor
s:
*1: Ignition coil, power transistor and camshaft position sensor built into distributor ~6: EVAP canister purge control valve
*2· EVAP shut valve 7 Crankshaft position sensor (OBD)
*3: Vacuum cut valve bypass valve ~a: Fuel filter

"'m
~
*4: EVAP control system pressure sensor
·s· EVAP canister purge volume control valve
~
-l
 ENGINE AND EMISSION CONTROL OVERALL SYSTEM

ECCS Component Parts Location

EGRC-BPT valve
EGA valve
EGR temperature sensor Fuel pressure regulator
Fuel filter
Crankshaft position sensor (OBD)
One-way valve
EVAP canister purge
volume control valve
Absolute pressure

valve

Swirl
control valve
control vacuum'--1~~---
check switch

control solenoid valve

Condenser
Mass air flow sensor IACV-FICD solenoid valve Camshaft position sensor,
EVAP canister purge- power transistor and
IACV-AAC valve
control solenoid valve ignition coil
Throttle position sensor Engine coolant temperature sensor (built into distributor)

EGRC-BPT valve
Mass air flow sensor

Throttle position sensor

Swirl control valve

EGR valve

Sw1rl control valve control solenoid valve

~~rc

SEF725T

EC-11 151
 ENGINE AND EMISSION CONTROL OVERALL SYSTEM
ECCS Component Parts Location (Cont'd)

''

Threeway catalyst
AEC127A

Crankshaft position
sensor (OBD)

SEF578P SEF227S

Under the front passenger's seat

\'" wo~ -•~• """'

I
I

/
/~ Front

~.--J SEF161S

152 EC-12
 ENGINE AND EMISSION CONTROL OVERALL SYSTEM

Vacuum Hose Drawing

EGRC-BPT valve
Swirl control
valve actuator

EGR

Fuel pressure
regulator
To air cllear,er-,

EVAP canister purge

volume control valve

EVAP canister ouroe --"

control solenoid valve
One-way

MAP/BARO
solenoid swltc,,--J

Vacuum gallery
To EGRC-solenoid valve
Swirl control valve corttro·l__j
vacuum check switch
valve
To fuel pressure
regulator

To air
cleaner

To swirl control
valve and solenoid valve.._
To throttle body

To EVAP canister
purge control
solenoid valve
To swirl control valve
control vacuum
connector
check switch
To MAP/BARO solenoid switch

Refer to "System Diagram", EC-10 for vacuum control system. AEC146A

EC-13 153
 ENGINE AND EMISSION CONTROL OVERALL SYSTEM

System Chart
Camshaft position sensor
Fuel injection & Injectors
mixture ratio control
Mass air flow sensor

Engine coolant temperature sen- Distributor ignition system Power transistor

sor

Front heated oxygen sensor Idle air control system IAGV-AAG valve and IAGV-FIGD
_I
solenoid valve

Ignition switch

Fuel pump control ~: Fuel pump relay

Throttle position sensor
I
.3
Front heated oxygen sensor Malfunction indicator lamp
Closed throttle position switch monitor & on board diagnostic (On the instrument panel)
I
system

Neutral position/Inhibitor switch

Swirl control valve control Swirl control valve control sole-

Air conditioner switch noid valve

.1
EGM
• EGA temperature sensor (EGGS EGR control EGRC-solenoid valve
• Intake air temperature sensor control
• Absolute pressure sensor module)
• EVAP control system pressure
sensor
Front heated oxygen sensor Front heated oxygen sensor
heater control heater
Battery voltage

Rear heated oxygen sensor Rear heated oxygen sensor

Power steering oil pressure
switch heater control heater

Vehicle speed sensor

Air conditioning cut control Air conditioner relay

Tank fuel temperature sensor

EVAP canister purge flow con- • EVAP canister purge volume
.1 trol control valve
Crankshaft position sensor • EVAP canister purge control
(OBD) solenoid valve
I
.2
Rear heated oxygen sensor • EVAP canister vent control
I
valve
.1 • Vacuum cut valve bypass
Swirl control valve control I valve
vacuum check switch • MAP/BARO switch solenoid
valve

*1: These sensors are not used to control the engine system. They are used only for the on board diagnosis.
*2: This sensor is not used to control the engine system under normal conditions.
*3: This switch will operate in place of the throttle position sensor to control EVAP parts if the sensor malfunctions.

154 EC-14
 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

Multipart Fuel Injection (MFI) System

INPUT/OUTPUT SIGNAL LINE
I Camshaft position sensor 1 Engine speed

1 Amount of intake air

I Mass air flow sensor

1 Engine coolant temperature

I Engine coolant temperature sensor

1 Density of oxygen in exhaust gas

j Front heated oxygen sensor

I_ Throttle position
I Throttle position sensor ECM
Throttle valve idle position (ECCS
· I Injector
control I
1 Gear position module)
I Neutral position/Inhibitor switch

1 Vehicle speed
I Vehicle speed sensor

1 Start signal
!Ignition switch

Air conditioner operation

I Air conditioner switch 1

Battery voltage
I Battery 1

BASIC MULTIPORT FUEL INJECTION VARIOUS FUEL INJECTION

SYSTEM INCREASE/DECREASE COMPENSATION
The amount of fuel injected from the fuel injector is In addition, the amount of fuel injection is compen-
l~;l~
determined by the ECM. The ECM controls the sated for to improve engine performance under vari-
length of time the valve remains open (injection ous operating conditions as listed below.
pulse duration). The amount of fuel injected is a (Fuel increase)
program value in the ECM memory. The program • During warm-up
value is preset by engine operating conditions. • When starting the engine
These conditions are determined by input signals • During acceleration
(for engine speed and air intake) from both the cam- • Hot-engine operation
shaft position sensor and the mass air flow sensor. • High-load, high-speed operation
(Fuel decrease)
• During deceleration
• During high engine speed operation

EC-15 155
 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
Multipart Fuel Injection (MFI) System (Cont'd)
MIXTURE RATIO FEEDBACK CONTROL

e
CLOSED LOOP
CONTROL ECM
The mixture ratio feedback system provides the best air-fuel mix-
(ECCS
control Injection pulse ture ratio for driveability and emission control. The three way cata-
Feedback signal
lyst can then better reduce CO, HC and NOx emissions. This sys-
Fmrit~ module) tem uses a front heated oxygen sensor in the exhaust manifold to

\euel
heated
( oxygen
sensor

Combustion
Engme
Injector

lnj8Ctlon

MEF025DA
monitor if the engine is rich or lean. The ECM adjusts the injection
pulse width according to the sensor voltage signal. For more infor-
mation about front heated oxygen sensor, refer to page EC-129.
This maintains the mixture ratio within the range of stoichiometric
(ideal air-fuel mixture).
This stage is referred to as the closed loop control condition.
The rear heated oxygen sensor is located downstream of the three
way catalyst Even if the switching characteristics of the front
heated oxygen sensor shift, the air-fuel ratio is controlled to sto-
ichiometric by the signal from the rear heated oxygen sensor.

OPEN LOOP CONTROL

The open loop system condition refers to when the ECM detects
any of the following conditions. Feedback control stops in order to
maintain stabilized fuel combustion.
• Deceleration and acceleration
• High-load, high-speed operation
• Engine idling
• Malfunction of front heated oxygen sensor or its circuit
• Insufficient activation of front heated oxygen sensor at low
engine coolant temperature
• High-engine coolant temperature
• During warm-up
• After shifting from "N" to "D"
• When starting the engine

MIXTURE RATIO SELF-LEARNING CONTROL

The mixture ratio feedback control system monitors the mixture
ratio signal transmitted from the front heated oxygen sensor. This
feedback signal is then sent to the ECM. The ECM controls the
basic mixture ratio as close to the theoretical mixture ratio as pos-
sible. However, the basic mixture ratio is not necessarily controlled
as originally designed. Both manufacturing differences (i.e. mass
air flow sensor hot wire) and characteristic changes during opera-
tion (i.e., injector clogging) directly affect mixture ratio.
Accordingly, the difference between the basic and theoretical mix-
ture ratios is monitored in this system. This is then computed in
terms of "injection pulse duration" to automatically compensate for
the difference between the two ratios.
"Fuel trim" refers to the feedback compensation value compared
against the basic injection duration. Fuel trim includes short-term
fuel trim and long-term fuel trim.
"Short-term fuel trim" is the short-term fuel compensation used to
maintain the mixture ratio at its theoretical value. The signal from
the front heated oxygen sensor indicates whether the mixture ratio
is RICH or LEAN compared to the theoretical value. The signal
then triggers a reduction in fuel volume if the mixture ratio is rich,
and an increase in fuel volume if it is lean.
"Long-term fuel trim" is overall fuel compensation carried out long-
term to compensate for continual deviation of the short-term fuel
trim from the central value. Such deviation will occur due to indi-
vidual engine differences, wear over time and changes in the usage
environment

156 EC-16
 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
Multiport Fuel Injection (MFI) System (Cont'd)
FUEL INJECTION TIMING @I
~ Injection pulse

No. 1 cylinder Two types of systems are used.

Sequential multiport fuel injection system
No. 2 cylinder IL
Fuel is injected into each cylinder during each engine cycle accord-
ing to the firing order. This system is used when the engine is run-
No. 3 cylinder
ning.
No. 4 cylinder

1--- 1 engine cycle - _,

Sequential multipart fuel injection system
MEF522D

Simultaneous multiport fuel injection system

No. 1cylinder~ Fuel is injected simultaneously into all four cylinders twice each
No. 2 cylinder J"L_______fl___
engine cycle. In other words, pulse signals of the same width are I'll"
simultaneously transmitted from the ECM.
No. 3 cylinder J"L_______fl___ The four injectors will then receive the signals two times for each

cylinder~ enhgine cycle: d h h . . b . d d/ 'I th ©L

No.4 T IS system 1s use w en t e engme IS emg starts an or 1 e
~ 1 engine cycle --j fail-safe system (CPU) is operating.
Simultaneous multipart fuel injection system
FUEL SHUT-OFF
MEF523D Fuel to each cylinder is cut off during deceleration or operation of
the engine at excessively high speeds.

Distributor Ignition (DI) System

INPUT/OUTPUT SIGNAL LINE
Engine speed
I Camshaft position sensor I
Amount of intake air
I Mass air flow sensor
I
Engine coolant temperature
[ Engine coolant temperature sensor
I
Throttle position
I Throttle position sensor EGM
I Throttle valve idle position (EGGS Power tran-
control sister
Vehicle speed
I Vehicle speed sensor module)
I
Start signal
1
: . Ignition switch
I
Gear position
Neutral position/Inhibitor switch
I
Battery voltage
. Battery
I

EC-17 157
 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
Distributor Ignition (DI) System (Cont'd)
Tp SYSTEM DESCRIPTION
(msec)
1.751-~o----+~--+~--+~* The ignition timing is controlled by the ECM to maintain the best
A air-fuel ratio for every running condition of the engine.
~ 1.50 ~-~,___..,,___,~--...~*
The ignition timing data is stored in the ECM. This data forms the
••
~ 1.251-~,___..,,___,~--...~* map shown.
~ The ECM detects information such as the injection pulse width and
c 1.00 1-~,___..,,___,~--...~-t- camshaft position sensor signal. Responding to this information,
0
ignition signals are transmitted to the power transistor.
~ 0.7Sf------1o---1o-----+~-+~-t-
5 e.g. N: 1,800 rpm, Tp: 1.50 msec
600 1,000 1,400 1,800 2,200 N
A 0 BTDC
Engine speed (rpm) SEF742M During the following conditions, the ignition timing is revised by the
ECM according to the other data stored in the ECM.
• At starting
• During warm-up
• At idle
• When swirl control valve operates
• Hot engine operation
• During acceleration

Air Conditioning Cut Control

INPUT/OUTPUT SIGNAL LINE

! Air conditioner switch 1 Air conditioner ON signal

1 Start signal
I Ignition switch
EGM
Air condi-
[ Throttle position sensor
1Throttle valve opening angle (EGGS
control tioner
module) relay
1 Engine speed
I Camshaft position sensor

1 Engine coolant temperature

I Engine coolant temperature sensor

SYSTEM DESCRIPTION
This system improves engine operation when the air
conditioner is used.
Under the following conditions, the air conditioner is
turned off.
• When the accelerator pedal is fully depressed.
• When cranking the engine.
• When the engine coolant temperature becomes
excessively high.

158 EC-18
 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION

Fuel Cut Control (at no load & high engine

speed)
INPUT/OUTPUT SIGNAL LINE
1 Vehicle speed
J Vehicle speed sensor

1 Neutral position
J Neutral position/Inhibitor switch
ECM
1 Throttle position (ECCS
Throttle position sensor control
J
I Injectors
module) I
1 Engine coolant temperature
/ Engine coolant temperature sensor

Engine speed
I Camshaft position sensor 1

If the engine speed is above 3,500 rpm with no load (for example, ('ill
in neutral and engine speed over 3,500 rpm) fuel will be cut off after
some time. The exact time when the fuel is cut off varies based on
engine speed. !:en
Fuel cut will operate until the engine speed reaches 1 ,500 rpm,
then fuel cut is cancelled.
NOTE: ~
This function is different than deceleration control listed
under multiport fuel injection on EC-15.

EC-19 159
 EVAPORATIVE EMISSION SYSTEM

Description
EVAP canister purge control solenoid valve

Intake manifold

EVAP canister purge control valve

t
Q :Air
pressure relief valve . . . Fuel vapor
and vacuum relief ~
valve ~ SEF229S
Fuel tank

The evaporative emission system is used to reduce hydrocarbons

emitted into the atmosphere from the fuel system. This reduction
of hydrocarbons is accomplished by activated charcoals in the
EVAP canister.
The fuel vapor in the sealed fuel tank is led into the EVAP canis-
ter which contains activated carbon and the vapor is stored there
when the engine is not operating.
The vapor in the EVAP canister is purged by the air through the
purge line to the intake manifold when the engine is operating.
EVAP canister purge volume control valve is controlled by engine
control module. When the engine operates, the flow rate of vapor
controlled by EVAP canister purge volume control valve is propor-
tionally regulated as the air flow increases.
EVAP canister purge control valve shuts off the vapor purge line
during decelerating and idling, and under normal operating condi-
tions the valve is usually open.
EVAP shut valve shuts off the vapor charge line when fuel is being
supplied to the fuel tank.

Inspection
EVAP CANISTER
Check EVAP canister as follows:
1. Pinch the fresh air vent hose.
2. Blow air in port® and check that it flows freely out of port@.

SEF230S

160 EC-20
 EVAPORATIVE EMISSION SYSTEM
Inspection (Cont'd)
TIGHTENING TORQUE :3JI
Tighten EVAP canister as shown in the figure_
Make sure new 0-ring is installed properly between EVAP can- [liftc
ister and EVAP canister vent control valve.

r~u:il

(0.85 - 1.10, 74.4 - 95.5)

~ : N•m (kg-m, in-lb) SEF231S

FUEL TANK VACUUM RELIEF VALVE (Built into fuel

filler cap)
1. Wipe clean valve housing.
2. Check valve opening pressure and vacuum.
Pressure:
15.3 - 20.0 kPa (0.156 - 0.204 kglcm 2 , 2.22 - 2.90
psi)

'-----c='~ Valve B
Vacuum:
-6.0 to -3.3 kPa (-0.061 to -0.034 kglcm 2 , -0.87 to
-0.48 psi)
ut1r
Fuel tank side 3. If out of specification, replace fuel filler cap as an assembly.
SEF427N
CAUTION: l0)i'
Use only a genuine fuel filler cap as a replacement. If an incor-
rect fuel filler cap is used, the MIL may come on.

One-way
valve
Fuel filler cap adapter
SEF943S

EVAPORATIVE EMISSION (EVAP) SHUT VALVE

~Mo•e than
21 {0.83) dia.
•

•
When pushing down the shutter inside the fuel filler opening,
the EVAP shut valve is closed.
When releasing the shutter, the valve is open.
1. Blow air from one side of the EVAP shut valve tube <!) or ®
valve and check that there is air flow.
Insert 2. Insert suitable steel tube as shown in the figure_
more than 3. Blow air from one side of the EVAP shut valve tube <!) or ®
130 (5.12) and check that there is no air flow.

Unit: mm (in)
EVAP CANISTER PURGE CONTROL VALVE
SEF319QA Refer to EC-199.
VACUUM CUT VALVE
Refer to EC-280.
EVAPORATIVE EMISSION (EVAP) CANISTER PURGE l.'Ji(,
VOLUME CONTROL VALVE
Refer to EC-281.
EVAPORATIVE EMISSION (EVAP) CANISTER PURGE
CONTROL SOLENOID VALVE
Refer to EC-199.
TANK FUEL TEMPERATURE SENSOR
Refer to EC-158.
EC-21 161
 EVAPORATIVE EMISSION SYSTEM

Evaporative Emission Line Drawing

EVAP canister purge volume control valve

EVAP canister
purge control valve

next page

SEF233S

162 EC-22
 EVAPORATIVE EMISSION SYSTEM
Evaporative Emission Line Drawing (Cont'd)

EVAP control systerr1-,

EVAP shut valve pressure sensor

EVAP canister vent ~L"

Vacuum cut valve

EVAP canister
B

SEF234S

EC-23 163
 POSITIVE CRANKCASE VENTILATION

Description
This system returns blow-by gas to the intake manifold collector.
The positive crankcase ventilation (PCV) valve is provided to con-
duct crankcase blow-by gas to the intake manifold.
During partial throttle operation of the engine, the intake manifold
Baffle plate sucks the blow-by gas through the PCV valve.
Normally, the capacity of the valve is sufficient to handle any
"-seal type oil blow-by and a small amount of ventilating air.
lever gauge The ventilating air is then drawn from the air duct into the crank-
¢:J: Fresh air case. In this process the air passes through the hose connecting
+: Blow-by gas
SEF156E air inlet tubes to the rocker cover.
Under full-throttle condition, the manifold vacuum is insufficient to
draw the blow-by flow through the valve. The flow goes through the
hose connection in the reverse direction.
On vehicles with an excessively high blow-by, the valve does not
meet the requirement. This is because some of the flow will go
through the hose connection to the intake collector under all con-
ditions.

Inspection
PCV (Positive Crankcase Ventilation) VALVE
With engine running at idle, remove PCV valve frorn breather sepa-
rator. A properly working valve makes a hissing noise as air passes
through it. A strong vacuum should be felt immediately when a fin-
ger is placed over the valve inlet.

SEC137A

PCV HOSE
1. Check hoses and hose connections for leaks.
2. Disconnect all hoses and clean with compressed air. If any
hose cannot be freed of obstructions, replace.

ET277

164 EC-24
 BASIC SERVICE PROCEDURE

Fuel Pressure Release

I FUEL PRES RELEASE I 0
Before disconnecting fuel line, release fuel pressure from fuel
FUEL PUMP WILL STOP BY line to eliminate danger.
TOUCHING START DURING
IDLE
ilil\ 1. Start engine.
CRANK A FEW TIMES AFTER
~) 2. Perform ""FUEL PRESSURE RELEASE" in "WORK
ENGINE STALL SUPPORT" mode with CONSULT. ~~'1'1!
(Touch "START", and after engine stalls, crank it two or
three times to release all fuel pressure.)
3. Turn ignition switch OFF. lCi
SEF823K

Remove fuse for fuel pump.

® ~: 3.
Start engine.
After engine stalls, crank it two or three times to release
all fuel pressure. :C!Ci
4. Turn ignition switch OFF and reinstall fuel pump fuse.

SEF235S

Unit: mm (in}
Fuel Pressure Check
a. When reconnecting fuel line, always use new clamps.
' '
-',_.l-
b. Make sure that clamp screw does not contact adjacent 'rl'
parts.
c. Use a torque driver to tighten clamps.
d. Use Pressure Gauge to check fuel pressure. ~tJ
28(1.10)
1. Release fuel pressure to zero.
~ Fuel hose clamps
1.0 - 1.5 N·m
2. Disconnect fuel hose between fuel filter and fuel tube (engine
(0.10 · 0.15 kg-m, side). f'ii
8.7- 13.0 in-lb) 3. Install pressure gauge between fuel filter and fuel tube.
~==============M=MA;::'=o4~A 4. Start engine and check for fuel leakage.
5. Read the indication of fuel pressure gauge.
At idling:
Approximately 235 kPa (2.4 kg/cm 2 , 34 psi)
A few seconds after ignition switch is turned OFF to
ON:
Approximately 294 kPa (3.0 kg/cm 2 , 43 psi)
[s)'J
6. Stop engine and disconnect fuel pressure regulator vacuum
hose from intake manifold.
7. Plug intake manifold with a rubber cap.
8. Connect variable vacuum source to fuel pressure regulator.

EC-25 165
 BASIC SERVICE PROCEDURE
Fuel Pressure Check (Cont'd)
9. Start engine and read indication of fuel pressure gauge as
vacuum is changed.
Vacuum Fuel pressure
Fuel pressure should decrease as vacuum increases. If results
are unsatisfactory, replace fuel pressure regulator.

AC~=--
f To pressure regulator

SEF718B

Injector Removal and Installation

1. Release fuel pressure to zero.
2. Remove injector tube assembly with injectors from intake
manifold.
3. Remove injectors from injector tube assembly.
• Push injector tail piece.
• Do not pull on the connector.
4. Install injector to fuel tube assembly.
a. Clean exterior of injector tail piece.
b. Use new 0-rings.
SEF238S

Always replace 0-rings with new ones.

Insulator--
'
~
~~ (0.30 - 0.39 kg-m, 2.9 - 3.8 N·m Lubricate 0-rings with a smear of engine oil.
--------~~ 26.0 - 33.9 in-lb)

'· , , ; ---- Locate plate

' I on thiS Side.
Fuel tube 1

assembly~ i bj__

~0-ringf;1
) (
~Insulator SEF118S

5. Install injectors with fuel tube assembly to intake manifold.

¢ Engine front Tighten in numerical order shown in the figure.
a. First, tighten all bolts to 9.3 to 10.8 N·m (0.95 to 1 .1 kg·m, 6.9
to 8.0 ft-lb).
b. Then, tighten all bolts to 21 to 26 N·m (2.1 to 2. 7 kg·m, 15 to
20 ft·lb).
6. Install fuel hoses to fuel tube assembly.
7. Reinstall any parts removed in reverse order of removal.
CAUTION:
Fuel tube assembly After properly connecting injectors to fuel tube assembly,
SEFtoos check connections for fuel leakage.
L-----------------------~

166 EC-26
BASIC SERVICE PROCEDURE

Fast Idle Cam (FIC) Inspection and Adjustment

1. Remove air cleaner assembly.
2. Make sure the FIG alignment mark is centered on the lever
roller as shown in the figure.
• An alignment mark is stamped on the FIG so that the top of the
cam will face in the correct direction. ~~il

• If necessary, adjust the FIG screw ® until the alignment mark

is centered on the lever roller.

3. Start engine and warm up to operating temperature.

4. Measure clearance @ between the lever roller and the top of
the FIG using a feeler gauge as shown in the figure.
Clearance@:
MIT model
2.0- 2.6 mm (0.079- 0.102 in)
AfT model
1.8 - 2.4 mm (0.071 - 0.094 in)

• If clearance @ is out of specification, adjust clearance @

using adjusting screw @ to 2.3 mm (0.091 in) (MIT) or 2.1 mm
(0.083 in) (AfT).

EC-27 167
 BASIC SERVICE PROCEDURE

Idle Speed/Ignition Timing/Idle Mixture Ratio

Adjustment
PREPARATION • On air conditioner equipped models,
• Make sure that the following parts are in checks should be carried out while the air
good order. conditioner is "OFF".
(1) Battery • When checking idle speed, ignition timing
(2) Ignition system and mixture ratio of AfT models, shift lever
(3) Engine oil and coolant levels to "N" position.
(4) Fuses • When measuring "CO" percentage, insert
(5) ECM harness connector probe more than 40 em (15.7 in) into tail
(6) Vacuum hoses pipe.
(7) Air intake system • Turn off headlamps, heater blower, rear win-
(Oil filler cap, oil level gauge, etc.) dow defogger.
(B) Fuel pressure • Keep front wheels pointed straight ahead.
(9) Engine compression • Make the check after the cooling fan has
(1 0) EGA valve operation stopped.
(11) Throttle valve
(12) Evaporative emission (EVAP) canister
purge control valve
Overall inspection sequence
INSPECTION

Perform diagnostic test mode II ~ Repair or replace.

(Self-diagnostic results).

OK

Check ignition timing .

•
Check & adjust idle speed.

~
Check front heated oxygen sensor
function.
~ Check front heated oxygen sen-
sor harness.
Repair or replace harness.
f.-
OK OK

Check CO%.
~ Replace front heated oxygen sen-
sor.
NG

Check emission control parts and NG Check front heated oxygen sensor I OK,
repair or replace if necessary. I+- function.

INSPECTION END
I

168 EC-28
 BASIC SERVICE PROCEDURE
Idle Speed/Ignition Timing/Idle Mixture Ratio
Adjustment (Cont'd)
TEMP
_t_
START

~~ :~,

t
120 270 Visually check the folfowing:
• Air cleaner clogging
• Hoses and ducts for leaks
• EGR valve operation
l • Electrical connectors
• Gasket
SEF246FI • Throt11e valve and throttle position sensor operations
~---------~~---------~

fi.1 t
Start engine and warm it up until engine coolant temperature
indicator points to the middle of gauge and ensure that engine
speed is below 1,000 rpm.

l
Open engine hood and run engine at about 2,000 rpm for about
2 minutes under no-load.

SEF247F r!J
~------------J_------------~
_l

. .e/
Pertorm the diagnostic test mode II (Self-diagnostic results).

~NG
\ I I OK

I Repair or replace components as necessary. lw

- CHECK-
/ ..... l
I I \ Run engine at about 2,000 rpm for about 2 minutes under no-
load.
Rev engine two or three times under no-load. then run engine for
Maltunct1on indicator
lamp about 1 minute at idle speed.

~~========================S=EF=0=5=1P~A L~----------------------~--------------------~
~ ~--------------~----------------, 1
'~'''~111\""1"'111;;,~ (i) L Select "IGNITION TIMING ADJ" in WORK SUPPORT
~,,N~~ 5 ,~ ~ mode.

~"
2. Touch "START"".
4
.:~2( ~ ~ 1. Stop engine and disconnect throttle position
: 1\ 6 ~- sensor harness connector.

t,
:::«= ~C1r' ;:!
7
=- 2. Start engine.

i
%-o x1000 r/min
BJ/ Rev engine (2,000 - 3.000 rpm) 2 or 3 times under no-load and
run engine at idle speed.
I SEF248F L_____________________, -____________________j

~~~~~.~IG~N~T~IM~IN~G~A~D~J~.~[J~==~rGI=----------------~1----------------~
Check ignition timing with a timing light.
IGNITION TIMING FEEDBACK
CONTROL WILL BE HELD BY MfT: 10"±2" BTDC
TOUCHING START AfT: 10"±2" BTDC (in "N" position)
AFTER DOING SO, ADJUST
IGNITION TIMING WITH A tOK tNG
TIMING LIGHT BY TURNING ® ®
THE CAMSHAFT POSITION I (Go to next page,) (Go to next page,)
SENSOR,

1'-----S=-T_,__A"'-R'-'-T_ __::'j i
SEF546NI

EC-29 169
 BASIC SERVICE PROCEDURE
Idle Speed/Ignition Timing/Idle Mixture Ratio
Adjustment (Cont'd)
® ®
l
Adjust ignition timing to the specified value by turning dis-
tributor after loosening bolts which secure distributor.

MfT: 10'±2' BTDC

AfT: 10'±2' BTDC (in "N" position)

SMA189AA ®
~
• IGN TIMING ADJ • 0 (ij\ 1. Select "IGNITION TIMING ADJ" in WORK
'~ SUPPORT mode.
IGNITION TIMING FEEDBACK
2. Touch "START".
CONTROL WILL BE HELD BY
TOUCHING START
1. Stop engine and disconnect throttle position
AFTER DOING SO. ADJUST
sensor harness connector.
IGNITION TIMING WITH A
2. Start engine.
TIMING LIGHT BY TURNING
THE CAMSHAFT POSITION
SENSOR.

START Check base idle speed.

SEF546N
Read idle speed in "IGN TIMING ADJ" mode

u1:::7/:: ~·
with CONSULT.

~:~
~~~);
Check idle speed.

MfT: 750±50 rpm

-;:-c;~f~;
'31
¥3-_q:
',J(, )\/("~
AfT: 750±50 rpm (in "N" position)

OK ~NG
Rev engine (2,000 - 3,000 rpm) 2 or 3 times under no-
load and run engine at idle speed.

~ SEF240SA

D Adjust base idle speed by turning idle speed adjusting

screw.

MfT: 750±50 rpm

AfT: 750±50 rpm (in "N" position)

D
Touch "Back".
SEF913J

1. Stop engine and connect throttle position sen-

sor harness connector.
2. Start engine.

Rev engine (2,000- 3,000 rpm) 2 or 3 times under no-

load and run engine at idle speed . I

©•
(Go to next page.)
SEF602K

170 EC-30
 BASIC SERVICE PROCEDURE
Idle Speed/Ignition Timing/Idle Mixture Ratio
II Adjustment (Cont'd)
1< MONITOR fr NO FAIL D ©
CMPS•RPM(REF) 800rpm II 1
Check target idle speed.

® Read idle speed in "DATA MONI-

TOR" mode with CONSULT.
OR

I RECORD I ® Check idle speed.

SEF712T MfT: 800o<50 rpm

AfT: 800o<50 rpm (in "N" position)
I)
OK ~NG

,
Check IACV-AAC valve and replace if neces- [S?,
il-'=
sary.
c
<?
·~
C' ~ ~
~ '" Check IACV-AAC valve harness and repair if
necessary.

~
SEF957D Check ECM function* by substituting another
known good ECM.
Ill t. MONITOR t. NO FAIL D
2000rpm • EC M may be !he "''"
CMPS•RPM (REF)
FR 02 MNTR RICH cau seofa Ju--
prob lem, but this is
rare Iy the case.
I)
Set the diagnostic test mode II (front heated
oxygen sensor monitor).

~
I RECORD I
SEF054P
Run engine at about 2,000 rpm for about 2
minutes under no-load.

m
\ I I
lllm l
®
Check front heated oxygen sensor signal.

'~
1. See "FR 02 MNTR" in "DATA
MONITOR'' mode.
- CHECK- 2. Maintaining engine at 2,000 rpm
under no-load (engine is warmed
/ ' up sufficiently), check that the
I I \ monitor fluctuates between
"LEAN" and "RICH" more than 5
times during 10 seconds.
1 cycle: RICH --+ LEAN --+ RICH NG
SEF051P 2 cycles: RICH --+ LEAN --+ RICH @
--+ LEAN --+ RICH (Go to next page.) ~'jl
OR

® Make sure that malfunction indicator

lamp goes on and off more than 5
times during 10 seconds at 2,000
rpm.

~OK
INSPECTION END

EC-31 171
 BASIC SERVICE PROCEDURE
Idle Speed/Ignition Timing/Idle Mixture Ratio
00 Adjustment (Cont'd)
Front heated oxygen sensor
harness connector
@
dn 00 l
'18'~ ~
Check front heated oxygen sensor harness:
1. Turn off engine and disconnect battery ground
cable.
2. Disconnect ECM harness connector from ECM.
-7 I 3. Disconnect front heated oxygen sensor harness
MEF031DA connector and connect terminal for front heated
oxygen sensor to ground with a jumper wire.
00 4. Check for continuity between terminal @ of

~
ECM harness connector and ground metal on
II ECM l1 CONNECTOR II
DISCQNNECT
vehicle body.
46

18 Continuity exists ... OK

Continuity does not exist ... NG
=

-
[ill
00 OK

I Repair harness.
~ NG

•®
I (Go to EC-30.)
7
SEF056P
Connect ECM harness connector to ECM.

~
® 1. Select "ENG COOLANT TEMP" m
"ACTIVE TEST" mode.
2. Set "COOLANT TEMP" at S"C (41"F).

® • Disconnect engine coolant temperature

sensor harness connector.
• Connect a resistor (4.4 k!1) between ter-
minals of engine coolant temperature
sensor harness connector.

~
Start engine and warm it up until engine coolant
temperature indicator points to the middle of gauge.
(Be careful to start engine after setting "COOLANT
TEMP" or installing a 4.4 k!1 resistor.)

~
Rev engine two or three times under no-load then
run engine at idle speed.

t
®
(Go to next page.)

172 EC-32
BASIC SERVICE PROCEDURE
Idle Speed/Ignition Timing/Idle Mixture Ratio
Adjustment (Cont'd) .jj1J
®
I
Check "CO"%.
Idle CO: less than 11% and engine runs smoothly.
After checking ''CO''%

@ 1. Touch "BACK"".

® 1. Disconnect the resistor from terminals of engine

coolant temperature sensor harness connector.
2. Connect engine coolant temperature sensor har-
ness connector to engine coolant temperature sen-
sor.
NG l OK

Replace front heated oxygen sensor, set the diagnostic test mode
II (Front heated oxygen sensor monitor) and make sure that mal-
function indicator lamp goes on and off more than 5 times during
10 seconds. (2,000 rpm, no-load)

NG OK

®
Connect front heated oxygen sensor harness connector to (Go to EC·30.)
front heated oxygen sensor.

1
Check fuel pressure regulator. Refer to EC-25.

l
Check mass air flow sensor and its circuit.
Refer to TROUBLE DIAGNOSIS FOR DTC P0100. EC·93.

l
Check injector and its circuit.
Refer to TROUBLE DIAGNOSIS FOR NON-DETECTABLE
ITEMS. EC-303.
Clean or replace if necessary.

l
Check engine coolant temperature sensor and its circuit. Refer
to TROUBLE DIAGNOSIS FOR DTC P0115. P0125. EC-113.
124.

l
Check ECM function~ by substituting another known good
ECM.

*: E~~ may be the cause of a problem, but

th1s 1s rarely the case.
®
(Go to EC·30.)
• If a vehicle contains a part which is operating outside of design speci· ~;l
fications with no MIL illumination, the part shall not be replaced prior
to emission testing unless it is determined that the part has been
tampered with or abused in such a way that the diagnostic system
cannot reasonably be expected to detect the resulting malfunction.

EC-33 173
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

Introduction
The ECM (ECCS control module) has an on board diagnostic system, which detects malfunctions related to
engine sensors or actuators. The ECM also records various emission-related diagnostic information. Includ-
ing:
• Diagnostic Trouble Code (DTC) .................................................................................Mode 3 of SAE J1979
• Freeze Frame data .....................................................................................................Mode 2 of SAE J1979
• System Readiness Test (SRT) code........ ........................................................ Mode 1 of SAE J1979
• 1st Trip Diagnostic Trouble Code (1st Trip DTC) ....................................................... Mode 7 of SAE J1979
• 1st Trip Freeze Frame data
• Test values and Test limits ......................................................................................... Mode 6 of SAE J1979
The above information can be checked using procedures listed in the table below.
Freeze Frame 1st trip Freeze
DTC 1st trip DTC SRT code Test value
data Frame data

Diagnostic test
mode II (Self-
diagnostic
0 o·1
results)
CONSULT 0 0 0 0 0 0
GST 0 o·2 0 0 0
..
1. When DTC and 1st tnp DTC Simultaneously appear on the display, they cannot be clearly d1St1ngu1shed from each other.
*2: 1st trip DTCs for self-diagnoses concerning SRT items cannot be shown on the GST display.

The malfunction indicator lamp (MIL) on the instrument panel lights up when the same malfunction is detected
in two consecutive trips (Two trip detection logic), or when the ECM enters fail-safe mode (Refer to EC-76.).

Two Trip Detection Logic

When a malfunction is detected for the first time, 1st trip DTC and 1st trip Freeze Frame data are stored in
the ECM memory. The MIL will not light up at this stage. (1st trip)
If the same malfunction is detected again during the next drive, the DTC and Freeze Frame data are stored
in the ECM memory, and the MIL lights up. The MIL lights up at the same time when the DTC is stored. (2nd
trip) The "trip" in the "Two Trip Detection Logic" means a driving mode in which self-diagnosis is performed
during vehicle operation. Specific on board diagnostic items will cause the ECM to light up or blink the MIL
and store DTC and Freeze Frame data, even in the 1st trip as shown below.
'
MIL DTC 1st trip DTC

Items 1st trip 2nd trip 1st trip 2nd trip 1st trip 2nd trip
Blinking Lighting up lighting up displaying displaying displaying displaying

Misfire (Possible three way catalyst

damage)
X X X
- DTC: P0300 - P0304 (0701,
0605 - 0608) is being detected
Misfire (Possible three way catalyst
damage)
X X X
- DTC: P0300 - P0304 (0701.
0605 - 0608) has been detected
Closed loop control - DTC: P0130
X X X
(0307)
Fail-safe items (Refer to EC-76.) X x·1 x·1

Except above X X X X
.. ..
1. Except " ECM .

174 EC-34
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

Emission-related Diagnostic Information

DTC AND 1ST TRIP DTC
The 1st trip DTC (whose number is the same as the DTC number) is displayed for the latest self-diagnostic
result obtained. II the ECM memory was cleared previously, and the 1st trip DTC did not reoccur, the 1sttrip
DTC will not be displayed. II a malfunction is detected during the 1st trip, the 1st trip DTC is stored in the ECM
memory. The MIL will not light up (two trip detection logic). II the same malfunction is not detected in the 2nd
trip (meeting the required driving pattern), the 1st trip DTC is cleared from the ECM memory. II the same mal-
function is detected in the 2nd trip, both the 1st trip DTC and DTC are stored in the ECM memory and the
MIL lights up. In other words, the DTC is stored in the ECM memory and the MIL lights up when the same
malfunction occurs in two consecutive trips. II a 1st trip DTC is stored and a non-diagnostic operation is per-
formed (lor example, driving pattern A, refer to EC-52) between the 1st and 2nd trips, only the 1st trip DTC
will continue to be stored. For malfunctions that blink or light up the MIL during the 1st trip, the DTC and 1st
trip DTC are stored in the ECM memory.
Procedures lor clearing the DTC and the 1st trip DTC from the ECM memory are described in "HOW TO
ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION". Refer to EC-43. i''"
For malfunctions in which 1st trip DTCs are displayed, refer to EC-41. These items are required by legal
regulation to continuously monitor the system/component. In addition, the items monitored non-continuously
are also displayed on CONSULT.
1st trip DTC is specified in Mode 7 of SAE J1979. 1st trip DTC detection occurs without lighting up the MIL
and therefore does not warn the driver of a problem. However, 1st trip DTC detection will not prevent the
vehicle from being tested, for example during Inspection/Maintenance (liM) tests.
When a 1st trip DTC is detected, check, print out or write down and erase (1st trip) DTC and Freeze Frame
data as specified in "Work Flow" procedure Step II, refer to page EC-70. Then perform "DTC confirmation
procedure" or "Overall function check" to try to duplicate the problem. II the malfunction is duplicated, the item
requires repair.

How to read DTC and 1st trip DTC

DTC and 1st trip DTC can be read by the following methods.

The number of blinks of the malfunction indicator lamp in the Diagnostic Test Mode II (Seii-Diagnos- ]"~)
tic Results) Examples: 0101, 0201, 1003, 1104, etc.
These DTCs are controlled by NISSAN.
®2. CONSULT or GST (Generic Scan Tool) Examples: P0340, P1320, P0705, P0750, etc.
These DTCs are prescribed by SAE J2012.
~t~ (CONSULT also displays the malfunctioning component or system.)

• 1st trip ore No. is the same as ore No.

• Output of a OTC indicates a malfunction. However, Mode II and GST do not indicate whether the
malfunction is still occurring or has occurred in the past and has returned to normal. 12~R1
CONSULT can identify malfunction status as shown below. Therefore, using CONSULT (if available)
is recommended.

A sample of CONSULT display lor DTC is shown at left. DTC or 1st

• SELF·DIAG RESULTS. 0 trip DTC of a malfunction is displayed in SELF-DIAGNOSTIC
RESULTS mode of CONSULT. Time data indicates how many
FAILURE DETECTED TIME times the vehicle was driven after the last detection of a DTC.
IACV·AAC VALVE 0 lithe DTC is being detected currently, the time data will be "0".
[P0505]

!ERASE!! PRINT I!FFdatal

SEF215T

EC-35 175
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Emission-related Diagnostic Information
(Cont'd)
• SELF-DIAG RESULTS. 0 If a 1st trip DTC is stored in the ECM, the time data will be "[11]".
FAILURE DETECTED TIME
IACV-AAC VALVE [11]
[P0505]

IERASEII PRINT IIFFdatal

SEF216T

FREEZE FRAME DATA AND 1ST TRIP FREEZE FRAME DATA

The ECM records the driving conditions such as fuel system status, calculated load value, engine coolant
temperature, short term fuel trim, long term fuel trim, engine speed and vehicle speed at the moment a mal-
function is detected.
Data which are stored in the ECM memory, along with the 1st trip DTC, are called 1st trip freeze frame data.
The data, stored together with the DTC data, are called freeze frame data and are displayed on CONSULT
or GST. The 1st trip freeze frame data can only be displayed on the CONSULT screen, not on the GST. For
details, see EC-56.
Only one set of freeze frame data (either 1st trip freeze frame data or freeze frame data) can be stored in the
ECM. 1st trip freeze frame data is stored in the ECM memory along with the 1st trip DTC. There is no prior-
ity for 1st trip freeze frame data and it is updated each time a different 1st trip DTC is detected. However, once
freeze frame data (2nd trip detection/MIL on) is stored in the ECM memory, 1st trip freeze frame data is no
longer stored. Remember, only one set of freeze frame data can be stored in the ECM. The ECM has the fol-
lowing priorities to update the data.

Priority Items

Freeze frame data Misfire- DTC: P0300- P0304 (0701, 0605- 0608)
1
Fuel Injection System Funct1on- DTC: P0171 (0115), P0172 (0114)
2 Except the above items (Includes AfT related items)

3 1st trip freeze frame data

For example, the EGR malfunction (Priority: 2) was detected and the freeze frame data was stored in the 2nd
trip. After that when the misfire (Priority: 1) is detected in another trip, the freeze frame data will be updated
from the EGR malfunction to the misfire. The 1st trip freeze frame data is updated each time a different mal-
function is detected. There is no priority for 1st trip freeze frame data. However, once freeze frame data is
stored in the ECM memory, 1st trip freeze frame data is no longer stored (because only one freeze frame data
or 1st trip freeze frame data can be stored in the ECM). If freeze frame data is stored in the ECM memory
and freeze frame data with the same priority occurs later, the first (original) freeze frame data remains
unchanged in the ECM memory.
Both 1st trip freeze frame data and freeze frame data (along with the DTCs) are cleared when the ECM
memory is erased. Procedures for clearing the ECM memory are described in "HOW TO ERASE EMISSION-
RELATED DIAGNOSTIC INFORMATION". Refer to EC-43.

SYSTEM READINESS TEST (SRT) CODE

System Readiness Test (SRT) code is specified in Mode 1 of SAE J1979. It indicates whether the self-diag-
nostic tests for non-continuously monitored items have been completed or not.
Inspection/Maintenance (1/M) tests of the on board diagnostic (OBD) II system may become the legal require-
ment in some states/areas. All SRT codes must be set in this case. Unless all SRT codes are set, conduct-
ing the 1/M test may not be allowed.
SRT codes are set after self-diagnosis has been performed two or more times. This occurs regardless of
whether the diagnosis is in "OK" or "NG", and whether or not the diagnosis is performed in consecutive trips.
The following table lists the 5 SRT items (9 test items) for the ECCS used in D21 models.

176 EC-36
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Emission-related Diagnostic Information
(Cont'd)
SAT items Self-diagnostic test items
Catalyst monitoring • Three way catalyst function P0420 (0702)

• EVAP control system (Small Leak) P0440 (0705)

EVAP system monitoring
• EVAP control system purge flow monitoring P1447 (0111)
• Front heated oxygen sensor P0130 (0503)
Oxygen sensor monitoring
• Rear heated oxygen sensor P0136 (0707)
• Front heated oxygen sensor heater P0135 (0901)
Oxygen sensor heater monitoring
• Rear heated oxygen sensor heater P0141 (0902)

• EGR function P0400 (0302)

EGR system monitoring
• EGRC-BPT valve function P0402 (0306)

Together w1th the DTC, the SRT code 1s cleared from the ECM memory using the method described later
(Refer to EC-43). In addition, after ECCS components/systems are repaired or if the battery terminals remain !"~
disconnected for more than 24 hours, all SRT codes may be cleared from the ECM memory.
How to display SRT code r:~1
(F-1\ 1. Selecting "SRT" in "SRT·OBD TEST VALUE" mode with CONSULT
\ll:!) For items whose SRTcodes are set, a "CMPLT" is displayed on the CONSULT screen; for items whose
SRT codes are not set, "INCMP" is displayed. I!U'J'
(~, 2. Selecting Mode 1 with GST (Generic Scan Tool)
~~
A sample of CONSULT display for SRT code is shown at left. JJi'
•
CATALYST
SRT

INCMP
• 0 "INCMP" means the self-diagnosis is incomplete and SRT is not
set. "CMPLT" means the self-diagnosis is complete and SRT is set. tl'
EVAPSYSTEM INCMP
02 SENSOR INCMP
02 SEN HEATER CMPLT
EGRSYSTEM INCMP

I PRINT I
SEF214T

How to set SRT code

To set all SRT codes, self-diagnosis for the items indicated above must be pertormed two or more times. Each
diagnosis may require a long period of actual driving under various conditions. The most efficient driving pat- lili~l
tern in which SRT codes can be properly set is explained on the next page. The driving pattern should be
pertormed two times or more to set all SRT codes.

EC-37 177
178

Note: Always drive vehicle in safe manner according to traffic conditions and obey all traffic laws. c
~
Driving pattern Refer to next page for more information and explanation of chart.
~----------------------~-----------,
~:
:I
SAT Item Self-diagnostic (Q
(CONSULT test item (CONSULT Pattern 1 Pattern 2 Pattern 3 Pattern 4
"C

~
screen term) screen term)

TW CATALYST ~
CATALYST
SYS :I

EVAP PURGE
0
FLOW/MON
SYSTEMj-~~~~~~-r~~~--~~~~~~~-+~~~~~~ z
EVAP (SMALL Ill
0
)>
FRONT 02
::0
02 SENSOR
SENSOR
c
REAR 02 c
SENSOR )>
FR 02 SEN --mG>
02 SEN
HTR ~3 z
HEATER ::J -· 0
RR 02 SEN rn en
- -rn
m HTR a.-· -1
..._o-
(')
::J (')
w
co
EGA SYSTEM ..., en
I

EGR SYSTEM f-~--------_j !!.-<

Q) en
EGRC-BPT VALVE
lD-1
a.m
c!!:
"1 iii' c
ICm
86 - 96
::J en
0 (')
(53 . 60
!!l,::O
('j' =ti
--I
-o
::J -
Q z
0 km/h
(0 MPH)
Idling
~----~~--r~,_~,--,~,--,--n

19 20
-
3Q)
o·
::J

w t
0

t
2 3 4 5 6 7 11 12 13 14 15 16 17 18
(minutes) t
m Engine
Engine Engine coolant temperature • · Zone A ~ · Zone B
~ start becomes 70°C (158°F)
stop
"l
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Emission-related Diagnostic Information
(Cont'd)
• The time required for each diagnosis varies with road sur- Suggested transmission gear position for
face conditions, weather, altitude, individual driving habits, AfT models
etc.
Zone A refers to the range where the time requ1red, for the Set the selector lever in the "D"" position with the
diagnosis under normal conditions*, is the shortest. Zone B overdrive switch turned ON.
refers to the range where the diagnosis can still be per-
formed if the diagnosis is not completed within zone A.
Normal conditions refer to the following: Suggested upshift speeds for MIT models
• Sea level
• Flat road Shown below are suggested vehicle speeds for
• Ambient air temperature: 20 - 3ooc (68 - 86°F) shifting into a higher gear. These suggestions relate
• Diagnosis is periormed as quickly as possible under normal to fuel economy and vehicle pertormance. Actual
conditions.
Under different conditions [For example: ambient air tem- upshift speeds will vary according to road
perature other than 20 - 30°C (68- 86cF)]. diagnosis may conditions. weather and individual driving habits.
also be performed.
Pattern 1: • The engine is started at the engine coolant
temperature of -10 to 35'C (14to 95'F)
For normal acceleration in low altitude areas [less
(whe~the vo)4lge between the ECM termi- than 1,219 m (4.000 It)]: [s~
nals ~ and (@) is 3.0 - 4.3V).
• The engine must be operated at idle speed ACCEL CRUISE
until the engine coolant temperature is Gear change shift point shift point
greater than 70'C (158'F) (w~J.!l.re the )!pltage km/h (MPH) km/h (MPH) c~l
between the ECM terminals ~ and (@) is
lower than 1.4V). 1st to 2nd 24 (15) 23 (14)
Pattern 2: • When steady-state driving is periormed again
even after it is interrupted, each diagnosis can
2nd to 3rd 40 (25) 28 (17) }H
be conducted. In this case, the time required for 3rd to 4th 65 (40) 44 (27)
diagnosis may be extended.
Pattern 3: • The driving pattern outlined in *2 must be 4th to 5th 75 (45) 61 (38)
repeated at least 3 times.
On MIT models, shift gears following "suggested
upshift speeds" schedule at right. For high altitude areas [over 1,219 m (4,000 It)] and
Pattern 4: • Tests are pertormed after the engine has been quick acceleration in low altitude areas:
operated for at least 12 minutes. Gear change km/h (MPH)
• The accelerator pedal must be held very steady
during steady-state driving. 1st to 2nd 24 (15)
• If the accelerator pedal is moved, the test must 2nd to 3rd 40 (25)
be conducted all over again.
*1: Depress the accelerator pedal until vehicle speed is 90
3rd to 4th 64 (40)
km/h (56 MPH), then release the accelerator pedal and 4th to 5th 72 (45)
keep it released for more than 10 seconds. Depress the
accelerator pedal until vehicle speed is 90 km/h (56 MPH)
again.
Suggested maximum speed in each gear
*2: Operate the vehicle in the following driving pattern. Downshift to a lower gear if the engine is not running
1) Decelerate vehicle to 0 km/h and let engine idle. smoothly, or if you need to accelerate.
2) Repeat driving pattern shown below at least 10 times.
• During acceleration, hold the accelerator pedal
Do not exceed the maximum suggested speed
as steady as possible. (The THRTL POS SEN
value of CONSULT should be between 0.8 to
(shown below) in any gear. For level road driving,
use the highest gear suggested for that speed.
1 ~l
1.2V.) Always observe posted speed limits and drive
3) Repeat steps 1 and 2 until the EGR system SRT is set. according to the road conditions to ensure safe
50 - 55 km/h· .. operation. Do not over-rev the engine when shifting lli1i"
(30 · 35 MPH) to a lower gear as it may cause engine damage or
loss of vehicle control.
Gear km/h (MPH)
4WD models
2WD models
(2H position)
0 km/h .. 1st 50 (30) 40 (25)
(0 MPH) j10s j iOS 20S 2nd 90 (55) 70 (43)
3rd 130 (80) 110 (68)
4th
SEF414S 5th
*3: The driving pattern may be omitted when EVAP (SMALL
LEAK) checks are performed using the FUNCTION TEST
mode of CONSULT.
*4: Checking the vehicle speed with CONSULT or GST is
advised.

EC-39 179
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Emission-related Diagnostic Information
(Cont'd)
TEST VALUE AND TEST LIMIT
The following is the information specified in Mode 6 of SAE J1979.
The test value is a parameter used to determine whether a system/circuit diagnostic test is "OK" or "NG" while
being monitored by the ECM during self-diagnosis. The test limit is a reference value which is specified as the
maximum or minimum value and is compared with the test value being monitored.
Items for which these data (test value and test limit) are displayed are the same as SRT code items (9 test
items).
These data (test value and test limit) are specified by Test ID (TID) and Component ID (CID) and can be dis-
played on the CONSULT screen or GST.

X: Applicable
Not applicable

Test value
SAT item
Self-diagnostic
(CONSULT GST display CONSULT Test limit Application
test item
display) display
TID CID
Warm-up three
CATALYST way catalyst 01H 01H Parameter 1 Max. X
function
EVAP control
system (Small OSH 03H Parameter 1 Max. X
leak)
EVAP SYSTEM
EVAP control
system purge 06H 83H Parameter 2 Min. X
flow monitoring
09H 04H Parameter 1 Max. X
OAH 84H Parameter 2 Min. X
Front heated
OBH 04H Parameter 3 Max. X
oxygen sensor
OCH 04H Parameter 4 Max. X
02 SENSOR ODH 04H Parameter 5 Max. X
19H 86H Parameter 6 Min. X

Rear heated 1AH 86H Parameter 7 Min. X

oxygen sensor 1BH 06H Parameter 8 Max. X
1CH 06H Parameter 9 Max. X
Front heated 29H 08H Parameter 1 Max. X
oxygen sensor
02 SENSOR heater 2AH 88H Parameter 1 Min. X
HEATER Rear heated 2DH OAH Parameter 1 Max. X
oxygen sensor
heater 2EH BAH Parameter i Min. X

31H 8CH Parameter i Min. X

32H 8CH Parameter 2 Min. X
EGA function 33H SCH Parameter 3 Min. X
EGR SYSTEM 34H 8CH Parameter 4 Min. X
35H OCH Parameter 5 Max. X

EGRC-BPT valve 36H OCH Parameter 6 Max. X

function 37H 8CH Parameter 7 Min. X

180 EC-40
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Emission-related Diagnostic Information
(Cont'd) @I

EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS

X: Applicable
- · Not applicable

DTC*3
Items Test value/
CONSULT SAT code 1st trip OTC Reference page
(CONSULT screen terms) ECM*1 Test limit
GST*2

NO SELF DIAGNOSTIC FAIL-

POOOO 0505 - - - -
URE INDICATED

MASS AIR FLOW SEN P0100 0102 - - X EC-93

ABSOL PRESS SENSOR P0105 0803 - - X EC-100

INT AIR TEMP SEN P0110 0401 - - X EC-107

COOLANT TEMP SEN P0115 0103 - - X EC-113

THROTTLE POSJ SEN P0120 0403 - - X EC-118

'COOLANT TEMP SEN P0125 0908 - - X EC-124

CLOSED LOOP P0130 0307 - - X EC-134

FRONT 02 SENSOR P0130 0503 X X X'4 EC-129

FR 02 SEN HEATER P0135 0901 X X X'4 EC-135

REAR 02 SENSOR P0136 0707 X X X'4 EC-139

RR 02 SEN HEATER P0141 0902 X X X'4 EC-143

FUEL SYS DIAG LEAN P0171 0115 - - X EC-148

FUEL SYS DIAG RICH P0172 0114 - - X EC-153

TANK FUEL TEMP SEN P0180 0402 - - X EC-158

MULTI CYL MISFIRE P0300 0701 - - X EC-162

CYL 1 MISFIRE P0301 0608 - - X EC-162

CYL 2 MISFIRE P0302 0607 - - X EC-162

CYL 3 MISFIRE P0303 0606 - - X EC-162

CYL 4 MISFIRE P0304 0605 - - X EC-162

CRANK POS SEN (OBD) P0335 0802 - - X EC-166

CAMSHAFT POSt SEN P0340 0101 - - X EC-171

EGR SYSTEM P0400 0302 X X X'4 EC-176

EGRC-BPT VALVE P0402 0306 X X X'4 EC-184

TW CATALYST SYS P0420 0702 X X X'4 EC-186

EVAP (SMALL LEAK) P0440 0705 X X X'4 EC-189

PURG CONTIV & SIV P0443 0807 - - X EC-199

VENT CONTROL VALVE P0446 0903 - - X EC-207

EVAP SYS PRES SEN P0450 0704 - - X EC-212

*1 In Diagnostic Test Mode II (Self-diagnostic results). These numbers are controlled by NISSAN.
*2 These numbers are prescribed by SAE J2012.
*3 1st trip DTC No. is the same as DTC No.
*4 These are not displayed with GST.

EC-41 181
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Emission-related Diagnostic Information
(Cont'd)
X: Applicable
- · Not applicable

DTC*3
Items Test value/
CONSULT SRT code 1st trip DTC Reference page
(CONSULT screen terms} ECM*1 Test limit
GST*2

VEHICLE SPEED SEN POSOO 0104 - - X EC-217

IACV-AAC VALVE ?0505 0205 - - X EC-221

CLOSED THRL POS SW P0510 0203 - - X EC-226

ECM ?0605 0301 - - X EC-230

PARK/NEUT POSI SW P0705 1003 - - X EC-232

MAP/BARO SW SOUV P1105 1302 - - X EC-237

SWIRL CONT S/V P1130 1004 - - X EC-243

SWIRUV CONT VC SW P1165 0112 - - X EC-251

IGN SIGNAL-PRIMARY P1320 0201 - - X EC-256

CRANK PiS (OBD) COG ?1336 0905 - - X EC-262

EGRC SOLENOIDN P1400 1005 - - X EC-267

EGA TEMP SENSOR P1401 0305 - - X EC-271

VCN BYPASSJV P1441 0801 - - X EC-276

PURGE VOLUME CONT/V P1445 1008 - - X EC-281

EVAP PURGE FLOW/MON P1447 0111 X X x·4 EC-288

TOR CONV CLUTCH SJV P1550 0904 - - X EC-295

*1 In Diagnostic Test Mode II (Self-diagnostic results). These numbers are controlled by NISSAN.
*2 These numbers are prescribed by SAE J2012.
'3 1st trip DTC No. is the same as DTC No.
*4 These are not displayed with GST.

182 EC-42
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Emission-related Diagnostic Information
(Cont'd)
HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION
The emission-related diagnostic information can be erased by the following methods.
®Selecting "ERASE"' in the "SELF-DIAG RESULTS" mode with CONSULT

qj) Selecting Mode 4 with GST (Generic Scan Tool)

@ Changing the diagnostic test mode from Diagnostic Test Mode II to Mode I by turning the mode selector
on the ECM (Refer to EC-46.) ~;!;
• If the battery is disconnected, the emission-related diagnostic information will be lost after approx.
24 hours.
• Erasing the emission-related diagnostic information using CONSULT or GST is easier and quicker
than switching the mode selector on the ECM.
The following data are cleared when the ECM memory is erased.
1. Diagnostic trouble codes
2. 1st trip diagnostic trouble codes
3. Freeze frame data
4. 1st trip freeze frame data
5. System readiness test (SRT) codes
6. Test values
7. Others
Actual work procedures are explained using a DTC as an example. Be careful so that not only the DTC, but
all of the data listed above, are cleared from the ECM memory during work procedures.

@ How to erase DTC (With CONSULT)

Note: If the diagnostic trouble code is not for AfT related items (see EC-2), skip steps 2 through 4.
1. If the ignition switch stays "ON" after repair work, be sure to turn ignition switch "OFF" once. Wait at least
7 seconds and then turn it "ON" (engine stopped) again.
2. Turn CONSULT "ON" and touch "AfT".
3. Touch "SELF-DIAG RESULTS".
4. Touch "ERASE". (The DTC in the AfT control unit will be erased.) Then touch "BACK" twice.
5. Touch "ENGINE".
6. Touch "SELF-DIAG RESULTS".
7. Touch "ERASE". (The DTC in the ECM will be erased.)
• If DTCs are displayed for both ECM and AfT control unit, they need to be erased individually from the ECM
and AfT control unit.

EC-43 183
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Emission-related Diagnostic Information
(Cont'd)
How to erase DTC (With CONSULT)
1. If the ignition switch stays "ON" after repair work, be sure to turn ignition switch "OFF" once. Wait at least 7 seconds
and then turn it "ON" (engine stopped) again.

I~ SELECT SYSTEM
I I~ SELECT DIAG MODE
Dl • SELF-DIAG RESULTS. D
ENGINE I SELF-DIAG RESULTS Uiil
I I FAILURE DETECTED
AfT I I DATA MONITOR I SHIFT SOLENOIDN A
~
I c::> I ECU PART NUMBER 1¢

ER~1==Sf]==E==u=l=P==R=IN==T====i
2. Turn CONSULT "ON", and touch 3. Touch "SELF-DIAG RESULTS". 4. Touch "ERASE". (The DTC in the
"AIT". AfT control unit will be erased.)

D___
----~Touch
_jl
/'------------,Touch
"BACK". ' - . r - - - - - - - - "BACK"
<c_,-----~_j
_____jn
I~ SELECT SYSTEM I ~ SELECT DIAG MODE Dl • SELF-DIAG RESULTS. D
I!=~~~~~=~
ENGINE I WORK SUPPORT FAILURE DETECTED TIME

I ArT I ~=~ SHIFT SOLENOIDN A 0

~==================~ c::> ~D~A~l~A~M~O~N~IT~O~R==========~ c::> [P0750]

I ACTIVE TEST
I SRT• OBD TEST VALUE
~1===;;;==:~:::=;-r=::=':===i
I I FUNCTION TEST [ER"ASEJI PRINT II FFdata I
5. Touch "ENGINE". 6. Touch "SELF-DIAG RESULTS". 7. Touch "ERASE". (The DTC in the
ECM will be erased.)
SEF372SA

~ How to erase DTC (With GST)

Note: If the diagnostic trouble code is not for AfT related items (see EC-2), skip step 2.
1. If the ignition switch stays "ON"" after repair work, be sure to turn ignition switch "OFF" once. Wait at least
7 seconds and then turn it "ON" (engine stopped) again.
2. Perform "SELF-DIAGNOSTIC PROCEDURE (Without CONSULT)" in AT section titled 'TROUBLE
DIAGNOSIS", "Self-diagnosis". (The engine warm-up step can be skipped when performing the diagno-
sis only to erase the DTC.)
3. Select Mode 4 with GST (Generic Scan Tool).

@ How to erase DTC (No Tools)

Note: If the diagnostic trouble code is not for AfT related items (see EC-2), skip step 2.
1. If the ignition switch stays "ON" after repair work, be sure to turn ignition switch "OFF" once. Wait at least
7 seconds and then turn it "ON" again.
2. Perform "SELF-DIAGNOSTIC PROCEDURE (Without CONSULT)" in AT section titled "TROUBLE
DIAGNOSIS", "Self-diagnosis". (The engine warm-up step can be skipped when performing the diagno-
sis only to erase the DTC.)
3. Change the diagnostic test mode from Mode II to Mode I by turning the mode selector on the ECM. (See
EC-46.)

184 EC-44
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

Malfunction Indicator Lamp (MIL)

o£
0
~

~
0
1. The malfunction indicator lamp will light up when the ignition
0 switch is turned ON without the engine running. This is a bulb il?,
~

?'
) c=
•
check.
If the malfunction indicator lamp does not light up, refer to EL
section ("WARNING LAMPS") or see EC-321. 'Bull
2. When the engine is started, the malfunction indicator lamp

r~nct;on
should go off.
If the lamp remains on, the on board diagnostic system has L(;
;nd;cator detected an engine system malfunction.
lamp SEF241S

ON BOARD DIAGNOSTIC SYSTEM FUNCTION

The on board diagnostic system has the following four functions.

Diagnostic Test Mode I

1. BULB CHECK This function checks the MIL bulb for damage (blown, open circuit,
etc.).
If the MIL does not come on, check MIL circuit and ECM test mode
selector. (See next page.)
2. MALFUNCTION This is a usual driving condition. When a malfunction is detected twice
WARNING in two consecutive driving cycles (two trip detection logic), the MIL will
light up to inform the driver that a malfunction has been detected.
The following malfunctions will light up or blink the MIL in the 1st trip.
• "Misfire (Possible three way catalyst damage)"
• "Closed loop control"
• Fail-safe mode
Diagnostic Test Mode II
3. SELF-DIAGNOSTIC This function allows DTCs and 1st trip DTCs to be read.
RESULTS
4. FRONT HEATED OXY- This function allows the fuel mixture condition (lean or rich), monitored
GEN SENSOR MONI- by front heated oxygen sensor, to be read.
TOR

MIL flashing without DTC [lJJ;

If the ECM is in Diagnostic Test Mode II, MIL may flash when engine is running. In this case, check ECM test
mode selector following "HOW TO SWITCH DIAGNOSTIC TEST MODES" on next page.
Refer to "HOW TO SWITCH DIAGNOSTIC TEST MODES" on next page @,Ri
Diagnostic Diagnostic
Condition
Test Model Test Mode II
Engine
stopped SELF-DIAGNOSTIC
BULB CHECK
Ignition switch
in "ON" posi-
tion
0 RESULTS

Engine

~
FRONT HEATED
running MALFUNCTION
OXYGEN SENSOR

ID WARNING
MONITOR

EC-45 185
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Malfunction Indicator Lamp (MIL) (Cont'd)
HOW TO SWITCH DIAGNOSTIC TEST MODES
~------~

NG NG
Turn ignition switch "ON". Check MIL circuit. (See Repair harness or connector.
(Do not start engine.) EC-321.)

OK

Diagnostic Test Mode I ~ MALFUNC- Check whether ECM test Repair or replace ECM test mode
No
TION INDICATOR LAMP CHECK. Yes mode selector can be selector.
Refer to EC-45. turned counterclockwise.
MIL should come on.

OK

1----~~ Q~ , --~ Diagnostic Test Mode I

r -MALFUNCTION WARNING.
Start engine. Refer to EC-45.

NG
NG Check MIL circuit. (See Repair harness or connectors.
EC-321.)

OK

(Turn diagnostic test mode selector on

Check ECM fail-safe.
ECM fully clockwise)
MIL should turn off. (See EC-76.)

OK OK

Wait at least 2 seconds.

• Switching the modes is not possible when the engine

is running.
• When ignition switch is turned off during diagnosis,
power to ECM will drop after approx. 7 seconds.
The diagnosis will automatically return to Diagnostic
Test Mode I.
(Turn diagnostic test mode selector • Turn back diagnostic test mode selector to the fully
fully counterclockwise.)
counterclockwise position whenever vehicle is in use.

~Q~
DIAGNOSTIC TEST MODE II Diagnostic Test Mode II
-SELF-DIAGNOSTIC RESULTS - FRONT HEATED OXYGEN SEN-
Start engine. SOR MONITOR

*1: If the selector is turned fully counterclockwise at this time, the emis-
sion-related diagnostic information will be erased from the backup
memory in the ECM.

The following emission-related diagnostic information is cleared

when the ECM memory is erased.
1. Diagnostic trouble codes
2. 1st trip diagnostic trouble codes
Wait at least 2 seconds. 3. Freeze frame data
4. 1st trip freeze frame data
5. System readiness test (SRT) codes
6. Test values
7. Others

186 EC-46
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Malfunction Indicator Lamp (MIL) (Cont'd)
DIAGNOSTIC TEST MODE I-BULB CHECK
In this mode, the MALFUNCTION INDICATOR LAMP on the instrument panel should stay ON. If it remains
OFF, check the bulb. Refer to EL section ("WARNING LAMPS") or see EC-321.
DIAGNOSTIC TEST MODE I-MALFUNCTION WARNING
MALFUNCTION
Condition
INDICATOR LAMP
ON When the malfunction is detected or the ECM's CPU is malfunctioning.
OFF No malfunction.

• These D1agnost1c Trouble Code Numbers are clarified 1n Diagnostic Test Mode II (SELF-DIAGNOSTIC
RESULTS).
DIAGNOSTIC TEST MODE II-SELF-DIAGNOSTIC RESULTS
In this mode, the DTC and 1st trip DTC are indicated by the number of blinks of the MALFUNCTION INDI-
CATOR LAMP.
The DTC and 1st trip DTC are displayed at the same time. If the MIL does not illuminate in diagnostic test
mode 1 (Malfunction warning), all displayed items are 1st trip DTCs. If only one code is displayed when the
MIL illuminates in diagnostic test mode II (SELF-DIAGNOSTIC RESULTS), it is a DTC; if two or more codes ,i~l
are displayed, they may be either DTCs or 1st trip DTCs. DTC No. is same as that of 1st trip DTC. These
unidentified codes can be identified by using the CONSULT or GST. A DTC will be used as an example for
how to read a code.
Example: Diagnostic trouble code No. 0102 and No. 0403

0.6 0.3 0.6 03

I I tr
JIU1]tnJ
ON r- - ,--

IJU 1-o-;--1 -W--

03 2.1
-
06 09

Diagnostic trouble code No 0403

21
Unit: second
Diagnostic trouble code No. 0102
SEF2980

Example: Diagnostic trouble code No. 1003

0.6 0.3
;--
ON
-~

'
It
OFF
. '

-~ _L
06

Diagnostic trouble code No. 1003 Unit: second

SEF162PA

Long (0.6 second) blinking indicates the number of ten digits, and short (0.3 second) blinking indicates the g~
number of single digits. For example, the malfunction indicator lamp blinks 10 times for 6 seconds (0.6 sec x
10 times) and then it blinks three times for about 1 second (0.3 sec x 3 times). This indicates the DTC "1 003"
and refers to the malfunction of the park/neutral position switch. ~r
In this way, all the detected malfunctions are classified by their diagnostic trouble code numbers. The DTC
"0505" refers to no malfunction. (See DIAGNOSTIC TROUBLE CODE INDEX, EC-2.)
HOW TO ERASE DIAGNOSTIC TEST MODE II (Self-diagnostic results) ~'lLi\
The diagnostic trouble code can be erased from the backup memory in the ECM when the diagnostic test mode
is changed from Diagnostic Test Mode II to Diagnostic Test Mode I. (Refer to "HOW TO SWITCH DIAGNOS-
TIC TEST MODES" on previous page.) ~~L.
• If the battery is disconnected, the diagnostic trouble code wilt be lost from the backup memory
after approx. 24 hours.
• Be careful not to erase the stored memory before starting trouble diagnoses .

EC-47 187
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Malfunction Indicator Lamp (MIL) (Cont'd)
DIAGNOSTIC TEST MODE II-FRONT HEATED OXYGEN SENSOR MONITOR
In this mode, the MALFUNCTION INDICATOR LAMP displays the condition of the fuel mixture (lean or rich)
which is monitored by the front heated oxygen sensor
Air fuel ratio feedback control
MALFUNCTION INDICATOR LAMP Fuel mixture condition in the exhaust gas
condition

ON Lean
Closed loop system
OFF Rich
*Remains ON or OFF Any condition Open loop system

*: Marntarns condrtrons JUSt before swrtchrng to open loop.

To check the front heated oxygen sensor function, start engine in Diagnostic Test Mode II. Then warm it up
until engine coolant temperature indicator points to middle of gauge.
Next run engine at about 2,000 rpm for about 2 minutes under no-load conditions. Make sure that the MAL-
FUNCTION INDICATOR LAMP comes ON more than 5 times within 10 seconds with engine running at 2,000
rpm under no-load.

OBD System Operation Chart

RELATIONSHIP BETWEEN MIL, 1ST TRIP DTC, DTC, AND DETECTABLE ITEMS
• When a malfunction is detected for the first time, the 1st trip DTC and the 1st trip freeze frame data are
stored in the ECM memory.
• When the same malfunction is detected in two consecutive trips, the DTC and the freeze frame data are
stored in the ECM memory, and the MIL will come on. For details, refer to 'Two Trip Detection Logic" on
EC-34.
• The MIL will go off after the vehicle is driven 3 times with no malfunction. The drive is counted only when
the recorded driving pattern is met (as stored in the ECM). If another malfunction occurs while counting,
the counter will reset.
• The DTC and the freeze frame data will be stored until the vehicle is driven 40 times (driving pattern A)
without the same malfunction recurring (except for Misfire and Fuel Injection System). For Misfire and Fuel
Injection System, the DTC and freeze frame data will be stored until the vehicle is driven 80 times (driv-
ing pattern C) without the same malfunction recurring. The "TIME" in "SELF-DIAGNOSTIC RESULTS"
mode of CONSULT will count the number of times the vehicle is driven.
• The 1st trip DTC is not displayed when the self-diagnosis results in "OK" for the 2nd trip.

SUMMARY CHART
Items Fuel Injection System Misfire Except the lefts
MIL (goes off) 3 (pattern B) 3 (pattern B) 3 (pattern B)
DTC, Freeze Frame Data (no
80 (pattern C) 80 (pattern C) 40 (pattern A)
display)
1st Trip DTC (clear) 1 (pattern C). •1 1 (pattern C), •1 1 (pattern B)
1st Trip Freeze Frame Data
• t •• 2 ·1 .• 2 t (pattern B)
(clear)
.. ..
Deta1ls about patterns "A , "B", and "C are on EC-50, 52 .
*1: Clear timing is at the moment OK is detected.
*2: Clear timing is when the same malfunction is detected in the 2nd trip.

188 EC-48
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
OBD System Operation Chart (Cont'd)
RELATIONSHIP BETWEEN MIL, DTC, 1ST TRIP DTC AND DRIVING PATTERNS FOR
"MISFIRE" <EXHAUST QUALITY DETERIORATION>, "FUEL INJECTION SYSTEM"

This driving pattern satisfies with B and C patterns.

NG
NG OK Detection NG
Detection Detection Detection

A
c
2
- Vehicle
8' speed
~
c
---:Tfip ::
> iNG !!
,§
V ON ii ---i~f---i--j r------i---1~
IGN OFF H . ui-·

"

MIL

"~v~ ~;: :: : - - - - -: - - - - - : - -':- - -;:- -2,~;- ~:- - - .~_.~- - -K~.,]' _;~--+---T-::_)~~:

' 2 2 '2 ;
:__M_'L~9~4·~_.s_o_t _.!((r~J~\~'--~---
i_<:__ D:

B · 0 !!o ' .-----.o io !!o : l)i

::: "' lr lr ' .. · ,.,~J' ·· .•,

~ ~~:~zee t-~-~;~:_!:N~O~D~,I~2P::!L~A:!Y~ii-i~-"""''i-t~-1:,_•----rii--~:f:=-=-"11!:---.+---n!:-----r:)0iii_;,;N_:):g1~1S~P~L~A-Y
o~- Data :DISPLAY"i , :i io1sPLAY, *3 ::
:: ::
:: *4 :, '.·,
- : ~ ':, "l " ' " "
~ ~;:~~: !!"!\ ii '!; CL!~R! ! ) ':.~:, ,!.!,, !:CLEAR!:!: !,: ~ ii iCf)i ii
~ Data !! i !! !!•6 i ii ' ii•7 i
CJ> ibiSPLAY'i i ii : DISPLAY

~~Ct;lp :i----K :
;
;;;

~ ,. , r. ·. .
:: : '5 ::
!: :,· l.·· CL;,'j: R
'
!, " J
·s ,
,
,li--:-----++------++-~--+:---______,_:-----++--
CLEAR

b~ cCounter!!' n '·;O i r-0 .

2 , .?._ll--+?._ll-__
o ! !i
4
~~S:
_;;___J2t--_j3r---~·::--::-~
79 1!80

" " "

SEF392S

*1: When the same malfunction is detected in two consecutive *5: When a malfunction is detected for the first time, the 1st
trips, MIL will light up. trip DTC and the i st trip freeze frame data will be stored
*2: MIL will go off after vehicle is driven three times (pattern in ECM.
B) without any malfunctions. *6: The 1st trip DTC and the 1st trip freeze frame data will be
*3: When the same malfunction is detected in two consecutive cleared at the moment OK is detected.
trips, the DTC and the freeze frame data will be stored in *7: When the same malfunction is detected in the 2nd trip, the
ECM. 1st trip freeze frame data will be cleared.
*4: The DTC and the freeze frame data will not be displayed *8: 1st trip DTC will be cleared when vehicle is driven once
any longer after vehicle is driven 80 times (pattern C) with- (pattern C) without the same malfunction after DTC is
out the same malfunction. stored in ECM.
(The DTC and the freeze frame data still remain in ECM.)

EC-49 189
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
OBD System Operation Chart (Cont'd)
EXPLANATION FOR DRIVING PATTERNS FOR "MISFIRE <EXHAUST QUALITY
DETERIORATION>", "FUEL INJECTION SYSTEM"
(Driving pattern B)
Driving pattern B means the vehicle operation as follows:
All components and systems should be monitored at least once by the OBD system.
• The B counter will reset when the malfunction is detected once regardless of the driving pattern.
• The B counter will be counted up when driving pattern B is satisfied without the malfunction.
• The MIL will go off when the B counter reaches 3. (•2 in "OBD SYSTEM OPERATION CHART")

(Driving pattern C)
Driving pattern C means the vehicle operation as follows:
(1) The following conditions should be satisfied at the same time:
Engine speed: (Engine speed in the freeze frame data) ±375 rpm
Calculated load value: (Calculated load value in the freeze frame data) x (1 ±0. 1) [%]
Engine coolant temperature (T) condition:
• When the freeze frame data shows lower than 70"C (158°F), "T" should be lower than 70"C (158"F).
• When the freeze frame data shows higher than or equal to 70°C (158°F), "T" should be higher than or
equal to 70"C (158°F).
Example:
If the stored freeze frame data is as follows:
Engine speed: 850 rpm, Calculated load value: 30%, Engine coolant temperature: 80"C (176"F)
To be satisfied with driving pattern C, the vehicle should run under the following conditions:
Engine speed: 475 - 1 ,225 rpm, Calculated load value: 27 - 33%, Engine coolant temperature: more
than ~ 70"C (158°F)
• The C counter will be cleared when the malfunction is detected regardless of (1 ).
• The C counter will be counted up when (1) is satisfied without the same malfunction.
• The DTC will not be displayed after C counter reaches 80.
• The 1st trip DTC will be cleared when C counter is counted once without the same malfunction after DTC
is stored in ECM.

190 EC-50
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
OBD System Operation Chart (Cont'd)
RELATIONSHIP BETWEEN MIL, DTC, 1ST TRIP DTC AND DRIVING PATTERNS EXCEPT FOR ~[
"MISFIRE <EXHAUST QUALITY DETERIORATION>", "FUEL INJECTION SYSTEM"

This driving pattern satisfies with A and 8 patterns

This driving pattern

I
satisfies with A but not B.
NG r This driving pattern
NG OK Detection NG
Detection Detection Detection satlstles with B but :not A.

II

~
c
0
~ Vehicle
<L :1st
rn speed
c TTrip ::
"?.:
iNG ii
v
0
IGN ON j
OFF;:
--ju
~f--' r--ii---i----i~ ~~--·____,~r---i~r---i~Y ~

MIL ' "

MIL lights up.

DTC & NO DISPLAY

/
1\ Freeze
2rn Frame
0 Data
rn
~ 1st trip
LL Freeze
~ Frame
~ Data
"-
Ci: 1st trip : "
E DTC

:
:
" " 3
2
0 "

" "

SEF393S

*1: When the same malfunction is detected in two consecutive *5: When a malfunction is detected for the first time, the 1st
trips, MIL will light up. trip DTC and the 1st trip freeze frame data will be stored
*2: MIL will go off after vehicle is driven three times (pattern in ECM.
B) without any malfunctions. *6: 1st trip DTC will be cleared after vehicle is driven once
*3: When the same malfunction is detected in two consecutive (pattern B) without the same malfunction.
trips, the DTC and the freeze frame data will be stored in *7: When the same malfunction is detected in the 2nd trip, the
ECM. 1st trip freeze frame data will be cleared.
*4: The DTC and the freeze frame data will not be displayed
any longer after vehicle is driven 40 times (pattern A) with-
out the same malfunction.
(The DTC and the freeze frame data still remain in ECM.)

EC-51 191
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
OBD System Operation Chart (Cont'd)
EXPLANATION FOR DRIVING PATTERNS EXCEPT FOR "MISFIRE <EXHAUST QUALITY
DETERIORATION>", "FUEL INJECTION SYSTEM"
(Driving pattern A)

Engine oc (oF)
coolant
1
temperature I
I
(1) Engine coolant temperature should go over 70°C (158°F)
I
70(158) -t----- -,-- ----
40(104)
20(68)
-~-- ---~----+--
-----~12)
---
Engine coolant temperature should change more than 20°C
(68°F) alter starting engine.
I time-
IGN ON IGN OFF
' I'
Engine
speed ~ (3) Ignition switch should be changed from "ON" to "OFF"

rpm I
I (4) Engine speed should go over 400 rpm

AEC574

• The A counter will be cleared when the malfunction is detected regardless of (1) - (4).
• The A counter will be counted up when (1) - (4) are satisfied without the same malfunction.
• The DTC will not be displayed after the A counter reaches 40.

(Driving pattern B)
Driving pattern B means the vehicle operation as follows:
All components and systems should be monitored at least once by the OBD system.
• The B counter will be cleared when the malfunction is detected once regardless of the driving pattern.
• The B counter will be counted up when driving pattern B is satisfied without any malfunctions.
• The MIL will go off when the B counter reaches 3 (•2 in "OBD SYSTEM OPERATION CHART").

192 EC-52
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

CONSULT
CONSULT INSPECTION PROCEDURE
1. Turn ignition switch OFF.
2. Connect "CONSULT" to data link connector for CONSULT.
(Data link connector for CONSULT is located behind the fuse
box cover.) ~IT~X

3. Turn ignition switch ON.

4. Touch "START".
NISSAN

CONSULT

i====GJD==~
START

I SUB MODE
lBR455D

5. Touch "ENGINE".
I~ SELECT~SYSTEM
I
I I ENGINE I

I
SEF895K

6. Perform each diagnostic test mode according to each service

[l1j SELECT DIAG MODE Gl procedure.
WORK SUPPORT For further information, see the CONSULT Operation Manual. ~~:

SELF-DIAG RESULTS

DATA MONITOR

I ACTIVE TEST I
I SAT• 080 TEST VALUE
I
I FUNCTION TEST
I
SEF374S

I~ SELECT DIAG MODE ~I

IECM PART NUMBER I

SEF374Q

EC-53 193
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT (Cont'd)
ECCS COMPONENT PARTS/CONTROL SYSTEMS APPLICATION
DIAGNOSTIC TEST MODE
SELF-DIAGNOSTIC
WORK RESULTS•1 FUNC- SRT·OBD
Item DATA ACTIVE
SUP- FREEZE TION TEST
MONITOR TEST
PORT FRAME TEST VALUE
DATA•2
Camshaft position sensor X X X
Mass air flow sensor X X
Engine coolant temperature sen-
X X X X
sor
Front heated oxygen sensor X X X X
Rear heated oxygen sensor X X X
Vehicle speed sensor X X X X
Throttle position sensor X X X X
Tank fuel temperature sensor X X
EVAP control system pressure
X X
sensor
Absolute pressure sensor X X
EGR temperature sensor X X
INPUT Intake air temperature sensor X X
Crankshaft position sensor
X
(OBD)
Ignition switch (start signal) X X
Closed throttle position switch X
Closed throttle position switch
X X
(throttle position sensor signal)
Air conditioner switch X
Park/Neutral position switch X X X
Power steering oil pressure
X X
en switch
1-
a: Swirl control valve control
X X
ct. vacuum check switch
1- Battery voltage X
zw Injectors X X
X
z X (lgni-
0
0.
:;; Power transistor (Ignition timing) X tion sig- X X X
0 nal)
'-' IACV-AAC valve X X X X X
en
'-' EVAP canister purge volume
'-'
w X X X
control valve
Air conditioner relay X
Fuel pump relay X X X X
EGRC-solenoid valve X X X X
Swirl control valve control sole-
X X X X
noid valve
OUTPUT Front heated oxygen sensor
X X X
heater
Rear heated oxygen sensor
X X X
heater
Torque converter clutch solenoid
X X
valve
EVAP canister purge control
X X X
solenoid valve
EVAP canister vent control valve X X
Vacuum cut valve bypass valve X X
MAP/BARO switch solenoid
X X X
valve
Calculated load value X X
X: Applicable
*1: This item includes 1st trip DTCs.
*2: This mode includes 1st trip freeze frame data or freeze frame data. The items appear on CONSULT screen in freeze frame data
mode only if a 1st trip DTC or DTC is detected. For details, refer to EC-36.

194 EC-54
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT (Cont'd)
FUNCTION
Diagnostic test mode Function

This mode enables a technician to adjust

some devices faster and more accurately by
Work support
following the indications on the CONSULT
unit.

Self-diagnostic results such as 1st trip DTC,

Self-diagnostic results DTCs and 1st trip freeze frame data or freeze
frame data can be read and erased quickly. "1

Data monitor Input/Output data in the ECM can be read.

Diagnostic Test Mode in which CONSULT
drives some actuators apart from the ECMs
Active test
and also shifts some parameters in a speci-
fied range.

The status of system monitoring tests and the

SRT·OBD test value
test values/test limits can be read.
Conducted by CONSULT instead of a techni-
Function test cian to determine whether each system is
"OK" or "NG".

ECM part numbers ECM part numbers can be read.

·1: The follow1ng em1ss1on-related d1agnost1c 1nformat1on 1s cleared when the ECM memory is erased.
1. Diagnostic trouble codes
2. 1st trip diagnostic trouble codes
3. Freeze frame data
4. 1st trip freeze frame data
5. System readiness test (SRT) codes
6. Test values
7. Others

WORK SUPPORT MODE

WORK ITEM CONDITION USAGE

THRTL POS SEN ADJ CHECK THE THROTTLE POSITION SENSOR SIGNAL. When adjusting throttle position
ADJUST IT TO THE SPECIFIED VALUE BY ROTATING sensor initial position
THE SENSOR BODY UNDER THE FOLLOWING CONDI-
TIONS.
• IGN SW "ON''
e ENG NOT RUNNING
e ACC PEDAL NOT PRESSED
IGNITION TIMING ADJ e IGNITION TIMING FEEDBACK CONTROL WILL BE When adjusting initial ignition
HELD BY TOUCHING "START". AFTER DOING SO. timing
ADJUST IGNITION TIMING WITH A TIMING LIGHT BY
TURNING THE CRANKSHAFT POSITION SENSOR.
IACV-AAC VALVE ADJ SET ENGINE SPEED AT THE SPECIFIED VALUE UNDER
IBJU
THE FOLLOWING CONDITIONS.
e ENGINE WARMED UP
• NO-LOAD
FUEL PRESSURE RELEASE e FUEL PUMP WILL STOP BY TOUCHING "START" When releasing fuel pressure
DURING IDLING. from fuel line
CRANK A FEW TIMES AFTER ENGINE STALLS.

EC-55 195
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT (Cont'd)
SELF-DIAGNOSTIC MODE
DTC and 1st trip DTC
Regarding items of "DTC and 1st trip DTC", refer to "EMISSION-RELATED DIAGNOSTIC INFORMATION
ITEMS" (See EC-41.)
Freeze frame data and 1st trip freeze frame data

Freeze frame data

Description
item*
DIAG TROUBLE
• ECCS component part/control system has a trouble code, it is displayed as "PXXXX". [Refer to "Alpha~
CODE
betical & P No. Index for DTC (EC·2).]
[PXXXX]
• "Fuel injection system status" at the moment a malfunction is detected is displayed.
• One mode in the following is displayed.
"MODE 2": Open loop due to detected system malfunction
FUEL SYS DATA
"MODE 3": Open loop due to driving conditions (power enrichment, deceleration enrichment)
"MODE 4": Closed loop- using oxygen sensor(s) as feedback for fuel control
"MODE 5": Open loop - has not yet satisfied condition to go to closed loop
CAULD VALUE[%] • The calculated load value at the moment a malfunction is detected is displayed.
COOLANT TEMP
0
• The engine coolant temperature at the moment a malfunction is detected is displayed.
[C] Or [°F]
• "Short-term fuel trim" at the moment a malfunction is detected is displayed.
S·FUEL TRIM [%] • The short-term fuel trim indicates dynamic or instantaneous feedback compensation to the base fuel
schedule.
• "Long-term fuel trim" at the moment a malfunction is detected is displayed.
L·FUEL TRIM [%] • The long-term fuel trim indicates much more gradual feedback compensation to the base fuel schedule
than short-term fuel trim.
ENGINE SPEED
• The engine speed at the moment a malfunction is detected is displayed.
[rpm]
VHCL SPEED [km/h]
• The vehicle speed at the moment a malfunction is detected is displayed.
or [mph]
ABSOL PRES [kPa]
• The intake manifold absolute pressure at the moment a malfunction is detected is displayed.
or [kg/cm 2 ] or [psi]
*: The 1tems are same as those of 1st tnp freeze frame data.

196 EC-56
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT (Cont'd)
DATA MONITOR MODE
Monitored item ECM
Main
[Unit] input Description Remarks
signals
signals
CMPS·RPM • Indicates the engine speed computed
(POS) [rpm]
0 0 from the POS signal (1° signal) of the
camshaft position sensor.
CMPS·RPM
(REF) [rpm]
• from
Indicates the engine speed computed
the REF signal (180° signal) of the
• The accuracy of detection becomes poor
if engine speed drops below the idle rpm.

0 camshaft position sensor. • If the signal is interrupted while the

engine is running, an abnormal value
may be indicated.
MAS AIR/FL SE [V] • The signal voltage of the mass air flow • When the engine is stopped, a certain
0 0 sensor is displayed. value is indicated.
COOLAN TEMP/S
['C] or ['F]
• The engine coolant temperature (deter-
mined by the signal voltage of the engine
• When the engine coolant temperature
sensor is open or short-circuited, ECM

0 0 coolant temperature sensor) is displayed. enters fail-safe mode. The engine cool-
ant temperature determined by the ECM
is displayed.
FR 02 SENSOR [V] • The signal voltage of the front heated ui!IT
0 0 oxygen sensor is displayed.
RR 02 SENSOR [V] • The signal voltage of the rear heated
0 0 oxygen sensor is displayed.
FR 02 MNTR
[RICH/LEAN]
• during
Display of front oxygen sensor signal
air-fuel ratio feedback control:
• After turning ON the ignition switch,
"RICH" is displayed until air-fuel mixture
RICH ... means the mixture became ratio feedback control begins .

0 0
"rich", and control is being affected
toward a leaner mixture.
• When the air-fuel ratio feedback is
clamped, the value just before the clamp-
LEAN. . means the mixture became ing is displayed continuously.
"lean", and control is being affected
toward a rich mixture.
RR 02 MNTR
[RICH/LEAN]
• signal:
Display of rear heated oxygen sensor • When the engine is stopped, a certain
value is indicated.
RICH ... means the amount of oxygen
downstream three way catalyst is rela-
0 tively small.
LEAN ... means the amount of oxygen
downstream three way catalyst is rela-
tively large.
VHCL SPEED SE • The vehicle speed computed from the
[km/h] or [mph] 0 0 vehicle speed sensor signal is displayed.

NOTE.
Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.

EC-57 197
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT (Cont'd)
Monitored item ECM
Main
[Unit] input Description Remarks
signals
signals
BATTERY VOLT [V] • The power supply voltage of ECM is dis-
0 0 played.
THRTL POS SEN [V] • The throttle position sensor signal volt-

0
0 0 age is displayed.
TANK F!TMP SE [ C] • The fuel temperature judged from the
or [°F]
0 tank fuel temperature sensor signal volt-
age is displayed.
EGR TEMP SEN [V] • The signal voltage of the EGR tempera-
0 ture sensor is displayed.
INT/A TEMP SE [0 C] • The intake air temperature determined by
or [°F]
0 the signal voltage of the intake air tem-
perature sensor is indicated.
START SIGNAL • Indicates [ON/OFF] condition from the • After starting the engine, [OFF] is dis-
[ON/OFF] 0 0 starter signal. played regardless of the starter signal.

0 •
CLSD THUP SW Indicates [ON/OFF] condition from the
[ON/OFF] 0 closed throttle position switch signaL
AIR COND SIG • Indicates [ON/OFF] condition of the air
[ON/OFF]
0 0 conditioner switch as determined by the
air conditioner signal.

0 •
P/N POSI SW Indicates [ON/OFF] condition from the
[ON/OFF] 0 park/neutral position switch signal.
PW/ST SIGNAL • [ON/OFF] condition of the power steering
[ON/OFF] oil pressure switch determined by the
0 0 power steering oil pressure signal is indi-
cated.
IGNITION SW • tion
Indicates [ON/OFF] condition from igni-
[ON/OFF] 0 switch.
SWLCON VCSW • Indicates [ON/OFF] condition of swirl
[ON/OFF] control valve control vacuum check
switch determined by ECM according to
0 the input signal.
ON ... Atmospheric pressure
OFF ... Vacuum pressure
INJ PULSE [msec] • Indicates the actual fuel injection pulse • When the engine is stopped, a certain

0 width compensated by ECM according to

the input signals.
computed value is indicated.

B/FUEL SCHDL
[msec]
• injection
"Base fuel schedule" indicates the fuel
pulse width programmed into
0 ECM, prior to any learned on-board cor-
rection.
IGN TIMING [BTDC] • Indicates the ignition timing computed by
0 ECM according to the input signals.

198 EC-58
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT (Cont'd)
Monitored item ECM
Main
[Unit] input Description Remarks
signals
signals
IACV-AACIV [%] • Indicates the idle air control valve (AAC

0 valve) control value computed by ECM

according to the input signals.
PURG VOL CIV [step] • Indicates the EVAP canister purge val-
ume control valve computed by the
engine control module according to the
input signals.
• The opening becomes larger as the
value increases.
A/F ALPHA[%] • The mean value of the air-fuel ratio feed- • When the engine is stopped, a certain
back correction factor per cycle is indi- value is indicated.
cated. •
This data also includes the data for the
air-fuel ratio learning control.

EVAP SYS PRES [V] • The signal voltage of EVAP control sys-
0 tem pressure sensor is displayed.

AIR COND RLY • The air conditioner relay control condition

[ON/OFF] (determined by ECM according to the
input signal) is indicated.
FUEL PUMP RLY
[ON/OFF]
• dition
Indicates the fuel pump relay control con-
determined by ECM according to
the input signals.
SWRL CONT SIV • The control condition of the swirl control
valve control solenoid valve (computed
by the ECM according to the input sig-
nal) is indicated.
ON ... Swirl control valve is closed
OFF ... Swirl control valve is open
EGRC SOUV • The control condition of the EGRC-sole-
[ON/OFF] noid valve (determined by ECM accord-
ing to the input signal) is indicated.
ON ... EGR operation is cut-off
OFF ... EGR is operational
TCC SOLIV • The control condition of the torque con-
verter clutch solenoid valve (determined
by ECM according to the input signal) is
indicated.
ON ... Lock-up is cancelled
OFF ... Lock-up is operational
VENT CONTIV • The control condition of the EVAP canis-
[ON/OFF] ter vent control valve (determined by
ECM according to the input signal) is
indicated.
ON ... Closed
OFF ... Open
FR 02 HEATER • heated
Indicates [ON/OFF] condition of front
oxygen sensor heater determined
by ECM according to the input signals.
VC/V BYPASS/V
[ON/OFF]
• The control condition of the vacuum cut
valve bypass valve (determined by ECM
according to the input signal) is indicated.
ON ... Open
OFF ... Closed

EC-59 199
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT (Cont'd)
Monitored item ECM
Main
[Unit] input Description Remarks
signals
signals

PURG CONT SN • The control condition of the EVAP canis-

[ON/OFF] ter purge control solenoid valve (com-
puted by the engine control module
according to the input signals) is indi-
cated.
• ON ... Canister purge is operational
OFF ... Canister purge operation is cut-
off

RR 02 HEATER • Indicates [ON/OFF] condition of front

heated oxygen sensor heater determined
by ECM according to the input signals.
CAULD VALUE [%] • "Calculated load value" indicates the
value of the current aitilow divided by
peak airflow.
ABSOL TH·P/S [%] • "Absolute throttle position sensor" indi-
cates the throttle opening computed by
ECM according to the signal voltage of
the throttle position sensor.
MASS AIRFLOW
[g·m/s]
• Indicates the mass airflow computed by
ECM according to the signal voltage of
the mass airflow sensor.
MAP/BARO SW/V • The control condition of the MAP/BARO
[MAP/BARO] switch solenoid valve (determined by
ECM according to the input signal) is
indicated.
MAP ... Intake manifold absolute pres-
sure
BARO ... Barometric pressure
ABSOL PRES/SE [V] • The signal voltage of the absolute pres-
sure sensor is displayed.
VOLTAGE
[V]
• Voltage measured by the voltage probe.
PULSE
[msec] or [Hz) or[%]
• Pulse width, frequency or duty cycle
measured by the pulse probe.
• Only "#" is displayed if item is unable to
be measured.
• Figures with "#"s are temporary ones .
They are the same figures as an actual
piece of data which was just previously
measured.

200 EC-60
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT (Cont'd)
ACTIVE TEST MODE
TEST ITEM CONDITION JUDGEMENT CHECK ITEM (REMEDY)

• Engine: Return to the original trouble

condition If trouble symptom disappears, see •• Harness and connector
FUEL INJECTION
• Change the amount of fuel injection
using CONSULT.
CHECK ITEM.
•
Fuel injectors
Front heated oxygen sensor

• Engine: After warming up, idle the

IACV-AAC!V OPEN- engme . Engine speed changes according to the • Harness and connector
lNG
• Change the IACV-AAC valve opening
percent using CONSULT.
opening percent. • IACV-AAC valve

ENG COOLANT
• Engine: Return to the original trouble
condition • Harness and connector

TEMP • Change the engine coolant tempera-

If trouble symptom disappears, see
CHECK ITEM. •• Engine coolant temperature sensor
Fuel injectors
lure using CONSULT.

• Engine: Return to the original trouble

condition
IGNITION TIMING • Timing light: Set
If trouble symptom disappears, see
• Adjust initial ignition timing
• Retard the ignition timing using CON-
SULT.
CHECK ITEM .

• Engine: After warming up, idle the

engine .
•• Harness and connector
Compression
POWER 13ALANCE •• Air conditioner switch "OFF'
Shift lever "N"
Engine runs rough or dies .
•
• Injectors
Power transistor
• Cut off each injector signal one at a • Spark plugs
time using CONSULT. • Ignition coils

•• Ignition switch: ON (Engine stopped)

Turn the fuel pump relay ·'ON" and Fuel pump relay makes the operating •• Harness and connector
FUEL PUMP RELAY
"OFF" using CONSULT and listen to sound. Fuel pump relay
operating sound.
liT~

••
Ignition switch: ON
EGRC SOLENOID Turn solenoid valve "ON" and "OFF" Solenoid valve makes an operating • Harness and connector
VALVE with CONSULT and listen to opera!-
ing sound .
sound.
• Solenoid valve

• Ignition switch: ON
(Engine stopped) •• Harness and connector
SWIRL CONT SOL
VALVE • Turn solenoid valve "ON" and "OFF''
with CONSULT and listen to opera!-
Solenoid valve makes an operating
sound. ••
Solenoid valve
Swirl control valve
Vacuum hose
ing sound.

SELF-LEARNING
CONT
• In this test. the coefficient of self-learning control mixture ratio returns to the original coefficient by touching "CLEAR" on
the screen .

• Engine: After warming up, run engine

at l ,500 rpm.
•• Harness and connector
PURG VOL CONT/V • Change the EVAP canister purge val-
ume control valve opening step using
Engine speed changes according to the
opening step.
EVAP canister purge volume control
valve
CONSULT.

•• Start engine.
Turn the EVAP canister purge control
EVAP canister purge control solenoid
valve makes an operating sound.
•• Harness and connector
Check vacuum signal for EVAP canister EVAP canister purge control solenoid
PURG CONT SN solenoid valve "ON" and "OFF" using
purge control valve. valve
CONSULT and listen for operating
sound.
VC ON ... Vacuum exists.
VC OFF .. Vacuum does not exist.
• Vacuum hose

• Ignition switch: ON
(Engine stopped)
MAP/BARO SWIV • Turn the MAP/BARD switch solenoid
valve between "MAP" and "BARO"
MAP/BARD switch solenoid valve makes
an operating sound.
•• Harness and connector
MAP/BARD switch solenoid valve
using CONSULT and listen for operat-
ing sound .

TANK F/TEMP SEN

• Change the tank fuel temperature using CONSULT.

EC-61 201
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT (Cont'd)
FUNCTION TEST MODE

FUNCTION TEST
CONDITION JUDGEMENT CHECK ITEM (REMEDY)
ITEM
• Ignition switch: ON
SELF-DIAG (Engine stopped) ~

Objective system
RESULTS • Displays the results of on
board diagnostic system.
• Ignition switch: ON • Harness and connector
(Engine stopped) • Throttle position sensor
CLOSED THROTILE • Closed throttle position Throttle valve: opened OFF (Closed throttle position
POSI switch circuit is tested when switch)
(CLOSED throttle is opened and • Throttle position sensor
THROTILE POSI- closed fully. (""IDLE POSI- (Closed throttle position
TION SWITCH CIR- TION" is the test item name switch) adjustment
CUlT) for the vehicles in which idle Throttle valve: closed ON • Throttle linkage
is selected by throttle posi- • Verify operation in DATA
tion sensor.) MONITOR mode.
• Harness and connector
• Ignition switch: ON • Throttle position sensor
(Engine stopped) Range (Throttle valve fully • Throttle position sensor
THROTILE POSI More than
• Throttle position sensor cir· opened -Throttle valve fully adjustment
SEN CKT 3.0V
cuit is tested when throttle closed) • Throttle linkage
is opened and closed fully. • Verify operation in DATA
MONITOR mode.
• Ignition switch: ON • Harness and connector
(Fngine stopped) OUT OF NiP-RANGE OFF • Neutral position switch/
PARKINEUT POSI
• Inhibitor/Neutral position Inhibitor switch
SWCKT
switch circuit is tested when IN NiP-RANGE • Linkage + Inhibitor switch
ON
shift lever is manipulated. adjustment
• Ignition switch: ON
• Harness and connector
(Engine stopped)
• Fuel pump
FUEL PUMP • Fuel pump circuit is tested There is pressure pulsation on the fuel
• Fuel pump relay
CIRCUIT by checking the pulsation in feed hose.
• Fuel filter clogging
fuel pressure when fuel tube
• Fuel level
is pinched.
• Ignition switch: ON
(Engine stopped)
EGRC SOUV CIR- The solenoid valve makes an operating • Harness and connector
• EGRC-solenoid valve circuit
CUlT sound every 3 seconds. • EGRC·solenoid valve
is tested by checking sole·
noid valve operating noise.
• Ignition switch: ON ---7
START
• Start signal circuit is tested
when engine is started by
operating the starter. Battery
START SIGNAL voltage and engine coolant • Harness and connector
Start signal: OFF --7 ON
CIRCUIT temperature before • Ignition switch
cranking, and average bat-
tery voltage, mass air flow
sensor output voltage and
cranking speed during
cranking are displayed.

202 EC-62
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT (Cont'd)
!E,ll
FUNCTION TEST
CONDITION JUDGEMENT CHECK ITEM (REMEDY)
ITEM
• Ignition switch: ON
(Engine running) Locked position ON • Harness and connector
• Power steering circuit is
PW/ST SIGNAL • Power steering oil pressure
tested when steering wheel
CIRCUIT switch
is rotated fully and then set
Neutral position OFF • Power steering oil pump
to a straight line running
position.
• Ignition switch: ON
(Engine stopped)
• Harness and connector
SWRL CONT S/V • Swirl control valve control The solenoid valve makes an operating • Solenoid valve
CIRCUIT solenoid valve circuit is sound every 3 seconds. • Vacuum
Swirl control valve
tested by checking solenoid
valve operating sound.
• hose

• Vehicle speed sensor circuit

• Harness and connector
VEHICLE SPEED is tested when vehicle is Vehicle speed sensor input signal is
• Vehicle speed sensor
SEN CKT running at a speed of 10 greater than 4 km/h (2 MPH)
• Speedometer
krnlh (6 MPH) or higher.
• After warming up, idle the
engine. • Adjust ignition timing (by
• Ignition timing adjustment is moving camshaft position
The timing light indicates the same value
IGN TIMING ADJ checked by reading ignition sensor or distributor)
on the screen.
timing with a timing light • Camshaft position sensor
and checking whether it drive mechanism
agrees with specifications.
e INJECTION SYS (Injector,
fuel pressure regulator, har-
ness or connector)
e IGNITION SYS (Spark plug,
• Air-fuel ratio feedback circuit
power transistor, ignition
(injection system, ignition
coil, harness or connector)
system, vacuum system,
MIXTURE RATIO Front heated oxygen sensor COUNT: More e VACUUM SYS (Intake air
etc.) is tested by examining
TEST than 5 times during 10 seconds leaks)
the front heated oxygen
• Front heated oxygen sensor
sensor output at 2,000 rpm
circuit
under non-loaded state.
• Front heated oxygen sensor
operation
• Fuel pressure high or low
• Mass air flow sensor
• After warming up, idle the
engine.
• Injector operation of each
• Injector circuit (Injector, har-
cylinder is stopped one after
ness or connector)
another, and resultant
Difference in engine speed is greater than • Ignition circuit (Spark plug,
change in engine rotation is
POWER BALANCE 25 rpm before and after cutting off the power transistor, ignition
examined to evaluate com-
injector of each cylinder. coil, harness or connector)
bustion of each cylinder.
• Compression
(This is only displayed for
• Valve timing
models where a sequential
multipart fuel injection sys-
tern is used.)

EC-63 203
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT {Cont'd)
FUNCTION TEST
CONDITION JUDGEMENT CHECK ITEM (REMEDY)
ITEM
• After warming up, idle the
• Harness and connector
engine.
e IACV-AAC valve
• IACV-AAC valve system is
Difference in engine speed is greater than • Air passage restriction
IACV-AAC/V tested by detecting change
150 rpm between when valve opening is at between air inlet and IACV-
SYSTEM in engine speed when
80% and at 20%. AAC valve
IACV-AAC valve opening is
• lAS (Idle adjusting screw)
changed to 0%, 20% and
adjustment
80%.
• Incorrect fuel tank vacuum
relief valve
• Incorrect fuel filler cap used
• Fuel filler cap remains open
or fails to close.
• Foreign matter caught in
fuel filler cap.
• Leak is in line between
intake manifold and EVAP
canister purge control valve.
• Foreign matter caught in
EVAP canister vent control
valve.
• EVAP canister or fuel tank
leaks
• EVAP purge line tube leaks
• EVAP purge line rubber
• After warming up, idle the
tube bent.
engine etc.
• Blocked or bent rubber tube
• EVAP system is tested by
*EVAP (SMALL • EVAP control system has no leak. to EVAP control system
using the evaporative gas
LEAK) • EVAP control system operates properly. pressure sensor
pressure in the fuel tank or
• EVAP canister purge control
engine intake manifold pres-
valve
sure.
• EVAP canister purge vol-
ume control valve
• EVAP canister purge control
solenoid valve
• Absolute pressure sensor
• Tank fuel temperature sen-
sor
• MAP/BARO switch solenoid
valve
• Blocked or bent rubber tube
to MAP/BARO switch sole-
noid valve
• Loose or disconnected rub-
ber tube
• 0-ring of EVAP canister
vent control valve is missing
or damaged

*:Always select "SINGLE TEST" w1th CONSULT when pertorm1ng the "FUNCTION TEST " .

204 EC-64
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT (Cont'd)
REAL TIME DIAGNOSIS IN DATA MONITOR MODE
CONSULT has two kinds of triggers and they can be selected by touching "SETTING" in "DATA MONITOR"
mode.
1. "AUTO TRIG" (Automatic trigger):
• The malfunction will be identified on the CONSULT screen in real time.
In other words, DTC/1 st trip DTC and malfunction item will be displayed at the moment the malfunc- [E[:i]
tion is detected by ECM.
DATA MONITOR can be performed continuously until a malfunction is detected. However, DATA MONI-
TOR cannot continue any longer after the malfunction detection.
2. "MANU TRIG" (Manual trigger): ll0
• DTC/1 st trip DTC and malfunction item will not be displayed automatically on CONSULT screen even
though a malfunction is detected by ECM.
DATA MONITOR can be performed continuously even though a malfunction is detected.
Use these triggers as follows:
1. "AUTO TRIG"
• While trying to detect the DTC/1st trip DTC by performing the "DTC CONFIRMATION PROCEDURE", 'fi"
be sure to select to "DATA MONITOR (AUTO TRIG)" mode. You can confirm the malfunction at the
moment it is detected.
• While narrowing down the possible causes, CONSULT should be set in "DATA MONITOR (AUTO
TRIG)" mode, especially in case the incident is intermittent.
When you are inspecting the circuit by gently shaking (or twisting) the suspicious connectors, compo-
nents and harness in the "DTC CONFIRMATION PROCEDURE", the moment a malfunction is found iff
the DTC will be displayed. (Refer to Gl section, "Incident Simulation Tests" in "HOW TO PERFORM
EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT".)
2. "MANU TRIG"
• If the malfunction is displayed as soon as "DATA MONITOR" is selected, reset CONSULT to "MANU
TRIG". By selecting "MANU TRIG" you can monitor and store the data. The data can be utilized for fur-
ther diagnosis, such as a comparison with the value for the normal operating condition. tiC

I~ SELECT MONITOR ITEM I~ SET RECORDING COND I ~ SET RECORDING COND

ECM INPUT SIGNALS AUTO TRIG MANU TRIG I AUTO TRIG MANU TRIG
MAIN SIGNALS HI SPEED I LONG TIME HI SPEED I LONG TIME

SELECTION FROM MENU I I I

I SETTING II START

"SETIING"
I
"AUTO TRIG"
I
"MANU TRIG"
A malfunction can be A malfunction can not be
displayed on "DATA displayed on "DATA
MONITOR" screen MONITOR" screen
automatically if detected. automatically even it
detected.

SEF529Q
~-------··

EC-65 205
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION

Generic Scan Tool (GST)

DESCRIPTION
Generic Scan Tool (OBDII scan tool) complying with SAE J1978
has 7 different functions explained on the next page.
IS09141 is used as the protocol.
The name "GST" or "Generic Scan Tool" is used in this service
manual.

SEF139P

GST INSPECTION PROCEDURE

1. Turn off ignition switch.
2. Connect "GST" to data link connector for GST. (Data link con-
nector for GST is located under LH dash panel near the fuse
box cover.)

3. Turn ON ignition switch.

4. Enter the program according to instruction on the screen or in
the operation manual.
VTX GENERIC OBD II
PROGRAM CARD
(': Regarding GST screens in this section, sample screens are
shown.)

Press [ENTER]

'---.,-sa=m::p-;:le"""'s::c::re""en'"'·------',sEF39BS

5. Perform each diagnostic mode according to each service pro-

OBD II FUNCTIONS cedure.
FO: DATA LIST For further information, see the GST Operation Manual of the
F1: FREEZE DATA
F2: DTCS
tool maker_
F3: SNAPSHOT
F4: CLEAR DIAG INFO
F5: 02 TEST RESULTS
F6: READINESS TESTS
F7: ON BOARD TESTS
FB: EXPAND DIAG PROT
F9: UNIT CONVERSION
'---s"'a=m=p"'le--:s::cr::e::en:-;•-----!SEF416S

206 EC-66
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Generic Scan Tool (GST) (Cont'd)
FUNCTION
Diagnostic test mode Function
This mode gains access to current emission-related data values, including analog
MODE 1 READINESS TESTS
inputs and outputs, digital inputs and outputs, and system status information.
This mode gains access to emission-related data value which were stored by ECM
MODE 2 (FREEZE DATA) during the freeze frame. [For details, refer to '·Freeze frame data and 1st trip freeze
frame data" (EC-56).]
This mode gains access to emission-related power train trouble codes which were
MODE 3 DTCs
stored by ECM.
This mode can clear all emission-related diagnostic information. This includes:
• Clear number of diagnostic trouble codes (MODE 1)
• Clear diagnostic trouble codes (MODE 3)
• Clear trouble code for freeze frame data (MODE 1)
MODE 4 CLEAR DIAG INFO
• Clear freeze frame data (MODE 2)
• Clear heated oxygen sensor test data (MODE 5)
• Reset status of system monitoring test (MODE 1)
• Clear on board monitoring test results (MODE 6 and 7)
This mode gains access to the on board heated oxygen sensor monitoring test
MODE 5 (02 TEST RESULTS)
results.
This mode accesses the results of on board diagnostic monitoring tests of specific
MODE 6 (ON BOARD TESTS)
components/systems that are not continuously monitored.
This mode enables the off board test drive to obtain test results for emission-related
MODE 7 (ON BOARD TESTS) powertraln components/systems that are continuously monitored during normal driv-
ing conditions.

EC-67 207
 TROUBLE DIAGNOSIS - Introduction

Introduction
Sensors The engine has an ECM to control major systems such as fuel
control, ignition control, idle air control system, etc. The ECM
~ ECM Actuatocs accepts input signals from sensors and instantly drives actuators.
It is essential that both input and output signals are proper and

~~·~
stable. At the same time, it is important that there are no problems
such as vacuum leaks, fouled spark plugs, or other problems with
the engine.
It is much more difficult to diagnose a problem that occurs intermit-
tently rather than continuously. Most intermittent problems are
MEF036D caused by poor electric connections or improper wiring. In this
case, careful checking of suspected circuits may help prevent the
replacement of good parts.
A visual check only may not find the cause of the problems. A road
test with CONSULT (or GST) or a circuit tester connected should
be pertormed. Follow the "Work Flow" on EC-70.
Before undertaking actual checks, take a few minutes to talk with
a customer who approaches with a driveability complaint. The cus-
tomer can supply good information about such problems, espe-
cially intermittent ones. Find out what symptoms are present and
under what conditions they occur. A "Diagnostic Worksheet" like
the example on the next page should be used.
Start your diagnosis by looking for "conventional" problems first.
This will help troubleshoot driveability problems on an electronically
controlled engine vehicle.

SEF234G

Diagnostic Worksheet
KEY POINTS There are many operating conditions that lead to the malfunction
of engine components. A good grasp of such conditions can make
WHAT ..... Vehicle & engine model troubleshooting faster and more accurate.
WHEN ..... Date, Frequencies In general, each customer feels differently about a problem. It is
WHERE ..... Road conditions important to fully understand the symptoms or conditions for a
HOW ..... Operating conditions, customer complaint.
Weather conditions, Utilize a diagnostic worksheet like the one on next page in order
Symptoms to organize all the information for troubleshooting.
Some conditions may cause the malfunction indicator lamp to
SEF907l come on steady or blink and DTC to be detected. Examples:
• Vehicle ran out of fuel, which caused the engine to misfire.
• Fuel filler cap was left off or incorrectly screwed on, allowing
fuel to evaporate into the atmosphere [for models with EVAP
(SMALL LEAK) diagnosis].

208 EC-68
 TROUBLE DIAGNOSIS- Introduction
Diagnostic Worksheet (Cont'd)
WORKSHEET SAMPLE :~U

Customer name MR/MS Model & Year VIN

Engine# Trans. Mileage
Incident Date Manuf. Date In Service Date
D Vehicle ran out of fuel causing misfire
Fuel and fuel filler cap
D Fuel filler cap was left off or incorrectly screwed on.
[1Impossible to start D No combustion D Partial combustion
D Partial combustion affected by throttle position
D Startability
D Partial combustion NOT affected by throttle position
D Possible but hard to start L: Others I l
D No fast idle D Unstable D High idle D Low idle
I J Idling
D Others I l
Symptoms
D Stumble D Surge D Knock D Lack of power
D Driveability Ll Intake backfire D Exhaust backfire
D Others I l
0 At the time of start [] While idling
D Engine stall D While accelerating D While decelerating
D Just after stopping D While loading
0 Just after delivery D Recently
Incident occurrence
[J In the morning U At night [J In the daytime

Frequency D AU the time D Under certain conditions D Sometimes

Weather conditions D Not affected
Weather 0 Fine DRaining C:::: Snowing D Others I l
Temperature [I Hot U Warm u Cool Ll Cold [J Humid OF
rJ Cold n During warm-up C:: After warm-up

Engine conditions Engine speed I I I I J

0 2,000 4,000 6,000 ' 8,000 rpm

Road conditions DIn town C In suburbs D Highway D Off road (up/down)

D Not affected
L At starting U While idling [J At racing
0 While accelerating D While cruising
Driving conditions D While decelerating D While turning (RH/LH)

Vehicle speed
0 '
10 20 30 40 50 60 MPH
Malfunction indicator lamp 0 Turned on D Not turned on

EC-69 209
 TROUBLE DIAGNOSIS - Work Flow

Work Flow
CHECK IN

~
CHECK INCIDENT CONDITIONS
STEP I
Listen to customer complaints. (Get symptoms.)

~
CHECK DTC AND FREEZE FRAME DATA
Check and print out (write down) (1st trip) Diagnostic Trouble Code (OTC) and STEP II
Freeze Frame Data (Pre-check). Then clear.
If DTC is not available even if MIL lights up, check ECM fail-safe. {Refer to EC-76.)
Also check related service bulletins for information.

Symptoms No symptoms, except MIL

collected. lights up, or (1st trip) DTC
exists at STEP II.

Verity the symptom by driving in the condition the cus-

- '1
tamer described. ··············································· .... STEP Ill

Normal Code Malfunction Code

(at STEP II) (at STEP II)

'1
INCIDENT CONFIRMATION ........ STEP IV
Verify the (1st trip) DTC by pertorming the "DTC CONFIRMATION PROCEDURE".

~
H Choose the appropriate action.
.2
STEP V
Malfunction Code (at STEP II or IV) ~Normal Code (at both STEP II and IV)

BASIC INSPECTION

.. ·························· ······················· ..........~SYMPTOM BASIS (at STEP I or Ill)

Periorm inspections
according to Symptom
Matrix Chart .

.. STEP VI
TROUBLE DIAGNOSIS FOR DTC PXXXX.
I
~
REPAIR/REPLACE
I I
~
NG FINAL CHECK
'-----
Confirm that the incident is completely fixed by periorming BASIC INSPECTION and
DTC CONFIRMATION PROCEDURE (or OVERALL FUNCTION CHECK). Then, STEP VII
erase the unnecessary (already fixed) 1st trip DTCs in ECM and AfT control unit.

~OK
CHECK OUT
If completion of SRT is needed, drive the vehicle
under the specific pattern.
Refer to EC-37.

'1: If the incident cannot be duplicated, see "Incident Simulation Tests" of "HOW TO PERFORM EFFICIENT DIAGNO-
SIS FOR AN ELECTRICAL INCIDENT" in Gl section.
*2: If the on board diagnostic system cannot be performed, check main power supply and ground circuit (See TROUBLE
DIAGNOSIS FOR POWER SUPPLY EC-89).

210 EC-70
 TROUBLE DIAGNOSIS - Work Flow

Description for Work Flow

STEP DESCRIPTION
Get detailed information about the conditions and the environment when the incident/symptom occurred using the
STEP I
"DIAGNOSTIC WORK SHEET", EC-68.
Before confirming the concern, check and write down (print out using CONSULT or Generic Scan Tool) the (1st
trip) Diagnostic Trouble Code (DTC) and the (1st trip) freeze frame data, then erase the code and the data. (Refer
to EC-43.) The (1st trip) DTC and the (1st trip) freeze frame data can be used when duplicating the incident at
STEP II STEP Ill & IV.
Study the relationship between the cause, specified by (1st trip) DTC, and the symptom described by the customer.
(The "Symptom Matrix Chart" will be useful. See EC-77.)
Also check related service bulletins for information.
Try to confirm the symptom and under what conditions the incident occurs.
The "DIAGNOSTIC WORK SHEET" and the freeze frame data are useful to verify the incident. Connect CONSULT
STEP Ill to the vehicle in DATA MONITOR (AUTO TRIG) mode and check real time diagnosis results.
If the incident cannot be verified, perform INCIDENT SIMULATION TESTS. (Refer to Gl section.)
If the malfunction code is detected, skip STEP IV and perlorm STEP V.
Try to detect the (1st trip) Diagnostic Trouble Code by driving in (or performing) the "DTC CONFIRMATION PRO-
CEDURE". Check and read the (1st trip) DTC and (1st trip) freeze frame data by using CONSULT or Generic Scan
Tool.
During the (1st trip) DTC verification, be sure to connect CONSULT to the vehicle in DATA MONITOR (AUTO
TRIG) mode and check real time diagnosis results.
STEP IV
lf the incident cannot be verified, perlorm INCIDENT SIMULATION TESTS. (Refer to Gl section.)
In case the "DTC CONFIRMATION PROCEDURE" is not available, pertorm the "OVERALL FUNCTION CHECK"
instead. The (1st trip) DTC cannot be displayed by this check, however, this simplified "check" is an effective alter-
native.
The "NG" result of the "OVERALL FUNCTION CHECK" is the same as the (1st trip) DTC detection.
Take the appropriate action based on the results of STEP I through IV.
If the malfunction code is indicated, proceed to TROUBLE DIAGNOSIS FOR DTC PXXXX.
STEP V
If the normal code is indicated, proceed to the BASIC INSPECTION on next page. Then perform inspections
according to the Symptom Matrix Chart. (Refer to EC-77.)
Identify where to begin diagnosis based on the relationship study between symptom and possible causes. Inspect
the system for mechanical binding, loose connectors or wiring damage using (tracing) "Harness Layouts".
Gently shake the related connectors, components or wiring harness with CONSULT set in ''DATA MONITOR
(AUTO TRIG)" mode.
Check the voltage of the related ECM terminals or monitor the output data from the related sensors with CON-
STEP VI
SULT. Refer to EC-79, 83.
The "DIAGNOSTIC PROCEDURE" in EC section contains a description based on open circuit inspection. A short
circuit inspection is also required for the circuit check in the DIAGNOSTIC PROCEDURE. For details, refer to Gl
section ("HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT", "Circuit Inspection").
Repair or replace the malfunctioning parts.
Once you have repaired the circuit or replaced a component, you need to run the engine in the same conditions
and circumstances which resulted in the customer's initial complaint.
Perlorm the "DTC CONFIRMATION PROCEDURE" and confirm the normal code [Diagnostic trouble code No.
STEP VII POOOO or 0505] is detected. If the incident is still detected in the final check, perform STEP VI by using a different
method from the previous one.
Before returning the vehicle to the customer, be sure to erase the unnecessary (already fixed) (1st trip) DTC in
ECM and A!f control unit. (Refer to EC-43.)

EC-71 211
 TROUBLE DIAGNOSIS - Basic Inspection

Basic Inspection
Precaution:
Perform Basic Inspection without electrical or mechanical
loads applied;
• Headlamp switch is OFF,
• Air conditioner switch is OFF,
• Rear window defogger switch is OFF,
• Steering wheel is in the straight-ahead position, etc.
F.i.1
SEF1421 BEFORE STARTING
1. Check service records for any recent
rn repairs that may indicate a related
problem, or the current need for sched-
j uled maintenance.
2. Open engine hood and check the fol-
lowing:
• Harness connectors for improper con-
nections
• Vacuum hoses for splits, kinks, or
improper connections
• Wiring for improper connections,
pinches, or cuts

~l!]:r:=;;;;~.~I~G~N~T~IM~I~N~G~A~D~J~.~~o~=~ CONNECT CONSULT TO THE VEHICLE.

Connect ''CONSULT" to the data link con-
nector for CONSULT and select
IGNITION TIMING FEEDBACK "ENGINE" from the menu. Refer to
CONTROL WILL BE HELD BY EC-53.
TOUCHING START
AFTER DOING SO. ADJUST
IGNITION TIMING WITH A
TIMING LIGHT BY TURNING
Ll_o_o_E_s_E_N_G_I_N_E_s_T_A,R~T~?~--------~~ Goto~
THE CAMSHAFT POSITION
SENSOR.

START
[!] res
r=----------~~-----------,NG
SEF555N CHECK IGNITION TIMING. Adjust ignition timing by
(ij\_1: Warm up engine sufficiently. turning camshaft position
\l!J .
2 Select "IGN TIMING ADJ'' in sensor.
"WORK SUPPORT' mode.
3. Touch "START'.
4. Check ignition timing at idle
using timing light.
Ignition timing:
MIT 1 0'±2' BTDC
AfT 1 0'±2' BTDC (in "N"
position)
~ i Warm up engine sufficiently.
~· 2~ Stop engine and disconnect
throttle position sensor harness
connector.
3. Start engine.
4. Check ignition timing at idle
using timing light.
Ignition timing:
MIT 1 0'±2" BTDC
AfT 10'±2" BTDC (in "N"
position)

OK

®
(Go to next page.)

SEF284G

212 EC-72
 TROUBLE DIAGNOSIS - Basic Inspection
Basic Inspection (Cont'd)
• IGN TIMING ADJ • D ®
IGNITION TIMING FEEDBACK
CONTROL WILL BE HELD BY I!J
~----------_J____________ -,NG
TOUCHING START CHECK IDLE SPEED ADJ. SCREW INI- Adjust base idle speed by
AFTER DOING SO, ADJUST TIAL SET RPM (BASE IDLE SPEED). turning idle speed adjust-
IGNITION TIMING WITH A (F.i\ 1. Select "IGN TIMING ADJ" in ing screw.
TIMING LIGHT BY TURNING "-_~ "WORK SUPPORT" mode.
THE CAMSHAFT POSITION 2. When touching "START", does
SENSOR engine speed fall to 750±50 rpm
(AfT in "N" position)?
1--::::---- OR ----------1 l-©
START
~ When disconnecting throttle posi-
SEF546N
~ tion sensor harness connector,
does engine run at 750±50 rpm
(AfT in "N" position)?

OK
1§1
~----------_J~----------~NG
CHECK CLOSED THROTTLE POSITION Adjust continuity signal by
SWITCH IDLE POSITION. rotating throttle position
rF.'l\ 1. Select "AfT", then "DATA sensor body.
\J!I) MONITOR" mode with CON-
SULT
2. Select "ENGINE SPEED" and
"CLOSEO THUSW" from the RESET IDLE POSITION
menu. MEMORY.
3. Read "CLOSED THUSW" sig- 1. Warm up engine suffi-
nal under the following condi- ciently.
tion: (F.i\ 2. Select "CLSD
'k MONITOR 1.7 NOFAIL 0 • Raise engine speed to 2,000 \J!I) THLIP SW" in
rpm. "DATA MONI-
THRTL POS SEN 1_2V • Gradually lower engine TOR" mode
ENGINE SPEED iOOOrpm speed. (Manual trigge;)
CLOSED THUSW ON "CLOSED THLISW" signal should with CONSULT,
turn "ON" at 1,000±150 rpm with then stop
transaxle in "N" position. engine.
f - . , - - - - - OR -------------1 3. Reconnect throttle posi-
~-- 1. Disconnect throttle position sen- tion sensor harness
~ sor harness connector and connector and closed
closed throttle position switch throttle position switch
RECORD harness connector. harness connector.
SEF814T
2. Check continuity between 4. Turn ignition switch
closed throttle position switch "ON".
terminals® and @ under the 5. Turn ignition switch
following conditions. "OFF" and wait at least
• Raise engine speed to 2,000 7 seconds.
rpm. 6. (i\ Repeat steps 4.
• Gradually lower engine \J!I) and 5. until
speed. "CLSD THUP
Continuity should exist (closed SW" in "DATA
throttle position switch closes) at MONITOR"
1,000±150 rpm with transaxle in mode with CON-
"N" position. SULT changes
to "ON".
OK ~ Repeat steps 4.
~ and 5. 20 times.
Reconnect throttle position sensor har-
ness connector and closed throttle posi-
Closed throttle tion switch harness connector.
position switch
connector

®
(Go to next page.)

SEF403T

EC-73 213
 TROUBLE DIAGNOSIS - Basic Inspection
Basic Inspection (Cont'd)
®
l
CHECK TARGET IDLE SPEED. NG Adjust idle speed. Refer to
Read the engine idle speed in
f---> EC·28.
® ""DATA MONITOR" mode with
CONSULT.
=
MIT 800±50 rpm
=
A/T 800±50 rpm
(in "N" position)
OR

® Check idle speed.

=
MIT 800±50 rpm
=
A/T 800±50 rpm
(in "N" position)

1 OK

After this inspection, unnecessary diag-

nostic trouble code No. might be dis-
played.
Erase the stored memory in ECM and AfT
control unit.
Refer to "ON BOARD DIAGNOSTIC SYS-
TEM DESCRIPTION" (EC-34) and "HOW
TO ERASE DTC" in AT section.

I OK
INSPECTION END

214 EC-74
 TROUBLE DIAGNOSIS - General Description

Diagnostic Trouble Code (DTC) Inspection

Priority Chart
If some DTCs are displayed at the same time, perform inspections one by one based on the following prior-
ity chart.
Priority Detected items (DTC)
~Ji1
• ECM (P0605, 0301) • Camshaft position sensor circuit • Engine coolant temperature sensor
(P0340, 01 Ot) circuit (P0115, Ot 03) (P0125,
0908) u;
• Mass air flow sensor circuit • Vehicle speed sensor circuit • Ignition signal circuit (P1320,
(P01 00, 01 02) (P0500, 0104) 0201)
• Throttle position sensor circuit • Intake air temperature sensor cir- • Park/Neutral position switch circuit
(P0120, 0403) cuit (P011 0, 0401) (P0705, 1003)

• EGRC~solenoid valve circuit • Tank fuel temperature sensor [S1':

(P1400, 1005) (P0180, 0402)
2 • EGR temperature sensor circuit • Crankshaft position sensor circuit • Front heated oxygen sensor circuit
(P1401, 0305) (P0335, 0802), (P1336, 0905) (P0130, 0303) :Gl
• Absolute pressure sensor circuit • Front heated oxygen sensor heater • Rear heated oxygen sensor circuit
(P0105, 0803) circuit (P0135, 0901) (P0136, 0707)
~~J
• MAP/BARO switch solenoid valve • EVAP control system pressure • EVAP canister purge volume con-
circuit (P1105, 1302) sensor circuit (P0450, 0704) trol valve circuit (P1445, 1008)

• EVAP canister purge control valve/ • EVAP canister vent control valve • EVAP control system purge flow J~:r
solenoid valve circuit (P0443, circuit (P0446, 0903) monitoring (P1447, 0111)
0807)
• Vacuum cut valve bypass valve • TIC clutch solenoid valve (P1550, • Closed throttle position switch cir~
(P1441, 0801) 0904) cuit (P0510, 0203)

• Rear heated oxygen sensor heater • Swirl control valve control vacuum
circuit (P0141, 0902) check switch (P1165, 0112)

3 • EGA function (P0400, 0302) • Misfire (P0300- P0304, 0701 - • Fuel injection system function
0605) (P0172, 0114), (P0171, 0115)

• EGRC~BPT valve function • Closed loop control • Three way catalyst function
(P0402, 0306) (P0130, 0307) (P0420, 0702)

• IACV-AAC valve circuit • EVAP control system (small leak)

(P0505, 0205) (P0440, 0705)

• Swirl control valve control solenoid

valve (P1130, 1004)

EC-75 215
 TROUBLE DIAGNOSIS - General Description

Fail-Safe Chart
The ECM enters fail-safe mode, if any of the following DTCs is recorded due to the open or short circuit. When
the ECM enters the fail-safe mode the MIL illuminates
'
DTC No.
CONSULT ECM• Detected items Engine operating condition in fail-safe mode
GST
P0100 0102 Mass air flow sensor cir- Engine speed will not rise more than 2,400 rpm due to the fuel cut.
cuit
P0110 0401 Intake air temperature The ECM controls on the assumption that the intake air temperature is
sensor circuit 20°C (68°F).
P0115 0103 Engine coolant tempera- Engine coolant temperature will be determined by ECM based on the time
ture sensor circuit after turning ignition switch "ON" or "START'.
CONSULT displays the engine coolant temperature decided by ECM.

Engine coolant temperature decided

Condition
(CONSULT display)

Just as ignition switch is turned ON or

20"C (68°F)
STAAT
More than approx. 6 minutes after igni-
80°C (176°F)
tion ON or START
20 - 80°C (68 - 176°F)
Except as shown above
(Depends on the time)

P0120 0403 Throttle position sensor Throttle position will be determined based on the injected fuel amount and
circuit the engine speed.
Therefore, acceleration will be poor.

Condition Driving condition

When engine is idling Normal
When accelerating Poor acceleration

Unable to Unable to ECM ECM fail-safe activating condition

access ECCS access The computing function of the ECM was judged to be malfunctioning.
Diagnostic When the fail-safe system activates (i.e., if the ECM detects a malfunction
Test Mode condi1ion in 1he CPU of ECM), 1he MALFUNCTION INDICATOR LAMP on
II the instrument panel lights to warn the driver.
However it is not possible to access ECCS and DTC cannot be confirmed.
Engine control with ECM fail-safe
When ECM fail-safe is operating, fuel injection, ignition timing, fuel pump
operation and IACV-AAC valve operation are controlled under certain limita-
tions.

ECM fail-safe operation

Engine speed Engine speed will not rise more than 3,000 rpm
Fuel injection Simultaneous multipart fuel injection system
Ignition timing Ignition timing is fixed at the preset valve
Fuel pump relay is "ON" when engine is running and ''OFF"
Fuel pump
when engine stalls
IACV-AAC valve Full open

Replace ECM, if ECM fail-safe condition is confirmed.

*: In D1agnost1C Test Mode II {Self-dJagnostJc results)

216 EC-76
 TROUBLE DIAGNOSIS - General Description

Symptom Matrix Chart

SYMPTOM
I
z '-'
0 I
'<
I ~ w
.... a: a: w
z
"'
u
X
0a_ w
~
w
:0
~
a:
0
i=
z
0
'-'
a:
~
.... "'~ z
0
u
u w
~
w
a_
a_
:> i=
a_ "'u
I
a:
>0
~

l'c ~ a: "' Q
w
:> :0

"'0z
:>
:0 a:
w
if)
w
CJ
z
z 0
0
.... 0
a_
w
~
'-'
z 12 ....a: u
if)
z 0
z
Reference page
a: (ij w Q
i=
z z z w 0
2
0: a: ~ ()

~
a:
~ 0
w :0 0 :0 w ~ 0
CJ
z
>0
"'
~
~

>0
:0
'!!
z "z "' "'Lil
()
0 0
a_
0 w a:~
I

~
....
w
a:
:0
0 w
LL
w w 0
~ > > >-
"' "'0~
(ij
a:
0 if) 0
LL ~
Q
"'
> 0 w u; u; a: "'a:
w
~ (ijz u;>0
i=
""a: 0 Q I
'-' ~ I if) if) w
0
u
I
()

a:
"'
I
z
UJ
UJ
I
a_
"' ""'
if)
()
~
I
'-'
I
CJ
:0
0
a:
z
"
Q
0
~

"'
a:
w
>
0
w
u
X
UJ
w
()
X
UJ
s"' a:
w
>
0
UJ
>
0
Warranty Symptom Code AA AB AC AD AE AF AG AH AJ AK AL AM HA 1P 1X
Fuel Fuel pump circuit
• • • 0 • • 0 0 0 EC-309
Fuel pressure regulator system • • • 0 •
•
0 • • 0 • EC-25
Injector circuit
• c• 0• 0 •0 0• • EC-303
E Evaporative emission system 0 0 • 0 0 0 EC-20

*
~
Air Positive crankcase ventilation system 0 c 0 0 • 0 0 0 0 0 0 EC 24

eE" Incorrect idle speed adjustment 0 0 0 0 0 0 0 EC-28

Swirl control valve circuit 0 0 • EC-243
0
u

.,
0
IACV AAC valve circuit • • • • • • • •
0 0 0 EC-221
c IACV-FICD solenoid valve circuit 0 0 0 0 c 0 0 0
0 0 EC-317
c
0 Ignition Incorrect ignition timing adjustment 0 0 • • • • • • EC-28
u

""'
Ignition circuit
• •0 • 0• 0• • • • EC-256
CD EGR EGRC-solenoid valve circuit • 0 EC-267
EGR system • • • 0• 0• • 0• 0• 0 • EC-176
Main power supply and ground circuit
Air conditioner circuit
•
0
• •
0 CJ 0 0 0 0 0 0
0 0
0
0
0
EC-89
HA section
ECCS Camshaft position sensor circuit • • • • • 0 00 0 EC-171
Mass air flow sensor circuit • • • 0• • • 0 0 EC-93
Front heated oxygen sensor circuit • • • • • EC-129
Engine coolant temperature sensor circuit
• • • 0 • • •0 0 • EC-113, 124
E
0 Throttle position sensor circuit • • • • • • • • EC-118

"~
m
if)
Incorrect throttle position sensor adjust-
ment
• 0 0 • 0 0 • 0 EC-72

u
0
w
Vehicle speed sensor circuit 0 c 0 0 EC-217
ECM 0 0 c 0 0 0 0 0 0 0 0 EC 76, 230
Start signal circuit 0 EC-306
Park/Neutral position switch circuit 0 0 0 0 0 EC-232
Power steering oil pressure switch circuit 0 0 0 EC-313

• , H1gh Poss1b11ity Item (contmued on next page)

Q; Low Possibility Item

EC-77 217
 TROUBLE DIAGNOSIS - General Description
Symptom Matrix Chart (Cont'd)
SYMPTOM
I
z ~
0
:< I
I ~ w
a:
<L
u
f-
0
a:
w ::> z w
X
""-
"-
"' z
~
w
u
!;:
a:
w
0
i=
"-
z
0
i=
"
a:
0:
!;: u w I

" " ""' ""'

f- 0 ~ "- "- u
a: 0: ::>
~
~
SYSTEM "- a: w ::> a:
>=' z z w
- Engine mechanical & other
"'a:w
(';
:;; 0
f-
0
0
"-
w
~ "
z
i= z
0
f-
z
f-
a:
w
0
u z
0
0
z
Reference page

":::>a: w a:w z 2-
"'
a: ~
~
"!
0

"'
u :;: " ilj
:;:
0
::> 0
~
a:
::>
f-
w
!;:
01=
~
w
:::>
"-
u
~

0
0
0:
w
"6z
>='
"'0z "'>='w
z
0
0
z
0
"-
~

w ~
a:
al
a:
"'
!;: w
>
w
>
0 "'00
~ a:

"
0:
"- ~
> 0 >-
~ "'"'a: z w 05 05 a: u
I
u
0
"" "
I I
z
0 f-
:;; ~ a: "'w u"'w w a: a:
0: u"' ~
I
a: 6z 05
~
:::> 0 w u w w
>
w 0 ~
> >< >< >
"' "' AE"'
~

Warranty Symptom Code

I

AA AB AC
w I

AD
~ I

"
a: en
AF AG AH AJ AK AL AM
0 w w
'"
HA
0
1P
0
1X
Fuel Fuel tank • •
Fuel piping
Vapor lock
• 0• 0 0 • 0 0 0

Valve deposit 0 0 0 0 0 0 0 0
Poor fuel (Heavy weight gasoline, Low
0 0 0 0 0 0 0 0 -
octane)
Air Air duct 0 0 0 0 0 0
Air cleaner
Air leakage from air duct
0 • • • 0 0
(Mass air flow sensor- throttle body) 0 0 0 0 0 0 0 0 0 0
Throttle body, Throttle wire 0 • • 0 • • 0 0 0 FE section
Air leakage from intake manifold/
Collector/Gasket 0 • 0 0 0 0 • 0 0 • -
Cranking Battery 0 0 0 0 0 0 0 0 0
Alternator circuit 0 0 0 0 0 0 0 0 0 EL section
Starter circuit •
Flywheel/Drive plate
•
Clutch interlock switch • CL section
Inhibitor switch • AT section
Engine Cylinder head
•0 0 • 0 0 • 0 0
Cylinder head gasket 0 0 0 0 • 0 • 0 0
Cylinder block 0 0 0 0 • 0 0 0 0
Piston 0 0 0 0 0 0 • 0 •
Piston ring 0 0 0 0 • • 0 0 •
Connecting rod • 0 0 0 0 0 0 0
Bearing
Crankshaft
• •
0 0
0
0
•
0
0
0
0
0
•
c
0
0
Valve Timing chain • 0 • 0 • 0 c 0
mechanism Camshaft
•0 0 0 00 00 0 c 0
Intake valve • • • 0 0 0
Exhaust valve • 0 • 0 • • c () • -
Exhaust Exhaust manifold!Tube/Muffler/Gasket
Three way catalyst
0 • • • •
0 • 0 0 •
•
0
0
0
•
0
Lubrication Oil pan/Oil strainer/Oil pump/Oil filter/Oil
gallery • 0 0 • • 0 0 0 •
Oil level (Low)/Filthy oil 0 0 0 0 0 0 0 0 0
Cooling Radiator/Hose/Radiator filler cap 0 0 0 0 0 0 0 • 0
Thermostat 0 0 0 0 0 0 • 0 0 • 0 0
Water pump
Water gallery
• 0 0 0 0 0 0 • 0
0 0 0 0 0 0 0 0 0
Cooling fan
Coolant level (low)/Contaminated coolant
0
0
0
0
0
0
0
0
•
0
0 •
0
0
0
0 •
0
0
0
0

• , High Possibility Item

Q; Low Possibility Item

218 EC-78
 TROUBLE DIAGNOSIS - General Description
@]
CONSULT Reference Value in Data Monitor
Mode
Remarks:
• Specification data are reference values.
• Specification data are output/input values which are detected or supplied by the ECM at the connector.
* Specification data may not be directly related to their components signals/values/operations. ~~:~/]
i.e. Adjust ignition timing with a timing light before monitoring IGN TIMING, because the monitor may show the specification data
in spite of the ignition timing not being adjusted to the specification data. This IGN TIMING monitors the data calculated by the
ECM according to the signals input from the camshaft position sensor and other ignition timing related sensors.
• If the real-time diagnosis results are NG and the on board diagnostic system results are OK when diagnosing the mass air flow lJ~
sensor first check to see if the fuel pump control circuit is normal
MONITOR ITEM CONDITION SPECIFICATION

CMPS·RPM (POS) • Tachometer: Connect Almost the same speed as the CON-
CMPS·RPM (REF) • Run engine and compare tachometer indication with the CONSULT value. SULT value.

•• Engine: After warming up

Air conditioner switch OFF
Idle 1.3- 1.7V

••
MAS AIR/FL SE
Shift lever ''N"'
2,500 rpm 1.7- 2.1V
No-load

COOLAN TEMP/S • Engine: After warming up More than 70"C (158°F)

FR 02 SENSOR 0 - 0.3V ~ Approx. 0.6 - 1.0V

• Engine: After warming up Maintaining engine speed at 2,000 rpm LEAN~ RICH
FR 02 MNTR Changes more tnan 5 times
during 10 seconds.

RR 02 SENSOR 0 - 0.3V ~ Approx. 0.6- 1.0V

• Engine: After warming up Maintaining engine speed at 2,000 rpm
RR 02 MNTR LEAN~ RICH

• Turn drive wheels and compare speedometer indication with the CONSULT Almost the same speed as
VHCL SPEED SE
value the CONSULT value

BATIERYVOLT • Ignition switch: ON (Engine stopped) 11 - 14V

THRTL POS SEN • Ignition switch: ON

(Engine stopped)
Throttle valve fully closed

Throttle valve fully opened

0.3- 0.7V

Approx. 4.0V

EGR TEMP SEN • Engine: After warming up Less than 4.5V

START SIGNAL
• Ignition switch: ON __,. START __,. ON OFF __,. ON __,. OFF

Throttle valve:
ON
• Ignition switch: ON Idle position
CLSDTHUP SW
(Engine stopped) Throttle valve:
OFF
Slightly open

Air conditioner switch OFF OFF

AIR COND SIG • Engine: After warming up, idle the
engme Air conditioner switch ON
ON
(Compressor operates.)

Shift lever "P" or "N" ON

PIN POSI SW • Ignition switch: ON
Except above OFF

Steering wheel in neutral position

PW/ST SIGNAL • Engine: After warming up, idle the
engine
(forward direction)
OFF

The steering wheel is turned ON

IGNITION SW • Ignition switch ON __,. OFF __,. ON ON __,. OFF __,. ON

SWLCON VC SW
• Engine is running at a speed of less than 3,600 rprn. OFF

• Except above ON

•• Engine: After warming up

Air conditioner switch OFF
Idle 2.4 - 3.2 msec .
INJ PULSE
•• Shift lever "N"
No-load 2,000 rprn 1.9 - 3.2 msec.

EC-79 219
 TROUBLE DIAGNOSIS- General Description
CONSULT Reference Value in Data Monitor
Mode (Cont'd)

MONITOR ITEM CONDITION SPECIFICATION

Idle 1.0- 1.6 msec

8/FUEL SCHDL
2,000 rpm 0.7- 1.3 msec

Idle 10G BTDC

IGN TIMING • Engine: After wanning up
•• Air conditioner switch: OFF
Shift lever "N"
2,000 rpm
Idle
More than 25° BTDC
20- 40%
IACV-AACN
• No-load
2,000 rpm -

Vehicle stopped 0 step

PURG VOLCN
Vehicle running -
NFALPHA • Engine: After warming up Maintaining engine speed at 2,000 rpm 52- 159%

EVAP SYS PRES • Ignition switch: ON Approx. 3.4V

AIR COND RLY • Air conditioner switch: OFF...,:. ON OFF---+ ON

• Ignition switch is turned to ON (Operates for 5 seconds)

• Engine running and cranking ON
FUEL PUMP RLY • When engine is stopped (Stops in 1.0 seconds)

• Except as shown above OFF

SWRL CONT S/V

• Engine is running at a speed of less than 3,600 rpm. ON

• Except above OFF

•••
Engine: After warming up ON
Idle
Air conditioner switch: OFF
EGRC SOLN
Shift lever: "N"
• No-load Revving up to 1,500 - 2,000 rpm OFF

VENT CONTIV • Ignition switch: ON OFF

•• Engine speed: Idle

Engine coolant temperature below 40°C (104°F)
ON

TCC SOLN
•
•
Engine: After warming up
Engine coolant temperature above 2,000 rpm OFF
40'C (104'F)

FR 02 HEATER
• Engine speed: Idle ON

• Engine speed: Above 3,000 rpm OFF

VCN BYPASSIV • Ignition switch: ON OFF

Idle OFF
PURG CONT SN • Engine: After warming up
2,000 rpm ON

RR 02 HEATER
• Engine speed: Below 6,000 rpm ON

• Ignition switch: ON (Engine stopped) OFF

•
•
Engine: After warming up
Air conditioner switch: OFF
Idle
16.8 - 34.7% (2WD models)
15.9-33.2% (4WD models)
CAULD VALUE
• Shift lever "N" 14.1-27.6% (2WD models)
• No-load 2,500 rpm
13.3- 26.1% (4WD models)

ABSOL TH·P/S • Ignition switch: ON

(Engine stopped)
Throttle valve fully closed
Throttle valve fully opened
0.0%
Approx. 84%

•• Engine: After warming up

Air conditioner switch: OFF
Idle
1.8 - 6.5 g·m/s (2WD models)
2.1 - 6.0 g·m/s (4WD models)
MASS AIRFLOW
•• Shift lever "N"
No-load 2,500 rpm
7.7- 15.0 g·m/s (2WD models)
6.8- 13.3 g·m/s (4WD models)

MAP/BARO SW/V
• Ignition switch: ON BARO

• Engine speed: Idle (More than 5 seconds after starting engine) MAP
Engine is not running Approx . 4.4V
ABSOL PRES/SE
• Engine: After warming up Idle (More than 5 seconds after starting
engine)
Approx. 1.2V

220 EC-80
 TROUBLE DIAGNOSIS - General Description

Major Sensor Reference Graph in Data Monitor

Mode
The following are the major sensor reference graphs in "DATA MONITOR" mode.
(Select "HI SPEED" in "DATA MONITOR" with CONSULT.)
THRTL POS SEN, ABSOL TH·P/S, CLSD THUP SW
Below is the data for "THRTL POS SEN", "ABSOL TH·P/S" and "CLSD THUP SW" when depressing the
accelerator pedal with the ignition switch "ON".
The signal of "THRTL POS SEN" and "ABSOL TH·P/S" should rise gradually without any intermittent drop or r"
b"'
rise after "CLSD THUP SW" is changed from "ON" to "OFF".
CLSDTHUPSW -00"09 ABSOL TH•P/S -00"09 THRTL POS SEN -00"09

.
10:22 +02n69 10:22 % +02"69 10:22 x0.1V +02"69
OFF ON 02550 75 100 0 13 26 38 51
.---~-------+--~ 1>-
Full {.,. ....... ...
Release
. ····-......................... ,
\
,,,,_1 :F~

~~[L
Full
Depress {

--~---~--~~~~~~~~~~~~~~---'
I ! SEF058P itll

CMPS·RPM (REF), MAS AIRIFL SE, THRTL POS SEN, RR 02 SENSOR, FR 02 SENSOR, INJ
PU~E M
Below is the data for "CMPS·RPM (REF)", "MAS AIR/FL SE", "THRTL POS SEN", "RR 02 SENSOR", "FR
02 SENSOR" and "INJ PULSE" when revving quickly up to 4,800 rpm under no load after warming up engine T¥'
sufficiently.
Each value is for reference, the exact value may vary.

'·'·
...... • "CMPS.RPM(REF)" should increase gradually
'·'·
while depressing the accelerator pedal and
.......................
should decrease gradually after releasing
.,
............... the pedal without any intermittent drop or rise .

" .. ~.... ..---·--···--·--·

"

>
-<O
o"' • "MAS AIRIFL SE" should increase when
X
w depressing the accelerator pedal and should
rn
.....J ····' decrease at the moment "THRTL POS SEN" is
~ M-
0: - closed (accelerator pedal is released).
;;'.,

~~0 A

SEF059P ~[d)}'Z

EC-81 221
 TROUBLE DIAGNOSIS - General Description
Major Sensor Reference Graph in Data Monitor
Mode (Cont'd)

"'"' ........
> • "THRTL POS SEN" should increase while

z
w
0X
""' depressing the accelerator pedal and should
decrease while releasing it.
U)
U)
0
Q_ "'
~
f-
"'o;
a:
:r:
f-
N

0
0 ..

>
0
0X
.
:"·---------------~~.
·.
• "RR 02 SENSOR" may increase immediately after
depressing the accelerator pedal and may
a: decrease after releasing the pedal.
0
U)
z
w
U)
N
0 "' ...........·
a:
a: "'"'
0
0
. ·~ ~- ··············'

t--
"'0
"' "'
0
9 0+
:;, ""'
N

>
"'
0

a:
0
X ""' ..................
0 ····,..···. ... • "FR 02 SENSOR" may increase immediately after
U)
z depressing the accelerator pedal and may
w
"'""
decrease after releasing the pedal.
U)

" "'
0 ··.......
a:
lL
""' 0
0 .. ··················· ,,,,,, .. ,.

"' :;,"'t-- "

0
0
0

9 0+
"'
u ·\.
w
U) 0 '·. .r:
"' • "INJ PULSE" should increase when depressing
the accelerator pedal and should decrease
w when the pedal is released.
U)
~
"'
::0 ...·..........·.:·'''""'''""""""• ......... .
Q_
"'
N
~
;;:: "'
0
0
..
SEF268S

222 EC-82
 TROUBLE DIAGNOSIS - General Description

Under the front passenger's seat ECM Terminals and Reference Value !Gil
ECM (EGGS control module)
I PREPARATION
1. ECM is located behind the front passenger seat side dash. For
/ this inspection, remove the front passenger side dash.

./
/c:,;:,
Front

~J SEF269S

2. Remove ECM harness protector.

ECM harness-
protector

3. Perform all voltage measurements with the connectors con- t~~r

nected. Extend tester probe as shown to perform tests easily.
j[F

Tester probe

SEF3671
ECM HARNESS CONNECTOR TERMINAL LAYOUT

01 02 03
07 08 09
113 114 115
0410o10E 1112131
1011112 15161718191
116117118 1111121131141
~
10
19 @J 11>012~
11321331
38 39 I40I4il 1531541551 I
42 43 l44145146157158ls9l6ol 61
49 50 ~7148 621631641651 70
L1 ~ 1161171181 s !1?~ I66167J68I69I

SEF064P

EC-83 223
 TROUBLE DIAGNOSIS- General Description
ECM Terminals and Reference Value (Cont'd)
ECM INSPECTION TABLE
Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

j Engine is running.j
0.3- 0.6V"
L Idle speed
t w Ignition signal
j Engine is running. I
Approximately O.BV*
L Engine speed is 2,000 rpm

1Engine is running. I
2 WIG Ignition check Approximately 12V*
L Idle speed

j Engine is running.j
3 w Tachometer Approximately 0.9V*
L Idle speed

IEngine is running. I
llgn1tion switch "OFF"" I 0- tV
L Less than 7 seconds after turning ignition
4 UR ECCS relay (Self-shutoff) switch "OFF".

II Ignition switch "'OFF"" I

BATTERY VOLTAGE
L 7 seconds passed after turning ignition switch (tt - t4V)
"OFF"

5 R Engine is running.j 0 - 0.4V or

EVAP canister purge val- j

BATTERY VOLTAGE
6 UG ume control valve L Idle speed (1t- t4V)

pgnition switch "ON"' I

L For 5 seconds after turning ignition switch Approximately 1V
"ON"'
8 W/R Fuel pump relay IEngine is running. I

pgnition switch "ON"' I BATTERY VOLTAGE

L 5 seconds after turning ignition switch "ON" (tt - t4V)

1Engine is running.!
tO B/P ECCS ground Engine ground
L Idle speed

1Engine is running. I

L Both air conditioner switch and blower switch Approximately 1V

t5 G/R Air conditioner relay are "ON".

1Engine is running. I BATTERY VOLTAGE

L Air conditioner switch is "OFF". (1t - t4V)

t6 G 1Engine is running. I 0 - 0.4V or

EVAP canister purge val-
BATTERY VOLTAGE
t7 y ume control valve L Idle speed (11 - t4V)

jlgnition switch "ON" I 0- tV

t8 R/W Malfunction indicator lamp II Engine is running. I

BATTERY VOLTAGE
L Idle speed (tt · t4V)
..
. Average voltage for pulse s1gnal (Actual pulse s1gnal can be confirmed by oscilloscope.)

224 EC-84
 TROUBLE DIAGNOSIS - General Description
ECM Terminals and Reference Value (Cont'd)
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

1 Engine is running. I
19 B/P ECCS ground Engine ground
L Idle speed

IIgnition switch "ON" I Approximately OV

20 OR Start signal
BATTERY VOLTAGE
jlgnition switch "START" I
(11 - 14V)

lEngine is running:J

L Both air conditioner switch and blower switch Approximately OV

21 G/R Air conditioner switch are "ON". (Compressor operates)

1 Engine is running.j BATTERY VOLTAGE

L Air conditioner switch is "OFF". (11- 14V)

jlgnition switch "ON" j

Neutral position switch r- Gear position is "Neutral position" (MIT mod- Approximately OV
(M!T models) els)
22 UB - Gear position is "N" or "P" (AfT models)
Inhibitor switch (ArT mod-
els) jlgnition switch "ON" j

Approximately SV
L Except the above gear position

pgnition switch "ON" I

I 0.3- 0.7V
L Accelerator pedal released
23 w Throttle position sensor
!Ignition switch "ON" 1

Approximately 4V
L Accelerator pedal fully depressed

1 Engine is running. I
ov
Power steering oil pres- L Steering wheel is being turned.
25 G
sure switch 1 Engine is running. I
Approximately 5V
L Steering wheel is not being turned.

1 Engine is running. I Approximately 1.8 - 2.4V*

26 W/L Vehicle speed sensor
L Slowly rotating front wheels (AC voltage)

pgnition switch "ON" I (Warm-up condition) BATTERY VOLTAGE

Throttle position switch L Accelerator pedal released (11- 14V)

27 y
(Closed position) I Ignition switch "ON" 1

Approximately OV
L Accelerator pedal depressed

Approximately 0 - 4.8V
Intake air temperature
28 Y/L I Engine is running. I Output voltage varies with
sensor
intake air temperature.

1 Engine is running.!
ov
Swirl control valve control L Engine speed is above 3,600 rpm.
32 R/Y
vacuum check switch 1 Engine is running. I
Approximately 4.8V
L Engine speed is less than 3,600 rpm .
..
. Average voltage for pulse s1gnal (Actual pulse s1gnal can be confirmed by oscilloscope.)

EC-85 225
 TROUBLE DIAGNOSIS - General Description
ECM Terminals and Reference Value (Cont'd)
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

llgnit1on switch "OFF" I ov

38 B/W Ignition switch
BATTERY VOLTAGE
jlgnition switch "ON" I
(11 - 14V)

1Engine is running. I
39 B ECCS ground Engine ground
L Idle speed

40 GY Camshaft position sensor

IEngine is running. I Approximately 0.3V*
44 R (Reference signal)

Camshaft position sensor

41 G 1 Engine is running.! Approximately 2.5V*
(Position signal)

jEngine is running. I
Approximately OV
Front heated oxygen sen- L Engine speed is below 3,000 rpm.
42 w sor heater
1 Engine is running.j BATTERY VOLTAGE
L Engine speed is above 3,000 rpm. (11 - 14V)

Engine ground
1Engine is running.j (Probe this terminal with
43 B ECCS ground
L Idle speed 8 tester probe when
measuring.)

I Engine is running. I
Front heated oxygen sen- I
0 - Approximately 1.0V
46 \II,/ After warming up sufficiently and eng1ne speed
sor L_
(periodically changes)
is 2,000 rpm.

II Engine is running. I (Warm-up condition)

1.3- 1.7V
L Idle speed
47 B Mass air flow sensor
II Engine is running. I (Warm-up condition)
1.7-2.1V
L Engine speed is 2,500 rpm.

Mass air flow sensor 1 Engine is running. I (Warm-up condition)

48 w ground
0.005 - 0.02V
L Idle speed

49 p Sensors' power supply jlgnition switch "ON" I Approximately 5V

1Engine is running. I (Warm-up condition)

50 B/G Sensors' ground 0.001 - 0.02V
L Idle speed

Approximately 0- 4.8V
Engine coolant tempera- Output voltage varies with
51 LG/R IEngine is running. I
ture sensor engine coolant tempera-
ture.

1Engine is running. I
Rear heated oxygen sen-
52 w sor L After warming up sufficiently and engine speed 0- Approximately 1.0V
is 2,000 rpm.

Crankshaft position sensor 1Engine is running. I (NT: N range, MIT Neutral) More than 0.2V*
53 R
(OBD) L Idle speed (Air conditioner switch "OFF".) (AC range)

56 G/R BATTERY VOLTAGE

Power supply for ECM jlgnition switch "ON" I
61 G/R (11 - 14V)
.
: Average voltage for pulse signal (Actual pulse Signal can be conf~rmed by oscilloscope.)

226 EC-86
 TROUBLE DIAGNOSIS - General Description
ECM Terminals and Reference Value (Cont'd)
@[
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

!Ignition switch "ON" 1

Approximately 4.4V
L Engine is not running
57 L Absolute pressure sensor 1 Engine is running. I

L Idle speed (More than 5 seconds after starting Approximately 1.2V

engine)

Data link connector for 1Engine is running. I

58 R Approximately 9V
GST L Idle speed (GST is disconnected.)

1 Engine is running.[ (Warm-up condition)

Less than 4.5V
L Idle speed
62 GIOR EGR temperature sensor
[Engine is running.[ (Warm-up condition)
0- 3.0V
L EGR system is operating.

Approximately 0 - 4.8V
Tank fuel temperature
63 L IEngine is running. I Output voltage varies with
sensor
fuel temperature.

64 y Approximately 0.1 V
· 1 Engine is running.[
Data link connector for
65 R
CONSULT L Idle speed (Connect CONSULT and select Approximately 4 - 9V

68 G DATA MONITOR mode.) Approximately 3.5V*

--- r--
EVAP control system
67 L
pressure sensor
IIgnition switch "ON" I Approximately 3.4V

BATTERY VOLTAGE
70 RIG Power supply (Back-up) IIgnition switch "OFF" I (11 - 14V)

BATTERY VOLTAGE
IIgnition sw1tch "ON". I (11 - 14V)
t 01 WIG IACV-AAC valve
1Engine is running.! (Warm-up condition)
0- 7V
L Engine speed is 2,000 rpm

t02 WIB Injector No. 1

104 WIR Injector No. 3 BATTERY VOLTAGE

j Engine is running.]
107 WIL Injector No. 2 (11 - 14V)

109 WIG Injector No. 4

II Engine is running. I (Warm-up condition) BATTERY VOLTAGE

L Engine speed is 2,000 rpm. (1t- 14V)
103 WIL EGRC-solenoid valve
1Engine is running. I (Warm-up condition)
0- 1V
L Idle speed

EVAP canister purge con- j Engine is running. I BATTERY VOLTAGE

105 WIR
trol solenoid valve L Idle speed (11 - 14V)

1 Engine is running. I Engine ground

106 BIP EGGS ground
L Idle speed
..
. Average voltage for pulse s1gnal (Actual pulse s1gnal can be confirmed by oscilloscope.)

EC-87 227
 TROUBLE DIAGNOSIS - General Description
ECM Terminals and Reference Value (Cont'd)
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

EVAP canister vent con- BATTERY VOLTAGE

108 R IIgnition switch "ON" I
trol valve (11 - 14V)

j Engine is running.]
110 B ECCS case ground Approximately OV
L Idle speed

j Engine is running.]
0- 1V
Swirl control valve control L Idle speed
111 GY
solenoid valve 1Engine is running.] BATTERY VOLTAGE
L Engine speed is above 3,600 rpm. (11 - 14V)

j Engine is running.]
112 B/P ECCS ground Engine ground
L Idle speed

11 Engine is running.] BATTERY VOLTAGE

113 G/R Current return
L Idle speed (11 - 14V)

j Engine is running.]

t Idle speed
Engine coolant temperature is below 40°C
Approximately OV

(1 04°F)

t
Torque converter clutch
114 UY IE~gine is running. I
solenoid valve

After warming up BATTERY VOLTAGE

Engine coolant temperature is above 40°C (11 - 14V)
(104°F)
Engine speed is 2,000 rpm

j Engine is running.]
Approximately OV
Rear heated oxygen sen- L Engine speed is below 6,000 rpm.
115 R
sor heater I Ignition switch "ON" 1 BATTERY VOLTAGE
L Engine is stopped. (11 - 14V)

IIgnition switch "ON" I 0- 1V

MAP/BARO switch sole- 1 Engine is running. I

116 W/R BATTERY VOLTAGE
noid valve
L Idle speed (More than 5 seconds after starting (11 - 14V)
engine)

Vacuum cut valve bypass BATTERY VOLTAGE

117 y jlgnition switch "ON" I
valve (11 - 14V)

1 Engine is running.j
118 B/P ECCS ground Engine ground
L Idle speed
.
:Average voltage for pulse s1gnal (Actual pulse s1gnal can be confirmed by oscilloscope.)

228 EC-88
 TROUBLE DIAGNOSIS FOR POWER SUPPLY

~~J
Main Power Supply and Ground Circuit

EC-MAIN-01
BATTERY

- : Detectable line for DTC

- · Non"detectable line for DTC

Refer to "EL-POWER".
w

~
@
<043>
10A
[3QJ
RIG

ifu

UR

I B B/P
--
m
,----'J'-f-.1!...-------!L!j'-"--, JOINT
m'91J
CONNECTOR-1
8
@:!9> .... .._ I
·-8/P-·

RIG UR G/R G/R G/R 8/W

~lbjdl~ll¥Jl~~l
8+ 8 + 8/Pt 8/P+ BIPt BIPt B/Pt
I
8

~rF.=illiffill~rFsill~rF3'9llrrls\lm'olirr*iiriffilimtsli~
r':'80:A';oT!;'T-;S'!;SC.:Oo;'Fc;,F-;C',;R,;:T".'N;.-"7;V:::C8"-"-::,V8:,""-...!I';'G":SCJ.W'--;JG,O:N":O_-';C"G":N_;;O'-'-"'c-'G'::N":D'"-'-,-'!Ge:'N",D~-1-;G":N_;;D':J-"E-;G!;'N_;;O'-'-E:,...eGC:N":O-.L:,.,E ECM (EGGS
CONTROL
GND- MODULE)
L-------------------------------------------------~C~A~SE~~
~

~
8

I
8
li
@ill)
Refer to last page (Foldout page}.

L
------------1
I

(M32) : f,il(M47)
:ti1 B B I
liJ@) :
LlJ
I
lbhl
r-------------1

: 1 (M48)
123 W
~(~) :I
t11G I
(M110)

._ ___________ J
I_------------ J

101 102 103

107108 109 104 111112
110 105 106 ,.J5'T-"6TJ,,"''"'s,'9"' ~~~9 Io I
113114 115 116 117 118 15

AEC038A

EC-89 229
 TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
(Cont'd)
ECM TERMINALS AND REFERENCE VALUE
Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TER·
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

IEngine is running. I

1 Llgnition switch '"OFF] 0 ·1V

L Less than 7 seconds after turning ignition
4 UR ECCS relay (Self-shutoff) switch "OFF".

IIgnition switch '"OFF'" I

BATTERY VOLTAGE
L 7 seconds passed after turning ignition switch (11- 14V)
""OFF'"

j Engine is running.j
10 B/P ECCS ground Engine ground
L Idle speed

j Engine is running.j
19 B/P ECCS ground Engine ground
L Idle speed

[Ignition switch '"OFF'"j ov

38 B/W Ignition switch
BATTERY VOLTAGE
[Ignition switch '"ON"" I (11 - 14V)

j jEngine is running.j
39 B ECCS ground Engine ground
L Idle speed

Engine ground
1 Engine is running.j (Probe this terminal with
43 B ECCS ground
L Idle speed 8 tester probe when
measuring.)

56 G/R BATTERY VOLTAGE

61 G/R
Power supply for ECM [Ignition switch ""ON"" I (11 - 14V)

BATTERY VOLTAGE
70 R/G Power supply (Back-up) jlgniti~n switch "OFF" I
(11 · 14V)

1Engine is running. I
106 B/P ECCS ground Engine ground
L Idle speed

I Engine is running. I
110 B ECCS case ground Approximately OV
L Idle speed

1 1Engine is running. I
112 B/P ECCS ground Engine ground
L Idle speed

; 1Engine is running. I BATTERY VOLTAGE

113 G/R Current return
L Idle speed (11 · 14V)

1Engine is running. I
118 B/P ECCS ground Engine ground
L Idle speed

230 EC-90
 TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
r.:.1 (Cont'd)
~CONNECT

II ECM ]Of CONNECTOR II £) I

INSPECTION START
I
I
38

[YJ r.:.1
No CHECK POWER SUP-
§'_= Start engine.
Is engine running? f----+ PLY-I.

~00
1. Turn ignition switch
Yes "ON''.
~
2. Check voltage between
SEF06SP ECM terminal @ and
ground with CONSULT
!;]
~i)
or tester.
Voltage: Battery volt-
age
II ECM lof CONNECTOR II If NG, check the following.
• Harness for open or
70
short between ECM and
ignition switch
If NG, repair harness or

@a [YJ connectors.

~ ~OK
SEFOBOS
Go to "CHECK GROUND
CIRCUIT" on next page.
r!l
I ECM lof CONNECTOR I ~i) !;]
56 61__:_ 113
I CHECK POWER SUPPLY-II. I NG I Check the following.
~
I

~
1. Stop engine. •10A fuse
2. Check voltage between ECM terminal • Harness connectors
@ and ground with CONSULT or @,<@§:>
tester. • Fusible link

~ ~ Voltage: Battery voltage • Harness for open or short

between ECM and battery
OK
~00
If NG, repair harness or con-
MEC894B nectors.

Iii r!l
~ 10 @a ~ 10
DISCONNECT DISCONNECT

CHECK POWER SUPPLY-Ill. OK Go to "CHECK GROUND

1. Turn ignition switch "ON" and then f----+ CIRCUIT" on next page.

I ECM ]OfcoNNECTOR II
56.61 •113
+ "OFF".
2. Check voltage between ECM terminals
@, @), @and ground with CON-
SULT or tester.
Voltage:
Case-1: Battery voltage does
not exist for a few
After turning ignition switch "OFF", seconds.
[ill battery voltage will exist for a few Case-2: Battery voltage exists
seconds, then drop to approxi- for more than a few
SEF065R mately OV. seconds.
NG

Case-2 Go to "CHECK ECCS

Case-1 RELAY" on next page.

®
(Go to next page.)

EC-91 231
 TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
(Cont'd)
~~?;;;, '1;'
I

I;;>~ I '
~ I!]

':;'
1
CHECK HARNESS CONTINUITY
BETWEEN ECCS RELAY AND ECM.
lNG' Repair harness or connec·
tors.

~ ~~ c:-,~ 1. Disconnect ECM harness connector.

2. Disconnect ECCS relay.
~~ P/8 re~~':"01r~a~k 0!>
3. Check harness continuity between ECM
terminals @, @), @ and terminal

//( ~ SEF~82S ®
Continuity should exist.
If OK, check harness for short.
~
~i5 ~
OK

~ CHECK VOLTAGE BETWEEN ECCS

NG Check the following.
RELAY AND GROUND. • Fusible link (Brown)
Check voltage between terminals ®, ® • Harness for open or
[YJ and ground with CONSULT or tester. short between ECCS
+ Voltage: Battery voltage relay and battery
-=----=- If NG, repair harness or

~ ~
OK connectors.

SEF604P
Iii
Iii CHECK OUTPUT SIGNAL CIRCUIT.
~ Repair harness or connec-

~i5 ~i5
Check harness continuity between ECM tors.
terminal @) and terminal G).

19 Continuity should exist.

II II
~
ECM CONNECTOR If OK, check harness for short.
' OK
[!I
[ill CHECK ECCS RELAY. ~ Replace EGGS relay.

~ -
1. Apply 12V direct current between relay
terminals G) and ®.
SEF207P 2. Check continuity between relay termi-
nals ~and@.
[!I 12V ( 1 • ®l applied:
Continuity exists.

,-D~
No voltage applied:
No continuity.

\~)-/"
3 '
5 ~ 1:1
OK

¥
12 X 1 I
-_!
CHECK GROUND CIRCUIT.
1. Turn ignition switch "OFF".
~ Check the following.
• Joint connector-1
2. Disconnect ECM harness connector. • Harness for open or
3. Check harness continuity between ECM short between ECM and
SEF511 P terminals@,@, @. @. @, ground
@, @, @and engine ground. If NG, repair harness or
1:1 Continuity should exist. connectors.

~ID If OK, check harness for short.

lof II ~OK
II ECM CONNECTOR
10
1~12~911:3' 106 Check ECM pin terminals for damage and
110
check the connection of ECM harness

LEln
connector.

@a ~
~ INSPECTION END
SEF086S
I I
232 EC-92
 TROUBLE DIAGNOSIS FOR DTC P01 00

Mass Air Flow Sensor (MAFS)

COMPONENT DESCRIPTION
The mass air flow sensor is placed in the stream of intake air. It
measures the intake flow rate by measuring a part of the entire
intake flow. It consists of a hot wire that is supplied with electric
current from the ECM. The temperature of the hot wire is controlled [gisl
by the ECM a certain amount. The heat generated by the hot wire
is reduced as the intake air flows around it. The more air, the
greater the heat loss. lCi
Therefore, the ECM must supply more electric current to the hot
wire as air flow increases. This maintains the temperature of the
hot wire. The ECM detects the air flow by means of this current
change.

ECM TERMINALS AND REFERENCE VALUE I'll':

Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.
'
1 Engine is running.j (Warm-up condition)
1.3·1.7V
L Idle speed
47 B Mass air flow sensor
1Engine is running. I (Warm-up condition)
1.7·2.1V
L Engine speed is 2,500 rpm.

Mass air f!ovv' sensor 1 Engine is running.! (Warm-up condition)

48 w 0.005 - 0.02V
ground L Idle speed

CONSULT REFERENCE VALUE IN DATA MONITOR MODE

Specification data are reference values.
MONITOR ITEM CONDITION SPECIFICATION
• Engine: After warming up
Idle 1.3- 1.7V
• Air conditioner switch OFF
MAS AIRIFL SE
• Shift lever "N"
2.500 rpm 1.7- 2.1V
• No-load

• Engine: After warming up 16.8- 34.7% (2WD models)

Idle
• Air conditioner switch: OFF 15.9. 33.2% (4WD models)
CAULD VALUE
• Shift lever "N" 14.1. 27.6% (2WD models)
2,500 rpm
• No-load 13.3 . 26.1 % (4WD models)

• Engine: After warming up 1.8- 6.5 g·m/s (2WD models)

Idle
• Air conditioner switch: OFF 2.1 - 6.0 g·m/s (4WD models)
MASS AIRFLOW
• Shift lever "N" 7.7· 15.0 g·m/s (2WD models)
• No-load
2,500 rpm
6.8- 13.3 g·m/s (4WD models)

EC-93 233
 TROUBLE DIAGNOSIS FOR DTC P0100
Mass Air Flow Sensor (MAFS) (Cont'd)
ON BOARD DIAGNOSIS LOGIC
Diagnostic
Check Item
Trouble Malfunction is detected when ...
(Possible Cause)
Code No.
P0100 A) An excessively high or low voltage from the sensor is • Harness or connectors
0102 sent to ECM.' (The sensor circuit is open or shorted.)
• Mass air flow sensor
B)C) Rationally incorrect voltage is sent to ECM, com-
pared with the calculated value by camshaft posi-
tion sensor signal and throttle position sensor sig-
nal.

·:When this malfunction 1s detected, the ECM enters fall-safe mode and the MIL lights up. (Refer to EC-76.)

Engine operating condition in fail-safe mode

Engine speed will not rise more than 2,400 rpm due to the fuel cut.

234 EC-94
 TROUBLE DIAGNOSIS FOR DTC P01 00
Mass Air Flow Sensor (MAFS) (Cont'd)
DIAGNOSTIC TROUBLE CODE CONFIRMATION
P: MONITOR P: NOFAIL 0 PROCEDURE
CMPS•RPM(REF) BOO rpm Perform "Procedure for malfunction A" first. If the 1st trip DTC ~it!'\
cannot be confirmed, perform "Procedure for malfunction B".
If there is no problem on "Procedure for malfunction B", per-
form "Procedure for malfunction C", "OVERALL FUNCTION '.~'!''
CHECK". L'."

Procedure for malfunction A

~ 1) Turn ignition switch "ON" and wait at least 6 seconds.
I RECORD I
SEF712T \_~!} 2) Select "DATA MONITOR" mode with CONSULT.
3) Start engine and wait at least 3 seconds.
----------OR----------
P: MONITOR P: NOFAIL 0 1) Turn ignition switch "ON" and wait at least 6 seconds.
2) Start engine and wait at least 3 seconds.
CMPS•RPM(REF) BOO rpm
COOLAN TEMP/S asoc 3) Select "MODE 7" with GST.
---------OR---------
60'\ 1) Turn ignition switch "ON" and wait at least 6 seconds.
'el' 2) Start engine and wait at least 3 seconds. ©.c
3) Turn ignition switch "OFF", wait at least 7 seconds and
then turn "ON".
4) Perform "Diagnostic Test Mode II (Self-diagnostic l0l1
I RECORD I
SEF715T
results)" with ECM.

Procedure for malfunction B

~ 1) Turn ignition switch "ON".
\l!J 2) Select "DATA MONITOR" mode with CONSULT.
3) Start engine and warm it up sufficiently.
4) Run engine for at least 10 seconds at idle speed.
--------OR--------
1) Turn ignition switch "ON".
2) Start engine and warm it up sufficiently.
3) Run engine for at least 10 seconds at idle speed.
4) Select "MODE 7" with GST.
-------OR-------
1) Turn ignition switch "ON".
2) Start engine and warm it up sufficiently.
3) Run engine for at least 10 seconds at idle speed.
4) Turn ignition switch "OFF", wait at least 7 seconds and
then turn "ON". '"l[R;
5) Perform "Diagnostic Test Mode II (Self-diagnostic
results)" with ECM.

EC-95 235
 TROUBLE DIAGNOSIS FOR DTC P01 00
Mass Air Flow Sensor (MAFS) (Cont'd)
OVERALL FUNCTION CHECK
Mass air flow
Engine speed Use this procedure to check the overall function of mass air flow
sensor voltage
sensor. During this check a 1st trip DTC might not be confirmed.

Procedure for malfunction C

1) Turn ignition switch "ON".
2) Start engine and warm it up sufficiently.
"z 3) Select "DATA MONITOR" mode with CONSULT.
4) Check the voltage of mass air flow sensor with "DATA
MONITOR".
64 48 32 16 0 51 38 26 13 0 5) Check for linear voltage rise in response to increases to
X100rpm X0.1V
CMPS•RPM(REF) MAS AIR/FL SE about 4,000 rpm in engine speed.
--------OR--------
1) Turn ignition switch "ON".
2) Start engine and warm it up sufficiently.
3) Select "MODE 1" with GST.
4) Check the mass air flow with "MODE 1".
"'0 \ \
5) Check for linear mass air flow rise in response to
' increases to about 4,000 rpm in engine speed.
--------OR--------
64 48 32 16
X100rpm
0 51 38 26 13 0 1) Turn ignition switch "ON".
XO.lV
CMPS•RPM(REF) MAS AI R/FL SE 2) Start engine and warm it up sufficiently.
SEF945S 3) Check the voltage between ECM terminal @ and
ground.
FUEL SYS #1 OPEN 4) Check for linear voltage rise in response to increases to
FUELSYS#2 UNUSED about 4,000 rpm in engine speed.
CALC LOAD 22%
COOLANT TEMP 3D"C
SHORT FT #1 0%
LONG FT #1 2%
ENGINESPD 1000RPM
VEHICLESPD Okm/h
IGNADVANCE 200°
INTAKE AIR 26"C
MAF O.Ogm/sec
THROTTLE POS 0%
02S LOCATION 3
02S 81,S1 0.680V
02FT 81AS1 0%
02S 81 ,,2 o.oaov
SEF003P

rr==:=:~=='l C~~~ ~
~E)
CONNECT
ECM JO[coNNECTORjl
47

236 EC-96
 TROUBLE DIAGNOSIS FOR DTC P0100
Mass Air Flow Sensor (MAFS) (Cont'd)

EC-MAFS-01

I B~RY I - : Detectable line for DTC

_. : Non-detectable line for DTC

w~~~,
Refer to
"EL-POWER".

,--,
I_.
w w
G/R

m
C
mECCS
RELAY MASS AIR
(M32) FLOW
SENSOR
(f,g§)
lbjdl~
UR G/R
1!4Jllbjdl

-r,
+ W B
_.
f:
I
I
I
I
I
I
I
I
+ I
I
I
lffii1 JOINT
I I CONNECTOR-I
I I
€W

i______.
I I
I
-._,I lbjdl
-i~ <: B

UR

m~
G!R GIR

~
r---S~S~O~F~F~C~R~T~N~------------~VB~--------~V~B~~Q~A~~Q~A~+'oECM(ECCS
CONTROL
G/R

~rr!il~
W B

MODULE)
(~)
.,I

Refer to last page (Foldout page).

+@
(M110)
,--------------,
ffi
(112'314)
(M~)
BR :I b±rl<M1a>
2 3 W
~(E22):
L G :
I

(M~2)~
j ______________ J

~
101 102 103 104 105 106 I 12 3 ~ 20 21 22 23 38 '39 !40I4i 53 54 55 ~
5 6 7 8 9 10 24 25 26 27 28 ~~ 44454657585960 61
107 108 109 110 tit 112 111 12113 14 19 29 30!31 32 33 fgfto' 47 48 62 63 64 65 70
113 114 115 116 117 118 l1.§..l l1illZ..L1.§J 34 35 36 37 L:.::.. ' l§.112gJ 66 67 68 69

AEC039A

EC-97 237
 TROUBLE DIAGNOSIS FOR DTC P01 00
Mass Air Flow Sensor (MAFS) (Cont'd)
DIAGNOSTIC PROCEDURE
INSPECTION START

CHECK SHIELD CIRCUIT. Repair harness or connectors.

1. Turn ignition switch "OFF".
2. Loosen and retighten engine ground screws.
3. Remove joint connector-1.
4. Check the following.
• Continuity between joint connector-1 termi-
nal CDand ground
• Joint connector-1
SEF089S
(Refer to "HARNESS LAYOUT" in EL sec-
tion.)
Continuity should exist.
If OK, check harness for short. Then recon-
nect joint connector-f.

OK

NG
CHECK POWER SUPPLY. Check the following.
1. Disconnect mass air flow sensor harness • Harness for open or short
connector. between mass air flow sen-
2. Turn ignition switch "ON". sor and ECM
3. Check voltage between terminal @ and • Harness for open or short
ground with CONSULT or tester between mass air flow sen-
harness connector Voltage: Battery voltage sor and ECCS relay
If NG, repair harness or con-
OK nectors.

NG
CHECK GROUND CIRCUIT. Repair harness or connectors.
1. Turn ignition switcn ··OFF'.
2. Disconnect ECM harness connector.
3. Check harness continuity between terminal
®and ECM terminal @.
Continuity should exist.
If OK, check harness for short.

OK
[!]
SEF088S c=o______________c'-----------------,

~""·;=================~' Check harness continuity between terminal f1\

CHECK INPUT SIGNAL CIRCUIT.
NG
Repair harness or connectors.

I:J ~""~
ffi eJ""'""" ~FF ~
rn l""'~o"' and ECM terminal @. \.V
Continuity should exist.
If OK, check harness for short.
II ECM JOfcoNNECTDRII
48
OK

CHECK COMPONENT Replace mass air flow sensor.

(Mass air flow sensor).
Refer to "COMPONENT INSPECTION" on next
page.

OK
SEF090S ,----------------L----------------,

~[!]=~=il;ll=8)='"""'="~=OFF===~=~='"b~'"
Disconnect and reconnect harness connectors
in the circuits. Then retest.

Trouble is not fixed.

ECM ]OfCONNECTOR II Check ECM pin terminals for damage and

check the connection of ECM harness connec-
" tor. Reconnect ECM harness connector and
retest.

INSPECTION END

SEF091S

238 EC-98
TROUBLE DIAGNOSIS FOR DTC P0100
Mass Air Flow Sensor (MAFS) (Cont'd)
COMPONENT INSPECTION
Mass air flow sensor
1. Turn ignition switch "ON".
2. Start engine and warm it up sufficiently.
3. Check voltage between terminal (i) and ground.
Conditions Voltage V
Ignition switch "ON" (Engine stopped.) Less than 1.0
Idle (Engine is warmed-up sufficiently.) 1.3-1.7
2,500 rpm 1.7- 2.3
Idle to about 4,000 rpm* 1.3- 1.7 to Approx. 4.0
*: Check for l1near voltage nse 1n response to Increases to about 4,000 rpm
in engine speed.

4. If NG, remove mass air flow sensor from air duct. Check hot
wire for damage or dust.

SEF893J

EC-99 239
 TROUBLE DIAGNOSIS FOR DTC P01 05

Absolute Pressure Sensor

Absolute
pressure sensor COMPONENT DESCRIPTION
The absolute pressure sensor is connected to the MAP/BARO
switch solenoid valve by a hose. The sensor detects ambient baro-
metric pressure and intake manifold pressure and sends the volt-
age signal to the ECM. As the pressure increases, the voltage
rises. The absolute pressure sensor is not used to control the
engine system. It is used only for on board diagnosis.

SEF428Q

5
4.5
> 4
~3.5 Ambient
m 3
barometic
15 2.5
pressure
> 2
~ 1.5 Vacuum

0" 0.51
0 '-o1*"3.~3-------'-,-;1o"'6".6~-
(1oo, 3.94) (BOO, 31.50)
Pressure kPa (mmHg, inHg)
(Absolute pressure) SEF946S

ECM TERMINALS AND REFERENCE VALUE

Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

49 p Sensors' power supply jlgnition switch "ON" I Approximately 5V

IEngine is running. I (Warm-up condition)

50 8/G Sensors' ground 0.001 - 0.02V
L Idle speed
pgnition switch "ON" 1
Approximately 4.4V
L Engine is not running
57 L Absolute pressure sensor 1Engine is running. I

L Idle speed (More than 5 seconds after starting Approximately 1.2V

engine)

CONSULT REFERENCE VALUE IN DATA MONITOR MODE

Specification data are reference values.
MONITOR ITEM CONDITION SPECIFICATION
Engine is not running Approx. 4.4V
ABSOL PRES/SE • Engine: After warming up Idle (More than 5 seconds after
Approx. 1.2V
starting engine)

240 EC-100
 TROUBLE DIAGNOSIS FOR DTC P0105
Absolute Pressure Sensor (Cont'd)
ON BOARD DIAGNOSIS LOGIC
Diagnostic Trouble Check Items
Malfunction is detected when ....
Code No. (Possible Cause)
P0105 A) An excessively low or high voltage from the sen- • Harness or connectors
0803 sor is sent to ECM. (Absolute pressure sensor circuit is open or
shorted.)
• Absolute pressure sensor
B) A low voltage from the sensor is sent to ECM • Absolute pressure sensor
under heavy load driving conditions.
C) A high voltage from the sensor is sent to ECM • Hoses
under light load driving conditions. (Hoses between the intake manifold and absolute
pressure sensor are disconnected or clogged.)
• Intake air leaks
• Absolute pressure sensor

r;··.ii''i"
u·.JJ J

DIAGNOSTIC TROUBLE CODE CONFIRMATION

* MONITOR * NOFAIL D PROCEDURE
CMPS•RPM(REF) Orpm Perform "Procedure for malfunction A" first. If the 1st trip DTC l'll'
cannot be confirmed, perform "Procedure for malfunction B",
"OVERALL FUNCTION CHECK". If there is no problem on
"Procedure for malfunction B", perform "Procedure for mal- 19Ci'
function C".
Procedure for malfunction A
~ 1) Turn ignition switch "ON".
I RECORD I SEF422T ~ 2) Select "DATA MONITOR" mode with CONSULT.
3) Wait at least 6 seconds.
----------OR----------
1) Turn ignition switch "ON" and wait at least 6 seconds.
2) Select "MODE 7" with GST.
----------OR----------
@ 1) Turn ignition switch "ON" and wait at least 6 seconds.
2) Turn ignition switch "OFF" and wait at least 7 seconds.
3) Perform "Diagnostic Test Mode II (Self-diagnostic \jJ
results)" with ECM.
If the 1st trip DTC cannot be confirmed, perform "Procedure for
malfunction 8", "OVERALL FUNCTION CHECK" on next page. l~i!1!

EC-101 241
 TROUBLE DIAGNOSIS FOR DTC P0105
Absolute Pressure Sensor (Cont'd)
Procedure for malfunction C
1t MONITOR *NO FAIL D 1) Start engine and warm it up sufficiently.
CMPS•RPM(REF) BOO rpm 2) Turn ignition switch "OFF" and wait at least 7 seconds.
COOLAN TEMP/S 85"C 3) Turn ignition switch "ON" and select "DATA MONITOR"
mode with CONSULT
4) Start engine and let it idle.
5) Wait at least 20 seconds.
---------OR---------
1) Start engine and warm it up sufficiently.
2) Turn ignition switch "OFF" and wait at least 7 seconds.
I RECORD I
SEF715T 3) Start engine.
4) Let engine idle and wait at least 20 seconds.
5) Select "MODE 7" with GST
---------OR---------
(iiO\ 1) Start engine and warm it up sufficiently.
~ 2) Turn ignition switch "OFF" and wait at least 7 seconds.
3) Start engine.
4) Let engine idle and wait at least 20 seconds.
5) Turn ignition switch "OFF".
6) Perform "Diagnostic Test Mode II (Self-diagnostic
results)" with ECM.

OVERALL FUNCTION CHECK

1t MONITOR 1t NO FAIL
Use this procedure to check the overall function of absolute pres-
A8SOL PRES/SE 4.4V sure sensor circuit. During this check, a 1st trip DTC might not be
confirmed.

Procedure for malfunction B

1) Turn ignition switch "ON".
2) Select "ABSOL PRES/SE" in "DATA MONITOR" mode
with CONSULT
RECORD _ _--,!EF577Q
'----=-:==.:..:.::_ J 3) Make sure that the voltage of "ABSOL PRES/SE" is
more than 1.74 [V].
---------OR---------
ENGINE SPD .................... ORPM 1) Turn ignition switch "ON".
COOLANT TEMP ............... 69"C 2) Select "MAP" in "MODE 1" with GST
VEHICLE SPD .................. OMPH
IGN ADVANCE ...................... 3.0" 3) Make sure that the pressure of "MAP" is more than 46
CALC LOAD ........................ 0.0%
kPa (0.47 kg/cm 2 , 6.7 psi).
MAF ........... . . ......... 0.25gm/s ----------OR----------
THROTILE POS ................ 0.0%
INTAKE AIR ......................... 27"C
0~~J 1) Turn ignition switch "ON".
FUEL SYS #1 ................. ..... OL ~ 2) Make sure that the voltage between ECM terminal ®
FUEL SYS #2 ............... UNUSED
SHORT FT #1 ......... 0.0% and ground is more than 1.74 [V].
LONG FT #i .................. 0.0% If the 1st trip DTC cannot be confirmed, perlorm "Procedure for
02S 81 S1 ·····················. o.ooov
02FT 81 S1 ........................ 0.0% malfunction C" above.
02S 81 S2 ...................... O.OOOV SEF518A

~i)
rr11=Ec::cM=1JOLF-c=oN""NE=cr='o"llR
II

57

SEF093S

242 EC-102
 TROUBLE DIAGNOSIS FOR DTC P0105
Absolute Pressure Sensor (Cont'd)

EC-AP/SEN-01
ABSOLUTE
PRESSURE
SENSOR

I'-;r-f,~~x\-r.------.r~-h----'!@9 3 - : Detectable line for DTC

: Non-detectable line for DTC

B/G L P

(
I -..
1
I
----- -- •
'I
I
I
I I
I
I
I
I
I

t iSll

--
--
,I
)
--
Ip
rrm ~
n·
p p

rrfill IFa JOINT

I CONNECTOR-1
(M110)

I
~ ~ ~
B/G L Pt B B

~ ~ ~ ITtoiJ I

il
GND-A PRES AVCC GND-C ECM (EGGS
CONTROL
MODULE)
@W
B B
-'--'-
<®J<r@;J
Refer to last page (Foldout page)
@2QJ

offi:D (M24)
GY
(M~2)~

~
~
~
101 102 103 104 105 106 1
5 6 7 2 83 9 10
107 108 109 110 111 112
111 2 13 14 19 0
113 114 115 116 117 118 15 16 17 18

AEC040A

EC-103 243
 TROUBLE DIAGNOSIS FOR DTC P0105
Absolute Pressure Sensor (Cont'd)
DIAGNOSTIC PROCEDURE
If the trouble is duplicated after "Procedure for malfunction A
or B", perform "Procedure A" below. If the trouble is dupli-
cated after "Procedure for malfunction C", perform "Proce-
dure B" on next page.
Procedure A

INSPECTION START

~
SEF089S , - - - - - - - - - - - - - ' - - - - - - - - - , NG
CHECK SHIELD CIRCUIT. Repair harness or connec-
1. Turn ignition switch "OFF". tors.
2. Loosen and retighten engine ground
screws.
3. Remove joint connector-1.
4. Check the following.
• Continuity between joint connector-1
terminal G) and ground
• Joint connector-1
(Refer to "HARNESS LAYOUT" in EL
section.)
Continuity should exist.
If OK, check harness for short. Then
reconnect joint connector-1.
SEF094S '----------,~:;---------'

..~===;;;============~
m ~ ~ 0 ~
m OK
j r=cH_E_c_K_P_o_w_E_R_s_u_P,_PL_v__- - - - - - - - - - , NG
Check the following.
t..l'l1 'SV ~ 1. Disconnect absolute pressure sensor har- • Joint connector-1
l e 1 fij 3) ness connector. • Harness for open or
short between absolute
2. Turn ignition switch "ON".
3. Check voltage between terminal and® pressure sensor and
engine ground with CONSULT or tester. ECM
Voltage: Approximately 5V If NG, repair harness or
connectors.
OK
rn
~----------~~-----------,NG
CHECK GROUND CIRCUIT. Repair harness or connec-
SEF095S 1. Turn ignition switch "OFF'". tors.
"-;;;:===============~ 2. Check harness continuity between ter-
1;) minal G) and engine ground.
Continuity should exist.

~io@a
If OK, check harness for short.

OK
cillhl [!!
~----------~----------,NG
CHECK INPUT SIGNAL CIRCUIT. Repair harness or connec-
1. Disconnect ECM harness connector. tors.
2. Check harness continuity between ECM
terminal @ and terminal ®.
Continuity should exist.
If OK, check harness for short.
SEF096S '--------,--,0;;-K:;---------"

~==================~,---------L---------,NG
[!! CHECK COMPONENT Replace absolute pressure
(Absolute pressure sensor). sensor.
Refer to "COMPONENT INSPECTION",
EC-106.

II ECM ]OfCONNECTOR I OK

" Disconnect and reconnect harness con-

nectors in the circuit. Then retest.

Trouble is not fixed.

®
(Go to next page.)
SEF097S

244 EC-104
 TROUBLE DIAGNOSIS FOR DTC P01 05
Absolute Pressure Sensor (Cont'd)
®
~
Check ECM pin terminals for damage and
check the connection of ECM harness
connector. Reconnect ECM harness con-
nector and retest.

INSPECTION END

r.i.1 Procedure B
ID ~ cf8'"-H II INSPECTION START

\Absolute pressure
sensor
Vacuum
r.i.1
gauge I
~
(?)
v
CHECK VACUUM SOURCE TO ABSO-
LUTE PRESSURE SENSOR.
~ CHECK VACUUM HOSE.
Check vacuum hose for

rtrJ 1. Start engine and warm it up sufficiently.

2. Stop engine.
clogging, cracks or

~
improper connection.
3. Disconnect vacuum hose between If NG, repair or replace the
absolute pressure sensor and MAP/ hose.
SEF718T BARO switch solenoid valve.
4. Install vacuum gauge between absolute OK
m
:,.
pressure sensor and MAP/BARO switch
solenoid valve.
~- 5. Restart engine and let it idle.
6. Read the indication of vacuum gauge at ji'f

- ~J~
idle speed. CHECK INTAKE SYSTEM.
Vacuum pressure: Check intake system for air
Approx. -66.7 kPa leaks.
Clogging (-500 mmHg, -19.69 inHg, -9,67
psi)

~-
""'-
m l OK
lmpmpe,connection
SEF~09L
CHECK HOSE BETWEEN ABSOLUTE
PRESSURE SENSOR AND MAP/BARO
H Repair or reconnect hose.

SWITCH SOLENOID VALVE.

1. Turn ignition switch "OFF".
2. Check hose for clogging, cracks or
improper connection.

ToK
NG
CHECK COMPONENT Replace absolute pressure
(Absolute pressure sensor). f-----> sensor.
Rete' to "COMPONENT INSPECTION"
on next page.

~OK
Disconnect and reconnect harness con-
nectars in the circuit. Then retest.

l Trouble is not fixed.

Check ECM pin terminals for damage and
check the connection of ECM harness
connector. Reconnect ECM harness con-
nectar and retest.

~
INSPECTION END

EC-105 245
 TROUBLE DIAGNOSIS FOR DTC P01 05
Absolute Pressure Sensor (Cont'd)
COMPONENT INSPECTION
• ACTIVE TEST •
Absolute pressure sensor
MAP/BARO SW/V MAP 1. Start engine and warm it up sufficiently.
l======oo=== MONITOR ===oo======l 2. Perform "MAP/BARO SW/V" in "ACTIVE TEST" mode with
CMPS•RPM(REF) BOO rpm CONSULT.
MAP/BARO SW/V MAP
ABSOL PRES/SE uv 3. Check the following.
• When "MAP" is selected, "ABSOL PRES/SE" indicates
approximately 1.3V.
• When "BARO" is selected, "ABSOL PRES/SE" indicates
approximately 4.3V.
4. If NG, check MAP/BARO switch solenoid valve.
(1) Turn ignition switch "OFF".
• ACTIVE TEST • D (2) Remove MAP/BARO switch solenoid valve.
(3) Check air passage continuity.
MAP/BARO SW/V BARD

========== MONITOR ========== Air passage Air passage

CMPS•RPM(REF) BOO rpm Condition continuity continuity
MAP/BARO SW/V
ABSOL PRES/SE
BARD
4.3V
between ® and @ between @ and ©
12V direct current supply
between terminals G) Yes No
and®
BARO MAP I
SEF714T No supply No Yes

(4) If NG, replace MAP/BARO switch solenoid valve; if OK, go

to step 5.

MEC488B

5. Remove absolute pressure sensor with its harness connector

connected.
6. Remove hose from absolute pressure sensor.
7. Turn ignition switch "ON" and check output voltage between
Absolute pressure terminal ® and engine ground.
The voltage should be 3.2 to 4.8 V.
8. Use pump to apply vacuum of -26.7 kPa (-200 mmHg,
-7.87 inHg, -3.87 psi) to absolute pressure sensor as shown
in figure and check the output voltage.
The voltage should be 1.0 to 1.4 V lower than the value
measured in step 3.
SEF098S
CAUTION:
Always calibrate the vacuum pump gauge when using it.
9. If NG, replace absolute pressure sensor.

246 EC-106
 TROUBLE DIAGNOSIS FOR DTC P0110

Intake Air Temperature Sensor

COMPONENT DESCRIPTION
The intake air temperature sensor is mounted to the air duct. The IJ]J',
sensor detects intake air temperature and transmits a signal to the
ECM.
The temperature sensing unit uses a thermistor, which is sensitive ~u:l
to the change in temperature. Electrical resistance of the thermistor
decreases in response to the temperature rise.
This sensor is not used to control the engine system. It is used only l©
for the on board diagnosis.

20 (Reference data)
18 Intake air temperature Voltage'
6 Resistance k!l
"C (of) (V)
4 Acceptable
'ii 2 20 (68) 3.5 2.1 - 2.9
•u
..8:.*
0

0.4
1.0
0.8 80 (176) 1.23 0.27- 0.38

": These data are reference values and are measured)<etween ECM term1nal @
©L
0.2 (Intake air temperature sensor) and ECM terminal ~ (EGGS ground).
0 ' 1 L_2;<;o.--lo,---c2!coc-i4o"6;';;o---,cso,--,-1olvo;----
l-41 (32) (66)(104)(140) (176) (212)
Temperature oc ("F)
SEF012P

ON BOARD DIAGNOSIS LOGIC

Diagnostic
Check Items
Trouble Code Malfunction is detected when .
(Possible Cause)
No.
P0110 A) An excessively low or high voltage from the sensor is • Harness or connectors
0401 sent to ECM.* (The sensor circuit is open or shorted.)
........ • Intake air temperature sensor
B) Rationally incorrect voltage from the sensor is sent to
ECM, compared with the voltage signal from engine
coolant temperature sensor.
*: When th1s malfunction IS detected, the ECM enters fall-safe mode and the MIL lights up. (Refer to EC-76.)

Engine operating condition in fail-safe mode

The ECM controls on the assumption that the intake air temperature is 20°C
(68"F).

EC-107 247
 TROUBLE DIAGNOSIS FOR DTC P0110
Intake Air Temperature Sensor (Cont'd)
DIAGNOSTIC TROUBLE CODE CONFIRMATION
1;: MONITOR * NOFAIL D PROCEDURE
CMPS•RPM(REF) Orpm Procedure for malfunction A
1) Turn ignition switch "ON".
(jj\
\J!J
2) Select "DATA MONITOR" mode with CONSULT.
3) Wait at least 5 seconds.
---------OR---------
~ 1) Turn ignition switch "ON" and wait at least 5 seconds.
2) Select MODE 7 with GST.
I RECORD I ---------OR---------
SEF422T
@ 1) Turn ignition switch "ON" and wait at least 5 seconds.
2) Turn ignition switch "OFF", wait at least 7 seconds and
then turn "ON".
3) Perform "Diagnostic Test Mode II (Self-diagnostic
results)" with ECM.

Procedure for malfunction B

tr: MONITOR f< NO FAIL
1) Lift up vehicle and open engine hood.
COOLAN TEMP/S 30'C 2) Wait until engine coolant temperature is less than 90'C
(194'F).
(a) Turn ignition switch "ON".
(b) Select "DATA MONITOR" mode with CONSULT.
(c) Check the engine coolant temperature.
(d) If the engine coolant temperature is not less than
90'C (194'F), turn ignition switch "OFF" and cool
RECORD
L__ _..:....:.:===------o!SEF002P
I down engine.
• Perform the following steps before engine coolant tem-
perature is above 90'C (194'F).
FUEL SYS #1 OPEN 3) Turn ignition switch "ON".
FUEL SYS #2 OPEN 4) Select "DATA MONITOR" mode with CONSULT.
CALC LOAD 0%
5) Start engine.
SHORT FT #1 0% 6) Shift selector lever to "D" position.
LONG FT#1 0% 7) Hold vehicle speed at 70 to 80 km/h (43 to 50 MPH) for
SHORT FT #2 0%
LONG FT#2 0% 2 minutes.
ENGINE SPD ORPM ---------OR---------
VEHICLE SPD OMPH
IGN ADVANCE 1.0' 1) Lift up vehicle and open engine hood.
INTAKE AIR 25"C 2) Wait until engine coolant temperature is less than 90'C
(194'F).
SEF549P
(a) Turn ignition switch "ON".
(b) Select MODE 1 with GST.
(c) Check the engine coolant temperature.
(d) If the engine coolant temperature is not less than
90'C (194°F), turn ignition switch "OFF" and cool
down engine.
• Perform the following steps before engine coolant tem-
perature is above 90'C (194'F).
3) Start engine.
4) Shift selector lever to "D" position.
5) Hold vehicle speed at 70 to 80 km/h (43 to 50 MPH) for
2 minutes.
6) Select MODE 7 with GST.
---------OR---------

248 EC-108
 TROUBLE DIAGNOSIS FOR DTC P0110
Intake Air Temperature Sensor (Cont'd)
(No\ 1) Lift up vehicle and open engine hood.
~
]OfF.c"='oN~N=Ec"='m"='R'illl L\~
2) Wait until engine coolant temperature is less than 90"C
II ECM ~ 1..m (194"F).
51
(a) Turn ignition switch "ON".
(b) Check voltage between ECM terminal@) and ground.
Voltage: More than 1.0 (V)
(c) If the voltage is not more than 1.0 (V), turn ignition !;IV~
switch "OFF" and cool down engine.
• Perform the following steps before the voltage is below
1.W W
3) Start engine.
SEF006P
4) Shift selector lever to "D" position.
5} Hold vehicle speed at 70 to 80 km/h (43 to 50 MPH) for
2 minutes.
6) Turn ignition switch "OFF", wait at least 7 seconds and
then turn "ON".
7) Perform "Diagnostic Test Mode II (Self-diagnostic
results)" with ECM.

EC-109 249
 TROUBLE DIAGNOSIS FOR DTC P0110
Intake Air Temperature Sensor (Cont'd)

EC-IATS-01

- . Detectable line for DTC

. Non-detectable line for DTC

I IINTAKEAIR
~~&;~6~ATURE
lbj:!l ~
Y/L B/G

Y/L B/G

~ ~
r--~T"-A"-----'JG-C'ND::'--"'A---, ECM (ECCS
CONTROL
MODULE)
@g)

,.c;::J... (~)
\..2.l.!U GY

AEC041A

250 EC-110
 TROUBLE DIAGNOSIS FOR DTC P0110
Intake Air Temperature Sensor (Cont'd)
DIAGNOSTIC PROCEDURE ~I

INSPECTION START

CHECK POWER SUPPLY. Repair harness or connec-

1. Turn ignition switch "OFF". tors.
2. Disconnect intake air temperature sen-
sor harness connector.
3. Turn ignition switch "ON".
4. Check voltage between terminal G)
and ground.

~&50~ Voltage:
Approximately SV
diD OK

CHECK GROUND CIRCUIT. NG Check the following.

1. Turn ignition switch "OFF". • Harness for open or
2. Check harness continuity between ter- short between ECM and
minal® and engine ground. intake air temperature
SEF101S Continuity should exist. sensor
~;:===============~ If OK, check harness for short. If NG, repair harness or
I;) connectors.
OK

~8)@a CHECK COMPONENT NG Replace intake air tem-

(Intake air temperature sensor). perature sensor.
diD Refer to "COMPONENT INSPECTION"
on next page.

OK

Disconnect and reconnect harness con-

nectors in the circuit. Then retest.
L___________________________s_E_F_1_02-"S L_-------------,~~~~~~~_j
Trouble is not fixed.

Check ECM pin terminals for damage and

check the connection of ECM harness
connector.
Reconnect ECM harness connector and
retest.

INSPECTION END

EC-111 251
 TROUBLE DIAGNOSIS FOR DTC P0110
Intake Air Temperature Sensor (Cont'd)
COMPONENT INSPECTION
Intake air temperature sensor
Check resistance as shown in the figure.

SEF103S

20 (Reference data)
1g Intake air temperature
6 Resistance kf!
"C ("F)
'ii 4 Acceptable
~ 2 20 (68) 2.1 - 2.9

..s 0.8
<ll

~ 0.4
1.0 80 (176) 0.27- 0.38

0.2 If NG, replace intake air temperature sensor.

o. 1 L,_2!no-o!c->2!no-c4i!<o-c6ilno-s<loo-c1,;,oo,----
l-41 (32) (68)(104)(14~~76)(212)
Temperature "C eF)
SEF012P

252 EC-112
 TROUBLE DIAGNOSIS FOR DTC P0115

!QJ]
Terminal Engine Coolant Temperature Sensor (ECTS)
COMPONENT DESCRIPTION
The engine coolant temperature sensor is used to detect the
engine coolant temperature. The sensor modifies a voltage signal
from the ECM. The modified signal returns to the ECM as the
engine coolant temperature input. The sensor uses a thermistor
which is sensitive to the change in temperature. The electrical
resistance of the thermistor decreases as temperature increases.
Gasket
SEF594K

(Reference data)
Engine coolant tempera-
Voltage• Resistance
ture
(V) (kil)
2
'C ('F)
i
YO
1.0
0.8
-10 (14) 4.4 7.0-11.4

~ 0.4 20 (68) 3.5 2.1 . 2.9

0.2 50 (122) 2.2 0.68- 1.00
0.1 L.._~~~~~~~~~­
·20 0 20 40 60 80 100 90 (194) 0.9 0.236 - 0.260
(-4) (32) (68)(104)(140)(176)(212)
Temperature oc (°F)
SEF012P *: These data are reference values and measured between ECM termmal @
(Engine coolant temperature sensor) and ECM terminal @ (ECCS ground).

ON BOARD DIAGNOSIS LOGIC

Diagnostic
Check Items
Trouble Code Malfunction is detected when .
(Possible Cause)
No.
POttS • An excessively high or low voltage from the sensor is • Harness or connectors
0103 sent to ECM. * (The sensor circuit is open or shorted.)
• Engine coolant temperature sensor
*: When th1s malfunction is detected, the ECM enters fail-safe mode and the MIL lights up. (Refer to EC-76.)

Engine operating condition in fail-safe mode

Engine coolant temperature will be determined by ECM based on the time
after turning ignition switch "ON" or "START". ~J!]
CONSULT displays the engine coolant temperature decided by ECM.

Engine coolant temperature decided

Condition
{CONSULT display)

Just as ignition switch is turned ON or

20"C (68'F)
START

More than approx. 6 minutes after igni-

80'C (176'F)
tion ON or START

20 - sooc {68 - 176°F)

Except as shown above
(Depends on the time)

EC-113 253
 TROUBLE DIAGNOSIS FOR DTC P0115
Engine Coolant Temperature Sensor (ECTS)
(Cont'd)
fr MONITOR * NOFAIL D DIAGNOSTIC TROUBLE CODE CONFIRMATION
CMPS•RPM(REF) Orpm PROCEDURE
M 1) Turn ignition switch "ON".
~ 2) Select "DATA MONITOR"' mode with CONSULT.
3) Wait at least 5 seconds.
--------OR--------
1) Turn ignition switch "ON" and wait at least 5 seconds.
2) Select "MODE 7" with GST.
I RECORD I -------OR--------
SEF422T 1) Turn ignition switch "ON" and wait at least 5 seconds.
2) Turn ignition switch "OFF", wait at least 7 seconds and
then turn "ON".
3) Perform "Diagnostic Test Mode II (Self-diagnostic
results)" with ECM.

254 EC-114
 TROUBLE DIAGNOSIS FOR DTC P0115
Engine Coolant Temperature Sensor (ECTS)
(Cont'd) @I

EC-ECTS-01

- : Detectable line for DTC

: Non-detectable line for DTC

I~ I
ENGINECOOLANT
TEMPERATURE
SENSOR
~~------~~(M1B)
l1jdJ lbjdJ
B/G LG/R

lfcll

B/G LG/R

rtstiJ ~
r-~G'-;'No"--"-A------"TW~"--, ECM (ECCS
CONTROL
MODULE)
(M112)

~(i@j)
'-!_E) GY

~
101 102 103 104 105 100 I [2 3 ~ 20212223 38 39 I4014il 53 54 55 ~
107 108 109
5 6 7 8 9 10 24 25 26 27 28 ~~ 44 45146 57 58 59 60 61
110 111 112 111 1211314 19 29 30 31 32 33 fg~ 47 48 62 63 64 65 70
113 114 115 116117118 l1lJ ~ 34 35136 37 ...:.::.. .::.::..J WJ2gJ 66 67 68 69

AEC042A

EC-115 255
 TROUBLE DIAGNOSIS FOR DTC P0115
Engine Coolant Temperature Sensor (ECTS)
(Cont'd)
DIAGNOSTIC PROCEDURE

INSPECTION START
~
No.1 injector

~
1\ Engine coolant
CHECK POWER SUPPLY.
1. Turn ignition switch "OFF".
NG Repair harness or connec-
tors.
~temperature sensor
2. Disconnect engine coolant temperature
harness connector SEF104S
sensor harness connector.
3. Turn ignition switch "ON".
4. Check voltage between terminal ®
r:it 18 ~€-J and ground with CONSULT or tester.
Voltage:
Approximately 5V
d'fu OK

CHECK GROUND CIRCUIT. NG Check the following.

1. Turn ignition switch "OFF". • Harness for open or
2. Check harness continuity between ter- short between ECM and
SEF515A
minal G) and engine ground. engine coolant tempera-
Continuity should exist. ture sensor

I~ If OK, check harness for short. If NG, repair harness or

connectors.
~10~ OK

dfu CHECK COMPONENT NG Replace engine coolant

(Engine coolant temperature sensor). temperature sensor.
Refer to "COMPONENT INSPECTION"
on next page.

OK
"=" SEF516R
,----------J-----------,
Disconnect and reconnect harness con-
nectors in the circuits. Then retest.

Trouble is not fixed.

Check ECM pin terminals for damage and

check the connection of ECM harness
connector. Reconnect ECM harness con-
nector and retest.

INSPECTION END

256 EC-116
 TROUBLE DIAGNOSIS FOR DTC P0115
Engine Coolant Temperature Sensor (ECTS)
(Cont'd) 1lll
COMPONENT INSPECTION
Engine coolant temperature sensor
Check resistance as shown in the figure.

(Reference data)
Resistance kn
20 (68) 2.1 - 2.9
SEF1 50 (122) 0.68- 1.00
90 (194) 0.236 - 0.260
20
1g If NG, replace engine coolant temperature sensor.
6
4
'i:l
~ 2

..£
ffi 1.0
;;; 0.8
0.4
0.2

o. c,_2tco~o;---;2c.co~•"'o'6"'o~a"'o'1*'oo,-­
1
l ·4) (32) (68) (104) (140) (176)(212)
Temperature °C (oF)
SEF012P

EC-117 257
 TROUBLE DIAGNOSIS FOR DTC P0120

Throttle Position Sensor

COMPONENT DESCRIPTION
The throttle position sensor responds to the accelerator pedal
movement. This sensor is a kind of potentiometer which transforms
the throttle position into output voltage, and emits the voltage sig-
nal to the ECM. In addition, the sensor detects the opening and
closing speed of the throttle valve and feeds the voltage signal to
the ECM.
Idle position of the throttle valve is determined by the ECM receiv-
ing the signal from the throttle position sensor. This controls engine
operation such as fuel cut. The throttle position sensor unit contains
a built-in "Wide open and closed throttle position switch".
----~

Supply voltage: 5V
~ (Applied between terminal
Wide open '"-g 6.0
No. 1 and 3)
throttle m

~4

L _
/
position
switch
N
0
z terminal No. 2 and 3)v
Output Joltage between

v
Closed ~ 4.0
~5 throttle E
L 2

l
}position
6 SWitCh c
ID
ID
/
~ 2.0
Throttle

/
~

21 position ID
~
sensor "l
L..a3 §!
0
5
~
0 45 90 135
5 Throttle valve opening angle (deg)
0

SEF105S

ECM TERMINALS AND REFERENCE VALUE

Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC vol1age)
NO.

11gnit1on switch "ON" 1

0.3- 0.7V
L Accelerator pedal released
23 w Throttle position sensor
pgnition swi1ch "ON" I
Approximately 4V
L Accelerator pedal fully depressed

49 p Sensors' power supply pgnition switch "ON" I Approximately SV

II Engine is running.] (Warm-up condition)

50 B/G Sensors' ground 0.001 - 0.02V
L Idle speed

258 EC-118
 TROUBLE DIAGNOSIS FOR DTC P0120
Throttle Position Sensor (Cont'd)
CONSULT REFERENCE VALUE IN DATA MONITOR MODE
Specification data are reference values
MONITOR ITEM CONDITION SPECIFICATION

• Ignition switch: ON Throttle valve fully closed 0.3- O.?V

THRTL POS SEN
(Engine stopped) Throttle valve fully opened Approx. 4.0V

• Ignition switch: ON Throttle valve fully closed 0.0%

ABSOL TH·P/S
(Engine stopped) Throttle valve fully opened Approx. 84%

ON BOARD DIAGNOSIS LOGIC

Diagnostic
Check Items
Trouble Malfunction is detected when ...
(Possible Cause)
Code No.
P0120 • An excessively low or high voltage from the sensor is • Harness or connectors
0403 sent to ECM.* (The sensor circuit is open or shorted.)
• Voltage sent to ECM is not practical when compared • Throttle position sensor
with mass air flow sensor and camshaft position sen-
sor signals.

When th1s malfunction 1s detected, the ECM enters fa1l-safe mode and the MIL lights up. (Refer to EC-76.)

Engine operating condition in fail-safe mode

Throttle position will be determined based on the injected fuel amount and the
engine speed.
Therefore, acceleration will be poor.

Condition Driving condition

When engine is idling Normal

When accelerating Poor acceleration

EC-119 259
 TROUBLE DIAGNOSIS FOR DTC P0120
Throttle Position Sensor (Cont'd)
OVERALL FUNCTION CHECK
"t< MONITOR "t< NO FAIL D Use this procedure to check the overall function of the throttle
THRTL POS SEN 0.48V position sensor circuit. During this check, a 1st trip DTC might not
ABSOL TH•P/S 0.0%
be confirmed.
1) Start engine and warm it up sufficiently.
2) Turn ignition switch "OFF" and wait at least 7 seconds.
3) Turn ignition switch "ON".
4) Select "MANU TRIG" and "HI SPEED" in "DATA MONI-
TOR" mode with CONSULT.
5) Select "THRTL POS SEN" and "ABSOL TH·P/S" in
I RECORD
!'l
I
SEF024P "DATA MONITOR" mode with CONSULT.
6) Press RECORD on CONSULT SCREEN at the same
time accelerator pedal is depressed.
NG data OK data 7) Print out the recorded data and check the following:
THRTL POS SEN oo·oo THRTL POS SEN 00'00
1~:38 1i ~iv ;~s·~ 1g:sa 1~ x~Jv
;f"~i
• The voltage when accelerator pedal fully released is
L___ 0.3- 0.7V.
• l.,. .. • The voltage rise is linear in response to accelerator
?·----·---1 - ·-,_____1 pedal depression.
• The voltage when accelerator pedal fully depressed
ABSOL TH-PJS 00'00 ABSOL TH-PIS 00"00
is approximately 4V.
1~·38 2~ %
7~os;~ 1~:38 2~ %
50 7;os;~ ---------OR---------
• " • .... 1) Start engine and warm it up sufficiently.
.. ...... ··· ... ..,, 2) Turn ignition switch "OFF" and wait at least 7 seconds .
,..... - ··.....
..-. 3) Turn ignition switch "ON" .
4) Check the voltage between ECM terminal @ and @
1 (ground) and check the following:
1 • The voltage when accelerator pedal fully released is
THRTL ABSOL THRTL ABSOL
15:38 POS TH/PO
15:38 POS TH/PO 0.3- 0.7V.
SEN SEN SEN SEN
(V) (%) (V) (%) • The voltage rise is linear in response to accelerator
00"36 2.14 39.9 00'46 2.88 57.4 pedal depression.
00"37 2.20 41.3 00'47 3.00 60.5
00"38 2.26 42.7 00"48 3.12 63.3 • The voltage when accelerator pedal fully depressed
00"39 2.32 44.4 00"49 3.24 66.1 is approximately 4 V.
00'41 2.26 42.7 00'50 3.34 68.9
00"42 2.20 41.3 00"51 3.46 71.4
00"43 2.58 50.4 00"52 3.56 74.2
00"44 2.66 52.5 00"53 3.68 77.0
00'45 2.76 54.9 00"54 3.80 79.8
SEF021 P

~i:)~
II ECM lof CONNECTOR II
23 43 (ground)

[Y]
ID <'1\A
=-..::.
SEF022P

260 EC-120
 TROUBLE DIAGNOSIS FOR DTC P0120
Throttle Position Sensor (Cont'd)

EC-TPS-01

- : Detectable line for DTC

: Non-detectable line for DTC

(I ,_
I
I
I
I
I
I
~-

·-
__ ... ,
I
I
I
I
I
I
I I ~~l
I I
I I
I
I
I
I
I
I p
Ip I+
p

~l; 11
------"-'T~'--"----"-T-'1
I
I 16
I
I
I .~ - ------"$'
.-"-T-"- -T-"--- J .~JECTOR-1
'JOINT
I
1
~~~~T.~-------------.1~;I
I
I
I
I
I p B
I
I
I I
I I
I I
I ~~ -, I
( 'l
' -- -~ '

B/G W P

~ ~ rr!ll
r-~G~N~D~-A~----~T~V~0~1----~A~V~C~C~-,ECM(ECCS
CONTROL
MODULE)
@E)

Refer to last page (Foldout page)_

<Mill)

~(~)
\..2..E.EJ BR

101 102 103 104 105 106 1 2 3

5 6 7 8 9 ~
~
107108109 110111 112 1112 1314
113114 115 116 117118 15 16 17 18

AEC043A

EC-121 261
 TROUBLE DIAGNOSIS FOR DTC P0120
Throttle Position Sensor (Cont'd)
DIAGNOSTIC PROCEDURE

INSPECTION START

ADJUST THROTTLE POSITION SEN-

SOR.
Pertorm BASIC INSPECTION, EC-72.

OK
,-----------L-----------,NG
SEF089S CHECK SHIELD CIRCUIT. Repair harness or connec-
~;:::=====:::;:;:=:::;::;::::======~ 1. Turn ignition switch "OFF". tors.
2. Loosen and retighten engine ground
screws.
3. Remove joint connector-1.
4. Check the following.
• ContinuitY. between joint connector-1
terminal G) and ground
• Joint connector-1
(Refer to "HARNESS LAYOUT" in EL
section.)
Continuity should exist.
If OK, check harness for short. Then
reconnect joint connector-1.
sensor harness
SEF106S OK
connector
~==;;:::::~~====~ r.i.1
r.i.1 ~ ."~"o"" _::' ~N 0-'
, CHECK
=--- __L
POWER _ _ - - - - - - , NG
SUPPLY.
1. Disconnect throttle position sensor har-
Check the following.
• Joint connector-1
~ ness connector. • Harness for open or
UlZ.UJ 2. Turn ignition switch "ON". short between throttle
3. Check voltage between terminal G) position sensor and
and ground with CONSULT or tester. ECM
Voltage: Approximately SV If NG, repair harness or
connectors.
OK
m
r=----------~~-----------,NG
CHECK GROUND CIRCUIT. Repair harness or connec-
~;=============S=E=F=1=07~S
r.;
1. Turn ignition switch "OFF".
2. Check harness continuity between ter-
tors.

li.J minal @ and engine ground.

Continuity should exist.
If OK, check harness for short.

OK
[!]
~----------~L_-----------,NG
CHECK INPUT SIGNAL CIRCUIT. Repair harness or connec-
1. Disconnect ECM harness connector. tors.
2. Check harness continuity between ECM
terminal @ and terminal ®-
Continuity should exist.
If OK, check harness for short.
SEF1 088 '-~~~~~~---,---;c,---~~~~~_j

~==================~ OK
,-----------~~-----------,NG

~i5 ~i5
CHECK COMPONENT Replace throttle position
(Throttle position sensor). sensor. To adjust it, per-
Refer to "COMPONENT INSPECTION" form BASIC INSPECTION,
lr;=o=Ec=M=40f coNNECTOR 11 Giill:l on next page. EC-72.
23
OK

®
(Go to next page.)

'----+ +---'
SEF566P

262 EC-122
 TROUBLE DIAGNOSIS FOR DTC P0120
Throttle Position Sensor (Cont'd)
®
~
Disconnect and reconnect harness con-
nectars in the circuit. Then retest.

~Trouble is not fixed.

Check ECM pin terminals for damage and

check the connection of ECM harness
connector. Reconnect ECM harness con-
nectar and retest.

~
INSPECTION END

COMPONENT INSPECTION
Throttle position sensor
1 Start engine and warm it up sufficiently.
2. Turn ignition switch "OFF".
3. Disconnect throttle position sensor harness connector.
4. Check resistance between terminals ® and ® while opening
throttle valve manually.
Throttle valve conditions Resistance at 25°C (7rF)
Frontc2'_.../ Completely closed Approximately 0.5 kH
Partially open 0.5. 4.0 kil
Completely open Approximately 4.0 kn

If NG, replace throttle pos11Jon sensor.

To adjust throttle position sensor, perform "BASIC
INSPECTION", EC-72.

EC-123 263
 TROUBLE DIAGNOSIS FOR DTC P0125

Terminal Engine Coolant Temperature (ECT) Sensor

COMPONENT DESCRIPTION
The engine coolant temperature sensor is used to detect the
engine coolant temperature. The sensor modifies a voltage signal
from the ECM. The modified signal returns to the ECM as the
engine coolant temperature input. The sensor uses a thermistor
which is sensitive to the change in temperature. The electrical
resistance of the thermistor decreases as temperature increases.
Gasket
SEF594K

20 (Reference data)
Engine coolant
Voltage' Resistance
temperature
oC (of) (V) (k!l)
~ 2

..
~ 1.0
uo

~ 0.4
0.8
-10 (14)
20 (68)
4.4
3.5
7.0-11.4
2.1 - 2.9
0.2 50 (122) 2.2 0.68- 1.00
0.1 Lc~~~~~~~'-,-~­
-20 0 20 40 60 80 100 90 (194) 0.9 0.236 - 0.260
(-4) (32) (68) (104)(140) (176) (212)
Temperature oc (°F)
SEF012P *: These data are reference values and measured betwer.ll ECM terminal @})
L~~~~~~-------=__,_.:-_ (Engine coolant temperature sensor) and ECM terminal 19 (ECCS ground).

ON BOARD DIAGNOSIS LOGIC

Diagnostic
Check Items
Trouble Malfunction is detected when .
(Possible Cause)
Code No.
P0125 • Rationally incorrect voltage from the sensor is sent to • Harness or connectors
0908 ECM, even when some time has passed after starting (High resistance in the circuit)
the engine. • Engine coolant temperature sensor
• Engine coolant temperature is insufficient for closed • Thermostat
loop fuel control.

264 EC-124
 TROUBLE DIAGNOSIS FOR DTC P0125
Engine Coolant Temperature (ECT) Sensor
(Cont'd) i!Ju
"t< MONITOR "t< NO FAIL
OVERALL FUNCTION CHECK
COOLAN TEMPIS 30oC
Use this procedure to check the overall function of the engine
coolant temperature sensor circuit. During this check, a t st trip
DTC might not be confirmed.
Note: If both DTC P0115 (0103) and P0125 (0908) are displayed, Iii!!]
first perform TROUBLE DIAGNOSIS FOR DTC P0115.
(See EC-113.)
@ 1) Turn ignition switch "ON".
RECORD
L__ _..:....::=-=..:...:::.-----,1SEF002P
I ~ 2) Select "COOLAN TEMP/S" in "DATA MONITOR" mode
with CONSULT.
3) Start engine and run it at idle speed.
FUEL SYS #1 OPEN
FUELSYS #2 UNUSED 4) Check that the engine coolant temperature rises to
CALC LOAD 22% 20°C (68°F) or more within 13 minutes. (Be careful not
COOLANT TEMP 30"C
SHORTFT#1 0% to overheat engine.)
LONG FT#1 2% ----------OR----------
ENGINESPD 1000RPM
VEHICLESPD Okm/h ~ 1) Turn ignition switch "ON".
IGNADVANCE
INTAKE AIR
20.0°
26'"C '~ 2) Select "MODE 1" with GST.
MAF O.Ogm/sec 3) Start engine and run it at idle speed.
THROTTLE POS 0%
02S LOCATION 3 4) Check that the engine coolant temperature rises to
02S B1 ,81 0.680V
G2FT B1AS1 0% 20°C (68°F) or more within 13 minutes. (Be careful not u:!lli'
028 B1 ,;,2 O.OBOV to overheat engine.)
SEF003P ---------OR---------
1) Turn ignition switch "ON". ffii,1J
2) Probe voltage meter between ECM terminal ® and
ground.
~CONNECT 3) Start engine and run it at idle speed. 1J[5
==Ec=CccM=='EfOJPI
"11 c=o""NN"'-"~:C:TccOR"llllAJ £) 4) Check that voltage of engine coolant temperature
" changes to less than 3.5 (V) within 13 minutes. (Be
careful not to overheat engine.) pt!J

SEF004P

EC-125 265
 TROUBLE DIAGNOSIS FOR DTC P0125
Engine Coolant Temperature (ECT) Sensor
(Cont'd)

EC-ECTS-01

- : Detectable line for DTC

: Non-detectable line tor DTC

~ll4Jl
ENGINE COOLANT
TEMPERATURE

I-lbjdl
'-;rtr,------~~W1~
SENSOR

B/G LG/R
'

8/G LG/R

,...;1!::;::':-'o;-I_ _..!lt;:;:Offl'---1
GND-A TW ECM (EGGS
CONTROL
MODULE)
(~)

,J:\Il... (!,ill)
'-!.EJ GY

AEC042A

266 EC-126
 TROUBLE DIAGNOSIS FOR DTC P0125
Engine Coolant Temperature (ECT) Sensor
(Cont'd)
m --1 L -. ~?,~
~·. .~ "~,"'j
E'~ IY. ~
DIAGNOSTIC PROCEDURE

~ n ~ -_;a;, !:': / II INSPECTION START

J~~
~-: "'"'~ ~ ~~
~i m 1
~
1\ Engrne coolant
~temperature sensor
harness connector
:~~~~
'

\
- ,'' :'=

SEF104S
CHECK POWER SUPPLY.
1. Turn ignition switch "OFF".
2. Disconnect engine coolant temperature
sensor harness connector.
3. Turn ignition switch "ON".
-NG
Repair harness or connec-
tors.

4. Check voltage between terminal ®

m and ground with CONSULT or tester.

~ ID
DISCONNCCT

Voltage:
Approximately 5V
cffu
[YJ ~
1 OK

NG
CHECK GROUND CIRCUIT. Check the following.
~
1. Turn ignition switch "OFF". ~ • Harness for open or
2. Check harness continuity between ter- short between ECM and

~ 8 .,., minalCD and engine ground. engine coolant tempera-

Continuity should exist. ture sensor
SEF645R
If OK, check harness for short. If NG, repair harness or

~
~ ID
DISCONUECT
l OK
connectors.

NG
CHECK COMPONENT _____. Replace engine coolant
uTh (Engine coolant temperature sensor). temperature sensor.
Refer to "COMPONENT INSPECTION"
[ill on next page.

l OK

tea 1SEF646R
CHECK THERMOSTAT OPERATION.
When the engine is cold [lower than 70°C
NG CHECK COMPONENT
(Thermostat).
(158°F)] condition, grasp lower radiator Refer to LC section.
hose and confirm the engine coolant does If NG, replace it.
not flow.

1 OK

Disconnect and reconnect harness con-

nectors in the circuit. Then retest.

1 Trouble is not fixed.

Check ECM pin terminals for damage and

check the connection of ECM harness
connector. Reconnect ECM harness con-
nector and retest.

l
INSPECTION END

EC-127 267
 TROUBLE DIAGNOSIS FOR DTC P0125
Engine Coolant Temperature (ECT) Sensor
(Cont'd)
COMPONENT INSPECTION
Engine coolant temperature sensor
Check resistance as shown in the figure.

(Reference data)
Temperature oc ("F) Resistance k!l
20 (68) 2.1 - 2.9
SEF152P 50 (122) 0.68-1.0
90 (194) 0.236 - 0.260
20
1g If NG, replace engine coolant temperature sensor.
6
li 4
~ 2
~ i.O
t5 0.8
~ 0.4
0.2
01
· t,·2c..o-o"-2C..o-4"'o~s""o-s"'-o-c1*'ooc-­
HI 1321 (68)(104)(140)(176)(2121
Temperature oc ("F)
SEF012P

268 EC-128
 TROUBLE DIAGNOSIS FOR DTC P0130

~~J
Louver
Front Heated Oxygen Sensor (Front H02S)
COMPONENT DESCRIPTION
The front H02S is placed into the exhaust manifold. It detects the
amount of oxygen in the exhaust gas compared to the outside air.
The sensor has a closed-end tube made of ceramic zirconia. The
zirconia generates voltage from approximately 1V in richer condi- ~T~l
lions to OV in leaner conditions. The sensor signal is sent to the
EGM. The EGM adjusts the injection pulse duration to achieve the
Zirconia tube ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical
change from 1V to OV.
SEF463R

J l
Rich ---- Ideal ratio
Mixture ratio
-..--_. Lean

SEF2880

ECM TERMINALS AND REFERENCE VALUE

Specification data are reference values and are measured between each terminal and @ (EGGS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

1 1Engine is running. I
Front heated oxygen sen~ 0 - Approximately 1.0V
46 w sor L After warming up sufficiently and engine speed (periodically change)
is 2,000 rpm.

CONSULT REFERENCE VALUE IN DATA MONITOR MODE

Specification data are reference values.
MONITOR ITEM CONDITION SPECIFICATION

FR 02 SENSOR 0 - 0.3V H Approx. 0.6 - l.OV

Maintaining engine speed at 2,000 LEAN H RICH

• Engine: After warming up Changes more than 5 times
FR 02 MNTR rpm
during 10 seconds.

ON BOARD DIAGNOSIS LOGIC

Diagnostic Trouble Check Items
Malfunction is detected when .
Code No. (Possible Cause)
P0130 • An excessively high voltage from the sensor is sent to ECM. • Harness or connectors
0303 • The voltage from the sensor is constantly approx. 0.3V. {The sensor circuit is open or shorted.)
• The maximum and minimum voltages from the sensor do not • Front heated oxygen sensor
reach the specified voltages. • Fuel pressure
• The sensor does not respond between rich and lean within • Injectors
the specified time. • Intake air leaks

EC-129 269
 TROUBLE DIAGNOSIS FOR DTC P0130
Front Heated Oxygen Sensor (Front H02S)
(Cont'd)
1;: MONITOR 1;: NO FAIL D OVERALL FUNCTION CHECK
CMPS•RPM(REF) 2i37rpm
Use this procedure to check the overall function of the front heated
MAS AI RIFL SE 1.96V
COOLAN TEMPIS 84°C
oxygen sensor circuit. During this check, a 1st trip DTC might not
FR 02 SENSOR 0.37V be confirmed.
FR02 MNTR LEAN fF.r\ 1) Start engine and warm it up sufficiently.
INJ PULSE 2.6msec \.llV 2) Select "MANU TRIG" and "HI SPEED" in "DATA MONI-
A!F ALPHA 101% TOR" mode with CONSULT, and select "FR 02 SEN-
~ SOR" and "FR 02 MNTR".
I RECORD I 3) Hold engine speed at 2,000 rpm under no load during
SEF405T the following steps.
4) Touch "RECORD" on CONSULT screen.
5) Check the following.
• "FR 02 MNTR" in "DATA MONITOR" mode changes
from "RICH" to "LEAN" to "RICH" 5 times in 10 sec-
onds.
5 times (cycles) are counted as shown below:

cycle I 1 I 2 I 3 I 4 I 5 I
FR 02 MNTR R-L-R-L-R-L-R-L-R-L-R

R = "FR 02 MNTR", "RICH"

L = "FR 02 MNTR", "LEAN"
• "FR 02 SENSOR" voltage goes above 0.6V at least
once.
• "FR 02 SENSOR" voltage goes below 0.3V at least
once.

CMPS
17:51 •RPM
(POS) ,•,'
Maximum
,"\
' '
.,
' '
,-,
' '
• Maximum voltage
should be over 0.6V
09"13
(rpm)
2050 0.
' ,' '' '' '\ 'I ' '' at least one time.
09"11 2050 0.18 a: > ~

09"09 2050 0.18 0 0 ~

Cl) ci <0
• Minimum voltage
09"07 2037 0.18 z X

09"05 2037 w should be below 0.3V

0.18 U)
09"03 2060 0.23 at least one time.
8 '',_'' '' '' '',./' ''
09"01 2012 0.43
a: ~ ' '' ·-' \_,'
~ Minimum
GRAPH CL

~0-L----------------------------------- SEF217T

----------OR----------
~ 1) Start engine and warm it up sufficiently.
@ 2) Set voltmeter probes between ECM terminal @ (sensor
signal) and @ (engine ground).
3) Check the following with engine speed held at 2,000
rpm constant under no load.
• Malfunction indicator lamp goes on more than 5 times
within 10 seconds in Diagnostic Test Mode II (FRONT
HEATED OXYGEN SENSOR MONITOR).
• The maximum voltage is over 0.6V at least one time.
• The minimum voltage is below 0.3V at least one time.
SEF085P

270 EC-130
 TROUBLE DIAGNOSIS FOR DTC P0130
Front Heated Oxygen Sensor (Front H02S)
(Cont'd) el
EC-FR02-01

- : Detectable line for OTC

: Non-detectable line for DTC
Refer to "EL-POWER".

15A
m
BNI

I
BNI
m
r---~~~--•FRONT
HEATED
OXYGEN
SENSOR
'-;r-;--r,--;r-,;-r.-'(M62)
l¥1
w
lbjdJ
w

•
I I
I
I
I
I I l'[S

~
I
I
I 8
I
I
I
ffi J OINT
~):D

I CONNECTOR-1
I
I + @19)
:J

l¥1
8
w w 8
rF.i;] ~ I
lffiil
02HF 02SF GND-C ECM(ECCS
CONTROL
MODULE)
@}g)
il8
...L
B
...L
(M~5) (.;i!B)

Refer to last page (Foldout page).

@19)

o:fil::D<~l
GY

~
1
0

AEC304A

EC-131 271
 TROUBLE DIAGNOSIS FOR DTC P0130
Front Heated Oxygen Sensor (Front H02S)
(Cont'd)
DIAGNOSTIC PROCEDURE
INSPECTION START

l
,-----------L-----------,NG
CHECK SHIELD CIRCUIT. Repair harness or connec-
1. Turn ignition switch "OFF". tors.
2. Loosen and retighten engine ground
screws.
3. Remove joint connector-1.
4. Check the following.
• Continuity between joint connector-1
terminal G) and ground
• Joint connector-1
(Refer to "HARNESS LAYOUT" in EL
section.)
Continuity should exist.
If OK, check harness for short. Then
reconnect joint connector-1.

OK

NG
CHECK INPUT SIGNAL CIRCUIT. Repair harness or connec-
1. Disconnect front heated oxygen sensor tors.
harness connector and ECM harness
connector.
2. Check harness continuity between ECM
terminal @ and terminal ®-
Continuity should exist.
li ECM iofcoNNECTORII
46
3. Check harness continuity between ECM
terminal @ (or terminal ®>and
ground.
Continuity should not exist.
If OK, check harness for short.

OK

SEF377R ®
(Go to next page.)

272 EC-132
 TROUBLE DIAGNOSIS FOR DTC P0130
Front Heated Oxygen Sensor (Front H02S)
m • ACTIVE TEST • D
(Cont'd)
SELF-LEARN 100% ®
CONTROL
===MONITOR===
CMPS·RPM (REF) 812rpm
m I
CLEAR THE SELF-LEARNING DATA
Yes
Go to 'TROUBLE DIAG-
COO LAN TEMPIS 93"C ~
FR 02 SENSOR
AJF ALPHA D
0.91V
102%
®
1. Start engine and warm it up sufficiently.
2. Select "SELF-LEARNING
CONT" in "ACTIVE TEST"
NOS IS FOR DTC P0171,
P0172", EC-148, 153.

mode with CONSULT.

I CLEAR 3. Clear the self-learning control
coefficient by touching
AEC547
"CLEAR".
4. Run engine for at least 10 min-
utes at idle speed.
Is the 1st trip DTC P0171 or
P0172 detected? Is it difficult
to start engine?
OR

® 2. Turn ignition switch "OFF" and

wait at least 7 seconds.
3. Disconnect mass air flow sensor
harness connector, and restart
and run engine for at least 3
seconds at idle speed.
4. Stop engine and reconnect
mass air flow sensor harness
connector.
5. Make sure 1st trip DTC No.
01 02 is displayed in Diagnostic
Test Mode II.
6. Erase the diagnostic test mode
II (Self-diagnostic results)
memory. Make sure diagnostic
trouble code No. 0505 is dis-
played 1n Diagnostic Test Mode
II.
7. Run engine for at least 10 min-
utes at idle speed.
Is the 1st trip OTC 0114 or
0115 detected? Is it difficult to
start engine?

~No
Disconnect and reconnect harness con-
nectars in the circuit. Then retest.

~ Trouble is not fixed.

Check ECM pin terminals for damage and

check the connection of ECM harness
connector. Reconnect ECM harness con-
nectar and retest.
-
NG
Replace front heated oxy-
gen sensor.

~OK

INSPECTION END

EC-133 273
 TROUBLE DIAGNOSIS FOR DTC P0130

Closed Loop Control

• The closed loop control has one trip detection logic.
Diagnostic
Check Items
Trouble Malfunction is detected when .
(Possible Cause)
Code No.

P0130 • The closed loop control function does not operate • The front heated oxygen sensor circuit is open or
0307 even when vehicle is driving in the specified condition. shorted.
• Front heated oxygen sensor
• Front heated oxygen sensor heater

OVERALL FUNCTION CHECK

'k MONITOR *NO FAIL D Use this procedure to check the overall function of the closed loop
CMPS•RPM(REF) 2137rpm control. During this check, a 1st trip DTC might not be confirmed.
MAS AIR/FL SE 1.96V (F.i\ 1) Start engine and warm it up sufficiently.
COOLAN TEMPIS 84°C \,!!) 2) Select "MANU TRIG" and "HI SPEED" in "DATA MONI-
FA 02SENSOR 0.37V TOR" mode with CONSULT, and select "FR 02 SEN-
FA 02 MNTR LEAN SOR" and "FR 02 MNTR".
INJ PULSE 2.6msec 3) Hold engine speed at 2,000 rpm under no load during
the following steps.
I RECdiRo I
SEF084P
4) Touch "RECORD" on CONSULT screen.
5) Check the following.
• "FR 02 MNTR" in "DATA MONITOR" mode changes
from "RICH" to "LEAN" to "RICH" 5 times in 10 sec-
onds.
5 times (cycles) are counted as shown below:

cycle I 1 I 2 I 3 I 4 I 5 I
FR 02 MNTR R-L-R-L-R-L-R-L-R-L-R

R = "FR 02 MNTR", "RICH"

L = "FR 02 MNTR", "LEAN"
-------OR-------
1) Start engine and warm it up sufficiently.
2) Check that malfunction indicator lamp goes on more
than 5 times in 10 seconds while keeping at 2,000 rpm
in Diagnostic Test Mode II (FRONT HEATED OXYGEN
SENSOR MONITOR).

DIAGNOSTIC PROCEDURE
Refer to TROUBLE DIAGNOSIS FOR DTC P0130, EC-129.
Refer to TROUBLE DIAGNOSIS FOR DTC P0135, EC-135.

274 EC-134
 TROUBLE DIAGNOSIS FOR DTC P0135

(!;]]
Front Heated Oxygen Sensor Heater
SYSTEM DESCRIPTION

j Camshaft position sensor

1 Engine speed
ECM Front

l Engine coolant temperature sensor

1 Engine coolant temperature (EGGS
control
heated oxy-
gen sensor
module) heater
Amount of intake air
I Mass air flow sensor 1

The ECM performs ON/OFF control of the front

F rant heated oxygen
heated oxygen sensor heater corresponding to the Engine speed (rpm) Engine condition
sensor heater
engine conditions.
Above 3,000 - OFF
Heavy load after
OFF
Below 3,000 warm-up

Except above ON

ECM TERMINALS AND REFERENCE VALUE

Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

1Engine is running. I
Approximately OV
Front heated oxygen sen- L Engine speed is below 3,000 rpm.
42 w sor heater 1Engine is running. I BATTERY VOLTAGE
L Engine speed is above 3,000 rpm. (11 - 14V)

CONSULT REFERENCE VALUE IN DATA MONITOR MODE

Specification data are reference values
MONITOR ITEM CONDITION SPECIFICATION
• Engine speed: Idle ON
FR 02 HEATER
• Engine speed: Above 3,000 rpm OFF

ON BOARD DIAGNOSIS LOGIC

Diagnostic Trouble Check Items
Malfunction is detected when .
Code No. (Possible Cause)
P0135 • The current amperage in the front heated oxygen • Harness or connectors
0901 sensor heater circuit is out of the normal range. (The front heated oxygen sensor heater circuit is
(An improper voltage drop signal is sent to ECM open or shorted.)
through the front heated oxygen sensor heater.) • Front heated oxygen sensor heater

EC-135 275
 TROUBLE DIAGNOSIS FOR DTC P0135
Front Heated Oxygen Sensor Heater (Cont'd)
DIAGNOSTIC TROUBLE CODE CONFIRMATION
1:< MONITOR 1:< NOFAIL 0 PROCEDURE
CMPS•RPM(REF) 800rpm (ii\ 1) Turn ignition switch "ON" and select "DATA MONITOR"
\)V mode with CONSULT
2) Start engine and run it for at least 6 seconds at idle
speed.
----------OR----------
1) Start engine and run it for at least 6 seconds at idle
speed.
2) Turn ignition switch "OFF" and wait at least 7 seconds.
I RECORD ISEF712T 3) Start engine and run it for at least 6 seconds at idle
speed.
4) Select "MODE 3" with GST.
---------OR---------
,0W\ 1) Start engine and run it for at least 6 seconds at idle
'~_o_ty
speed.
2) Turn ignition switch "OFF", wait at least 7 seconds and
then turn "ON".
3) Perform "Diagnostic Test Mode II" (Self-diagnostic
results) with ECM.
• When using GST, "DIAGNOSTIC TROUBLE CODE CON-
FIRMATION PROCEDURE" should be performed twice as
much as when using CONSULT or ECM (Diagnostic Test
Mode II) because GST cannot display MODE 7 (1st trip
DTC) concerning this diagnosis. Therefore, using CON-
SULT or ECM (Diagnostic Test Mode II) is recommended.

276 EC-136
 TROUBLE DIAGNOSIS FOR DTC P0135
Front Heated Oxygen Sensor Heater (Cont'd)

EC-FR02/H-01

- : Detectable line for DTC

: Non-detectable line for DTC
Refer to "EL-POWER".

15A
[2]
BFN

I
BfoN

ffi
r----.!1..;'-l!_--,FAONT
HEATED
•
OXYGEN
SENSOR
'-,--.,...-...,.-,,--' (~)
lbjd1 ~
w w
-
rr II
I
I
I
I
- I
G

m 1f,3'jl
J OINT
CONNECTOR-1
I
I + (Mjjjj)
L-
~
-;!

lbjd
w w B B
I
~ rrlBll rrl3ll
02HF 02SF GND-C ECM (ECCS
CONTROL
MODULE)
@W
il
~
B _._
B

(f,jjj) <'ill>
Refer to last page (Foldout page).
(MttO) r~@

---+=h-..(~)
~GY

~
1
0

AEC305A

EC-137 277
 TROUBLE DIAGNOSIS FOR DTC P0135
Front Heated Oxygen Sensor Heater (Cont'd)
DIAGNOSTIC PROCEDURE
Front heated oxygen
INSPECTION START

m
r=----------~-------------,NG
CHECK POWER SUPPLY. Check the following.
1. Disconnect front heated oxygen sensor • 15A fuse
harness connector. • Harness for open or short
2. Turn ignition switch "ON". between front heated
3. Check voltage between terminal @ and oxygen sensor and fuse
ground. If NG, repair harness or
Voltage: Battery voltage connectors.

OK

CHECK GROUND CIRCUIT. NG Repair harness or connec-

1. Turn ignition switch "OFF". tors.
2. Disconnect ECM harness connector.
3. Check harness continuity between termi-
nalCD and ECM terminal @.
Continuity should exist.
If OK, check harness for short.

OK
AEC743
CHECK COMPONENT NG Replace front heated oxy-
(Front heated oxygen sensor heater). gen sensor.
Refer to ""COMPONENT INSPECTION""
below.

OK

II ECM ]OfCONNECTOR I Disconnect and reconnect harness connec-

42 tors in the circuit, and retest.

Trouble is not fixed.

Check ECM pin terminals for damage and

check the connection of ECM harness con-
nector. Reconnect ECM harness connector
SEF111S
and retest.

INSPECTION END

COMPONENT INSPECTION
Front heated oxygen sensor heater
Check resistance between terminals @ and G).
Resistance: 2.3 - 4.3U at 25"C (77"F)
OISCONNHT Check continuity between terminals @ and CD, @ and @.
18 Continuity should not exist.
If NG, replace the front heated oxygen sensor.
CAUTION:
00 SEF586Q
Discard any heated oxygen sensor which has been dropped
from a height of more than 0.5 m (19.7 in) onto a hard surface
such as a concrete floor; use a new one.
278 EC-138
 TROUBLE DIAGNOSIS FOR DTC P0136

Rear Heated Oxygen Sensor (Rear H02S)

COMPONENT DESCRIPTION
The rear heated oxygen sensor (Rear H02S), after three way
catalyst, monitors the oxygen level in the exhaust gas.
Even if switching characteristics of the front heated oxygen sensor
are shifted, the air fuel ratio is controlled to stoichiometric, by the U'J!l
signal from the rear heated oxygen sensor.
This sensor is made of ceramic zirconia. The zirconia generates
voltage from approximately 1V in richer conditions to OV in leaner ll'
conditions.
SEF327R
Under normal conditions the rear heated oxygen sensor is not used •
for engine control operation.

ECM TERMINALS AND REFERENCE VALUE

Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

1Engine is running.[
Rear heated oxygen sen·
52 w sor L After warming up sufficiently and engine speed 0 - Approximately 1.0V
is 2,000 rpm.

CONSULT REFERENCE VALUE IN DATA MONITOR MODE

Specification data are reference values
MONITOR ITEM CONDITION SPECIFICATION
RR 02 SENSOR Maintaining engine speed at 2,000 0 - 0.3V o Approx. 0.6- t .OV
• Engine: After warming up
RR 02 MNTR rpm LEAN H RICH

ON BOARD DIAGNOSIS LOGIC 15J,

The rear heated oxygen sensor has a much longer switching time between rich and lean than the front heated
oxygen sensor. The oxygen storage capacity of the three way catalyst causes the longer switching time. To
judge the malfunctions of rear heated oxygen sensor, ECM monitors the sensor's voltage value and the ~li'c
switching response during the various driving condition such as fuel-cut.
Diagnostic Trouble Check Items
Malfunction is detected when .
Code No. (Possible Cause)
P0136 • An excessively high voltage from the sensor is sent to ECM. • Harness or connectors
0707 • The maximum and minimum voltages from the sensor are not (The sensor circuit is open or shorted.)
reached to the specified voltages. • Rear heated oxygen sensor
• It takes more time for the sensor to respond between rich and • Fuel pressure
lean than the specified time. • Injectors
• Intake air leaks

EC-139 279
 TROUBLE DIAGNOSIS FOR DTC P0136
Rear Heated Oxygen Sensor (Rear H02S)
(Cont'd)
• ACTIVE TEST • D OVERALL FUNCTION CHECK
FUEL INJECTION 25%
Use this procedure to check the overall function of the rear heated
========== MONITOR ========== oxygen sensor circuit. During this check, a 1st trip DTC might not
CMPS•RPM (POS) 725rpm
be confirmed.
RR02SENSOR 0.94V
(F.~', 1) Start engine and warm it up sufficiently.
~ 2) Select "FUEL INJECTION" in "ACTIVE TEST" mode,
and select "RR 02 SENSOR" as the monitor item with
CONSULT.
m!ll UP I OWN I~SEF815T 3) Check "RR 02 SENSOR" at idle speed when adjusting
"FUEL INJECTION" to ±25%.
"RR 02 SENSOR" should be above 0.48V at least

~i)~fi)
once when the "FUEL INJECTION" is +25%.
"RR 02 SENSOR" should be below 0.43V at least
once when the "FUEL INJECTION" is -25%.
II iof II ECM CONNECTOR ---------OR---------
52 43
~ 1) Start engine and warm it up sufficiently.
~ 2) Set voltmeter probes between ECM terminals @ (sen-
cff~~H sor signal) and @ (engine ground).
3
3) Check the voltage when racing up to 4,000 rpm under
t)~,
o-- 6 --5- SEF218S
no load at least 10 times.
(depress and release accelerator pedal as soon as pos-
sible)
The voltage should be above 0.48V and below 0.43V
at least once during this procedure.
If the voltage can be confirmed in step 3, step 4 is
not necessary.

4) Keep vehicle at idling for 10 minutes, then check the

voltage. Or check the voltage when coasting from
80 km/h (50 MPH) in 3rd gear position.
The voltage should be above 0.48V and below 0.43V
at least once during this procedure.
~ ~ ~
v ~ ~

"
N
0 0
+
'
~-
> 00
0 S"
0
X
a:
0 ............. ······...
"'w
z v
~
The voltage should be above
0 48V at least one t1me
"'0
N

a: cr;
a: 0
N
N

0
················'
}
. . . . . . . . . . . . . · · · · · · · · · . . . . . . . . . . . }~~;~o~t:T:a:th~~~: t~~8below
SEF219S

280 EC-140
 TROUBLE DIAGNOSIS FOR DTC P0136
Rear Heated Oxygen Sensor (Rear H02S)
(Cent' d)

IGNITION SWITCHl
ON or START
ER-RR02-01
Refer to
15A "EL-POWER''.
m - : Detectable line for DTC
: Non-detectable line for DTC

B!W
..,b.@
1 1
[}] cM•o1l
w
lcDI REAR HEATED
OXYGEN SENSOR

.(~)
~lrlp~l~~l"'qp~I~-.ILD"~"I~
I
G/R B GY

G/R B GY
lcpl---- ---1CfJ1" ---- -1~1(~)
(~)
A W B

~
/
"
I
I
------ ~
I
I
I I
I I
I

·-----,
I
I
'
·~

I+ ~
L-------------------------~~Lb+~~(W110
JOINT

I
CONNECTOR-1

~
A

~
W

r0":'2,CH:!,R'-------'0":'2:::S::':R'-, ECM (ECCS

CONTROL
MODULE)
@g)
,--··
B
I

B
-:!:-
<@>
B
-!=-
(~)

Refer to last page (Foldout page).

(M110)

&(M61) &c~J
\::ttY GY \::ttY GY

101 102 103

107108109
104 105 106
110111112
5 6123
789;o
11 12 13 14
~~
0
19
113114 115 116117 118 15 16 17 18

AEC306A

EC-141 281
 TROUBLE DIAGNOSIS FOR DTC P0136
Rear Heated Oxygen Sensor (Rear H02S)
(Cont'd)
DIAGNOSTIC PROCEDURE
INSPECTION START

l
,-----------~-----------,NG
CHECK SHIELD CIRCUIT. Repair harness or connec-
1. Turn ignition switch "OFF". tors.
2. Loosen and retighten engine ground
screws.
3. Remove joint connector~ 1.
4. Check the following.
• Continuity between joint connector-1
terminal G) and ground
• Joint connector-1
(Refer to ""HARNESS LAYOUT"" in EL
section.)
Continuity should exist.
If OK, check harness for short. Then
reconnect joint connector-1.

OK
m
~~----~~~~~~----'NG
CHECK INPUT SIGNAL CIRCUIT. Check the following.
1. Disconnect rear heated oxygen sensor • Harness connectors
harness connector and ECM harness <@). Q§)
connector. • Harness for open or short

m~i()~ 2. Check harness continuity between ECM

terminal @ and terminal ®.
between rear heated oxy-
gen sensor and ECM
Continuity should exist. If NG, repair harness or con-
ECM iol'coNNECTORII 3. Check harness continuity between ECM I nectars.
52
terminal @ (or terminal ®land
ground.
Continuity should not exist.
If OK, check harness for short.

OK

SEF114S CHECK GROUND CIRCUIT. NG Check the following.

~:================~ Check harness continuity between terminal • Harness connectors
m ® and engine ground. <@). Q§)
Continuity should exist. • Joint connector-1
If OK, check harness for short, • Harness for open or short
between rear heated oxy-
OK gen sensor and engine
ground
If NG, repair harness or con-
nectors.

Disconnect and reconnect harness connec-

tors in the circuit. Then retest.
SEF115S ' - - - - - - - - - - , - - - - - - - - - - "
'-----------------------' Trouble is not fixed.

Check ECM pin terminals for damage and Replace rear heated oxy-
check the connection of ECM harness con- gen sensor.
nector. Reconnect ECM harness connector
and retest.
OK

INSPECTION END

282 EC-142
 TROUBLE DIAGNOSIS FOR DTC P0141

Rear Heated Oxygen Sensor Heater

SYSTEM DESCRIPTION

ECM Rear
(EGGS
r Camshaft position sensor I Engine speed control
heated oxy·
gen sensor
module) heater

The ECM performs ON/OFF control of the rear OPERATION

heated oxygen sensor heater corresponding to the
Rear heated oxygen sensor
engine speed. Engine speed rpm
heater
Above 6,000 OFF
Below 6,000 ON

ECM TERMINALS AND REFERENCE VALUE

Specification data are reference values and are measured between each terminal and @ (ECCS ground).
liiii'l
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

IEngine is running.j
Approximately OV
Rear heated oxygen sen- L Engine speed is below 6,000 rpm.
115 R
sor heater I Ignition switch "ON" I BATIERY VOLTAGE
L Engine is stopped. (11 - 14V)

CONSULT REFERENCE VALUE IN DATA MONITOR MODE

Specification data are reference values
MONITOR ITEM CONDITION SPECIFICATION
• Engine speed; Below 6,000 rpm ON
RR 02 HEATER
• Ignition switch; ON (Engine stopped) OFF

ON BOARD DIAGNOSIS LOGIC

Diagnostic Trouble Check Items
Malfunction is detected when
Code No. (Possible Cause)
POt4t • The current amperage in the rear heated oxygen • Harness or connectors
0902 sensor heater circuit is out of the normal range. (The rear heated oxygen sensor heater circuit is
(An improper voltage drop signal is sent to ECM open or shorted.)
through the rear heated oxygen sensor heater.) • Rear heated oxygen sensor heater

EC-143 283
 TROUBLE DIAGNOSIS FOR DTC P0141
Rear Heated Oxygen Sensor Heater (Cont'd)
DIAGNOSTIC TROUBLE CODE CONFIRMATION
1:1: MONITOR * NOFAIL D PROCEDURE
CMPS•RPM(REF) BOO rpm ~ 1) Turn ignition switch "ON" and select "DATA MONITOR"
~ mode with CONSULT.
2) Start engine and run it for at least 6 seconds at idle
speed.
---------OR---------
1) Start engine and run it for at least 6 seconds at idle
speed.
I RECORD I
SEF712T
2) Turn ignition switch "OFF"' and wait at least 7 seconds.
3) Start engine and run it for at least 6 seconds at idle
speed.
4) Select "MODE 3" with GST.
---------OR---------
1) Start engine and run it for at least 6 seconds at idle
speed.
2) Turn ignition switch "OFF", wait at least 7 seconds and
then turn "ON".
3) Perform "Diagnostic Test Mode II (Self-diagnostic
results)" with ECM.
• When using GST, "DIAGNOSTIC TROUBLE CODE CON-
FIRMATION PROCEDURE" should be performed twice as
much as when using CONSULT or ECM (Diagnostic Test
Mode II) because GST cannot display MODE 7 (1st trip
DTC) concerning this diagnosis. Therefore, using CON-
SULT or ECM (Diagnostic Test Mode II) is recommended.

284 EC-144
 TROUBLE DIAGNOSIS FOR DTC P0141
Rear Heated Oxygen Sensor Heater (Cont'd)
(Ci]
EC-RR02/H-01

IGNITION
ON or START
SWITCHl
Refer to
ISA "EL-POWER". - : Detectable line for DTC
: Non-detectable line for DTC
[I]
B/W
I~I(M61)
......... @Qj)
w
lcb REAR HEATED

I
~-~..-~~c-~~-~~0 I~XYGEN SENSOR

llpl ilfll llpl

GIR B GY

III
G/R
.......
IWf---IWf--iWI
B
.-L-,
GY
.-L-, @Qj)
.,=' '=y=' '=y=' (M61)
R W B

~ ---- -l
I
I
I
I
I

·~
L--

•
R
I~
.
~
......__
L-----------------------~~LU~:~I ~''~
_L_
~~lm
CONNECTOR-1

l"i115il
,----,
B
02HR 02SR ECM (EGGS
CONTROL
MODULE)
I ~~~-~'
@W

Refer to last page (Foldout page).

(Mi10) fJ~-

£(M61) £@Qi)
\:jty GY \:jty GY

101 102 103

107108 109
104 105 106
110 111 112
~
113114 115 116 117 118 15 16 17 18
§j

AEC307A

EC-145 285
 TROUBLE DIAGNOSIS FOR DTC P0141
Rear Heated Oxygen Sensor Heater (Cont'd)
DIAGNOSTIC PROCEDURE
INSPECTION START

CHECK POWER SUPPLY. NG Check the following.

1. Turn ignition switch "OFF". • Harness connectors
2. Disconnect rear heated oxygen sensor @,@
harness connector. • 15A fuse
3. Turn ignition switch "ON". • Harness for open or short
4. Check voltage between terminal @) and between rear heated oxy-
ground. gen sensor and fuse
Voltage: Battery voltage If NG, repair harness or con-
nectors.
OK
(;]
~~~~~~~~--------,NG
CHECK GROUND CIRCUIT. Check the following.
1. Turn ignition switch "OFF". • Harness connectors
2. Disconnect ECM harness connector. @,@
3. Check harness continuity between termi- • Harness for open or short
nal CD and ECM terminal @. between ECM and rear
Continuity should exist. heated oxygen sensor
If OK, check harness for short. If NG, repair harness or con-
nectors.
OK
SEF220S r-c--:----::-::-:-:::--::-:-=-=-----------,
~============================~
(;I
CHECKCOMPONENT
(Rear heated oxygen sensor heater).
NG Replace rear heated oxy-
gen sensor.
Refer to "COMPONENT INSPECTION" on
~ID next page.

IFII=EC:;;M:==='!]OfCONNECTOR II
Disconnect and reconnect harness connec-
"' tors in the circuit. Then retest.

Trouble is not fixed.

Check ECM pin terminals for damage and

check the connection of ECM harness con-
L sE_F_2_2_ts_j
_______________ nector. Reconnect ECM harness connector
and retest.

INSPECTION END

286 EC-146
 TROUBLE DIAGNOSIS FOR DTC P0141
Rear Heated Oxygen Sensor Heater (Cont'd)
COMPONENT INSPECTION @II

~
DISCONNECT
ct8Ji @a Rear heated oxygen sensor heater
Check the following.
e) 1. Check resistance between terminals @ and G).

~
laJ Resistance: 11.4- 17.4!2 at 25°C (77°F)
2. Check continuity.
Terminal No. Continuity
t'H

.8
DISCONNECT ~3
®and G).@),@
@and G),®.@
If NG, replace the rear heated oxygen sensor.
CAUTION:
No

Discard any heated oxygen sensor which has been dropped

from a height of more than 0.5 m (19.7 in) onto a hard surface [p~
such as a concrete floor; use a new one.

SEF116S

EC-147 287
 TROUBLE DIAGNOSIS FOR DTC P0171

Fuel Injection System Function (Lean side)

ON BOARD DIAGNOSIS LOGIC
With Mixture Ratio Self-Learning Control, the actual mixture ratio can be brought closely to the theoretical
mixture ratio based on the mixture ratio feedback signal from the front heated oxygen sensor. The ECM cal-
culates the necessary compensation to correct the offset between the actual and the theoretical ratios.
In case the amount of the compensation value is extremely large (the actual mixture ratio is too lean), the ECM
judges the condition as a fuel system malfunction and lights up the MIL (2 trip detection logic).
ECM
~~~~~~:;~~----~D~e~ns~i~~o~fo~x~y~ge~n~i~n~ex~h~a~us~t~g~as~ (ECCS
LI_Fr_o_nt_h_e_at_e_d_ox_y_g_en_s_e_n_so_r____jl (Mixture ratio feedback signal) control I Injectors
I
module)

Diagnostic Trouble Check Items

Malfunction is detected when ...
Code No. (Possible Cause)
P0171 • Fuel injection system does not operate properly. • Intake air leak
0115 • The amount of mixture ratio compensation is too large. • Front heated oxygen sensor
(The mixture ratio is too lean.) • Injectors
• Exhaust gas leak
• Incorrect fuel pressure
• Lack of fuel
• Mass air flow sensor

DIAGNOSTIC TROUBLE CODE CONFIRMATION

I ACTIVE TEST I 0 PROCEDURE (Overall)
SELF-LEARN 100%
CONTROL rF.i\ 1) Start engine and warm it up sufficiently.
\.IV 2) Turn ignition switch "OFF" and wait at least 7 seconds.
========== MONITOR ========== 3) Turn ignition switch "ON" and select "SELF-LEARN
CMPS•RPM (REF) 750rpm CONTROL" in "ACTIVE TEST" mode with CONSULT.
COOLAN TEMP/S 93°C 4) Clear the self-learning control coefficient by touching
FR02 SENSOR 0.18V
AJF ALPHA 100%
"CLEAR".
5) Select "DATA MONITOR" mode with CONSULT.
~
I CLEAR I
SEF423T
6) Start engine again and run it for at least 10 minutes at
idle speed.
The 1st trip DTC should be detected at this stage, if a
malfunction exists.
7) If it is difficult to start engine at step 6, the fuel injection
system has a malfunction, too.
Crank engine while depressing accelerator pedal. If
engine starts, go to "DIAGNOSTIC PROCEDURE",
EC-151. If engine does not start, check exhaust and
intake air leak visually.
---------OR---------

288 EC-148
TROUBLE DIAGNOSIS FOR DTC P0171
Fuel Injection System Function (Lean side)
(Cont'd) Clll
(~ 1) Start engine and warm it up sufficiently.
~'WJ 2) Turn ignition switch "OFF" and wait at least 7 seconds.
3) Disconnect mass air flow sensor harness connector.
Then restart and run engine for at least 3 seconds at
idle speed.
4) Stop engine and reconnect mass air flow sensor har-
ness connector.
5) Select "MODE 7" with GST. Make sure 1st trip DTC
lo:~
POt 00 is detected.
6) Select "MODE 4'' with GST and erase the 1st trip DTC
P0100.
7) Start engine again and run it for at least 10 minutes at
idle speed.
8) Select "MODE 7" with GST. The 1st trip DTC P0171 i'!O
should be detected at this stage, if a malfunction exists.
9) If it is difficult to start engine at step 8, the fuel injection
system has a malfunction.
Crank engine while depressing accelerator pedal. If 1~1L
engine starts, go to "DIAGNOSTIC PROCEDURE",
EC-151. If engine does not start, check exhaust and
intake air leak visually.
OR---------------
~ 1) Start engine and warm it up sufficiently.
'@ 2) Turn ignition switch "OFF" and wait at least 7 seconds. if.J'
3) Disconnect mass air flow sensor harness connector.
4) Start engine and run it for at least 3 seconds at idle
speed. fl'
5) Stop engine and reconnect mass air !low sensor har-
ness connector.
6) Turn ignition switch "ON". fJI]J
7) Pertorm Diagnostic Test Mode II (Sell-diagnostic
results) with ECM. Make sure 1st trip DTC 0102 is
detected. Ei!,
8) Erase the 1st trip DTC 0102 by changing from Diagnos-
tic Test Mode II to Diagnostic Test Mode I.
9) Perform Diagnostic Test Mode II (Sell-diagnostic
results) with ECM. Make sure DTC 0505 is detected.
10) Start engine again and run it for at least 10 minutes at
idle speed. ~'~I
The 1st trip DTC 0115 should be detected at this stage,
if a malfunction exists.
11) II it is difficult to start engine at step 10, the fuel injec- i')ll
tion system also has a malfunction.
Crank engine while depressing accelerator pedal. If
engine starts, go to "DIAGNOSTIC PROCEDURE", ~:0
EC-151 . If engine does not start, check exhaust and
intake air leak visually.

EC-149 289
 TROUBLE DIAGNOSIS FOR DTC P0171
Fuel Injection System Function (Lean side)
(Cont'd)

EC-FUEL-01

T WFUS18LE
LINK
(M47),@)
8/W
15A
CD
Refer to "EL-POWER".

-
-
Detectable line lor DTC
Non-detectable line for DTC

l.bjdl I
8/W
W/B
ffi
I r-----~~-----,FRONT
HEATED
OXYGEN
SENSOR
IGNITION L--.,lr.:,-r,--1----,1,-;;:--r;--'1 (M62)
ST SWITCH
<MW w w

8/W c -:.• -----------.

'''

I• -- •
I I •I I
'
'
I
I
I
I
''
'''

~
8~ ~7
BNI/ B/W I

~ ~
I
I
INJECTOR INJECTOR INJECTOR INJECTOR I
I
N0.1 N0.2 NO.3 NO.4 I
@D @ @ @ I

~ ~ ~ ~
-
_")I
W/B W/L W/R WIG
I
W/B
I
W/L
I
W/R
I
WIG W W B

,.-ifl1: ;.:2~;!!1---:~!7'~'i;!7~~------:!~7;1~:;!4;-l-----;!;~1'70~9'!'-1------';'~~4~7,'~'-----'1:';:;4,~~~----;!~S4~~~ ECM

INJ#1 INJ#2 INJ#3 INJ#4 02HF 02SF GND-C (ECCS
·~l
CONTROL
MODULE) 8 B
@) 7- ~
~----------------------------------------------------~ (M15){M1~

Refer to last page (Foldout page).

cffb@
B
,@B , (&llij) , @D
B B
@!g)

---------------
I I

~(M47) ~@):
I I
I
cfu(~) llliHJ<MW
<M~2l~
I
I 8 8 1 GY w
· - - - - - - - - - - - - __ .J

~~
101 102 103 104 105 106
~ 1201211221231 '38 39 !4ol4il 53 54 55 ~
107 108 109 110 111 112
5 61728 9 3 10 t42 43 44 45 46 57 58 59 60 61
11 12 13 14 19 ~~ 474862636465 70
113 114 115 116 117 118 §~ L..:.:. ~ 66676869

AEC308A

290 EC-150
 TROUBLE DIAGNOSIS FOR DTC P0171
Fuel Injection System Function (Lean side)
(Cont'd)
DIAGNOSTIC PROCEDURE
INSPECTION START

l Repair or replace.

OK
SEF099P
CHECK INTAKE AIR LEAK. Repair or replace.
Start engine and run it at idle. Listen for an
intake air leak after the mass air flow sensor.

OK

CHECK FRONT HEATED OXYGEN SEN- Repair harness or connec-

SOR. tors.
1. Turn ignition switch "OFF".
2. Disconnect front heated oxygen sensor
harness connector and ECM harness con-
nector.
3. Check harness continuity between ECM
terminal @ and terminal ®.
Continuity should exist.
4. Check harness continuity between ECM
terminal @ (or terminal ®) and ground.
Continuity should not exist.
If OK, check harness for short.
ECM JO[coNNili§hl] Gfib) OK
46
CHECK FUEL PRESSURE. Check fuel pump and cir-
1. Release fuel pressure to zero. cuit. Refer to EC-309.
Refer to page EC-25.
2. Install fuel pressure gauge and check
fuel pressure.
At idle:
Approx. 235 kPa
(2.4 kg/cm 2 , 34 psi)
AEC717
A few seconds after ignition switch is
turned OFF to ON:
Approx. 294 kPa
(3.0 kg/em', 43 psi)

OK

CHECK MASS AIR FLOW SENSOR. NG Check connectors for

rF.f\ Check "MASS AIR FLOW" in rusted terminals or loose
\_ll!) "DATA MONITOR" mode with connections in the mass air
CONSULT. flow sensor circuit or engine
1.8 - 6.5 g·m/sec: at idling (2WD) grounds.
2.1 - 6.0 g·m/sec: at idling (4WD) Refer to EC-93.
7.7- 15.0 g·m/sec: at 2,500 rpm
(2WD)
6.8 - 13.3 g·m/sec: at 2,500 rpm
(4WD)
OR - - - - - - - - 1
Check "mass air flow" in MODE 1
with GST.
1.8 - 6.5 g·m/sec: at idling (2WD)
2.1 - 6.0 g·m/sec: at idling (4WD)
7.7- 15.0 g·m/sec: at 2,500 rpm
(2WD)
6.8 - 13.3 g·m/sec: at 2,500 rpm
(4WD)

OK
®
(Go to next page.)

EC-151 291
 TROUBLE DIAGNOSIS FOR DTC P0171
Fuel Injection System Function (Lean side)
[!) (Cont'd)
• ACTIVE TEST •
D ®
••• POWER BALANCE •·•

=CMPS·RPM(REF)
= = MONITOR =737rpm
= = [!) l
MAS AIR/FL SEN 0.98V
CHECK FUNCTION OF INJECTORS.
1. Install all parts removed.
~ Pertorm TROUBLE DIAG-
NOSIS FOR NON-DE-
41%
®
•DODD
IACV-AAC/V 2. Start engine. TECTABLE ITEMS,
3. Pertorm "POWER BALANCE" in "Injectors", EC~303 .

00~8
"ACTIVE TEST" mode with Repair harness or connec~
CONSULT. tors.
4. Make sure that each circuit pro-
EF354F duces a momentary engine
speed drop.
[!) OR

~~~ ®
3. Listen to each injector operating

00 ~"tD
sound.
\j ~ Clicking noise should be
Click heard.
At idle
C;,.•lr
+OK

Confirm that the engine is cooled down

-/I Clicle
Su1table tool
and there are no fire hazards near the
vehicle.

c,,.elr
SEF730L I!] ~
1. Turn ignition switch "OFF".
I!] 2. Remove injector assembly.

--~'
Refer to EC-26.
Keep fuel hose and all injectors con-
nected to injector gallery.

+
-
__... .....- /i
I I NG
/ 1. Disconnect ignition coil harness connec- Replace injectors from
I
tor. which fuel does not spray
2. Crank engine for about 3 seconds. Make out.
sure that fuel sprays out from injectors.

~ ~OK
SEF595Q
Check ECM pin terminals for damage and
check the connection of ECM harness con-
nectar. Reconnect ECM harness connector
and retest.

+
INSPECTION END

292 EC-152
 TROUBLE DIAGNOSIS FOR DTC P0172

Fuel Injection System Function (Rich side)

ON BOARD DIAGNOSIS LOGIC
With Mixture Ratio Self-Learning Control, the actual mixture ratio can be brought closely to the theoretical Uijjji,
mixture ratio based on the mixture ratio feedback signal from the front heated oxygen sensor. The ECM cal-
culates the necessary compensation to correct the offset between the actual and the theoretical ratios.
In case the amount of the compensation value is extremely large (the actual mixture ratio is too rich), the ECM l~i:1l
judges the condition as a fuel system malfunction and lights up the MIL (2 trip detection logic).
EGM [L,!~
r - - - - - - - - - - - - - - - , Density of oxygen in exhaust gas (EGGS
l
1
I Injectors
Front heated oxygen sensor
c __ _ _ _ _ _ _ _ _ _..J I (Mixture ratio feedback signal) control
module)
I

Diagnostic Trouble Check Items

Malfunction is detected when ...
Code No. (Possible Cause)
P0172 • Fuel injection system does not operate properly. • Front heated oxygen sensor
0114 • The amount of mixture ratio compensation is too large. • Injectors
(The mixture ratio is too rich.) •Exhaust gas leak
• Incorrect fuel pressure
• Mass air flow sensor

• ACTIVE TEST • D DIAGNOSTIC TROUBLE CODE CONFIRMATION

SELF-LEARN 100% PROCEDURE (Overall)
CONTROL @ 1) Start engine and warm it up sufficiently.
========== MONITOR ========== \JV 2) Turn ignition switch "OFF" and wait at least 7 seconds.
CMPS•RPM (REF) 750rpm
3) Turn ignition switch "ON" and select "SELF-LEARN
GOOLAN TEMP/S 93"C CONTROL" in "ACTIVE TEST" mode with CONSULT. ~'Jl
FR 02 SENSOR 0.91V 4) Clear the self-learning control coefficient by touching
AIF ALPHA 100% "CLEAR".
~==::cc;=!L~-=:=A'='R====I 5) Select "DATA MONITOR" mode with CONSULT.
6) Start engine again and run it for at least 10 minutes at
SEF424T
idle speed.
The 1st trip DTC P0172 should be detected at this ,]2!J;,
stage, if a malfunction exists.
7) If it is difficult to start engine at step 6, the fuel injection
system has a malfunction, too. IB!Jii
Crank engine while depressing accelerator pedal. If
engine starts, go to "DIAGNOSTIC PROCEDURE",
EC-156. If engine does not start, remove ignition plugs \Jf
and check for fouling, etc.
---------OR---------
1) Start engine and warm it up sufficiently. i)l[~
2) Turn ignition switch "OFF" and wait at least 7 seconds.
3) Disconnect mass air flow sensor harness connector.
Then restart and run engine for at least 3 seconds at ~~~
idle speed.
4) Stop engine and reconnect mass air flow sensor har-
ness connector. ~~L~
5) Select "MODE 7" with GST. Make sure 1st trip DTC
P01 00 is detected.
6) Select "MODE 4" with GST and erase the 1st trip DTC '-"l
P0100.
7) Start engine again and run it for at least 10 minutes at
idle speed. ulilJ?!:
8) Select "MODE 7" with GST. The 1st trip DTC P0172
should be detected at this stage, if a malfunction exists.

EC-153 293
 TROUBLE DIAGNOSIS FOR DTC P0172
Fuel Injection System Function (Rich side)
(Cont'd)
9) If it is difficult to start engine at step 8, the fuel injection
system has a malfunction.
Crank engine while depressing accelerator pedal. If
engine starts, go to "DIAGNOSTIC PROCEDURE",
EC-156. If engine does not start, remove ignition plugs
and check for fouling, etc.
----------OR----------
~ 1) Start engine and warm it up sufficiently.
~ 2) Turn ignition switch "OFF" and wait at least 7 seconds.
3) Disconnect mass air flow sensor harness connector.
4) Start engine and run it for at least 3 seconds at idle
speed.
5) Stop engine and reconnect mass air flow sensor har-
ness connector.
6) Turn ignition switch "ON".
7) Perform Diagnostic Test Mode II (Self-diagnostic
results) with ECM. Make sure 1st trip DTC 0102 is
detected.
8) Erase the 1st trip DTC 0102 by changing from Diagnos-
tic Test Mode II to Diagnostic Test Mode I.
9) Perform Diagnostic Test Mode II (Self-diagnostic
results) with ECM. Make sure DTC 0505 is detected.
10) Start engine again and run it for at least 10 minutes at
idle speed.
The 1st trip DTC 0114 should be detected at this stage,
if a malfunction exists.
11) If it is difficult to start engine at step 10, the fuel injec-
tion system also has a malfunction.
Crank engine while depressing accelerator pedal. If
engine starts, go to "DIAGNOSTIC PROCEDURE",
EC-156. If engine does not start, remove ignition plugs
and check for fouling, etc.

294 EC-154
 TROUBLE DIAGNOSIS FOR DTC P0172
Fuel Injection System Function (Rich side)
(Cont'd)

EC-FUEL-01 ii;2,

TIII FUSIBLE
LINK
(M47), {gj)
B/W
15A
[£]
Refer to "EL-POWER".

-
-
: Detectable line for DTC
: Non-detectable line for DTC

~ IB/W
W/B

I m
r-----~~-----,FRONT
HEATED
OXYGEN
SENSOR
IGNITION
SWITCH
L---;,.-::,-,;-l---,
1 1
-,;-r.1--'(M62)
ST
<19 w w

ll4Jl
BNI
,_ ~­
-:.•-~---. ~
~

I
I

I•
I
I
I
I
I
I
I

•I •I
~
I

I
I
I
I
BNI B/W B/W B/W
I
I
I

~~~
~ ~
I

INJECTOR INJECTOR INJECTOR INJECTOR

I
I +
I
N0.1 N0.2 NO.3 NO.4 I
@1) (M10) @ @ I
I -
lbjdJ lbjdJ lbjdJ lbjdJ (_

.,l
W/8 W/L W/R WIG
I
W/B
I
W/L
I
W/R
I
WIG W W 8

~ ~ ~ ~ ~
rf.IN~J~#~,------~IN~J~#2~------~IN~J2#3~------~IN~J~#4~----~0~2~H~F~--~0~2~S~F~~G~N~D~-C~~~~S
~ ~
CONTROL

*
MODULE) B B

-7-
L-----------------------------------------------------' i§g) ~W1s)
Reier to last page (Foldout page).
,-J>,<L,.@ , @ , (M10) , @j) (M110)
Ull.JS B 8 B
~---------------

: 1?1cM41> l:il@: ~(M62)

1tds Ws, I..!J1..LU GY
' - - - - - - - - - - - ___ _j

~ ~
~
li'l
till 0
101 102 103 104 105 106 i 2 3
5 6 8 1
107108 109 110 111 112 ,, ,/,3 , /
0
113114 115 116 117 118 15 16 17 18

AEC308A

EC-155 295
 TROUBLE DIAGNOSIS FOR DTC P0172
Fuel Injection System Function (Rich side)
(Cont'd)
DIAGNOSTIC PROCEDURE
INSPECTION START

l
CHECK EXHAUST AIR LEAK. Repair or replace.
Start engine and run it at idle. Listen for an
exhaust air leak before three way catalyst.

OK
SEF099P , - - - - - - - - - ' - - - - - - - - ,
~;;;::::;:::==;::=====:;:;:;:::==~ CHECK INTAKE AIR LEAK. Repair or replace.
r Start engine and run it at idle. Listen for an
intake air leak after mass air flow sensor.

OK
m
'~'r"?'-.,\):1\\1'-.1 rc:-::c----:-:------'----:------, NG
'-" CHECK FRONT HEATED OXYGEN SEN· Repair harness or connec-
SOR. tors.
1. Turn ignition switch "OFF".
2. Disconnect front heated oxygen sensor
harness connector and ECM harness con-
nector.
3. Check harness continuity between ECM
terminal @and terminal ®.
Continuity should exist.
4. Check harness continuity between ECM
terminal @ (or terminal ®)and ground.
~io Continuity should not exist.
If OK, check harness for short.
ECM jO[coNNECTORJI
46 OK

CHECK FUEL PRESSURE. Check fuel pump and cir-

i. Release fuel pressure to zero. cuit. Refer to EC-309.
Refer to page EC-25.
2. Install fuel pressure gauge and check
fuel pressure.
At idle:
Approx. 235 kPa
AEC717 (2.4 kg/em', 34 psi)
~----------------' A few seconds after ignition switch is
turned OFF to ON:
Approx. 294 kPa
(3.0 kg/em', 43 psi)

OK
,-----------~------------,NG
CHECK MASS AIR FLOW SENSOR. Check connectors for
(F.i\
Check "MASS AIR FLOW"" in rusted terminals or loose
~ "DATA MONITOR"' mode with connections in the mass air
CONSULT. flow sensor circuit or engine
1.8 - 6.5 g·rnlsee: at idling (2WD) grounds.
2.1- 6.0 g·rnlsee: at idling (4WD) Refer to EC·93.
7.7- 15.0 g·rnlsee: at2,500 rpm
(2WD)
6.8- 13.3 g·rnlsee: at 2,500 rpm
(4WD)
f--::c=:---- OR - - - - - - - t
® Check "mass air flow" in MODE 1
with GST.
1.8 • 6.5 g·rnlsee: at idling (2WD)
2.1 • 6.0 g·rnlsee: at idling (4WD)
7.7- 15.0 g·rn/see: at 2,500 rpm
(2WD)
6.8 - 13.3 g·rnlsee: at 2,500 rpm
(4WD)

OK
@
(Go to next page.)

296 EC-156
 TROUBLE DIAGNOSIS FOR DTC P0172
Fuel Injection System Function (Rich side)
1!1 (Cont'd)
• ACTIVE TEST •
D ®
l
••• POWER BALANCE •••

===MONITOR=== 1!1
CMPS·RPM(REF) 737rpm NG
CHECK FUNCTION OF INJECTORS. Pertorm TROUBLE DIAG·
MAS AIR/FL SEN 0.98V 1. Install all parts removed. ~ NOSIS FOR NON-DE-
41%
®
•
IACV-AAC/V 2. Start engine. TECTABLE ITEMS,
3. Pertorm "POWER BALANCE" in "Injectors'', EC-303 .

00~8
"ACTIVE TEST" mode with Repair harness or connec-
CONSULT. tors.

DODD EF354F
4. Make sure that each circuit pro-
duces a momentary engine
speed drop.
OR
1!1
~~~ ®
3. Listen to each injector operating

@a ftfJ
')' ~

At idle
Click
sound.
Clicking noise should be
heard.
c,,.~~,
' ~OK

~~
1. Turn ignition switch "OFF".
2. Remove injector assembly.
SUitable tool
Refer to EC-26.
Keep fuel hose and all injectors con-
c1•'tlr nected to injector gallery
SEF730L
~
Confirm that the engine is cooled down
and there are no fire hazards near the
vehicle.

~
1. Disconnect all injector harness connec- ~ Replace the injectors from
tors. which fuel is dripping.
2. Disconnect ignition coil harness connec-
tor.
3. Crank engine for about 3 seconds.
Make sure fuel does not drip from injec-
tor.

+Does not drip.

Check ECM pin terminals tor damage and

check the connection of ECM harness con-
nectar. Reconnect ECM harness connector
and retest.

t
INSPECTION END

EC-157 297
 TROUBLE DIAGNOSIS FOR DTC P0180

Tank Fuel Temperature Sensor

COMPONENT DESCRIPTION
The tank fuel temperature sensor is used to detect the fuel tem-
perature inside the fuel tank_ The sensor modifies a voltage signal
from the ECM. The modified signal returns to the ECM as the fuel
temperature input The sensor uses a thermistor which is sensitive
to the change in temperature. The electrical resistance of the ther-
mistor decreases as temperature increases_

20 (Reference data)
Fluid temperature Voltage" Resistance

Acceptable
oc ('F) (V) (kll)
20 (68) 3.5 2.3 - 2.7
50 (122) 2.2 0.79- 0.90

*:These data are reference values and measure,<:(between ECM terminal @ (Tank
0.2 fuel temperature sensor) and ECM terminal ~ (ECCS ground).
0 ' 1 c,_2o,o----,co--,;,2o,---;4!co--;s;';;o--.:;ao"'1o"'o_ __
1-41 (32) 168) 1104) (140) 076)(212)
Temperature °C (°F)
SEF012P

ON BOARD DIAGNOSIS LOGIC

Diagnostic
Check Items
Trouble Code Malfunction is detected when ...
(Possible Causes)
No.
P0180 • An excessively high or low voltage is sent to ECM. • Harness or connectors
0402 • Rationally incorrect voltage is sent to ECM, compared (The sensor circuit is open or shorted.)
with the voltage signals from engine coolant tempera- • Tank fuel temperature sensor
ture sensor and intake air temperature sensor.

DIAGNOSTIC TROUBLE CODE CONFIRMATION

*:MONITOR * NOFAIL D PROCEDURE
CMPS•RPM(REF) Orpm 1) Turn ignition switch "ON"_
2) Select "DATA MONITOR" mode with CONSULT
3) Wait at least 12 seconds.
---------OR---------
1) Turn ignition switch "ON" and wait at least 12 seconds.
2) Select "MODE 7" with GST
---------OR---------
1) Turn ignition switch "ON" and wait at least 12 seconds.
I RECORD ISEF422T 2) Turn ignition switch "OFF", wait at least 7 seconds and
then turn "ON".
3) Perform "Diagnostic Test Mode II (Self-diagnostic
results)" with ECM.

298 EC-158
 TROUBLE DIAGNOSIS FOR DTC P0180
Tank Fuel Temperature Sensor (Cont'd)

EC-TFTS-01

- : Detectable line for DTC

: Non-detectable line for DTC

I I
~TEMPERATURE
FUEL
GAUGETANK
UNIT
(TANK FUEL

l~l lli.JI SENSOR)

.,= .,=@
L B/G

.='6
I· I
L

.......
.='6@
1m~------- --1m1
.......~
BIG

L B/G

TF

L 8/G

.---:~1
:~3Ll_ __cl'l:":~o
TFUEL GND-A
!_I,
ECM (ECCS
CONTROL
MODULE)
@W

D
r1 2 3 4 s@ ~@
[6Ty B 911il W ~GY

~
sa 39
58 59 601 ~
101 102 103 104 105 106 1 2 3 ~ 20 21 22 23
107 108 109 110111 112
5678910 24 25126 27 28 ~Jf3 44I40I4il l53154l5sl
45 46 57 61
1112 1314 19 29 30 31 32 33 47 48 62 63 64 65 70
113 114 115 116117 118 llli ~ ~@
34 35136 37 l21.lgJ 66 67 68/691

AEC049A

EC-159 299
 TROUBLE DIAGNOSIS FOR DTC P0180
Tank Fuel Temperature Sensor (Cont'd)
DIAGNOSTIC PROCEDURE
~~~
-~------- - I
Fuel pump aod ta7 I
INSPECTION START
I
Rtght stde -fuel temperature
-frame sensor harness m l
4~7~
CHECK POWER SUPPLY. NG Check the following.
1. Disconnect tank fuel temperature sensor ~ • Harness connectors
1,~ I,' harness connector. @.~
,, 1\ \ \ 2. Turn ignition switch "ON". • Harness for open or short

\
1
\(,_ Q Fcoot
3. Check voltage between terminal ®and between ECM and tank
ground with CONSULT or tester. fuel temperature sensor
MEF468FA
Voltage: Approximately sv If NG, repair harness or con-

m OK
nectar.

~ io~~ m
EilliD 6
CHECK GROUND CIRCUIT.
1. Turn ignition switch "OFF".
2. Check harness continuity between termi-
nal @ and body ground.
Continuity should exist.
-
NG Check the following.
• Harness connectors
@.~
• Harness for open or short
between ECM and tank
[J[] If OK, check harness for short. fuel temperature sensor
If NG, repair harness or con·
OK
~ nectars.
SEF119S

m CHECK COMPONENT
~
Replace tank fuel tempera-

~85 ~
(Tank fuel temperature sensor). lure sensor.
Refer to "COMPONENT INSPECTION" on

a 6
next page.

~OK
Disconnect and reconnect harness connec-
~ tors in the circuit. Then retest.

~lfl SEF120S
~ Trouble is not fixed.

Check ECM pin terminals for damage and

check the connection of ECM harness con-
nector. Reconnect ECM harness connector
and retest.

1
INSPECTION END

300 EC-160
 TROUBLE DIAGNOSIS FOR DTC P0180
Tank Fuel Temperature Sensor (Cont'd)
COMPONENT INSPECTION
Hot water
Tank fuel temperature
sensor connector
Tank fuel temperature sensor
Check resistance by heating with hot water or heat gun as shown ~~~ffi1
in the figure.

(Reference data) ~~~~

Temperature 'C ('F) Resistance kH
20 (68) 2.3- 2.7

AEC145A
50 (122) 0.79- 0.90

20 If NG, replace tank fuel temperature sensor.

18
6
Acceptable
" 4
~ 2

..a 1.0
iii 0.8

~ 0.4

0.2

' t,_2!no--!co-----;!2o"'4~o--c6iliio:--it.ao'"1o0io---
01
l-41 (32) (68) (104)(140) ~76)(212)
Temperature oc (°F)
SEF012P

'iil"

EC-161 301
 TROUBLE DIAGNOSIS FOR DTC P0300 - P0304

No. 4 - 1 Cylinder Misfire, Multiple Cylinder

Misfire
ON BOARD DIAGNOSIS LOGIC
If a misfire occurs, the engine speed will fluctuate. If the fluctuation is detected by the crankshaft position sen-
sor (OBD), the misfire is diagnosed.
The misfire detection logic consists of the following two conditions.
Crankshaft position sensor (OBD) Engine speed ECM

1. One Trip Detection Logic (Three Way Catalyst Damage)

When a misfire is detected which will overheat and damage the three way catalyst, the malfunction indi-
cator lamp (MIL) will start blinking; even during the first trip. In this condition, ECM monitors the misfire
every 200 revolutions.
If the misfire frequency decreases to a level that will not damage the three way catalyst, the MIL will change
from blinking to lighting up.
(After the first trip detection, the MIL will light up from engine starting. If a misfire is detected that will cause
three way catalyst damage, the MIL will start blinking.)
2. Two Trip Detection Logic (Exhaust quality deterioration)
When a misfire that will not damage the three way catalyst (but will affect exhaust emission) occurs, the
malfunction indicator lamp will light up based on the second consecutive trip detection logic. In this
condition, ECM monitors the misfire for every 1,000 revolutions of the engine
Diagnostic Trouble Check Items
Malfunction is detected when ...
Code Nos. (Possible Cause)

• Improper spark plug

P0300 (0701) • Multiple cylinders misfire.
• Insufficient compression
• Incorrect fuel pressure
P0301 (0608) • No. i cylinder misfires. • EGR valve
• The injector circuit is open or shorted
P0302 (0607) • No. 2 cylinder misfires. • Injectors
• Intake air leak
P0303 (0606) • No. 3 cylinder misfires. • The ignition secondary circuit is open or
shorted
• Lack of fuel
P0304 (0605) • No. 4 cylinder misfires.
• Magnetized flywheel (drive plate)

DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE (Overall)

~\ 1) Turn ignition switch "ON", and select "DATA MONITOR" mode with CONSULT.
~ 2) Start engine and warm it up sufficiently.
3) Turn ignition switch "OFF" and wait at least 3 seconds.
4) Start engine again and drive at 1,500 - 3,000 rpm for at least 3 minutes.
Hold the accelerator pedal as steady as possible during driving.
Note: Refer to the freeze frame data for the test driving condition.
------------------------------OR------------------------------
1) Start engine and warm it up sufficiently.
2) Turn ignition switch "OFF" and wait at least 3 seconds.
3) Start engine again and drive at 1,500 - 3,000 rpm for at least 3 minutes.
Hold the accelerator pedal as steady as possible during driving.
4) Select "MODE 7" with GST.
Note: Refer to the freeze frame data for the test driving condition.
-------------------------------OR-------------------------------
(i.O\ 1) Start engine and warm it up sufficiently.
\~
2) Turn ignition switch "OFF" and wait at least 3 seconds.
3) Start engine again and drive at 1,500 - 3,000 rpm for at least 3 minutes.
Hold the accelerator pedal as steady as possible during driving.
4) Perform "Diagnostic Test Mode II (Self-diagnostic results)" with ECM.

302 EC-162
 TROUBLE DIAGNOSIS FOR DTC P0300 - P0304
No. 4 - 1 Cylinder Misfire, Multiple Cylinder
Misfire (Cont'd) ~!]
I ACTIVE TEST I 0
DIAGNOSTIC PROCEDURE
** * POWER BALANCE ** *
= = = MONITOR = = = INSPECTION START
CMPS·RPM (REF) 825rpm
MAS AIR/FL SE
IACV-AAC/V
1.53V
26%
~
CHECK FOR INTAKE AIR LEAK. Discover air leak location
Start engine and run it at idle speed. Listen and repair.

•000 TEST
for an intake air leak.

OK
DDDDL_s_TA_RT---:!
SEF564N 'c=-:-:Hc:EC=-:-:K-:E:cX::-HccA::-Uc:S::T-:G=-'A:-:S:-::cC:-LO::-G::-G=IN-:G:-.-----, Repair or replace it.
~;===============~ Stop engine and visually check exhaust
tube, three way catalyst and muffler for
dent.
OK
B
r---,--~--~------,No
PERFORM POWER BALANCE TEST. Go to ~ on next page.
rF.f\ 1. Pertorm "POWER BALANCE"" in ~~b
\.!!) "ACTIVE TEST" mode.
2. Is there any cylinder which does
not produce a momentary
engine speed drop?
f - - . , - - - - - OR - - - - - - t
~ When disconnecting each injector
~ harness connector one at a time, is
there any cylinder which does not
produce a momentary engine
speed drop?
Yes

CHECK SPARK PLUGS. NG Repair or replace spark

1. Turn ignition switch "OFF". plug(s).
2. Remove the spark plugs and check for
fouling, etc.
OK
[!) SEF1561
~============================~,-C~H-E-C::-K--IG::-N-1-T-IO~N--S~PA
__R_K__---------,NG
CHECK COMPONENT
1. Disconnect ignition wire from spark (Ignition wires).
plug. Refer to "COMPONENT
2. Connect a known good spark plug to INSPECTION", EC-165.
the ignition wire.
3. Place end of spark plug against a suit- OK NG
able ground and crank engine.
4. Check tor spark. ) Replace.

... OK
Check ignition coil, power
~ transistor and their circuits.
Refer to EC-261.
7 SEF451 R

~================~!!]
l!l ,---------~-----------,

~~t
CHECK INJECTOR. Check injector(s) and cir-

@] ID ";I, -4..
At Idle
Clic:k
c,.'·~.+
1. Install all parts removed.
2. Start engine.
3. Does each injector make an operating
sound at idle?
cuit(s). Refer to EC-303.

Yes
@
Suitable tool (Go to next page.)

SEF730L

EC-163 303
 TROUBLE DIAGNOSIS FOR DTC P0300 - P0304
No. 4 - 1 Cylinder Misfire, Multiple Cylinder
Misfire (Cont'd)
®
liil
CHECK EGR FUNCTION.
l NG Repair EGR system.
Perform "Procedure for malfunction 8"
''OVERALL FUNCTION CHECK", EC-179.

OK

NG Check fuel pump and cir-

1. Release fuel pressure to zero. (Refer to cuit.
page EC-25.) '--------------"
2. Install fuel pressure gauge and check
fuel pressure.
At idle:
Approx. 235 kPa
(2.4 kg/cm 2 , 34 psi)

OK

CHECK COMPRESSION PRESSURE. NG Check pistons, piston rings,

• Check compression pressure. valves, valve seats and cyl-
Standard: inder head gaskets.
kPa (kg/cm 2 , psi)/300 rpm
1,236 (12.6, 179)
Minimum:
kPa (kg/cm 2 , psi)/300 rpm
1,040 (10.6, 151)
Difference between each cylinder:
kPa (kg/cm 2 , psi)/300 rpm
98 (1.0, 14)

OK

CHECK IGNITION TIMING. NG Adjust ignition timing.

Pertorm BASIC INSPECTION, EC-72.

OK

CHECK MASS AIR FLOW SENSOR. Check connectors for

~ Check "MASS AIR FLOW" in rusted terminals or loose
~ "DATA MONITOR" mode with connections in the mass air
CONSULT. flow sensor circuit or engine
1.8 - 6.5 g·m/sec: at idling (2WD) grounds.
2.1 - 6.0 g·m/sec: at idling (4WD) Refer to EC-93.
7.7- 15.0 g·m/sec: at 2,500 rpm If NG, repair or replace it.
(2WD)
6.8 - 13.3 g·m/sec: at 2,500 rpm
(4WD)
1------ OR - - - - - - f
Check "mass air flow" in MODE 1
with GST.
1.8 - 6.5 g·m/sec: at idling (2WD)
2.1 - 6.0 g·m/sec: at idling (4WD)
7.7 -15.0 g·m/sec: at 2,500 rpm
(2WD)
6.8 - 13.3 g·m/sec: at 2,500 rpm
(4WD)
OK

@
(Go to next page.)

304 EC-164
TROUBLE DIAGNOSIS FOR DTC P0300 • P0304
No. 4 - 1 Cylinder Misfire, Multiple Cylinder
'~~

.
Misfire (Cont'd)
®
~
CHECK SYMPTOM MATRIX CHART.
Check items on the rough idle symptom in
NG_J Repair or replace.
I
"Symptom Matrix Chart", EC-77.

tOK

Some tests may cause a 1st trip DTC to

be set.
Erase the 1st trip DTC from the ECM
memory after performing the test. Refer to
EC·43.

+
Check ECM pin terminals for damage and
check the connection of ECM harness con-
nectar. Reconnect ECM harness connector
and retest.

+
INSPECTION END

COMPONENT INSPECTION
Ignition wires
1. Inspect wires for cracks, damage, burned terminals and for ~[Fl
improper fit.
2. Measure the resistance of wires to their distributor cap termi-
nal. Move each wire while testing to check for intermittent ©L'
breaks.
Resistance:
13.6 • 18.4 killm (4.15 • 5.61 killft) at 25°C (7rF) l'il©
If the resistance exceeds the above specification, inspect igni-
SEF174P
tion wire to distributor cap connection. Clean connection or
replace the ignition wire with a new one. @ll

EC-165 305
 TROUBLE DIAGNOSIS FOR DTC P0335

Crankshaft Position Sensor (CKPS) (OBD)

Core,
COMPONENT DESCRIPTION
I The crankshaft position sensor (OBD) is located on the transmis-
sion housing facing the gear teeth (cogs) of the flywheel or drive

~~91;~
plate. It detects the fluctuation of the engine revolution.
The sensor consists of a permanent magnet, core and coil.
When the engine is running, the high and low parts of the teeth
L Permanent magnet
cause the gap with the sensor to change.
The changing gap causes the magnetic field near the sensor to
SEF956N
change.
Due to the changing magnetic field, the voltage from the sensor
changes.
The ECM receives the voltage signal and detects the fluctuation of
the engine revolution.
This sensor is not used to control the engine system. It is used only
for the on board diagnosis of misfire.

c= Crankshaft position
sensor (080)
harness connector
Front left brake hose SEF124S

ECM TERMINALS AND REFERENCE VALUE

Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

jjEngine is running.j (Warm-up condition)

50 BIG Sensors' ground 0.001 - 0.02V
L Idle speed

Crankshaft position sensor I

jEngine is running. (AfT: N range, MIT: Neutral) More than 0.2V*
53 R
(OBD) L Idle speed (Air conditioner switch "OFF".) (AC range)
..
. Average voltage for pulse s1gnal (Actual pulse s1gnal can be confirmed by oscilloscope.)

ON BOARD DIAGNOSIS LOGIC

Diagnostic
Check Items
Trouble Code Malfunction is detected when .
(Possible Cause)
No.
P0335 • The proper pulse signal from the crankshaft position • Harness or connectors
0802 sensor (OBD) is not sent to ECM while the engine is (The crankshaft position sensor (OBD) circuit is
running at the specified engine speed. open.)
• Crankshaft position sensor {OBD)

306 EC-166
 TROUBLE DIAGNOSIS FOR DTC P0335
Crankshaft Position Sensor (CKPS) (OBD)
(Cont'd)
*:MONITOR *NO FAIL D DIAGNOSTIC TROUBLE CODE CONFIRMATION
CMPS•RPM(REF) 800rpm PROCEDURE
1) Turn ignition switch "ON" and select "DATA MONITOR"
mode with CONSULT.
2) Start engine and run it for at least 10 seconds at idle 1lliil
speed.
----------OR----------
1) Start engine and run it for at least 10 seconds at idle [L'~
I RECORD ISEF712T speed.
2) Select "MODE 7" with GST.
---------OR---------
60'\ 1) Start engine and run it for at least 10 seconds at idle
~~ speed.
2) Turn ignition switch "OFF", wait at least 7 seconds and ~
then turn "ON".
3) Perform "Diagnostic Test Mode II (Self-diagnostic
results)" with ECM. ~~

EC-167 307
 TROUBLE DIAGNOSIS FOR DTC P0335
Crankshaft Position Sensor (CKPS) (080)
(Cont'd)

EC-CKPS-01

CRANKSHAFT
POSITION - : Detectable line for DTC
ISENSOR (OBD)
~~------"00"'~·~
: Non-detectable line for DTC

llpl ~
R G

I
~= -.::.::::::: __ -~
I

G
•
· - B/G+ To EC-ECTS
BIG •
•
· - B/G+ To EC-TPS

R 8/G

~ ~
,-;ORG~C;:,/~S----.,;G':';N:"'D_-'iA----,ECM (ECCS
CONTROL
MODULE)
(~)
il
B
.L
B
.L

<®> <M!"B>
Refer to last page (Foldout page).
@jQ)

xrffin.._ (M43) ~ ~
~ GY UJ.U GY

~1
0

AEC063A

308 EC-168
 TROUBLE DIAGNOSIS FOR DTC P0335
Crankshaft Position Sensor (CKPS) (OBD)
(Cont'd)
'~ngine gr~) )/; Yn) ~

1~ '~Yi~~
DIAGNOSTIC PROCEDURE

injector~
No.i~ lf-i
'02 II
INSPECTION START

~~ "fto
j_
NG
CHECK SHIELD CIRCUIT. Repair harness or connec-
1. Turn ignition switch "OFF". f----. tors.
M15 ~ "'\ - I

()
~
~ -~\!j
, , ,.-)
;/1 .-,) fTij
I I
2. Loosen and retighten engine ground
screws.
' 3. Remove joint connector-1.
SEF089S
4. Check the following.
• Continuity between joint connector-1
_j 0 terminal G) and ground
::J ~-=- \\>._ • Joint connector-1
(Refer to "HARNESS LAYOUT" in EL
section.)
Continuity should exist.
If OK, check harness for short. Then
reconnect joint connector-1.

C!:: c='- "'•'"""""""""

sensor (OBD)
m
l OK

............__
L Front left brake hose
harness connector
SEF124S
CHECK INPUT SIGNAL CIRCUIT.
1. Disconnect crankshaft position sensor ~ Check the following.
• Harness connectors
(080) harness connector and ECM @,@
m harness connector. • Harness for open or short

~ ID @a
DISOONIIECT
2. Check harness continuity between ECM between ECM and crank-
terminal @ and terminal G). shaft position sensor
Continuity should exist. (OBD)
If OK, check harness for short. If NG, repair harness or con-
cffu II ]OfCONNECTOR II
l
ECM
nectars.
53
OK
~

Till
SEF126S
CHECK GROUND CIRCUIT.
1. Turn ignition switch "OFF".
2. Reconnect ECM harness connector.
3. Check harness continuity between ter-
minal ® and engine ground.
-
NG
Check the following.
• Harness connectors
@.@
• Harness for open or short
between ECM and crank-
Continuity should exist. shaft position sensor
~
~
DISCONNf.CT

~8 @a If OK, check harness for short. (OBD)

dfu l OK
If NG, repair harness or con-
nectars.

NG
CHECK COMPONENT Replace crankshaft posi-
[Crankshaft position sensor (OBD)]. ~ tion sensor (080).

TillS}
Refer to "COMPONENT INSPECTION"
on next page.

~OK
SEF127S Disconnect and reconnect harness connec-
tors in the circuit. Then retest.

+Trouble is not fixed.

Check ECM pin terminals for damage and

check the connection of ECM harness con-
nectar. Reconnect ECM harness connector
and retest.

~
INSPECTION END

EC-169 309
 TROUBLE DIAGNOSIS FOR DTC P0335
Crankshaft Position Sensor (CKPS) (080)
(Cont'd)
COMPONENT INSPECTION
Crankshaft position sensor (OBD)
1. Disconnect crankshaft position sensor (OBD) harness connec-
tor.
2. Loosen the fixing bolt of the sensor.
3. Remove the sensor.
4. Visually check the sensor for chipping.

SEF960N

5. Check resistance as shown in the figure.

Resistance: Approximately 166.5 - 203.5!1 at 20°C
(68°F)

310 EC-170
 TROUBLE DIAGNOSIS FOR DTC P0340

head Camshaft Position Sensor (CMPS)

Light COMPONENT DESCRIPTION
The camshaft position sensor is a basic component of the ECCS. fiuJI,
It monitors engine speed and piston position. These input signals
to the ECM are used to control fuel injection, ignition timing and
other functions. ~u!J
The camshaft position sensor has a rotor plate and a wave-form-
Photo i
Ignition coil ing circuit. The rotor plate has 360 slits for a 1" signal and 4 slits
with power for a 180" signal. The wave-forming circuit consists of Light Emit- 1©
transistor ling Diodes (LED) and photo diodes.
SEF998R
The rotor plate is positioned between the LED and the photo diode.
The LED transmits light to the photo diode. As the rotor plate turns,
the slits cut the light to generate rough-shaped pulses. These
pulses are converted into on-off signals by the wave-forming circuit
and sent to the ECM. l'ii'i
The distributor is not repairable and must be replaced as an
assembly, except distributor cap.

ECM TERMINALS AND REFERENCE VALUE

Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

40 GY Camshaft position sensor

j Engine is running.j Approximately 0.3V*
44 R (Reference signal)

Camshaft position sensor

41 G
(Position signal)
IEngine is running. I Approximately 2.5V*

..
. Average voltage for pulse s1gnal (Actual pulse s1gnal can be confirmed by oscilloscope.)

ON BOARD DIAGNOSIS LOGIC

Diagnostic
Check items
Trouble Code Malfunction is detected when .
(Possible cause)
No.
P0340 • Either 1o or 180° signal is not sent to ECM for the • Harness or connectors
0101 first few seconds during engine cranking. (The camshaft position sensor circuit is open or
shorted.)
• Camshaft position sensor
• Either 1o or 180° signal is not sent to ECM often • Starter motor (Refer to EL section.)
enough while the engine speed is higher than the • Starting system circuit (Refer to EL section.)
specified engine speed. • Dead (Weak) battery

• The relation between 1 o and 180° signal is not in the

normal range during the specified engine speed.

EC-171 311
 TROUBLE DIAGNOSIS FOR DTC P0340
Camshaft Position Sensor (CMPS) (Cont'd)
DIAGNOSTIC TROUBLE CODE CONFIRMATION
11: MONITOR * NOFAIL D PROCEDURE
CMPS•RPM(REF) BOO rpm Note: Before performing the following procedure, confirm that
battery voltage is more than 1O.SV.
1) Turn ignition switch "ON" and select "DATA MONITOR"
mode with CONSULT.
2) Start engine and run it for 2 seconds. (If engine does not
run, crank engine for at least 2 seconds.)
----------OR----------
I RECORD ISEF712T 1) Start engine and run it for 2 seconds. (If engine does not
run, crank engine for at least 2 seconds.)
2) Select "MODE 7" with GST.
---------OR---------
rHO\ 1) Start engine and run it for 2 seconds. (If engine does not
~''o/ run, crank engine for at least 2 seconds.)
2) Turn ignition switch "OFF", wait at least 7 seconds and
then turn "ON".
3) Perform "Diagnostic Test Mode II (Self-diagnostic
results)" with ECM.

312 EC-172
 TROUBLE DIAGNOSIS FOR DTC P0340
Camshaft Position Sensor (CMPS) (Cont'd)

EC-CMPS-01

T 2
FUSIBLE
Ll NK
@48 .(§)
Refer to
"EL-POWER".
- : Detectable line for OTC
: Non-detectable line for DTC

lbwfJJ

,--,
I_. Ill
w w

M 3
ECCS
G/R

w ~ 5
RELAY rrtil"-----,DISTRIBUTOR
<!W (CAMSHAFT
POSITION SENSOR)
5 + (\lill ioiu
UR GIR
lbjdl I'""""!-r.-1-;r,l;,--,!1
_.

I•
G R B JOINT
I
so@: 1-- CONNECTOR-I

-.
@W
_.
_. f: --
-- ~ 1--
• I
I
I
I
I
I
I
I
I
I l!:l=il
I I B

l: --
I I
...__,
--

G/R G/R

SSOFF CRTN
~
VB
~
VB POS REF REF EGM (EGGS
CONTROL
MODULE)
-~~
@W
B B
..,!,. ..L
@:§) @:§)
Refer to last page (Foldout page).
@W
.JL@ ~----------------

~ L : F,l <fM§)
rtiQ:jw
rn (§>
2 G
:
r
I I
L---------------~

101 102 103 104 105 106 1 2 3

5 6 7 8 9
107 108 109 110 111 112
113 114 115 116117118

AEC050A

EC-173 313
 TROUBLE DIAGNOSIS FOR DTC P0340
Camshaft Position Sensor (CMPS) (Cont'd)
DIAGNOSTIC PROCEDURE (DETECTABLE CIRCUIT)
INSPECTION START

,------------L-----------,NG
CHECK SHIELD CIRCUIT. Repair harness or connec-
t. Turn ignition switch "OFF". tors.
2. Loosen and retighten engine ground
screws.
3. Remove joint connector-1.
4. Check the following.
SEF089S • Continuity between joint connector-1
terminal G) and ground
• Joint connector-1
(Refer to "HARNESS LAYOUT" in EL
section.)
Continuity should exist.
If OK, check harness for short. Then
reconnect joint connector-1.

OK
Ei.1
r=C~H=E~C~K~P~O~W~E=R~S~U~P=P~LY~.----------,NG Check the following.
1. Disconnect camshaft position sensor • Harness for open or short
harness connector. between camshaft posi-
2. Turn ignition switch "ON". tion sensor and ECM
3. Check voltage between terminal ® and • Harness for open or short
ground with CONSULT or tester. between camshaft posi-
Voltage: Battery voltage tion sensor and ECCS
relay
OK If NG, repair harness or
connectors.

CHECK INPUT SIGNAL CIRCUIT. NG Repair harness or connec-

1. Turn ignition switch "OFF". tors.
2. Disconnect ECM harness connector.
3. Check harness continuity between termi-
SEF129S nal @ and ECM terminal @ W
0Qna)1 terminal® and ECM terminals
~. ~ (180° signal).
Continuity should exist.
If OK, check harness for short.
OK

CHECK COMPONENT NG Replace camshaft position

(Camshaft position sensor). sensor.
Refer to "COMPONENT INSPECTION""
on next page.
OK

SEF130S Disconnect and reconnect harness connec~

L _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ j tors in the circuit. Then retest.

Trouble is not fixed.

Check ECM pin terminals for damage and

check the connection of ECM harness con-
nector. Reconnect ECM harness connector
and retest.

INSPECTION END

314 EC-174
 TROUBLE DIAGNOSIS FOR DTC P0340
Camshaft Position Sensor (CMPS) (Cont'd)
DIAGNOSTIC PROCEDURE (NON-DETECTABLE @I
fi.1
CIRCUIT)
~ lo@a INSPECTION START
( 1l2l:ffllsl6)
fi.1
CHECK GROUND CIRCUIT.
t ING Check the following.
0

lFlfl
1. Disconnect camshaft position sensor • Joint connector-1
harness connector. • Harness for open or short
2. Check harness continuity between termi- between camshaft posi-
SEF131S
nal ® and engine ground. tion sensor and ground
Continuity should exist. If NG, repair harness or
If OK, check harness for short. connectors.

+OK

CHECK COMPONENT NG Replace camshaft position

(Camshaft position sensor). sensor.
Refer to ''COMPONENT INSPECTION""
below.

~OK
Disconnect and reconnect harness connec- IT:oif
tors in the circuit. Then retest.

+Trouble is not fixed.

Check ECM pin terminals for damage and
check the connection of ECM harness con-
nectar. Reconnect ECM harness connector
j[p
and retest.

...
INSPECTION END

COMPONENT INSPECTION
~15ID Camshaft position sensor
~ 1.
2.
Start engine.
Check voltage between terminals @, ® and ground with DC
range.
[YJ
'-l---j(f)=--::;Elf---....
Condition Terminals Voltage
@and ground Approximately 0.3V*
Engine running at idle
@and ground Approximately 2.5V*
SEF750R
Average voltage for pulse s1gnal (Actual pulse s1gnal can be confirmed by @1]'
oscilloscope.)
Signal plate
If NG, replace distributor assembly with camshaft position sen-
sor.
3. Visually check signal plate for damage or dust.

AEC148A

EC-175 315
 TROUBLE DIAGNOSIS FOR DTC P0400

EGA Function
SYSTEM DESCRIPTION
I Engine speed
I Camshaft position sensor

I Amount of intake air

I Mass air flow sensor
I
ECM
EGRC-
I Engine coolant temperature (ECCS
I Engine coolant temperature sensor control
solenoid
valve
module)
l Start signal
I Ignition switch

1 Throttle position
I Throttle position sensor

This system cuts and controls vacuum applied to the • Low engine coolant temperature
EGR valve to suit engine operating conditions. This • Engine starting
cut-and-control operation is accomplished through • Engine stopped
the ECM and the EGRC-solenoid valve. When the • Engine idling
ECM detects any of the following conditions, current • Excessively high engine coolant temperature
flows through the solenoid valve. This causes the • Mass air flow sensor malfunction
port vacuum to be discharged into the atmosphere
and the EGR valve remains closed.

EGR and vacuum EGRC-solenoid valve

valve
Throttle
body
SEF6410

ECM TERMINALS AND REFERENCE VALUE

Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.
[[Engine is running.[ (Warm-up condition)
50 B/G Sensors' ground 0.001 - 0.02V
L Idle speed
]Engine is running.] (Warm-up condition)
Less than 4.5V
L Idle speed
62 G/OR EGR temperature sensor
j Engine is running.] {Warm-up condition)
0- 3.0V
L EGR system is operating.

1 Engine is running.] {Warm-up condition) BATTERY VOLTAGE

L Engine speed is 2,000 rpm. (11 - 14V)
103 W/L EGRC-solenoid valve
I Engine is running. I (Warm-up condition)
0- 1V
L Idle speed

316 EC-176
 TROUBLE DIAGNOSIS FOR DTC P0400
EGR Function (Cont'd)
@]
COMPONENT DESCRIPTION
Exhaust gas recirculation (EGR) valve
The EGR valve controls the amount of exhaust gas routed to the ~y1,Q,
intake manifold. Vacuum is applied to the EGR valve in response
to throttle valve opening. The vacuum controls the movement of a
taper valve connected to the vacuum diaphragm in the EGR valve. ~G!TI

To EGA valve

,..
EGRC-solenoid valve
The EGRC-solenoid valve responds to signals from the ECM.
When the ECM sends an ON (ground) signal, the coil in the sole-
noid valve is energized. A plunger will then move to cut the vacuum
signal (from the throttle body to the EGR valve).
•
FIE

Vacuum When the ECM sends an OFF signal, the vacuum signal passes C:L
signal
through the solenoid valve. The signal then reaches the EGR valve.

SEF240PD

ON BOARD DIAGNOSIS LOGIC

EGR temperature If the absence of EGR flow is detected by EGR temperature sen-
sensor sor under the condition that calls for EGR, a low-flow malfunction 1J'!F
is diagnosed.
EGA If EGR temperature sensor detects EGR flow under the condition
temperature that does not call for EGR, a high-flow malfunction is diagnosed. ~'!CD

I ECM I
SEF073P

Diagnostic Trouble Check Items

Malfunction is detected when ...
Code No. (Possible Cause)
P0400 A) The exhaust gas recirculation (EGA) flow is exces- • EGA valve stuck closed
0302 sively low during the specified driving condition. • EGRC-BPT valve leaking
• Passage blocked
• EGRC-solenoid valve
• Tube leaking for EGR valve
• EGA temperature sensor

B) The exhaust gas recirculation (EGR) flow is exces- • EGRC-solenoid valve

sively high during the specified driving condition. • EGR valve leaking or stuck open
• EGR temperature sensor

OVERALL FUNCTION CHECK

Use this procedure to check the overall EGR function. During this check, a 1st trip DTC might not be con- ~5\
firmed.

Before starting with the following procedure, check the engine coolant temperature of the freeze frame data !§;l
with CONSULT or Generic Scan Tool.
If the engine coolant temperature is higher than or equal to 55°C (131 °F), perform only "Procedure for mal-
function A". I[Q);:!
If the engine coolant temperature is lower than 55°C (131 °F}. perform both "Procedure for malfunction A" and
"Procedure for malfunction B". In this case, check DTCs in the ECM and perform inspections one by one based
on "INSPECTION PRIORITY", refer to EC-75.
EC-177 317
 TROUBLE DIAGNOSIS FOR DTC P0400
EGR Function (Cont'd)
Procedure for malfunction A
1) Start engine and warm it up sufficiently.
2) Check for the EGR valve lifting when revving from 2,000 rpm
up to 4,000 rpm under no load.
EGR valve should lift up and down without sticking.
If EGR valve does not lift up and down, try again with either of the
following methods:
~ • Select "EGRC SOLENOID VALVE" in "ACTIVE TEST"
~ mode with CONSULT and turn the solenoid valve
"OFF".
®· Disconnect EGRC-solenoid valve harness connector.
(The 1st trip DTC for EGRC-solenoid valve will be
displayed, however, ignore it.)
3) Check voltage between EGR temperature sensor harness con-
nector terminal G) and ground at idle speed.
Less than 4,5V should exist.
4) Turn ignition switch "OFF".
Check harness continuity between EGR temperature sensor
harness connector terminal ® and ECM terminal @).
Continuity should exist.
5) Perform "COMPONENT INSPECTION", "EGR temperature
sensor", EC-183.

~i)ID~
~

SEF618T

~i) ~i)~
~ II ECM McoNNECTDRII
50

SEF134S

Check the EGR valve

lifting when revving
engine from 2,000 rpm
up to 4,000 rpm.

SEF642Q

318 EC-178
 TROUBLE DIAGNOSIS FOR DTC P0400
EGR Function (Cont'd)
Procedure for malfunction B ell I
• ACTIVE TEST •
(F.!\ 1)Start engine.
EGRC souv ON ~ 2) Turn EGRC-solenoid valve "ON" in "ACTIVE TEST"
mode with CONSULT.
l===o======= MONITOR ===o=======l 3) Check for the EGR valve lifting when revving from 2,000
CMPS•RPM (REF) 2580rpm rpm up to 4,000 rpm under no load.
EGR valve should be closed and should not lift up. ~ucu
EGR TEMP SEN 4.08V

---------OR---------
~.a= 1) Confirm the engine coolant temperature is lower than
~ ~,:g
55°C (131 °F) in "Mode 1" with generic scan tool.
Perform the following steps before its temperature
becomes higher than 55°C (131°F).
2) Start engine.

~i)~8 3) Check for the EGR valve lifting when revving from 2,000
rpm up to 4,000 rpm under no load.
EGR valve should be closed and should not lift up. l"'~
ECM ]OfCONNECTOR II ---------OR---------
51 43
@ 1) Confirm the voltage between ECM terminals @) and @ ©l

~
is higher than 2.08V.
Perform the following steps before the voltage becomes
lower than 2.08V.
2) Start engine.
3) Check for the EGR valve lifting when revving from 2,000
SEF620T
rpm up to 4,000 rpm under no load.
EGR valve should be closed and should not lift up. 3c'f

Check the EGR valve

lilting when revving
engine from 2,000 rpm
up to 4,000 rpm.

SEF642Q

EC-179 319
 TROUBLE DIAGNOSIS FOR DTC P0400
EGR Function (Cont'd)

EC-EGRC1-01

- : Detectable line for DTC

: Non-detectable line for DTC

BfW

~
B!W
1
EGRC~
SOLENOID
VALVE
@
lbjdl
W/L

W/L G/OR B/G

~ I"FsTI ~ ECM (ECCS

EGA EGRTS GND-A
CONTROL
MODULE)
@W

...r::;:t._@ ~@
l.l.llJ GY W2J B

AEC309A

320 EC-180
 TROUBLE DIAGNOSIS FOR DTC P0400
EGR Function (Cont'd)
DIAGNOSTIC PROCEDURE @il

INSPECTION START

CHECK VACUUM SOURCE TO EGR CHECK COMPONENTS

VALVE. (EGR valve. and EGRC-
1. Start engine and warm it up sufficiently. BPT valve).
2. Disconnect vacuum hose to EGR valve. Refer to ""COMPONENT
connected 3. Check for vacuum existence. INSPECTION"" on next
to EGR valve SEF135S Vacuum should not exist at idle. page.

If.~~~~~~~~~~~~~;;:;==~ 4. Check for vacuum existence when rev-

ving from 2,000 rpm up to 4,000 rpm NG
• ACTIVE TEST • with the following methods.
M • Select ""EGRC SOLENOID
EGRC SOUV OFF ~ VALVE" in '"ACTIVE TEST"
mode with CONSULT and turn
the solenoid valve "OFF".
I==="======
MONITOR =="=======I
f . - - - - - - OR - - - - - . . . . . j
CMPS•RPM(REF) Orpm
~ • Disconnect EGRC-solenoid Replace malfunctioning
~ valve harness connector. (The component(s).
1st trip DTC for EGRC-sofe-
noid valve will be displayed,
however, ignore it.)
Vacuum should exist when revving
engine.

NG

CHECK VACUUM HOSE.

Check vacuum hose for clogging, cracks
or improper connection.
Clogging
NG

NG Replace EGRC-solenoid
Improper connection CHECK COMPONENT
(EGRC-solenoid valve). valve.
SEF109L
rF.f\
1. Turn ignition switch "ON".
~ 2. Pertorm ""EGRC SOUV CIR-
CUIT" in "'FUNCTION TEST"
• EGRC SOL/V CIRCUIT I
mode with CONSULT.
DOES THE SOLENOID f . - - - - - - OR - - - - - . . . . . j
1. Turn ignition switch "ON".
VALVE MAKE 2. Turn EGRC-solenoid valve "ON"
and ""OFF" in "'ACTIVE TEST"
AN OPERATING SOUND
mode with CONSULT and check
EVERY 3 SECONDS? operating sound.
1----- OR --------i
NEXT II NO II YES 1. Turn ignition switch "ON".
2. Check operating sound of the
MEF957D solenoid valve when disconnect-
ing and connecting EGRC-sole-
noid valve harness connector.
I ACTIVE TEST • D (The DTC or 1st trip DTC for the
EGRC-solenoid valve will be
EGRC SOL/V ON displayed, however, ignore it.)

OK
= = =MONITOR = = = ®
CMPS·RPM(REF) Orpm
(Go to next page.)

ON OFF I
MEF298F

EC-181 321
 TROUBLE DIAGNOSIS FOR DTC P0400
EGR Function (Cont'd)
@
~
CHECK COMPONENT
(EGRC-solenoid valve). ~ Replace EGRC-solenoid
valve.
Refer to "COMPONENT INSPECTION"
on next page.

~OK
CHECK COMPONENT
(EGRC-BPT valve).
H_ Replace EGRC-BPT valve.

Refer to "COMPONENT INSPECTION"

below.

~OK
Disconnect and reconnect harness con-
nectars in the circuit. Then retest.

~ Trouble is not fixed.

Check ECM pin terminals for damage and

check the connection of ECM harness
connector. Reconnect ECM harness con-
nectar and retest.

~
Check resistance of EGR temperature
sensor.
Refer to "COMPONENT INSPECTION"
on next page.

~
INSPECTION END

COMPONENT INSPECTION
EGR valve
EGA valve
Apply vacuum to EGR valve vacuum port with a hand vacuum
pump.

EGA valve spring should lift.

If NG, replace EGR valve.

MEF137D

EGRC-BPT valve
1. Plug one of two ports of EGRC·BPT valve.
2. Vacuum from the other port and check for leakage while apply·

-
ing a pressure above 0.981 kPa (1 00 mmH 2 0, 3.94 inH 2 0)
from under EGRC·BPT valve.
3. If a leakage is noted, replace the valve.

+ Apply pressure

SEF083P

322 EC-182
 TROUBLE DIAGNOSIS FOR DTC P0400
EGA Function (Cont'd)
EGRC-solenoid valve
Check solenoid valve , following the table as shown below·
Air passage Air passage
Conditions continuity continuity
between ® and @ between @ and ©
12V direct current supply
between terminals G) Yes No
and®
No supply No Yes

~============M=E=c=4=ss~s If NG, replace the solenotd valve.

EGA temperature sensor
Check resistance change and resistance value.

(Reference data)
EGA temperature Voltage Resistance
oc CF) (V) (Mil)
0 (32) 4.81 7.9- 9.7
50 (122) 2.82 0.57- 0.70 if[
100 (212) 0.8 0.08-0.10
SEF643Q

If NG, replace EGR temperature sensor.

10,000

1,000
Acceptable range

10

0 50 100 150 200

(32) (122) (212) (302) (392)
Temperature °C (°F)

SEF526Q

EC-183 323
 TROUBLE DIAGNOSIS FOR DTC P0402

EGRC-BPT Valve Function

ECM

Ignition switch
(power supply)
Throttle
body

EGRC-solenoid valve
To EGA
valve
Vacuum source r.=:============::J
Air
filter
ECM
Air EGA valve
bleed EGR
temperature
sensor
Exhaust pressure
valve
EGRC-BPT l~======~~[i===:::JI:':==
~
-----Intake
-----manifold

. ~======-----
'- ----- Exhaust
manifold
SEF453PB

SYSTEM DESCRIPTION
The EGRC-BPT valve monitors exhaust pressure to activate the diaphragm, controlling throttle body vacuum
applied to the EGR valve. In other words, recirculated exhaust gas is controlled in response to positioning of
the EGR valve or to engine operation.

ON BOARD DIAGNOSIS LOGIC

If too much EGR flow exists due to an EGRC-BPT valve malfunction, off idle engine roughness will increase.
If the roughness is large, then the vacuum to the EGR valve is interrupted through the EGRC-solenoid valve.
If the engine roughness is reduced at that time, the EGRC-BPT valve malfunction is indicated.
Diagnostic Trouble Check Items
Malfunction is detected when ...
Code No. (Possible Cause)

P0402 • The EGRC-BPT valve does not operate properly. • EGRC-BPT valve
0306 • Misconnected rubber tube
• Blocked rubber tube
• Intake manifold EGA passage

324 EC-184
 TROUBLE DIAGNOSIS FOR DTC P0402
EGRC-BPT Valve Function (Cont'd)
OVERALL FUNCTION CHECK
Use this procedure to check the overall function of the EGRC-BPT valve. During this check, a 1st trip DTC
might not be confirmed.
1. Disconnect the rubber tube to the EGRC-solenoid valve at the intake manifold.
2. Disconnect the rubber tube to the EGRC-solenoid valve at the EGRC-BPT valve.
Connect the intake manifold and the EGRC-BPT valve. (The intake manifold vacuum will be directly applied
~[-~~
to the EGRC-BPT valve.)
3. Start engine.
4. Check for the EGR valve lifting with engine at less than 1,500 rpm under no load.
EGR valve should remain closed.
5. Check the EGR valve lifting when revving from 2,000 rpm up to 4,000 rpm under no load.
EGR valve should lift up, and go down without sticking when the engine is returned to idle.
6. Check rubber tube between EGRC-solenoid valve and throttle body for misconnection, cracks or block-
ages.

Check the EGA valve lifting iff

!i~-1!

Uf

f:' ~Throttle body

~V"//.\~1 ~~~~
Removed EGR hose AEC124A ~lffil

COMPONENT INSPECTION
EGRC-BPT valve

\ ~]'rnPiug====~- Q) ?)
1) Plug one of two ports of EGRC-BPT valve.
2) Vacuum from the other port and check leakage without apply-
ing any pressure from under EGR-BPT valve.
Leakage should exist.

~ No pressure
SEF172P

EC-185 325
 TROUBLE DIAGNOSIS FOR DTC P0420

Three Way Catalyst Function

ON BOARD DIAGNOSIS LOGIC The ECM monitors the switching frequency ratio of
front heated oxygen sensor and rear heated oxygen
EGM (EGGS control module)
I I sensor.
A three way catalyst with high oxygen storage
capacity will indicate a low switching frequency of
rear heated oxygen sensor. As oxygen storage
Front Rear capacity decreases, the rear heated oxygen sensor
heated heated switching frequency will increase.
oxygen oxygen When the frequency ratio of front heated oxygen
sensor sensor sensor and rear heated oxygen sensor approaches

Exhaus~
Three
way
catalyst
u a specified limit value, the three way catalyst mal-
function is diagnosed.

gas

Diagnostic Trouble Check Items

Malfunction is detected when .
Code No. (Possible Cause)
P0420 • Three way catalyst does not operate properly. • Three way catalyst
0702 • Three way catalyst does not have enough oxygen storage • Exhaust tube
capacity. • Intake air leak
• Injectors
• Injector leak

OVERALL FUNCTION CHECK

Use this procedure to check the overall function of the three way catalyst. During this check, a 1st trip DTC
might not be confirmed.

1) Start engine and warm it up sufficiently.

'tl MONITOR *NO FAIL D 2) Set "MANU TRIG" and "HI SPEED", then select "FR 02
CMPS•RPM(REF) 2137rpm SENSOR", "RR 02 SENSOR", "FR 02 MNTR", "RR
MAS AIR/FL SE 1.96V 02 MNTR" in "DATA MONITOR" mode with CONSULT.
COOLAN TEMP/S 84"C 3) Touch "RECORD" on CONSULT screen with engine
FR 02SENSOR 0.37V speed held at 2,000 rpm constant under no load.
FR02 MNTR LEAN 4) Make sure that the switching frequency between
RR02 SENSOR 1.30V "RICH" and "LEAN" of "RR 02 MNTR" is much less
RR 02 MNTR ~ A ICH than that of "FR 02 MNTR".
Switching frequency ratio =
I RECORD I
SEF097P
Rear heated oxygen sensor switching frequency
Front heated oxygen sensor switching frequency

This ratio should be less than 0.6 (2WD models) and

0.8 (4WD models).
If the ratio is greater than above, the three way catalyst
is not operating properly.
----------OR----------

326 EC-186
 TROUBLE DIAGNOSIS FOR DTC P0420
Three Way Catalyst Function (Cont'd)
~ 1) Start engine and warm it up sufficiently. @I
~ """"' ~ ~ ~ 2) Set voltmeter probes between ECM terminals @ (front
t.m£)~ w~ heated oxygen sensor signal) and @ (engine ground),
and ECM terminals @ (rear heated oxygen sensor sig-
=E;:::C:;:M==i]OfCONNECTOR II
lr;=l
nal) and @ (engine ground).
3) Keep engine speed at 2,000 rpm constant under no

kJ~
load. il'['il
4) Make sure that the voltage switching frequency (high &
low) between ECM terminals @ and @ is much less
than that of ECM terminals @ and @.
Switching frequency ratio =
SEF098P

Rear heated oxygen sensor voltage switching fre-

quency
Front heated oxygen sensor voltage switching fre- ifll'
quency

This ratio should be less than 0.6 (2WD models) and

0.8 (4WD models). ©IL
If the ratio is greater than above, it means three way
catalyst does not operate properly.

Note: If the voltage at terminal @ does not switch periodi-

cally more than 5 times within 10 seconds at step 3,
perform TROUBLE DIAGNOSIS FOR DTC P0130 ffio1i'
(Front heated oxygen sensor) first. (See page
EC-129.)
1iF

liF

EC-187 327
 TROUBLE DIAGNOSIS FOR DTC P0420
Three Way Catalyst Function (Cont'd)
B DIAGNOSTIC PROCEDURE

(() I INSPECTION START

I
1
,, ~
)
"--~';)
'-.-.._~?
[J CHECK EXHAUST SYSTEM.
Visually check exhaust tubes and muffler
H Repair or replace it.
I
for dent.

({) B
l OK

SEF099P CHECK EXHAUST AIR LEAK. NG_J Repair or replace.

Start engine and run it at idle. Listen for an

m ~ 00""" ~0
exhaust air leak before three way catalyst.

£) ~' ON ~OK

It ECM ]OfCONNECTOR II CHECK INTAKE AIR LEAK.

Start engine and run it at idle. Listen for an
NG_J Repair or replace.
102, 104, 107, 109
intake air leak after mass air flow sensor.

l
lwl SEF621T
m
CHECK INJECTORS.
1. Refer to WIRING DIAGRAM for
Injectors, EC-303.
OK

2. Stop engine and then turn ignition switch

"ON".
~
NG Pertorm TROUBLE DIAG-
NOSIS FOR NON-DE-
TECTABLE ITEMS, "lnjec-
tors". (See page EC-303.)
Repair harness or connec-
3. Check voltage between ECM terminals tors.
@, @ , @ . o r @ and ground
with CONSULT or tester.
Battery voltage should exist.
4. Turn ignition switch "OFF".

~OK
Remove injector assembly.
Refer to EC-26.
Keep fuel hose and all injectors connected
to injector gallel)l.

~
1. Turn ignition switch "OFF".
2. Disconnect camshaft position sensor
harness connector.
3. Turn ignition switch "ON".
Make sure fuel does not drip from injec-
-
Drips Replace the injectors from
which fuel is dripping.

tor.

+Does not drip. Trouble is not fixed

Check ECM pin terminals for damage and M Replace three way catalyst.
check the connection of ECM harness con-
nector. Reconnect ECM harness connector
and retest.

+ Trouble is fixed.

INSPECTION END

328 EC-188
 TROUBLE DIAGNOSIS FOR DTC P0440

Evaporative Emission (EVAP) Control System

(Small Leak)
Note: If both DTC P0440 and P0446 are displayed, perform TROUBLE DIAGNOSIS FOR P0446 first. (See
EC-207.)
ON BOARD DIAGNOSIS LOGIC
This diagnosis uses two methods to detect leaks in the EVAP purge line.
The first method, the pressure test, makes use of vapor pressure in the fuel tank. The second method, the
vacuum test, makes use of engine intake manifold vacuum.

Pressure test
The EVAP canister vent control valve is closed to shut the EVAP purge line. The vacuum cut valve bypass
valve will then be opened to clear the line between the fuel tank and the EVAP canister purge control valve.
The EVAP control system pressure sensor can now monitor the pressure inside the fuel tank.
If pressure increases, the ECM will check for leaks in the line between the vacuum cut valve and EVAP can- I'~
ister purge control valve. If no pressure does not increase, the ECM will perform the "Vacuum test".

Vacuum test
If pressure does not increase in the "Pressure test", the ECM will check for leaks in the line between the fuel
tank and EVAP canister purge control valve, under the following "Vacuum test" conditions.
The vacuum cut valve bypass valve is opened to clear the line between the fuel tank and the EVAP canister iluJ
purge control valve. The EVAP canister vent control valve will then be closed to shut the EVAP purge line off.
The EVAP canister purge volume control valve and EVAP canister purge control valve are opened to depres-
surize the EVAP purge line using intake manifold vacuum. After this occurs, the EVAP canister purge control b\11
valve and EVAP canister purge volume control valve will be closed.
EVAP canister
EVAP control system pressure sensor purge control
solenoid valve
Vacuum cut valve bypass valve
EVAP shut valve

EVAP canister
purge control valve
Fuel tank

EVAP canister_:,.
vent control purge volume
valve control valve SEF782Q

EC-189 329
 TROUBLE DIAGNOSIS FOR DTC P0440
Evaporative Emission (EVAP) Control System
(Small Leak) (Cont'd)

Diagnostic
Check Items
Trouble Code Malfunction is detected when ....
(Possible Cause)
No.
P0440 • EVAP control system has a leak. • Incorrect fuel tank vacuum relief valve
0705 • EVAP control system does not operate properly. • Incorrect fuel filler cap used
• Fuel filler cap remains open or fails to close
• Foreign matter caught in fuel filler cap
• Leak is in line between intake manifold and EVAP
canister purge control valve.
• Foreign matter caught in EVAP canister vent control
valve.
• EVAP canister or fuel tank leaks
• EVAP purge line (pipe and rubber tube) leaks
• EVAP purge line rubber tube bent
• Blocked or bent rubber tube to EVAP control system
pressure sensor
• Loose or disconnected rubber tube
• EVAP canister purge control valve
• EVAP canister purge volume control valve
• EVAP canister purge control solenoid valve
• Absolute pressure sensor
• Tank fuel temperature sensor
• MAP/BARO switch solenoid valve
• Blocked or bent rubber tube to MAP/BARO switch
solenoid valve
• 0-ring of EVAP canister vent control valve is missing
or damaged

CAUTION:
• Use only a genuine fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL
may come on.
• If the fuel filler cap is not tightened properly, the MIL may come on.
• Use only a genuine rubber tube as a replacement.

DIAGNOSTIC TROUBLE CODE CONFIRMATION

I~ SELECT DIAG MODE Gl PROCEDURE
IWORK SUPPORT CAUTION:
ISELF·DIAG RESULTS • Always select "SINGLE TEST" with CONSULT when
performing the "FUNCTION TEST".
DATA MONITOR
• Perform "FUNCTION TEST" when the fuel level is
ACTIVE TEST Wj less than 3/4 full. If not, inspect fuel filler cap and fuel
FUNCTION TEST====~ tank separately. Refer to EC-193.
1) Select "EVAP (SMALL LEAK)" in "FUNCTION TEST"
FREEZE FRAME DATA mode with CONSULT.
SEF373Q 2) Make sure that "OK" is displayed with "EVAP (SMALL
LEAK)". (If "NG" is displayed, refer to "DIAGNOSTIC
PROCEDURE".)
3) Check fuel filler cap and fuel tank when the fuel tank is
more than 3/4 full.
Refer to "DIAGNOSTIC PROCEDURE", EC-193.

330 EC-190
 TROUBLE DIAGNOSIS FOR DTC P0440
Evaporative Emission (EVAP) Control System
(Small Leak) (Cont'd) ~~
~i) 1) Start engine and warm it up sufficiently.
fi="':E':'CMc:=='i]Off:c':'ON=N':'EC:=T':'OR'llll 2) Check voltage between ECM terminal @ and ground
63
(Voltage 1).
Voltage: 1.9 - 4.2V
3) Check voltage between ECM terminal ® and ground.
Voltage: O.B - 1.5V
Perform the following procedure before the voltage
drops below O.BV. If the voltage drops below O.BV, Lf~
cool down the engine and perform the entire proce-
SEF532T dure over again.
4) Check voltage between ECM terminal @ and ground.
Voltage: 1.9- 4.1V
~i) 5) Turn ignition switch "OFF" and wait at least 7 seconds.
6) Turn ignition switch "ON" and wait at least 12 seconds. f'[e'
rr=11 ===Ec=M=='i]Ofi=c=oN=NE""cr""oR'llll 7) Restart engine and let it idle for at least 70 seconds.
51
8) Maintain the following conditions for at least 40 seconds
consecutively.
Gear position: Suitable gear position
Vehicle speed: 50- 70 km/h (31 - 43 MPH)
Engine speed: 1,500 - 2,500 rpm
9) Decelerate the vehicle to 0 km/h and let engine idle.
SEF819T
10) Maintain the following conditions for at least 5 seconds
consecutively.
Gear position: "1" or "2" position
~i) Vehicle speed: 40 - 60 km/h (25 - 37 MPH)
Engine speed: 1,500 - 2,500 rpm
===Ec""Mc==='iJOfi=co""'N=NE""cr=='oR=jJII
rr=11
11) Perform steps 9, 10 more than 10 times.
28 12) Decelerate the vehicle to 0 km/h and let engine idle.
13) Maintain the following condition for at least continuous
10 seconds. N!i
Gear position: Suitable gear position
Vehicle speed: 40- BO km/h (25- 50 MPH)
Engine speed: 1,000 - 3,000 rpm
14) Decelerate the vehicle to 0 km/h and let engine idle,
SEF851T
then wait at least 11 minutes.
15) Check voltage between ECM terminal @ and ground
~i) (Voltage 2).
Voltage: 1.9 - 4.2V
rr==E==c""M=='iJOfi=co""N=NE""cr""oR'llll 16) Check voltage decrease between voltage 1 and 2.
23 Voltage 1 - Voltage 2 ~ 0.1 V
17) Check voltage between ECM terminal @ and ground
(Voltage 3).
Voltage: 0.3 - 0. 7V
18) Maintain the following conditions for 9 minutes measur-
ing voltage between ECM terminal @ and ground (Volt-
age 4) after 12 minutes have passed from restarting
SEF820T engine in step 7.
Gear position: Suitable gear position
Vehicle speed: 20- BO km/h (12- 50 MPH)
Engine speed: BOO - 2,200 rpm (AfT models)
BOO - 3,000 rpm (MIT models)
Voltage 4 - Voltage 3 ~ O.SV (2WD MIT)
0.7V (2WD AfT)
O.BV (4WD) C,:l_
19) Stop the vehicle, turn ignition switch "OFF", wait at least
7 seconds, and then turn "ON".
20) Perform "Diagnostic Test Mode II (Self-diagnostic
results)" with ECM.

EC-191 331
 TROUBLE DIAGNOSIS FOR DTC P0440
Evaporative Emission (EVAP) Control System
(Small Leak) (Cont'd)
NOTE:
• Hold the accelerator pedal as steady as possible during
driving in steps 8, 10, 13 and 18.
• If the driving conditions do not conform to those specified
in steps 8, 10, 13 and 18, the procedure must be performed
again under the specified conditions.
• It is better that the fuel level is low.
• While warming up the engine or idling it for more than 30
seconds, keep the engine hood open. Close the engine
hood before driving the vehicle.

332 EC-192
 TROUBLE DIAGNOSIS FOR DTC P0440
Evaporative Emission (EVAP) Control System
(Small Leak) (Cont'd)
DIAGNOSTIC PROCEDURE
INSPECTION START

CHECK FUEL FILLER CAP. NG 1. Open fuel filler cap, then

1. Check that fuel filler cap does not clean cap and fuel filler
remain open, closes properly and does neck threads using air
SEF4340 not contain foreign matter. blower.
~;::::==============~ 2. Check for genuine fuel filler cap design. 2. Replace with genuine
.A f---..__ 3. Check fuel tank vacuum relief valve. fuel filler cap.
Reier to "EVAPORATIVE EMISSION
SYSTEM", EC-20.

OK

CHECK COMPONENT NG Replace EVAP canister

~
Air cleaner (EVAP canister purge volume control purge volume control

! hous1ng
;;//
I(
~
SEF141S
valve).
Reier to "COMPONENT INSPECTION",
valve.

EC-196.

OK

CHECK COMPONENT NG Replace EVAP canister

(EVAP canister purge control valve). purge control valve.
Refer to "COMPONENT INSPECTION",
EC-197.

OK

CHECK COMPONENT NG Replace EVAP canister

(EVAP canister vent control valve). vent control valve.
Refer to "COMPONENT INSPECTION",
EC-197.

OK

®
(Go to next page.)

EC-193 333
 TROUBLE DIAGNOSIS FOR DTC P0440
Evaporative Emission (EVAP) Control System
(Small Leak) (Cont'd)
®

l NG Check the following.

• EVAP canister purge con-
trol solenoid valve
Refer to "COMPONENTS
INSPECTION", EC-197.
AEC136-A • Vacuum hoses for clog-
ging or disconnection
Refer to "Vacuum Hose
• ACTIVE TEST •
Drawing", EC-22.
PURG CONT SN Q N
(PURG CONT VAG) VC ON
---------- MONITOR =:=_,,==,,===1
PURG CONT SN ON
CMPS•RPM (REF) 2000rpm
CLSD THUP SW OFF

OK

~======~~~~r~------~----~ CHECK COMPONENT NG Replace absolute pressure

(Absolute pressure sensor). sensor.
Refer to "COMPONENT INSPECTION",
EC-197.

OK

CHECK COMPONENT NG Replace MAP/BARO

(MAP/BARO switch solenoid valve). switch solenoid valve.
Refer to "COMPONENT INSPECTION",
EC-198.

OK

®
(Go to next page.)

~
Air cleaner/

! hOUSing\ (

SEF146S

334 EC-194
 TROUBLE DIAGNOSIS FOR DTC P0440
Evaporative Emission (EVAP) Control System
(Small Leak) (Cont'd) @il
@

CHECK COMPONENT
1 NG Replace tank fuel tempera-
(Tank fuel temperature sensor). ture sensor.
Refer to "COMPONENT INSPECTION",
Q Front EC-198.

OK

CHECK EVAP PURGE LINE.

Check EVAP purge line (pipe, rubber tube,
fuel tank and EVAP canister) for cracks or
NG Repair or reconnect the
hose. Ill
improper connection.
Refer to "EVAPORATIVE EMISSION
SYSTEM," EC-20.

OK

Clean EVAP purge line (pipe and rubber JJii'

tube) using air blower.

Disconnect and reconnect harness connec-

tors in the circuit. Then retest.

Trouble is not fixed.

Check ECM pin terminals for damage and

check the connection of ECM harness con-
nector. Reconnect ECM harness connector
and retest.

INSPECTION END

EC-195 335
 TROUBLE DIAGNOSIS FOR DTC P0440
Evaporative Emission (EVAP} Control System
(Small Leak} (Cont'd}
COMPONENT INSPECTION
~m
EVAP canister purge volume control valve
r-& r1fi1. Disconnect EVAP canister purge volume control valve
6 5 4
~ harness connector.
2. Check resistance between the following terminals.
terminal ® and terminals G), ®
terminal ® and terminals @1, ®
[ill Resistance:
_!: f-- Approximately 300 [At 25"C (77"F)]
3. Reconnect EVAP canister purge volume control valve
harness connector.
4. Remove EVAP canister purge volume control valve
from intake manifold collector and disconnect hoses
from the valve.
(Plug the purge hoses. The EVAP canister purge vol-
ume control valve harness connector should remain
connected.)
5. Turn ignition switch "ON".
6. Perform "PURG VOL CONTN" in "ACTIVE TEST"
mode with CONSULT. Check that EVAP canister purge
volume control valve shaft moves smoothly forward and
SEF3530
backward according to the valve opening.
If NG, replace the EVAP canister purge volume control
• ACTIVE TEST • D valve.
----------OR----------
PURG VOL CONTIV 20Step 1. Disconnect EVAP canister purge volume control valve
========== MONITOR ========== harness connector.
CMPS•RPM(REF) Orpm 2. Check resistance between the following terminals.
FR 02 MNTR RICH
NF ALPHA 100%
terminal ® and terminals G), ®
THRTL POS SEN 0.48V terminal ® and terminals @1, ®
Resistance:
Approximately 30fl [At 25"C (77"F)]
~I UP II OWN 1/0dl SEF507R
3. Reconnect EVAP canister purge volume control valve
harness connector.
4. Remove EVAP canister purge volume control valve
from intake manifold collector and disconnect hoses
from the valve.
(Plug the purge hoses. The EVAP canister purge vol-
ume control valve harness connector should remain
connected.)
5. Turn ignition switch "ON" and "OFF". Check that EVAP
canister purge volume control valve shaft moves
smoothly forward and backward according to the igni-
tion switch position.
If NG, replace the EVAP canister purge volume control
SEF763P valve.

~
Air cleaner

f housmg
/,// ~
I( SEF141S

336 EC-196
 TROUBLE DIAGNOSIS FOR DTC P0440
Evaporative Emission (EVAP) Control System
(Small Leak) (Cont'd) ~~
EVAP canister purge control solenoid valve
Check air passage continuity.

Air passage Air passage

Condition continuity continuity
between @ and @ between @ and @
12V direct current supply
Yes No
between terminals

SEF313Q No supply No Yes

If NG, replace solenoid valve.

EVAP canister purge control valve

Check EVAP canister purge control valve as follows:
1. Plug the port @. Tl'
2. Apply pressure [80.0 kPa (600 mmHg, 23.62 inHg, 11.60 psi)]
to port @. Then keep it for 15 seconds, and check there is no
leakage. I"IQ
3. Repeat step 2 for port ©.

SEF285PA

EVAP canister vent control valve

Check air passage continuity.

Air passage continuity

Condition
between @ and @
12V direct current supply between ter~
No
minals CD
and ®
No supply Yes

If NG, clean valve using air blower or replace as necessary.

Make sure new 0-ring is installed properly.
Absolute pressure sensor
1. Remove absolute pressure sensor from bracket with its har-
ness connector connected.
2. Remove hose from absolute pressure sensor.
Absolute pressure 3. Turn ignition switch "ON" and check output voltage between
terminal ® and engine ground. I'll
The voltage should be 3.2 to 4.8 V.
4. Use pump to apply vacuum of -26.7 kPa (-200 mmHg, -7.87
inHg, -3.87 psi) to absolute pressure sensor as shown in fig-
ure and check the output voltage.
The voltage should be 1.0 to 1.4 V lower than the value
SEF0988
measured in step 3.
EC-197 337
 TROUBLE DIAGNOSIS FOR DTC P0440
Evaporative Emission (EVAP) Control System
(Small Leak) (Cont'd)
CAUTION:
Always calibrate the vacuum pump gauge when using it.
5. If NG, replace absolute pressure sensor.

MAP/BARO switch solenoid valve

• ACTIVE TEST •
1. Start engine and warm it up sufficiently.
MAP/BARO SWN MAP 2. Perform "MAP/BARO SWN" in "ACTIVE TEST" mode
with CONSULT.
l==oo======= MONITOR ===co====== I 3.
Check the following.
CMPS•RPM(REF) 700rpm
MAP/BARO SWN MAP • When "MAP" is selected, "ABSOL PRES/SE" indi-
ABSOL PRES/SE 1.3V cates approximately 1 .3V.
• When "BARO" is selected, "ABSOL PRES/SE" indi-
cates approximately 4.3V.
4. If NG, replace solenoid valve.
----------OR----------
1. Remove MAP/BARO switch solenoid valve.
2. Check air passage continuity.
• ACTIVE TEST • D
Air passage Air passage
MAP/BARO SWN BARO
Condition continuity continuity
=========' MONITOR ========== between @ and @ between @ and ©
CMPS•RPM(REF) 700rpm
MAP/BARO SWN BARO 12V direct current supply
ABSOL PRES/SE 4.3V between terminals CD Yes No
and®
No supply No Yes
BARO MAP
SEF498R
3. If NG, replace solenoid valve.

MEC488B

Tank fuel temperature sensor

Hot water
Tank fuel temperature Check resistance by heating with hot water or heat gun as shown
sensor connector in the figure.

(Reference data)
Temperature "C ("F) Resistance k.O

20 (68) 2.3. 2.7

50 (122) 0.79. 0.90

AEC145A
If NG, replace tank fuel temperature sensor.

338 EC-198
 TROUBLE DIAGNOSIS FOR DTC P0443

Evaporative Emission (EVAP) Canister Purge

Control Valve/Solenoid Valve iiJ,
SYSTEM DESCRIPTION
I Camshaft position sensor 1 Engine speed

I Engine coolant temperature sensor I Engine coolant temperature EVAP canister

ECM purge control sole-

l Closed throttle position switch 1 Closed throttle position (ECCS

control
noid valve

Vacuum
1 Vehicle speed module)
j Vehicle speed sensor signal

'Ignition switch I Start signal EVAP canister

purge control valve

This system controls the vacuum signal applied to • Ignition switch "START"
the EVAP canister purge control valve. • Closed throttle position
When the ECM detects any of the following • Low or high engine coolant temperature
conditions, current does not flow through the EVAP • During deceleration
canister purge control solenoid valve. • Engine stopped
The solenoid valve cuts the vacuum signal so that • Low vehicle speed (MIT models)
the EVAP canister purge control valve remains
closed.
ECM TERMINALS AND REFERENCE VALUE
Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

EVAP canister purge con- IEngine is running. I BATIERY VOLTAGE

105 W/R
trol solenoid valve L Idle speed (11 - 14V)

CONSULT REFERENCE VALUE IN DATA MONITOR MODE

Specification data are reference values.
MONITOR ITEM CONDITION SPECIFICATION

Idle OFF
PURG CONT SN • Engine: After warming up
2,000 rpm ON

To EVAP canister purge control valve COMPONENT DESCRIPTION

Intake
manifold 1..
t To intake
EVAP canister purge control solenoid valve
vacuum . . air duct The EVAP canister purge control solenoid valve responds to sig-
signal
nals from the ECM. When the ECM sends an OFF signal, the
vacuum signal (from the intake manifold to the EVAP canister ~~
purge control valve) is cut.
When the ECM sends an ON (ground) signal, the vacuum signal
passes through the EVAP canister purge control solenoid valve.
The signal then opens the EVAP canister purge control valve.
SEF673P

EC-199 339
 TROUBLE DIAGNOSIS FOR DTC P0443
Evaporative Emission (EVAP} Canister Purge
Control Valve/Solenoid Valve (Cont'd}
EVAP canister purge control valve
When the vacuum signal is cut by EVAP canister purge control
valve
solenoid valve, EVAP canister purge control valve closes.

From
EVAP
canister

SEF343QA

EVAPORATIVE EMISSION SYSTEM DIAGRAM

EVAP canister
EVAP control system pressure sensor purge control
solenoid valve
Vacuum cut valve bypass valve
EVAP shut valve
p

Fuel tank Vacuum

cut valve
EVAP canister EVAP canister
vent control purge volume
valve control valve SEF782Q

Diagnostic
Check Items
Trouble Code Malfunction is detected when .
(Possible Cause)
No.
P0443 A) An improper voltage signal is sent to ECM through • Harness or connectors
0807 EVAP canister purge control solenoid valve. (The EVAP canister purge control solenoid valve cir-
cuit is open or shorted.)
• EVAP canister purge control solenoid valve

B) EVAP canister purge control valve does not operate • EVAP canister purge control valve
properly (stuck open). • EVAP canister purge control solenoid valve
• Vacuum hoses for clogging or disconnection
• EVAP control system pressure sensor

DIAGNOSTIC TROUBLE CODE CONFIRMATION

PROCEDURE
Perform "Procedure for malfunction A" first. If the 1st trip DTC
cannot be confirmed, perform "Procedure for malfunction B"
on next page.

Procedure for malfunction A

*MONITOR *NO FAIL D 1) Turn ignition switch "ON".
CMPS•RPM(REF) Orpm 2) Select "DATA MONITOR" mode with CONSULT
3) Wait at least 5 seconds.
---------OR---------
(~\ 1) Turn ignition switch "ON" and wait at least 5 seconds.
~ 2) Select "MODE 7" with GST.
---------OR---------
rNo\. 1) Turn ignition switch "ON" and wait at least 5 seconds.
~"Y 2) Turn ignition switch "OFF", wait at least 7 seconds and
I RECORD I
SEF422T
then turn "ON".
3) Perform "Diagnostic Test Mode II (Self-diagnostic
results)" with ECM.
340 EC-200
 TROUBLE DIAGNOSIS FOR DTC P0443
Evaporative Emission (EVAP) Canister Purge
Control Valve/Solenoid Valve (Cont'd) ~r
1:< MONITOR -/< NO FAIL
Procedure for malfunction B
CMPS•RPM (POS) 2000rpm rF.f\ 1) Lift up vehicle.
COOLAN TEMP/S
VHCL SPEED SE
SO"C
65km/h
\.J!J 2) Turn ignition switch "ON" and select "DATA MONITOR"
22°C
mode with CONSULT.
TANK FITMP SE
3) Start engine and warm it up sufficiently. ~81J
4) Check that tank fuel temperature is above O"C (32"F).
5) Turn ignition switch "OFF" and wait at least 7 seconds.
6) Turn ignition switch "ON" and wait at least 12 seconds. lCi
I RECORD ISEF816T 7) Start engine and let it idle for at least 70 seconds.
8) Maintain the following conditions for at least 10 sec-
onds.
Gear position:
"2" or "D" range (AfT)
"3rd" or "4th" gear (Mff) rp"'
Vehicle speed:
50 - 80 kmlh (31 - 50 MPH)
Engine speed: t::l
1 ,500 - 2,500 rpm
Coolant temperature:
Less than 100"C (212"F) t2iii'

ENGINESPD .. .. 825RPM ---------OR---------

COOLANT TEMP ........... 69"C
VEHICLE SPD ................... OMPH 1) Lift up vehicle.
IGN ADVANCE ........... 8.0" 2) Turn ignition switch "ON" and select "MODE 1" with T?
CALC LOAD ...... .. ...... 28.2%
MAP .............................. 36KPaA GST.
MAF .. . ......... 5.20gm/s 3) Start engine and warm it up sufficiently.
THROTILE POS ............ 0.0%
INTAKE AIR ........................ 27"C 4) Check that voltage between ECM terminal @ and IP!J
FUEL SYS #1 .... .... OLDRIVE ground is less than 4.2V.
FUEL SYS #2 .. .. UNUSED
SHORT FT #1 ..................... 0.8% 5) Turn ignition switch "OFF" and wait at least 7 seconds.
LONG FT #1 0.0% 6) Turn ignition switch "ON" and wait at least 12 seconds. [5;1,
02S 81 S1 ...................... 0.200V
02FTB1 51.... ......... 0.8% 7) Start engine and let it idle for at least 70 seconds.
025 81 S2 ............... .... 0.010V SEF519R 8) Maintain the following conditions for at least 10 sec-
onds.

~i)
Gear position:
"2" or "D" range (AfT)
"3rd" or "4th" gear (Mff) ~Iii
===Ec=M==ifli'=co=N=NE""cr""oR311I
lr.=l
Vehicle speed:
63
50 - 80 kmlh (31 - 50 MPH)
Engine speed: i'ii'ii'
1,500 - 2,500 rpm
Coolant temperature:
Less than 100"C (212"F) ifi@
9) Select "MODE 7" with GST.
SEF817T

EC-201 341
 TROUBLE DIAGNOSIS FOR DTC P0443
Evaporative Emission (EVAP) Canister Purge
Control Valve/Solenoid Valve (Cont'd)
~i) ---------OR---------
1) Lift up vehicle.
rr=E':':C:':':M="i]Ofi"'co='N""NE==cr'=oR"illj
63 ' """
~ 2) Start engine and warm it up sufficiently.
3) Check that voltage between ECM terminal @ and
ground is less than 4.2V.
4) Turn ignition switch "OFF" and wait at least 7 seconds.
5) Turn ignition switch "ON" and wait at least 12 seconds.
6) Start engine and let it idle for at least 70 seconds.
7) Maintain the following conditions for at least 10 sec-
SEF817T onds.
Gear position:
"2" or "0" range (AfT)
"3rd" or "4th" gear (MIT)
Vehicle speed:
50 - 80 km/h (31 - 50 MPH)
Engine speed:
1 ,500 - 2,500 rpm
Voltage between ECM terminal ® and ground:
More than O.BV
8) Turn ignition switch "OFF", wait at least 7 seconds and
then turn "ON".
9) Perform "Diagnostic Test Mode II (Self-diagnostic
results)" with ECM.

342 EC-202
TROUBLE DIAGNOSIS FOR DTC P0443
Evaporative Emission (EVAP) Canister Purge
Control Valve/Solenoid Valve (Cont'd)

EC-CANIN-01

- : Detectable line for DTC

: Non-detectable line for DTC

WIB

I•
W/B

·-WIB+To EL-METER
•
BNI

W/R

mtsn
,----";'C:';';PC~----, ECM (EGGS
CONTROL
MODULE)
@ill)

AEC310A

EC-203 343
 TROUBLE DIAGNOSIS FOR DTC P0443
Evaporative Emission (EVAP) Canister Purge
Control Valve/Solenoid Valve (Cont'd)
DIAGNOSTIC PROCEDURE
Procedure for malfunction A
INSPECTION START

CHECK POWER SUPPLY. Check the following.

1. Disconnect EVAP canister purge control • 10A fuse
solenoid valve harness connector. • Harness for open or short
2. Turn ignition switch "ON". between EVAP canister
3. Check voltage between terminal G) purge control solenoid
and ground with CONSULT or tester. valve and fuse

~15~0
Voltage: Battery voltage If NG, repair harness or
connectors.
OK

d'fu
CHECK OUTPUT SIGNAL CIRCUIT. NG Repair harness or connec-
1. Tum ignition switch "OFF". tors.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM
terminal @ and terminal @.
Continuity should exist.
SEF488R If OK, check harness for short.

OK
'c~H~E~C~K~C~O~M~PO~N~EN~T~-----------,NG
~«5~~18
Replace EVAP canister
(EVAP canister purge control solenoid purge control solenoid
valve). valve.
II ECM JOI'coNNECTORII cfib Refer to ''COMPONENT INSPECTION",
105 EC-206.

OK

Disconnect and reconnect harness connec-

tors in the circuit. Then retest.
SEF489R Trouble is not fixed.

Check ECM pin terminals for damage and

check the connection of ECM harness con-
nector. Reconnect ECM harness connector
and retest.

INSPECTION END

344 EC-204
 TROUBLE DIAGNOSIS FOR DTC P0443
Evaporative Emission (EVAP) Canister Purge
Control Valve/Solenoid Valve (Cont'd) ©l~
Procedure for malfunction B
~~ffi\
INSPECTION START

ll'!1TI
NG CHECK COMPONENTS
Disconnect vacuum hose to (EVAP canister purge con-
EVAP canister purge control trol solenoid valve). ~·"'
"'
valve. Refer to "COMPONENTS
SEF142S 2. Start engine. INSPECTION" on next
3. Pertorm "PURG CONT SN" in page.
"ACTIVE TEST" mode .
• ACTIVE TEST • D 4. Select "ON" on CONSULT
OK
PURG CONT SN Q N screen to turn on "PURG CONT
(PURG CONT VAG) VC ON SN". [5[['
========== MONITOR ===·''======! 5. Check vacuum hose for vacuum
PURG CONT SN ON when revving engine up to 2,000
CMPS•RPM (REF) 2000rpm
CLSD THUP SW OFF
rpm. ©l
Vacuum should exist.
f - - - - - - - OR - - - - - - t

® 1. Start engine and warm it up suf-

ficiently.
2. Stop engine.
Check vacuum hoses for
clogging or disconnection.
~mr

3. Lift up vehicle. Refer to "Vacuum Hose

4. Disconnect vacuum hose to Drawing", EC-13. L~L!
EVAP canister purge control
valve.
5. Start engine.
6. Check vacuum hose for vacuum
1?
when revving engine up to
2,000 rpm.
Vacuum should exist. ['l[g

OK

CHECK COMPONENT NG Replace EVAP canister

(EVAP canister purge control valve). purge control valve.
L.__ _ _ _ _ _ _ _ _ _ _ _ _ s_E_F_14_s~s Refer to "COMPONENT INSPECTION" on
next page.
OK

Go to "TROUBLE DIAGNOSIS FOR DTC

?0450", "EVAP Control System Pressure
Sensor", EC-212.

OK

CHECK EVAPORATIVE EMISSION LINE. NG Repair EVAP purge line

Check EVAP purge line hoses for leak or hoses.
clogging.
Refer to "Evaporative Emission Line
Drawing", EC-22.

OK

INSPECTION END

EC-205 345
 TROUBLE DIAGNOSIS FOR DTC P0443
Evaporative Emission (EVAP) Canister Purge
Control Valve/Solenoid Valve (Cont'd)
COMPONENT INSPECTION
EVAP canister purge control solenoid valve
Check air passage continuity.

Air passage Air passage

Condition continuity continuity
between ® and @ between @ and ©
12V direct current supply
Yes No
SEF313Q between terminals
No supply No Yes

If NG, replace solenoid valve.

EVAP canister purge control valve

Check EVAP canister purge control valve as follows.
1. Plug the port @.
2. Apply pressure [80.0 kPa (600 mmHg, 23.62 inHg, 11.60 psi)]
to port@. Then keep it for 15 seconds, and check there is no
leakage.
3. Repeat step 2 for port @.

SEF285PA

346 EC-206
 TROUBLE DIAGNOSIS FOR DTC P0446

Atmospheric pressure Coil Terminal Evaporative Emission (EVAP) Canister Vent

Control Valve
Note: If both DTC P0440 and P0446 are displayed, perform
TROUBLE DIAGNOSIS FOR P0446 first.
COMPONENT DESCRIPTION
The EVAP canister vent control valve is located on the EVAP can-
ister and is used to seal the canister vent.
This solenoid (the EVAP canister vent control valve) responds to 1©
signals from the ECM.
When the ECM sends an ON signal, the coil in the solenoid valve
is energized.
A plunger will then move to seal the canister vent. The ability to seal
the vent is necessary for the on board diagnosis of other evapora-
tive loss system components. 'f[i';
This solenoid valve is used only for diagnosis, and usually remains
opened.
When the vent is closed, under normal purge conditions, the ©1o
evaporative loss system is depressurized and allows "EVAP Con-
trol System (Small Leak)" diagnosis.

ECM TERMINALS AND REFERENCE VALUE

Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

EVAP canister vent con~ BATTERY VOLTAGE

108 R ]Ignition switch "ON" j
trol valve (11 - 14V)

CONSULT REFERENCE VALUE IN DATA MONITOR MODE

Specification data are reference values
MONITOR ITEM CONDITION SPECIFICATION
VENTCONTN • Ignition switch: ON OFF

ON BOARD DIAGNOSIS LOGIC

Diagnostic
Check Items
Trouble Code Malfunction is detected when
(Possible Cause)
No.
P0446 A) An improper voltage signal is sent to ECM through • Harness or connectors
0903 EVAP canister vent control valve. (EVAP canister vent control valve circuit is open or
shorted.)

B) EVAP canister vent control valve does not operate • EVAP canister vent control valve
properly. • EVAP control system pressure sensor
• Blocked rubber tube to EVAP canister vent control
valve

EC-207 347
 TROUBLE DIAGNOSIS FOR DTC P0446
Evaporative Emission (EVAP) Canister Vent
Control Valve (Cont'd)
DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE
Perform "Procedure for malfunction A". If the 1st trip DTC
cannot be confirmed, perform "Procedure for malfunction 8"
on next page.
Procedure for malfunction A
1) Turn ignition switch "ON".
2) Select "DATA MONITOR" mode with CONSULT.
3) Start engine and wait at least 5 seconds.
----------OR----------
(if' 1) Start engine and wait at least 5 seconds.
'I&J 2) Select "MODE 7" with GST.
----------OR----------
{NO\ 1) Start engine and wait at least 5 seconds.
~ 2) Turn ignition switch "OFF", wait at least 7 seconds and
then turn "ON".
3) Perform "Diagnostic Test Mode II (Self-diagnostic
results)" with ECM.

OVERALL FUNCTION CHECK

Use this procedure to check the overall function of the EVAP can-
ister vent control valve circuit. During this check, a 1st trip DTC
might not be confirmed.
Procedure for malfunction B
1) Remove EVAP canister vent control valve from EVAP canister
and disconnect hoses from the valve.
2) Check air passage continuity.

Air passage continuity

Condition
between ® and @
12V direct current supply between ter-
No
minals CD and ®
No supply Yes

Make sure new 0-ring is installed properly.

348 EC-208
 TROUBLE DIAGNOSIS FOR DTC P0446
Evaporative Emission (EVAP) Canister Vent
Control Valve (Cont'd) !li~

EC-VENTN-01 1~3,

- : Detectable line for DTC

- :Non-detectable line for DTC

BfW

I
BM/
1rt,1<MW I'~
'T'@
BM/

I ~~~

/[I]'

1~1l

'li'l"

[1'[1
R
lrt,l@
'-r' (/ill)
'Fffic

~
IR

,---;C~D:;:C'!-;V------, ECM (ECCS

~L~

~:Fl
CONTROL
MODULE)
@W
~'T

~~
0

~u
1 =2 D
3 4 516 7 81 @) 12345@)
9 10 11h2 13141 w 6 7 8 9 10 w
;g:~

~
101 102 103 104105 106 1 2 3 ~ 20 21 22 23 38 39 !4ol41l 53 54 55 ~ [1;~
24 25 26 27 28 42 43 44 45 46 57 58 59 60 61
107 108 109 110111112115678910
11 12 13 14 19 29 30 31 32 33 fglfo 47 48 62 63 64 65 70
113 114 115 1161171181112J 16 17 18 134 35 36 37 ~ 66676869
l~l:\

AEC311A

EC-209 349
 TROUBLE DIAGNOSIS FOR DTC P0446
Evaporative Emission (EVAP) Canister Vent
Control Valve (Cont'd)
~ DIAGNOSTIC PROCEDURE
\_ EVAP canister INSPECTION START

CHECK POWER SUPPLY.

NG Check the following.
1. Disconnect EVAP canister vent control • Harness connectors
valve harness connector. @.@
2. Turn ignition switch "ON". • 15A fuse
3. Check voltage between terminal ® • Harness for open or short
and ground with CONSULT or tester. between EVAP canister
Voltage: Battery voltage vent control valve and
fuse
OK If NG, repair harness or con-
nectors.

CHECK OUTPUT SIGNAL CIRCUIT.

NG Check the following.
1. Turn ignition switch "OFF". • Harness connectors
2. Disconnect ECM harness connector. @.@
3. Check harness continuity between ECM • Harness for open or short
terminal @ and terminal CD. between EVAP canister
Continuity should exist. vent control valve and
SEF150S
If OK, check harness for short. ECM
If NG, repair harness or con-
OK nectors.

II ECM JOI'coNNECTDRII CHECK RUBBER TUBE FOR CLOG-

GING.
108
Check obstructed rubber tube to EVAP
canister vent control valve and clean the
rubber tube using air blower.

OK
,-----------~----------,NG
CHECK COMPONENT Replace EVAP canister
SEF151S (EVAP canister vent control valve). vent control valve.
L----------------' Refer lo "COMPONENT INSPECTION""
on next page.

OK
,-----------~----------,NG
CHECK COMPONENT Replace EVAP control sys-
(EVAP control system pressure sensor). tem pressure sensor.
Refer lo "COMPONENT INSPECTION"
on next page.

OK

Disconnect and reconnect harness con-

nectors in the circuit. Then retest.

Trouble is not fixed.

Check ECM pin terminals for damage and

check the connection of ECM harness
connector. Reconnect ECM harness con-
nector and retest.

INSPECTION END

350 EC-210
 TROUBLE DIAGNOSIS FOR DTC P0446
Evaporative Emission (EVAP) Canister Vent
Control Valve (Cont'd) '"'I
COMPONENT INSPECTION
EVAP canister vent control valve
Check air passage continuity.

Air passage continuity

Condition
between @ and @
12V direct current supply between ter-
No
minals G) and @
No supply Yes

If NG, clean valve using air blower or replace as necessary.

Make sure new 0-ring is installed properly.

~ ''""' ~il'ib\ EVAP control system pressure sensor

~E)u\\!k1
- ~
EVAP control system
pressure sensor
I 1.

2.
3.
Remove EVAP control system pressure sensor with its har-
ness connector connected.
Remove hose from EVAP control system pressure sensor.
Use pump to apply vacuum and pressure to EVAP control
[J[) system pressure sensor as shown in figure. PIJ:
4. Check output voltage between terminal @ and engine ground.
Pressure (Relative to atmospheric pressure) Voltage (V)
Pump
0 kPa (0 mmHg, 0 inHg, 0 psi) 3.0- 3.6
SEF400S -9.3 kPa (-70 mmHg, -2.76 inHg, -1.35 psi) 0.4- 0.6

CAUTION:
Always calibrate the vacuum pump gauge when using it.
5. If NG, replace EVAP control system pressure sensor.

!El

EC-211 351
 TROUBLE DIAGNOSIS FOR DTC P0450

Evaporative Emission (EVAP) Control System

/ r- Evaporative Pressure Sensor
/ emission (EVAP)
control system COMPONENT DESCRIPTION
-.........__ / pressure sensor
The EVAP control system pressure sensor detects pressure in the
purge line. The sensor output voltage to the ECM increases as
pressure increases. The EVAP control system pressure sensor is
not used to control the engine system. It is used only for on board
diagnosis.

SEF429Q

5
4.5
> 4
~3.5
• 3
-3 2.5
> 2
~ 1.5
5 1
0 0.5
oL_-_cg~.3~----------~.~4".o----
(-70. -2.76. -1.35) (+30, +1.18. +0.58)
Pressure kPa (mmHg. inHg, psi)
(Relative to atmospheric pressure) SEF954S

ECM TERMINALS AND REFERENCE VALUE

Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

49 p Sensors' power supply IIgnition switch "ON"" I Appro xi mately 5V

1Engine is running. I (Warm-up condition)

50 B/G Sensors' ground O.OOt - 0.02V
L Idle speed

EVAP control system

67 L jlgnit1on switch "'ON'' I Approximately 3.4V
pressure sensor

CONSULT REFERENCE VALUE IN DATA MONITOR MODE

Specification data are reference values
MONITOR ITEM CONDITION SPECIFICATION

EVAP SYS PRES e Ignition switch: ON Approx. 3.4V

ON BOARD DIAGNOSIS LOGIC

Diagnostic Trouble Check Items
Malfunction is detected when ....
Code No. (Possible Cause)

P0450 • An improper voltage signal from EVAP control • Harness or connectors

0704 system pressure sensor is sent to ECM. (The EVAP control system pressure sensor circuit
is open or shorted.)
• EVAP control system pressure sensor
• EVAP canister vent control valve (The valve is
stuck open.)

352 EC-212
 TROUBLE DIAGNOSIS FOR DTC P0450
Evaporative Emission (EVAP) Control System
Pressure Sensor (Cont'd)
ti MONITOR *NO FAIL D DIAGNOSTIC TROUBLE CODE CONFIRMATION
CMP&RPM(REF) Orpm PROCEDURE
COOLAN TEMP/S asoc 1)
Start engine and warm it up sufficiently.
TANK F!fMP SE 22°C
2)
Check that tank fuel temperature is above O'C (32'F).
Turn ignition switch "OFF" and wait at least 7 seconds. ~l'i
3)
4)
Turn ignition switch "ON".
5) Select "DATA MONITOR" mode with CONSULT.
6) Wait at least 5 seconds.
I RECORD ISEF818T ----------OR----------
1) Start engine and warm it up sufficiently.
2) Check that voltage between ECM terminal @! and

~i5
ground is less than 4.2V.
~ 3) Turn ignition switch "OFF" and wait at least 7 seconds.
4) Turn ignition switch "ON" and wait at least 5 seconds. :p;::
lof I
I ECM
63
CONNECTOR
ID 5) Select "MODE 7" with GST.
---------OR---------
cf6~H {NO\
~y
1) Start engine and warm it up sufficiently. ©IL
2) Check that voltage between ECM terminal @! and
1Yi ground is less than 4.2V.
3) Turn ignition switch "OFF" and wait at least 7 seconds. fylJ
---~ ~ 4) Turn ignition switch "ON" and wait at least 5 seconds.
SEF817T 5) Turn ignition switch "OFF", wait at least 7 seconds and
then turn "ON". ;!,1]'
6) Perform "Diagnostic Test Mode II (Self-diagnostic
results)" with ECM.

EC-213 353
 TROUBLE DIAGNOSIS FOR DTC P0450
Evaporative Emission (EVAP) Control System
Pressure Sensor (Cont'd)

EC-PRE/SE-01

I~I
~~~~ECMONTROL
PRESSURE
SENSOR - : Detectable line for DTC
3 "1-,-I+!'"!-"!~H.!@
'r-l:!c- : Non-detectable line for DTC

p L BIG

r... '.t
I I
I
I
I
I
I
I
I
I

.
I
I
I
I
I
')

P L B/G

P L B/G

.--------·-· I
I
I
I
- '
I
I
I
I
I
I
I
I
~
'
--
I•
P L B/G

~~~

~
il
8 8
--'-
~~~~==~~~~ECM
AVCC FTPRS

L ---------'MODULE)
GND-A (ECCS
CONTROL

@
cgj:§> CM16>

Refer to last page (Foldout page).

@jg)
D
12345@ ~@
6 7 8 9 10 W l2..E.U.) GY

101102 103 104 105 106 ,.,-~'H;i.;-,

1071os1o9 110 ,,, 112 'i7.-~:!:2cr

113 114 115

AEC054A

354 EC-214
 TROUBLE DIAGNOSIS FOR DTC P0450
Evaporative Emission (EVAP) Control System
Pressure Sensor (Cont'd)
DIAGNOSTIC PROCEDURE
INSPECTION START

CHECK SHIELD CIRCUIT. Repair harness or connec·

1. Turn ignition switch "OFF". tors.
2. Loosen and retighten engine ground
screws.
3. Remove joint connector-1.
4. Check the following.
• Continuity between joint connector-1
terminal G) and ground
• Joint connector-1
(Refer to "HARNESS LAYOUT"" in EL
section.)
Continuity should exist.
1f OK, check harness for short. Then
reconnect joint connector-1.

OK

NG
CHECK POWER SUPPLY. Check the following.
~;==============S=E=F=1=52~S 1. Disconnect EVAP control system pres- • Harness connectors
li sure sensor harness connector. <§!>.@
EJ 2. Turn ignition switch "ON". • Joint connector~ 1
3. Check voltage between terminal @) • Harness for open or short
and engine ground with CONSULT or between EVAP control
tester. system pressure sensor
Voltage: Approximately SV and ECM
If NG, repair harness or con~
OK nectars.

NG
CHECK GROUND CIRCUIT. Check the following.
1. Turn ignition switch "OFF". • Harness connectors
SEF410Q 2. Check harness continuity between ter~ <§!>.@
minal CD and engine ground. • Harness for open or short
Continuity should exist. between ECM and EVAP
If OK, check harness for short. control system pressure
sensor
OK If NG, repair harness or con·
nectars.

[!)
~----------I-----------,NG
CHECK INPUT SIGNAL CIRCUIT. Check the following.
1. Disconnect ECM harness connector. • Harness connectors
2. Check harness continuity between ECM <§!).@
terminal @> and terminal ®. • Harness for open or short
Continuity should exist. between ECM and EVAP
SEF411Q
If OK, check harness for short. control system pressure
sensor
OK If NG, repair harness or con·
nectars.

CHECK COMPONENT
ECM ]OfCONNECTOR II (EVAP canister vent control valve).
67 Refer to "COMPONENT INSPECTION"".
EC-211.

OK

®
SEF496A
(Go to next page.)

EC-215 355
 TROUBLE DIAGNOSIS FOR DTC P0450
Evaporative Emission (EVAP) Control System
Pressure Sensor (Cont'd)
@
l
CHECK COMPONENT
(EVAP control system pressure sensor). ~ Replace EVAP control sys-
tern pressure sensor.
Refer to "COMPONENT INSPECTION"
below.

1OK
Disconnect and reconnect harness con-
nectars in the circuit. Then retest.

l Trouble is not fixed.

Check ECM pin terminals for damage and
check the connection of ECM harness
connector.
Reconnect ECM harness connector and
retest.

1
INSPECTION END

COMPONENT INSPECTION
~150~~
~
EVAP control system
pressure sensor-
I EVAP control system pressure sensor
1. Remove EVAP control system pressure sensor with its har-
ness connector connected.
2. Remove hose from EVAP control system pressure sensor.
3. Use pump to apply vacuum and pressure to EVAP control
system pressure sensor as shown in figure.
4. Check output voltage between terminal ® and engine ground.
Pump
Pressure (Relative to atmospheric pressure) Voltage (V)
SEF400S 0 kPa (0 mmHg, 0 inHg, 0 psi) 3.0- 3.6
-9.3 kPa (-70 mmHg, -2.76 inHg, -1.35 psi) 0.4- 0.6

CAUTION:
Always calibrate the vacuum pump gauge when using it.
5. If NG, replace EVAP control system pressure sensor.

356 EC-216
 TROUBLE DIAGNOSIS FOR DTC P0500

Vehicle Speed Sensor (VSS)

COMPONENT DESCRIPTION
Vehicle speed
The vehicle speed sensor is installed in the transmission. It con- [@§!,
sensor tains a pulse generator which provides a vehicle speed signal to
the speedometer. The speedometer then sends a signal to the
~M. ~

AEC110

ECM TERMINALS AND REFERENCE VALUE

Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

1Engine is running. I Approximately 1.8 - 2.4V"

26 W/L Vehicle speed sensor
L Slowly rotating front wheels (AC voltage)
.
:Average voltage for pulse sJgnal (Actual pulse s1gnal can be conf1rmed by oscJiloscope.)

ON BOARD DIAGNOSIS LOGIC

Diagnostic
Check items
Trouble Code Malfunction is detected when ....
(Possible cause)
No. l'f
P0500 • The almost 0 km/h (0 MPH) signal from the vehicle • Harness or connector
0104 speed sensor is sent to ECM even when the vehicle is (The vehicle speed sensor circuit is open or shorted.)
driving. • Vehicle speed sensor

EC-217 357
 TROUBLE DIAGNOSIS FOR DTC P0500
Vehicle Speed Sensor (VSS) (Cont'd)
OVERALL FUNCTION CHECK
·V~HICLE SPEED SEN CKT.
Use this procedure to check the overall function of vehicle speed
AFTER TOUCH START. sensor circuit. During this check, a t st trip DTC might not be con-
DRIVE VEHICLE firmed.
AT IOkm/h (6mphl OR 1) Jack up drive wheels.
MORE WITHIN 15 sec
~ 2) Start engine.
1
~ 3) Perform "VEHICLE SPEED SEN CKT" in "FUNCTION
TEST" mode with CONSULT.
----------OR----------
2) Start engine.
MEF559D 3) Read vehicle speed sensor signal in "DATA MONITOR"
mode with CONSULT.

* MONITOR * NO FAIL D The vehicle speed on CONSULT should be able to

exceed 10 km/h (6 MPH) when rotating wheels with suit-
VHCL SPEED SE 20km/h able gear position.
P/N POSI SW OFF -----------OR-----------
1) Jack up drive wheels.
2) Start engine.
3) Read vehicle speed sensor signal in "MODE 1" with
GST.
The vehicle speed on GST should be able to exceed 10
RECORD km/h (6 MPH) when rotating wheels with suitable gear
SEF941N position.
----------OR----------
FUEL SYS #1 CLOSED
FUELSYS#2 UNUSED DIAGNOSTIC TROUBLE CODE CONFIRMATION
CALC LOAD 57% PROCEDURE
COOLANT TEMP 87"C
SHORTFT#1 1%
LONG FT #1 -3% 1) Start engine and warm it up sufficiently.
ENGINE SPD 2225RPM 2) Perform test drive for at least 10 seconds continuously
VEHICLESPD 57MPH
IGNADVANCE 34.Q" in the following recommended condition.
INTAKE AIR 43C
MAF 26.2gm/sec Engine speed : 1,400- 2,500 rpm (A/T models)
THROTTLE POS 12"/o 1,700 - 2,600 rpm (2WD MIT
02S LOCATION 3
02S 81 ,S1 0.090V models)
02FT 81.-S1 0%
02S 81,~2 0.070V 1,850 - 2,850 rpm (4WD MIT
SEF942N models)
Intake
manifold vacuum : (A/T models) -53.3 to -33.3
kPa
(-400 to -250 mmHg, -15.75
to -9.84 inHg, -7.73 to -4.83
psi)
(MIT models) -46.7 to -32.0
kPa
(-350 to -240 mmHg, -13.78
to -9.45 inHg, -6.77 to -4.64
psi)
Gear position : Suitable position (except "N" or
"P" position)
3) Stop the vehicle, turn ignition switch "OFF", wait at least
7 seconds and then turn "ON".
4) Perform "Diagnostic Test Mode II (Self-diagnostic
results)" with ECM.
Even though 1st trip DTC is not detected, perform the
above test drive at least one more time.

358 EC-218
 TROUBLE DIAGNOSIS FOR DTC P0500
Vehicle Speed Sensor (VSS) (Cont'd)
(~[

EC-VSS-01

Refer to "EL-POWER"
10A
IT!] - : Detectable line for DTC
: Non-detectable line for DTC
W/8

b~~~ECTOR-2
L W/B~WIB--_...---,1
WIB

l~lt£:\
WIB

rrffil COMBINATION
(Mjis>® I METER
ISPEEDOMETER)
.._ B~B-B~!.. @.@.@
SPEEDOMETER

I J
~
WIL
~~
W R
1il"
l$f---fl~l®
I
B

~
(M155)
JOINT W R

II
CONNECTOR-2
@ill> WIL

~ 1$1®
(~)
B WIL

I I
i-ii I
VEHICLE
SPEED
SENSOR

L-------------~~

Refer to last page (Foldout page}.

~(~) ~@) @ill>

~ GY UllJ GY @jj) ®

~1
0

AEC055A

EC-219 359
 TROUBLE DIAGNOSIS FOR DTC P0500
Vehicle Speed Sensor (VSS} (Cont'd}
r:i.1 DIAGNOSTIC PROCEDURE
INSPECTION START

~18@a ~18
II ror
ECM CONNECTOR 11 IMo~~r
3 2 r:i.1
26 @ NG
CHECK INPUT SIGNAL CIRCUIT. Check the following.
1. Turn ignition switch "OFF".
[----- • Harness connectors
[ill 2. Disconnect ECM harness connector @.<§§>
and combination meter harness con- • Harness for open or short
SEF153S nectar. between ECM and combi-
3. Check harness continuity between ECM nation meter
terminal @ and terminal (j). If NG, repair harness or con-
Continuity should exist. nectars.
If OK, check harness for short.

OK

CHECK SPEEDOMETER FUNCTION.

Make sure that speedometer functions
properly.

OK
-
NG Check the following.
• Harness connectors
@,<§§>
• Harness connectors
@,@
• Harness for open or short
between combination
meter and vehicle speed
sensor
If NG, repair harness or con-
nectars.
Check vehicle speed sensor
and its circuit.
(Refer to EL section.)

Disconnect and reconnect harness con-

nectars in the circuit. Then retest.

Trouble is not fixed.

Check ECM pin terminals for damage and

check the connection of ECM harness
connector. Reconnect ECM harness con-
nectar and retest.

INSPECTION END

360 EC-220
 TROUBLE DIAGNOSIS FOR DTC P0505

Idle Air Control Valve (IACV) - Auxiliary Air

Control (AAC) Valve
SYSTEM DESCRIPTION
I Engine speed
Camshaft position sensor
I
I Amount of intake air
Mass air flow sensor
I

I Engine coolant temperature

Engine coolant temperature sensor
I

Start signal
Ignition switch

1 Throttle position
Throttle position sensor ECM
(ECCS
control J IACV-AAC valve
Inhibitor switch (AfT models)/ Park/Neutral position module) I
Neutra position switch (MIT models)
1

Air conditioner operation

Air conditioner switch

1 Power steering load signal

Power steering oil pressure switch

I Battery voltage
Battery
I
I Vehicle speed
Vehicle speed sensor

This system automatically controls engine idle speed to a specified level. Idle speed is controlled through fine
adjustment of the amount of air which by-passes the throttle valve via IACV-AAC valve. The IACV-AAC valve
repeats ON/OFF operation according to the signal sent from the ECM. The camshaft position sensor detects
the actual engine speed and sends a signal to the ECM. The ECM then controls the ON/OFF time of the
IACV-AAC valve so that engine speed coincides with the target value memorized in ECM. The target engine
speed is the lowest speed at which the engine can operate steadily. The optimum value stored in the ECM is
determined by taking into consideration various engine conditions, such as during warm up, deceleration, and ©'J
engine load (air conditioner and power steering operation).

ECM TERMINALS AND REFERENCE VALUE

Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

BATTERY VOLTAGE
IIgnition switch "ON". I
(11 - 14V)
101 WIG IACV-AAC valve
, 1 Engine is running. I (Warm-up condition)
0 -7V
L Engine speed is 2,000 rpm

EC-221 361
 TROUBLE DIAGNOSIS FOR DTC P0505
Idle Air Control Valve (IACV) -Auxiliary Air
Control (AAC) Valve (Cont'd)
CONSULT REFERENCE VALUE IN DATA MONITOR MODE
Specification data are reference values.
MONITOR ITEM CONDITION SPECIFICATION

• Engine: After warming up

Idle 20- 40%
• Air conditioner switch: OFF
IACV-AACN
• Shift lever "N"
2,000 rpm -
• No-load

COMPONENT DESCRIPTION
IACV-ACC valve
The IACV-AAC valve is moved by ON/OFF pulses from the ECM.
The longer the ON pulse, the greater the amount of air that will flow
through the valve. The more air that flows through the valve, the
higher the idle speed.

Air

SEF040E

ON BOARD DIAGNOSIS LOGIC

Diagnostic
Check Items
Trouble Code Malfunction is detected when ....
(Possible cause)
No.
P0505 A) The IACV-AAC valve does not operate properly. • Harness or connectors
0205 (The IACV-AAC valve circuit is open.)
• IACV-AAC valve
························ ············· ························· .................... ............................... ........ .......................
B) The IACV-AAC valve does not operate properly. • Harness or connectors
(The IACV-AAC valve circuit is shorted.)
• IACV-AAC valve

DIAGNOSTIC TROUBLE CODE CONFIRMATION

-k MONITOR -k NOFAIL 0 PROCEDURE
CMPS•RPM(REF) BOO rpm Perform "Procedure for malfunction A" first If the 1st trip DTC
COOLAN TEMP/S 85"C cannot be confirmed, perform "Procedure for malfunction B".
Procedure for malfunction A
1) Turn ignition switch "ON".
® 2) Select "DATA MONITOR" mode with CONSULT.
3) Start engine and run it for at least 2 seconds at idle
speed.
I RECORD I OR
SEF715T
- 1 Start en gine and run it for at least 2 seconds at idle
speed.
2) Select "MODE 7" with GST.
----------OR----------
/NO\ 1) Start engine and run it for at least 2 seconds at idle
'~''o/ speed.
2) Perform "Diagnostic Test Mode II (Self-diagnostic
results)" with ECM.

362 EC-222
 TROUBLE DIAGNOSIS FOR DTC P0505
Idle Air Control Valve (IACV) -Auxiliary Air
Control (AAC) Valve (Cont'd)
1>: MONITOR * NOFAIL D Procedure for malfunction B
CMPS•RPM(REF) BOOrpm ~ 1) Start engine and warm it up sufficiently.
COOLAN TEMPIS ssoc ~ 2) Turn ignition switch "OFF" and wait at least 7 seconds.
3) Turn ignition switch "ON" again and select "DATA
MONITOR" mode with CONSULT.
4) Start engine and run it for at least 1 minute at idle
speed.
-----------OR LG
I RECORD I
SEF715T ~ 2) Turn ignition switch "OFF" and wait at least 7 seconds.
1) Start engine and warm it up sufficiently.

3) Start engine again and run it for at least 1 minute at idle

speed.
4) Select "MODE 7'" with GST.
- - - - - - - - - - - O R - - - - - - - - - - - 11'~
@ 1) Start engine and warm it up sufficiently.
2) Turn ignition switch "OFF'' and wait at least 7 seconds.
3) Start engine again and run it for at least 1 minute at idle J::L
speed.
4) Turn ignition switch "OFF", wait at least 7 seconds and
then turn "ON". ~:::lr
5) Perform "Diagnostic Test Mode II (Self-diagnostic
results)" with ECM.

EC-223 363
 TROUBLE DIAGNOSIS FOR DTC P0505
Idle Air Control Valve (IACV) -Auxiliary Air
Control (AAC) Valve (Cont'd)

EC-AACN-01

- Detectable line for OTC

: Non-detectable line for DTC

Refer to "El-POWER"

B/W

B/W

~
IACV-AAC
SOLENOID
VALVE
~@)
WIG

WIG

~
ISC ECM (EGGS
CONTROL
MODULE}
(iJill)

£@)
\JI:Y GY

AEC312A

364 EC-224
 TROUBLE DIAGNOSIS FOR DTC P0505
Idle Air Control Valve (IACV) - Auxiliary Air
Control (AAC) Valve (Cont'd)
DIAGNOSTIC PROCEDURE
INSPECTION START

CHECK POWER SUPPLY. Check the following.

1. Stop engine. • 15A fuse
2. Disconnect IACV-AAC valve harness • Harness for open or short
connector. between IACV~AAC valve
3. Turn ignition switch "ON". and fuse
4. Check voltage between terminal ® and If NG, repair harness or
ground with CONSULT or tester. connectors.

~~5~8
Voltage: Battery voltage

OK

ffiB CHECK OUTPUT SIGNAL CIRCUIT.

1. Turn ignition switch "OFF".
Repair harness or
tors.
connec~

2. Disconnect ECM harness connector.

3. Check harness continuity between ECM
terminal @ and terminal @).
Continuity should exist.
If OK, check harness for short.
SEF155S L------~------_j

~========~
lEI
OK

CHECK COMPONENT NG Replace IACV~AAC valve.

(IACV·AAC valve).

l:j lv@a Refer to "COMPONENT INSPECTION"

below.

II ECM JOfcoNNECTORII OK
101
Disconnect and reconnect harness connec~
tors in the circuit. Then retest.

Trouble is not fixed.

L _ _ _ _ _ _ _ _ _ _ _ __cs_cEF'-1-'56CCJS Check ECM pin terminals for damage and

check the connection of ECM harness con-
nector. Reconnect ECM harness connector
and retest.

INSPECTION END

COMPONENT INSPECTION
IACV-AAC valve
IACV-AAC valve
Disconnect IACV-AAC valve harness connector.
• Check IACV-AAC valve resistance.
Resistance:
Approximately 1on at 25°C (77°F)
• Check plunger for seizing or sticking.
• Check for broken spring.

EC-225 365
 TROUBLE DIAGNOSIS FOR DTC P0510

Throttle position switch Closed Throttle Position Switch

built into throttle
position sensor COMPONENT DESCRIPTION
A closed throttle position switch and wide open throttle position
switch are built into the throttle position sensor unit. The wide open
throttle position switch is used only for AfT control.
When the throttle valve is in the closed position, the closed throttle
position switch sends a voltage signal to the ECM. The ECM only
uses this signal to open or close the EVAP canister purge control
valve when the throttle position sensor is malfunctioning.
SEF157S

ECM TERMINALS AND REFERENCE VALUE

Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

I
!Ignition switch "ON" (Warm-up condition) BATTERY VOLTAGE

Throttle position switch L Accelerator pedal released (11 - 14V)

27 y
(Closed position) pgnition switch "ON"' I
Approximately OV
L Accelerator pedal depressed

CONSULT REFERENCE VALUE IN DATA MONITOR MODE

Specification data are reference values.
MONITOR ITEM CONDITION SPECIFICATION
Throttle valve:
ON
• Ignition switch: ON Idle position
CLSDTHUP SW
(Engine stopped) Throttle valve:
OFF
Slightly open

ON BOARD DIAGNOSIS LOGIC

Diagnostic Trouble Check Items
Malfunction is detected when
Code No. (Possible Cause)
P0510 • Battery voltage from the closed throttle position • Harness or connectors.
0203 switch is sent to ECM with the throttle valve (The closed throttle position switch circuit is
opened. shorted.)
• Closed throttle position switch.

OVERALL FUNCTION CHECK

Use this procedure to check the overall function of the closed
throttle position switch circuit. During this check, a 1st trip DTC
II ECM ]OfcoNNECTORij cf8'~-H might not be confirmed.
1) Start engine and warm it up sufficiently.
27
2) Check the voltage between ECM terminal @ and ground
under the following conditions.
At idle: Battery voltage
At 2,000 rpm: Approximately OV

SEF661R

366 EC-226
 TROUBLE DIAGNOSIS FOR DTC P0510
Closed Throttle Position Switch (Cont'd)
@[.

EC-TP/SW-01

- : Detectable line lor DTC

: Non-detectable line for DTC

!llill

©L
8/W

m
,-----~~--------------oTHROTILE
POSITION
SWITCH
WIDE (CLOSED THROTILE POSITION
OFF SWITCH AND WIDE OPEN

•', ,• OPEN
THROTILE POSITION SWITCH)
<M??l
CLOSED
•-' OFF

t!iJJ
y

l@bl
IDLE ECM (EGGS
CONTROL
MODULE)

~------------~~ I

~
101 102 103 104 105 106 fiT2l3 ~
5 6 7 8
20 21 22 23
~~ 401W~~
""
24 25 26 27 28 ~ 43
107 108 109 110 111112 gJ 10
11 12 13 14 19 2930313233 70
113 114 115 116 1171181l12J 16 17 181 34 35 36 37f
L±?.c:!!! !J.gJ

AEC057A

EC-227 367
 TROUBLE DIAGNOSIS FOR DTC P0510
Closed Throttle Position Switch (Cont'd)
DIAGNOSTIC PROCEDURE

~f'"~11 INSPECTION START

~ :0 r~
CHECK FIC.
Perform "Fast Idle Cam (FIG) Inspection
and Adjustment", EC-27.
/ -;u . ~ ?'

~ ~ ~ Cl~~~~ ~ J
-
. poM,on
(~ sw1tch harness connector r.:J
-, I ',, SEF158S NG
CHECK POWER SUPPLY. Repair harness or connec-
1. Turn ignition switch "OFF". tors.
r.:J 2. Disconnect throttle position switch har-
ness connector.

@'fuJ ~i5 3. Turn ignition switch "ON".

4. Check voltage between terminal @
and ground with CONSULT or tester.
Voltage: Battery voltage

~ m~
~~
~
rK

£J -~
CHECK INPUT SIGNAL CIRCUIT.
1. Turn ignition switch "OFF".
2. Disconnect ECM harness connector.
NG
~
Repair harness or connec-
tors.
SEF405Q
3. Check harness continuity between ECM
terminal @ and terminal @.
~
~ID ~18
Continuity should exist.
If OK, check harness for short.

lof II o:ffu) l OK

-
II ECM CONNECTOR
[!!
27 NG
CHECK INPUT SIGNAL CIRCUIT. Repair harness or connec-
1. Turn ignition switch "ON". tors.
2. Check voltage between ECM terminal
[ill @ and engine ground.
@a Voltage: Approx. OV

SEF662R tOK

[!! ADJUST THROTTLE POSITION SWITCH.

~ ID~
Pertorm BASIC INSPECTION, EC-72.
8 ~OK
!of II
II ~
ECM coNNECTOR CHECK COMPONENT Replace throttle position
27 (Closed throttle position switch). switch.
Refer to "COMPONENT INSPECTION"
on next page.
[YJ
~
l ~
~OK
Disconnect and reconnect harness con-
SEF663R nectars in the circuit. Then retest.

.+- Trouble is not fixed.

Check ECM pin terminals for damage and

check the connection of ECM harness
connector.
Reconnect ECM harness connector and
retest.

~
INSPECTION END

368 EC-228
TROUBLE DIAGNOSIS FOR DTC P0510
Closed Throttle Position Switch (Cont'd)
COMPONENT INSPECTION
Closed throttle position switch
1. Start engine and warm it up sufficiently. ilil'i\
2. Turn ignition switch "OFF".
3. Disconnect throttle position switch harness connector.
4. Check continuity between terminals ® and ® while opening !lliiiil
throttle valve manually.
Throttle valve conditions Continuity
IL©
Completely closed Yes
SEF159S
Partially open or completely open No

If NG, replace throttle position switch.

i\fil

EC-229 369
 TROUBLE DIAGNOSIS FOR DTC P0605

Engine Control Module (ECM)-ECCS Control

Module
COMPONENT DESCRIPTION
The ECM consists of a microcomputer, diagnostic test mode
selector, and connectors for signal input and output and lor power
supply. The unit controls the engine.

SEC220B

ON BOARD DIAGNOSIS LOGIC

Diagnostic Trouble Check Item
Malfunction is detected when ....
Code No. (Poss1ble Cause)
P0605 • ECM calculation function is malfunctioning. e ECM
0301 (EGGS control module)

DIAGNOSTIC TROUBLE CODE CONFIRMATION

PROCEDURE
1) Turn ignition switch "ON".
(j)2) Select "DATA MONITOR" mode with CONSULT.
3) Start engine.
4) Run engine lor at least 2 seconds at idle speed.
----------OR----------
1) Turn ignition switch "ON".
2) Start engine.
3) Run engine lor at least 2 seconds at idle speed.
4) Select "Mode 7" with GST.
---------OR---------
1) Turn ignition switch "ON".
2) Start engine and wait at least 2 seconds.
3) Turn ignition switch "OFF" and wait at least 7 seconds.
4) Perform "Diagnostic Test Mode II (Sell-diagnostic
results)" with ECM.

DIAGNOSTIC PROCEDURE
INSPECTION START

+
@ 1. Turn ignition switch "ON".
2. Select "SELF DIAG RESULTS"
mode with CONSULT.
3. Touch "ERASE".
OR
~Gj) 1. Turn ignition switch "ON".
2. Select MODE 4 with GST.
3. Touch "ERASE".
OR
~
~_::_Lj.
1. Turn ignition switch "ON".
2. Erase the diagnostic test mode
ll (Self-diagnostic results)
memory.

®
•
(Go to next page.)

370 EC-230
TROUBLE DIAGNOSIS FOR DTC P0605
Engine Control Module (ECM)-ECCS Control
Module (Cont'd) '!ll~
@
~
PERFORM DIAGNOSTIC TROUBLE
CODE CONFIRMATION PROCEDURE.
See previous page.

~
Is the DTC P0605 (0301) displayed
again?
.r
Yes Replace ECM.
I
.j.No
INSPECTION END

loll!'

EC-231 371
 TROUBLE DIAGNOSIS FOR DTC P0705

Park/Neutral Position Switch

COMPONENT DESCRIPTION
When the gear position is "P" (Afr models only) or "N", park/
neutral position is "ON".
ECM detects the position because the continuity of the line (the

'·~
"ON" signal) exists.

r Neutral pos1t1on SWitch

SEF508P

ECM TERMINALS AND REFERENCE VALUE

Specification data are reference values and are measured between each terminal and @ (EGGS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

pgnition switch "ON" 1

Neutral position switch f- Gear position is "Neutral position" (MIT mod- Approximately OV
(Mff models) els)
22 UB - Gear position is "N" or "P" (AfT models)
Inhibitor switch (AfT mod-
els) pgnition switch "ON" 1
Approximately SV
L Except the above gear position

CONSULT REFERENCE VALUE IN DATA MONITOR MODE

Specification data are reference values
MONITOR ITEM CONDITION SPECIFICATION
Shift lever "P" or "N" ON
PiN POSI SW • Ignition switch: ON
Except above OFF

ON BOARD DIAGNOSIS LOGIC

Diagnostic
Check Items
Trouble Code Malfunction is detected when .
(Possible cause)
No.
P0705 • The signal of the park/neutral position switch is not • Harness or connectors
1003 changed in the process of engine starting and driving. (The neutral position switch or inhibitor switch circuit
is open or shorted.)
• Neutral position switch (MIT models)
• Inhibitor switch (AfT models)

372 EC-232
 TROUBLE DIAGNOSIS FOR DTC P0705
Park/Neutral Position Switch (Cont'd)
(~[
OVERALL FUNCTION CHECK
• PARKINEUT POSI SW CKT •
Use this procedure to check the overall function of the park/neutral
SHIFT position switch circuit. During this check, a 1st trip DTC might not j;flik
be confirmed.
OUT OF N/P -RANGE (F.i\ 1) Turn ignition switch "ON".
THEN ~ 2) Perform "PARK!NEUT POSI SW CKT" in "FUNCTION il'iiu
TEST" mode with CONSULT.
TOUCH START ----------OR----------
~ 2) Select "P/N POSI SW" in "DATA MONITOR" mode with U~
~ CONSULT.
I NEXT
II START I
tiEF962N 3) Check the "P/N POSI SW" signal under the following •
conditions.
<[}:MONITOR *NO FAIL D Condition (Gear position) Known good signal

START SIGNAL OFF "N" and "P" (AfT only) position ON

CLSDTHUPSW ON Except the above position OFF
P/N POSI SW ON

----------OR----------
1) Turn ignition switch "ON".
2) Check voltage between ECM terminal @ and body
ground under the following conditions. Li'i!
I RECORD I
SEF096T
Condition (Gear position) Voltage (V) (Known good data)
"N" and "P" (A/T only) position Approx. 0
~i) Except the above position Approx. 5

I ECM lofCONNECTOR,,
22

iD~ ~~
00~ ~
SEF160S

EC-233 373
 TROUBLE DIAGNOSIS FOR DTC P0705
Park/Neutral Position Switch (Cont'd)

EC-PNP/SW-01
<:E/ :AfT models - · Detectable line for DTC
<B): MIT models : Non-detectable line for DTC

Refer to "EL-POWER".
1DA
QI]

@ (M44)

~LiB~ us--:::~::---o ':£::----..1

I UB y

OTHERS
~
,---"-;..-<--,NEUTRAL
POSITION
SWITCH
~
1[ ]"'"' "c NEUTRAL
POSITION
RELAY
(~)
~ ~~
' N B B

ll4Jl
B L!
I
I i-i--,

AEC313A

374 EC-234
 TROUBLE DIAGNOSIS FOR DTC P0705
Park/Neutral Position Switch (Cont'd)
DIAGNOSTIC PROCEDURE
/~ I Neutral position switch I

~ m
INSPECTION START
I

~~
~-

~10 I?' CHECK GROUND CIRCUIT. NG Repair harness or connec-

~ Neutral posrtron swrtch
1. Disconnect neutral position switch har- f----> tors.
ness connector.
SEF508P 2. Check harness continuity between termi-
nal ® and body ground.
m Continuity should exist.
If OK, check harness for short.

~ID@a OK
m
~ CHECK INPUT SIGNAL CIRCUIT.
1. Disconnect ECM harness connector.
NG Check the following.
---+ • Harness connectors
@,@

[illlfl
2. Check harness continuity between ECM
terminal @ and terminal G). • Harness for open or short
Continuity should exist. between ECM and neutral
If OK, check harness for short. position switch
If NG, repair hamess or con-
SEF162S OK
nectars.

m CHECK COMPONENT NG Replace neutral position

(Neutral position switch). f---. switch.

~iD@a ~15
Refer to MT section

~OK
II ECM ]OfcoNNECTOR II m Disconnect and reconnect harness connec-

[il
22
tors in the circuit. Then retest.

+Trouble is not fixed.

Check ECM pin terminals for damage and

SEF163S check the connection of ECM harness con-
nectar. Reconnect ECM harness connector
and retest.

+
INSPECTION END

EC-235 375
 TROUBLE DIAGNOSIS FOR DTC P0705
Park/Neutral Position Switch (Cont'd)
jlnhibitor switch (AfT models)
I
INSPECTION START
I I
l!l I
CHECK POWER SUPPLY.
~ Check the following.

~~·~~
1. Turn ignition switch "OFF". • 10A fuse
2. Disconnect park and neutral position • Harness for open or short
® , ~\\ relay. between inhibitor switch

~~ ~/' SEF164SA
3. Make sure that selector lever is in "P" or
"N" position.
and fuse
• Harness for open or short
4. Turn ignition switch "ON". between inhibitor switch
l!l 5. Check voltage between terminal ®
and and park and neutral

~~5~~ ground with CONSULT or tester.

Voltage: Battery voltage
position relay
If NG, repair harness or
connector.
~5 OK
~OK
CHECK COMPONENT
(INHIBITOR SWITCH).

~Lfl
Refer to AT section.

I!]

~
SEF165S Repair harness or connec-
CHECK GROUND CIRCUIT.
1. Turn ignition switch "OFF". tors.
I!] 2. Check harness continuity between relay

~
DISCONNECT

IV @a terminals (!), ®
and engine ground.
Continuity should exist.
If OK, check harness for short.
~5
OK
li!l

Til]Jl
- ~
CHECK INPUT SIGNAL CIRCUIT.
1. Disconnect ECM harness connector.
2. Check harness continuity between ECM
terminal @ and relay terminal @.
~ tors.
Repair harness or connec-

SEF166S Continuity should exist.

If OK, check harness for short.
li!l
~ 10@3 ~15
OK

II ECM ]OfcoNNECTOR II
22
~5
li
PARK AND NEUTRAL POSITION RELAY
1. Apply 12V direct current between relay
terminals (j) and ®.
2. Check contin@ between relay termi-
nals ®and 5.
-
NG
Replace park and neutral
position relay.

12V ((j) - ®l
applied:
[ill Continuity exists.
~
No voltage applied:
SEF167S No continuity

~OK
li
2 Disconnect and reconnect harness connec-

.~
tors in the circuit. Then retest.

~mn
~=o--
+Trouble is not fixed.
~
/

w
M
Check ECM pin terminals for damage and INSPECTION END
check the connection of ECM harness con-
nectar. Reconnect ECM harness connector
and retest.
~
5 ®
SEF054F

376 EC-236
 TROUBLE DIAGNOSIS FOR DTC P1105

Manifold Absolute Pressure (MAP)/Barometric

Pressure (BARO) Switch Solenoid Valve
SYSTEM DESCRIPTION
I Engine speed
I Camshaft position sensor I

I Start signal ECM

I Ignition switch I (ECCS MAP/BARO
control switch solenoid
module) valve
Throttle position
I Throttle position sensor I

I Vehicle
I Vehicle speed sensor speed

This system allows the absolute pressure sensor to Solenoid Conditions

monitor either ambient barometric pressure or
• Ignition switch is "ON". (Engine is not run-
intake manifold pressure. The MAP/BARO switch
ning.)
solenoid valve switches between two passages by
ON-OFF pulse signals from the ECM. (One passage • For 5 seconds after starting engine
or
is from the intake air duct, the other is from the
• More than 5 minutes after the solenoid valve
intake manifold.) Either ambient barometric pres-
shuts OFF.
sure or intake manifold pressure is applied to the ON
and
absolute pressure sensor.
• Throttle valve is shut or almost fully shut for
more than 5 seconds
and
• Vehicle speed is less than 100 km/h (62
MPH).

ECM TERMINALS AND REFERENCE VALUE

Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

I Ignition switch "ON" I 0 -1V

MAP/BARO switch sole- j Engine is running.]

116 W/R BATTERY VOLTAGE
noid valve
L Idle speed (More than 5 seconds after starting (t1 - 14V)
engine)

CONSULT REFERENCE VALUE IN DATA MONITOR MODE

Specification data are reference values.
MONITOR ITEM CONDITION SPECIFICATION
• Ignition switch: ON BARO
MAP/BARO SWN
• Engine speed: Idle (More than 5 seconds after starting engine) MAP

EC-237 377
 TROUBLE DIAGNOSIS FOR DTC P1105
Manifold Absolute Pressure (MAP)/Barometric
Absolute pressure sensor
Pressure (BARO) Switch Solenoid Valve
(Cont'd)
COMPONENT DESCRIPTION
The MAP/BARO switch solenoid valve switches its air flow pas-
Intake sage according to the voltage signal sent from the ECM. When
manifold voltage is supplied from the ECM, the MAP/BARO switch solenoid
vacuum
signal
turns "ON". Then, the absolute pressure sensor can monitor the
ambient barometric pressure. When voltage is not supplied from
the ECM, the MAP/BARO switch solenoid valve turns "OFF". Then,
the sensor monitors intake manifold pressure.
SEF417

ON BOARD DIAGNOSIS LOGIC

Diagnostic Trouble Check Items

Malfunction is detected when ....
Code No. (Possible Cause)

P1105 • MAP/BARO switch solenoid valve receives the • Harness or connectors

1302 voltage supplied though ECM does not supply the (MAP/BARO switch solenoid valve circuit is open
voltage to the valve. or shorted.)
• There is little difference between MAP/BARO • Hoses
switch solenoid valve input voltage at ambient (Hoses are clogged or disconnected.)
barometric pressure and voltage at intake mani- • Absolute pressure sensor
fold pressure. • MAP/BARO switch solenoid valve

DIAGNOSTIC TROUBLE CODE CONFIRMATION

1<: MONITOR *NO FAIL D PROCEDURE
1) Start engine and warm it up sufficiently.
CMPS•RPM(REF)
COOLAN TEMP/S
BOO rpm
BS"C ® 2) Turn ignition switch "OFF" and wait at least 7 seconds.
3) Turn ignition switch "ON" and select "DATA MONITOR"
mode with CONSULT.
4) Start engine and let it idle.
5) Wait at least 15 seconds.
OR
I RECORD ISEF715T
~ 1) Start engine and warm it up sufficiently.
2) Turn ignition switch "OFF" and wait at least 7 seconds.
3) Sta rt e ng in e a nd Iet it id Ie .
4) Wait at least 15 seconds.
5) Select "MODE 7" with GST.
---------OR---------
60\ 1) Start engine and warm it up sufficiently.
~ 2) Turn ignition switch "OFF" and wait at least 7 seconds.
3) Start engine and let it idle.
4) Wait at least 15 seconds.
5) Turn ignition switch "OFF", wait at least 7 seconds and
then turn "ON".
6) Perform "Diagnostic Test Mode II (Self-diagnostic
results)" with ECM.

378 EC-238
TROUBLE DIAGNOSIS FOR DTC P1105
Manifold Absolute Pressure (MAP)/Barometric
Pressure (BARO) Switch Solenoid Valve @u
(Cont'd)

EC-SWN-01
- Detectable line for DTC
Refer to ·'EL-POWER". Non-detectable line tor DTC
15A
[I]
8/W

•
BIW

~
MAPIBARO
SWITCH
SOLENOID
VALVE
l.bjdl(~)
WIR

W/R
I@II
SOL ECM(ECCS
CONTROL
MODULE)
L-------------~~11~ I

AEC314A

EC-239 379
 TROUBLE DIAGNOSIS FOR DTC P1105
Manifold Absolute Pressure (MAP)/Barometric
Pressure (BARO) Switch Solenoid Valve
(Cont'd)
DIAGNOSTIC PROCEDURE
INSPECTION START

CHECK VACUUM HOSE.

Check vacuum hose for
clogging, cracks or
improper connection.
If NG, repair or replace the
hose.
Vacuum OK
gauge Vacuum pressure:
Approx. -66.7 kPa
I (-500 mmHg, -19.69 inHg, -9.67
CHECK INTAKE SYSTEM.
Check the intake system
psi)
for air leaks.
OK
I •
MAP/BARO switch
SEF419Q CHECK HOSE BETWEEN ABSOLUTE NG Repair or reconnect the

~========~
151
PRESSURE SENSOR AND MAP/BARO
SWITCH SOLENOID VALVE.
hose.

1. Turn ignition switch "OFF".

2. Check hose for clogging, cracks or
improper connection.

OK
OK(with®
Clogging (without®
CHECK POWER

-£\
"'-._
'-.. Improper connection
SUPPLY AND
OUTPUT SIGNAL
SEF109L CIRCUIT.
1. Turn ignition
switch "ON".
• ACTIVE TEST • D 2. Select "MAP/
BARO SW/V" in
MAP/BARO SW/V BARO
"ACTIVE TEST'
========== MONITOR ========== mode with CON-
CMPS•RPM(REF) BOOrpm
MAP/BARO SW/V BARO NG SULT
ABSOL PRES/SE 4.3V 3. Touch "MAP"
and "BARO"
alternatively.
4. Check for oper-
BARO MAP I
'-------'=O'---_j<SEF714T ating sound.

OK

®
(Go to next page.)
®
(Go to next page.)

380 EC-240
 TROUBLE DIAGNOSIS FOR DTC P1105
Manifold Absolute Pressure (MAP)/Barometric
I!] Pressure (BARO) Switch Solenoid Valve
~ 15~0 (Cont'd)
®
dfu I!]
CHECK POWER SUPPLY.
1 NG
Check the following.
1. Turn ignition switch "OFF". I---> • 15A fuse

IYJS}
~~
2. Disconnect MAP/BARO switch solenoid
valve harness connector.
3. Turn ignition switch "ON".
• Harness for open or
short between MAP/
BARO switch solenoid
SEF169S 4. Check voltage between terminal G) valve and fuse
and ground with CONSULT or tester. If NG, repair harness or
(at Voltage: Battery voltage connectors.

~i5@a ~ID If OK, check harness for short

I ECM M CONNECTOR I dfu

OK

-
116
(at
NG Repair harness or connec-
CHECK OUTPUT SIGNAL CIRCUIT.
1. Turn ignition switch "OFF". tors.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM
[ill terminal @ and terminal @.
Continuity should exist.
SEF170S If OK, check harness for short.

OK

®
r
CHECK COMPONENT
(Absolute pressure sensor). ~ Replace absolute pressure
sensor.
Refer to ""COMPONENT INSPECTION"' of
"'TROUBLE DIAGNOSIS FOR DTC
P0105"". EC-106.

~OK
NG
CHECK COMPONENT Replace MAP/BARO
(MAP/BARD switch solenoid valve). I---> switch solenoid valve.
Refer to ""COMPONENT INSPECTION""
on next page.

~OK
Disconnect and reconnect harness con-
nectors in the circuit. Then retest.

~Trouble is not fixed.

Check ECM pin terminals for damage and

check the connection of ECM harness
connector. Reconnect ECM harness con-
nector and retest.

~
INSPECTION END

EC-241 381
 TROUBLE DIAGNOSIS FOR DTC P1105
Manifold Absolute Pressure (MAP)/Barometric
Pressure (BARO) Switch Solenoid Valve
• ACTIVE TEST •
(Cont'd)
MAP/BARO SWN MAP COMPONENT INSPECTION
========='MONITOR ===,,======/
CMPS•RPM(REF) BOOrpm MAP/BARO switch solenoid valve
MAP/BARO SWN MAP 1. Start engine and warm it up sufficiently.
ABSOL PRES/SE 1.3V
2. Perform "MAP/BARO SWN" in "ACTIVE TEST" mode
with CONSULT.
3. Check the following.
• When "MAP" is selected, "ABSOL PRES/SE" indi-
cates approximately 1.3V.
• When "BARO" is selected, "ABSOL PRES/SE" indi-
• ACTIVE TEST • D cates approximately 4.3V.
4. If NG, replace solenoid valve.
MAP/BARO SWN BARO ----------OR----------
========='MONITOR =========o 1. Remove MAP/BARO switch solenoid valve.
CMPS•RPM(REF) BOO rpm 2. Check air passage continuity.
MAP/BARO SWN BARO
ABSOL PRES/SE 4.3V Air passage Air passage
Condition continuity continuity
between @ and @ between @ and ©
BARO MAP 12V direct current supply
SEF714T between terminals G) Yes No
and®
No supply No Yes

3. If NG, replace solenoid valve.

MEC488B

382 EC-242
 TROUBLE DIAGNOSIS FOR DTC P1130

Swirl Control Valve Control Solenoid Valve i1~

SYSTEM DESCRIPTION
I Throttle position sensor I Throttle position (Idle position)

~Ignition switch l Start signal

Swirl con-
ECM
trol valve
Engine speed (ECCS
I Camshaft position sensor 1 control
control
solenoid
module)
valve
I Mass air flow sensor I Amount of intake air

r Engine coolant temperature sensor I Engine coolant temperature

This system has a swirl control valve in the intake The solenoid valve controls swirl control valve's
passage of each cylinder. shuVopen condition. This solenoid valve is operated ·C:L
While idling and during low engine speed operation, by the ECM
the swirl control valve closes. Thus the velocity of
Swirl control
the air in the intake passage increases, promoting Throttle posi-
valve control Swirl control
the vaporization of the fuel and producing a swirl in tion switch Engine speed
solenoid valve
the combustion chamber. (Idle position)
valve
Because of this operation, this system tends to
increase the burning speed of the gas mixture, ON
Below
ON Closed
improve fuel consumption, and increase the stabil- 3,600 rpm
ity in running conditions. Less than
Also, except when idling and during low engine ON Closed
3,200 rpm
speed operation, this system opens the swirl control OFF
More than
valve. In this condition, this system tends to OFF Open
4,000 rpm
increase power by improving intake efficiency via
reduction of intake flow resistance, intake flow. When eng1ne coolant temperature 1s below ooc (32cF) sw1rl
control valve is kept open.

ECM TERMINALS AND REFERENCE VALUE

Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

IEngine is running. I
0- tV
Swirl control valve control L Idle speed
t 11 GY
solenoid valve I Engine is running. I BATTERY VOLTAGE
L Engine speed is above 3,600 rpm. (11 - 14V)

CONSULT REFERENCE VALUE IN DATA MONITOR MODE

Specification data are reference values
MONITOR ITEM CONDITION SPECIFICATION
• Engine is running at a speed of less than 3,600 rpm. ON
SWRL CONT S/V
• Except above OFF

EC-243 383
 TROUBLE DIAGNOSIS FOR DTC P1130
Swirl Control Valve Control Solenoid Valve
(Cont'd)
COMPONENT DESCRIPTION
Swirl control valve control solenoid valve
The swirl control valve control solenoid valve responds to signals
from the ECM. When the ECM sends an ON (ground) signal, the
solenoid valve is bypassed to apply intake manifold vacuum to the
swirl control valve actuator. This operation closes the swirl control
valve. When the ECM sends an OFF signal, the vacuum signal is
cut and the swirl control valve opens.

ON BOARD DIAGNOSIS LOGIC

Diagnostic
Check Items
Trouble Malfunction is detected when ...
(Possible Cause)
Code No.
P1130 A) An improper voltage signal is sent to ECM through • Harness or connectors
1004 swirl control valve control solenoid valve. (The swirl control valve control solenoid valve circuit is
open or shorted.)
B) The vacuum signal is not sent to swirl control valve • Harness or connector
under specified driving conditions, even though swirl (The swirl control valve control solenoid valve circuit is
control valve control solenoid valve is ON. open.)
• Swirl control valve control solenoid valve
• Intake system
(Intake air leaks)
• Hoses
• Swirl control valve
• Swirl control valve control vacuum check switch
• One-way valve
• Vacuum tank
C) The vacuum signal is sent to swirl control valve even • Harness or connector
though swirl control valve control solenoid valve is (The swirl control valve control solenoid valve circuit is
OFF. shorted.)
• Blocked vacuum pipe or hose
• Swirl control valve control solenoid valve

Note. If DTC P1130 (1004) and P1165 (0112) are displayed, first perform TROUBLE DIAGNOSIS FOR
DTC P1165 (0112). (See EC-251.)

DIAGNOSTIC TROUBLE CODE CONFIRMATION

i:r: MONITOR * NOFAIL D PROCEDURE
CMPS•RPM(REF) Orpm Perform "Procedure for malfunction A" first. If the 1st trip DTC
cannot be confirmed, perform "Procedure for malfunction B
and C".
Procedure for malfunction A
1) Turn ignition switch "ON".
2) Select "DATA MONITOR" mode with CONSULT.
3) Wait at least 5 seconds.
I RECORD I
SEF422T
---------OR---------

384 EC-244
 TROUBLE DIAGNOSIS FOR DTC P1130
Swirl Control Valve Control Solenoid Valve
(Cont'd)

~ ~l
Turn ignition switch "ON" and wait at least 5 seconds.
Select "MODE 7" with GST.
---------OR---------
1) Turn ignition switch "ON" and wait at least 5 seconds.
2) Turn ignition switch "OFF", wait at least 7 seconds and
then turn "ON". ~uti
3) Perform "Diagnostic Test Mode II (Sell-diagnostic
results)" with ECM.

Procedure for malfunction B

1:< MONITOR * NOFAIL D 1) Start engine and warm it up sufficiently.
CMPS•RPM(REF) 800rpm 2) Turn ignition switch "OFF" and wait at least 7 seconds. f'[g
COOLAN TEMP/S BS"C 3) Turn ignition switch "ON" again and select "DATA
MONITOR" mode with CONSULT.
4) Start engine and run it lor at least 20 seconds at idle ©l~
speed.
----------OR----------
1) Start engine and warm it up sufficiently. Iilli'
2) Turn ignition switch "OFF" and wait at least 7 seconds.
I RECORD I
SEF715T 3) Start engine again and run it lor at least 20 seconds at
idle speed.
4) Select "MODE 7" with GST.
OR----------
1) Start engine and warm it up sufficiently. TJ'
2) Turn ignition switch "OFF" and wait at least 7 seconds.
3) Start engine and run it lor at least 20 seconds at idle
speed.
4) Turn ignition switch "OFF", wait at least 7 seconds and
F;D
then turn "ON".
5) Perform "Diagnostic Test Mode II (Sell-diagnostic !';!,
results)" with ECM.

Procedure for malfunction C

1<: MONITOR * NOFAIL D T 1) Start engine and warm it up sufficiently.
CMPS•RPM(REF) 3800rpm ~ 2) Turn ignition switch "OFF" and wait at least 7 seconds. il!!m'
COOLAN TEMP/S 85°C 3) Turn ignition switch "ON" again and select "DATA
MONITOR" mode with CONSULT.
4) Start engine and run it for at least 20 seconds at 3,800 1811
rpm under no load.
----------OR----------
1) Start engine and warm it up sufficiently. R§
2) Turn ignition switch "OFF" and wait at least 7 seconds.
I RECORD ISEF720T 3) Start engine and run it for at least 20 seconds at 3,800
rpm under no load. ll!f
4) Select "MODE 7" with GST.
OR - - - - - - - - - -
1) Start engine and warm it up sufficiently. [~},
2) Turn ignition switch "OFF" and wait at least 7 seconds.
3) Start engine and run it for at least 20 seconds at 3,800
rpm under no load. Ifill.
4) Turn ignition switch "OFF", wait at least 7 seconds and
then turn "ON".
5) Perform "Diagnostic Test Mode II (Self-diagnostic ID!?I
results)" with ECM.

EC-245 385
 TROUBLE DIAGNOSIS FOR DTC P1130
Swirl Control Valve Control Solenoid Valve
(Cont'd)

EC-SWUV-01
- : Detectable line for DTC
Refer to "EL-POWER". : Non-detectable line for DTC
15A
0
Bf.N

I-
u-~-,~~~>
'-r'@
Bf.N

I
Bf.N

i
lbjJJ@)
GY
SWIRL CONTROL
VALVE
CONTROL SOLENOID
VALVE

IriJ®
GY

Lbjdl(~)
GY

I
GY
leinl
swuv ECM (ECCS
CONTROL
MODULE)

~---------------"~"~ I

~@ ,..c;:~.._@)
~GY \..2.illBR

AEC315A

386 EC-246
 TROUBLE DIAGNOSIS FOR DTC P1130
Swirl Control Valve Control Solenoid Valve
@[
(Cont'd)
DIAGNOSTIC PROCEDURE
INSPECTION START

CHECK INTAKE SYSTEM. Repair intake system.

Check intake system for air leaks.

OK

AEC149A
NG Repair vacuum hose.
CHECK VACUUM SOURCE TO SWIRL
CONTROL VALVE CONTROL SOLE-
NOID VALVE.
Vacuum 1. Start engine and warm it up sufficiently.
gauge 2. Disconnect vacuum hose connected to
the solenoid valve.
I 3. Check the vacuum pressure with
vacuum gauge with engine running at ©l.
idle under no load.
Manifold vacuum should exist.
Swirl control valve Minimum vacuum pressure:
-22.7 kPa
Jill
control solenoid valve
SEF719T (-170 mmHg, -6.69 inHg)
I L------------.~O~K~--------~

NG
CHECK HOSES BETWEEN SWIRL CON- Repair or reconnect the
TROL VALVE CONTROL SOLENOID hose.
VALVE, SWIRL CONTROL VALVE CON-
TROL VACUUM CHECK SWITCH AND
Clogging SWIRL CONTROL VALVE ACTUATOR.
1. Turn ignition switch "OFF".
2. Check hose for clogging, cracks or
improper connection.
Improper connection
OK
SEF109L I!J
~--------~----------~
NG
CHECK POWER SUPPLY. Check the following.
1. Disconnect swirl control valve control • Harness connectors
solenoid valve harness connector. @.<§
2. Turn ignition switch "ON". • 15A fuse
3. Check voltage between terminal CD • Harness for open or short
and ground with CONSULT or tester. between swirl control
Voltage: Battery voltage valve control solenoid
valve and fuse
OK If NG, repair harness or con-
nectors.

SEF212S .::!!]=-____________..__________~
;;;==============~ CHECK INPUT SIGNAL CIRCUIT. NG Check the following.
l!l 1. Turn ignition switch "OFF". • Harness connectors
rn
""' ID'"00""'" @aF ~ l"~'"o"'"
~~>,~ 2. Disconnect ECM harness connector.
3. Check continuity between terminal ®
@@
• Harness for open or short
!f:l! and ECM terminal @). between swirl control
cf[b II ECM JOt CONNECTOR II Continuity should exist. valve control solenoid
111 If OK, check harness for short. valve and ECM
If NG, repair harness or con-
OK nectors.

®
(Go to nex1 page.)
SEF213S

EC-247 387
 TROUBLE DIAGNOSIS FOR DTC P1130
Swirl Control Valve Control Solenoid Valve
(Cont'd)

CHECK COMPONENT
(Vacuum tank).
k Replace vacuum tank.

Refer to "COMPONENT INSPECTION"

on next page.

~OK
CHECK COMPONENT ~ Replace one-way valve.
(One-way valve).
Refer to "COMPONENT INSPECTION"
on next page.

~OK
CHECK COMPONENT
(Swirl control valve control vacuum check
switch).
Refer to "COMPONENT INSPECTION",
-
NG Replace swirl control valve
control vacuum check
switch.

"TROUBLE DIAGNOSIS FOR DTC

P1165", EC-251.

~OK

CHECK COMPONENT ~ Replace swirl control valve.

(Swirl control valve).
Refer to "COMPONENT INSPECTION"
on next page.

~OK
CHECK COMPONENT
(Swirl control valve control solenoid
valve).
Refer to "COMPONENT INSPECTION"
on next page.
-
NG Replace swirl control valve
control solenoid valve.

~OK
Disconnect and reconnect harness con-
nectars in the circuit. Then retest.

~Trouble is not fixed.

Check ECM pin terminals for damage and

check the connection for ECM harness
connector. Reconnect ECM harness con-
nectar and retest.

~
INSPECTION END

388 EC-248
 TROUBLE DIAGNOSIS FOR DTC P1130
Swirl Control Valve Control Solenoid Valve
(Cont'd) '~[
COMPONENT INSPECTION
Swirl control valve
Supply vacuum to actuator and check swirl control valve operation.
Condition Swirl control valve
Supply vacuum to actuator Close
No supply Open

SEF371H

Swirl control valve control solenoid valve

Check solenoid valve air passage continuity.

Air passage Air passage

Condition continuity continuity
between @ and @ between @ and ©
12V direct current supply
between terminals G) Yes No
and®
No supply No Yes
MEC488B

If NG, replace solenoid valve.

One-way valve
Check one-way valve air passage continuity.

Condition Air passage continuity

Blow air from side B to A Yes
Blow air from side A to B No

If NG, replace one-way valve.

AEC140A

Vacuum tank
Check vacuum tank leakage.
Apply vacuum -80.0 kPa (-600 mmHg, -23.62 inHg, -11.60 psi). }1]51
Then keep it for 10 seconds and check there is no leakage.

1~1

C@J;Rnd cap SEF405S

EC-249 389
 TROUBLE DIAGNOSIS FOR DTC P1130
Swirl Control Valve Control Solenoid Valve
(Cont'd)
~i3ID~~ Swirl control valve control vacuum check switch
Swirl control valve control
vacuum check switch
I 1.

2.
Disconnect swirl control valve control vacuum check switch
harness connector.
Use vacuum pump to apply vacuum to swirl control valve con-
trol vacuum check switch as shown in figure.
3. Start engine.
4. Check voltage between terminal ® and engine ground with
Vacuum pump CONSULT or tester.

SEF378S Pressure Voltage (V)

More than -18.7 kPa
Engine ground
(-140 mmHg, -5.51 inHg)
-16.7 to -22.7 kPa
Engine ground or
(-140 to -170 mmHg.
Approx. 4.8
-5.51 to -6.69 inHg)
Less than -22.7 kPa
Approx. 4.8
(-170 mmHg. -6.69 inHg)

5. If NG, replace swirl control valve control vacuum check switch.

390 EC-250
 TROUBLE DIAGNOSIS FOR DTC P1165

Swirl Control Valve Control Vacuum Check ell

Switch
COMPONENT DESCRIPTION
The swirl control valve control vacuum check switch detects
vacuum signal to the swirl control valve, and sends "ON" or "OFF"
signal to the ECM.
When vacuum is supplied to the valve, the swirl control valve con-
trol vacuum check switch sends "OFF" signal to the ECM. L©
The swirl control valve control vacuum check switch is not used to
control the engine system, it is used for on board diagnosis.

ECM TERMINALS AND REFERENCE VALUE

Specification data are reference values and are measured between each terminal and @ (ECCS ground}.
TER·
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

II Engine is running. I
OV
Swirl control valve control L Engine speed is above 3,600 rpm.
32 R/Y
vacuum check switch
i!tlr
1 Engine is running.!
Approximately 4.8V
L Engine speed is less than 3,600 rpm.

ON BOARD DIAGNOSIS LOGIC

Diagnostic Trouble Check Items
Malfunction is detected when ...
Code No. (Possible cause)
P1165 The swirl control valve control vacuum check switch • Harness or connectors
0112 remains "OFF" under specified engine conditions. {Swirl control valve control vacuum check switch
circuit is open.)
• Hoses
{Hoses are connected incorrectly.)
• Swirl control valve control solenoid valve
• Swirl control valve control vacuum check switch

CONSULT REFERENCE VALUE IN DATA MONITOR MODE

Specification data are reference values.
MONITOR ITEM CONDITION SPECIFICATION
• Engine is running at a speed of less than 3,600 rpm. OFF
SWLCONVC SW
• Except above ON

EC-251 391
 TROUBLE DIAGNOSIS FOR DTC P1165
Swirl Control Valve Control Vacuum Check
Switch (Cont'd)
i:z: MONITOR i:z: NO FAIL 0 DIAGNOSTIC TROUBLE CODE CONFIRMATION
CMPS•RPM(REF) 3800rpm PROCEDURE
COOLAN TEMP/S 85°C 1) Start engine and warm it up sufficiently.
2) Turn ignition switch "OFF" and wait at least 7 seconds.
3) Turn ignition switch "ON".
4) Select "DATA MONITOR" mode with CONSULT.
5) Start engine and run it for at least 5 seconds at 3,800
rpm under no load.
I RECORD I
SEF720T
----------OR----------
1) Start engine and warm it up sufficiently.
2) Turn ignition switch "OFF" and wait at least 7 seconds.
3) Start engine and run it for at least 5 seconds at 3,800
rpm under no load.
4) Select "MODE 7" with GST.
----------OR----------
{NO\ 1) Start engine and warm it up sufficiently.
'ell 2) Turn ignition switch "OFF" and wait at least 7 seconds.
3) Turn ignition switch "ON".
4) Start engine and run it for at least 5 seconds at 3,800
rpm under no load.
5) Turn ignition switch "OFF", wait at least 7 seconds and
then turn "ON".
6) Perform "Diagnostic Test Mode II (Self-diagnostic
results)" with ECM.

392 EC-252
TROUBLE DIAGNOSIS FOR DTC P1165
Swirl Control Valve Control Vacuum Check
Switch (Cont'd) iiilu

EC-S/VCSW-01

- : Detectable line for DTC

- · Non-detectable line for DTC b©

!¥'~

R!Y
Ci!L

r-
--"-' T-'~'--'-----, SWIRL CONTROL
VALVE CONTROL l!i'ii'
VACUUM CHECK
SWITCH

·---
OFF ON (M 3g)

lAY

'ii'IP

~~'

[F(A

~.,~i

•I i l ~[g)

B
~
_._ B B
~
~'[]'

crill9l (~) (~)

~~~

®·1

~Jl

Jl1

~~2:£

AEC061A

EC-253 393
 TROUBLE DIAGNOSIS FOR DTC P1165
Swirl Control Valve Control Vacuum Check
Switch (Cont'd)
DIAGNOSTIC PROCEDURE
INSPECTION START

CHECK HOSES BETWEEN SWIRL CON- Repair or reconnect the

TROL VALVE CONTROL SOLENOID hose.
VALVE, SWIRL CONTROL VALVE CON-
TROL VACUUM CHECK SWITCH AND
SWIRL CONTROL VALVE ACTUATOR.
1. Turn ignition switch "OFF".
2. Check hose for clogging, cracks or
improper connection.

OK

Clogging CHECK INPUT SIGNAL CIRCUIT. NG Repair harness or connec-

1. Turn ignition switch "OFF". tors.
2. Disconnect swirl control valve control
vacuum check switch harness connec-
Improper connection
tor.
SEF109L
3. Check voltage between terminal ®
and ground with CONSULT or tester.
Voltage: Approximately 5V

OK

CHECK GROUND CIRCUIT. NG Repair harness or connec-

1. Turn ignition switch "OFF". tors.
2. Check harness continuity between ter-
minal CD and engine ground.
Continuity should exist.
If OK, check harness for short.
SEF215S '----------,--o:-c;-------'
~==================~ OK
CHECK COMPONENTS NG Replace swirl control valve
(Swirl control valve control vacuum check control vacuum check
switch). switch.
Refer to "COMPON~NT INSPECTION"
on next page.

OK

CHECK COMPONENT NG Replace swirl control valve

(Swirl control valve control solenoid control solenoid valve.
SEF216S
valve).
Refer to "COMPONENT INSPECTION"
on next page.

OK

Disconnect and reconnect harness con-

nectors in the circuit. Then retest.

Trouble is not fixed.

®
(Go to next page.)

394 EC-254
 TROUBLE DIAGNOSIS FOR DTC P1165
Swirl Control Valve Control Vacuum Check
Switch (CoU'd)

~
Check ECM pin terminals for damage and
check the connection of ECM harness
connector. Reconnect ECM harness con-
nector and retest.

INSPECTION END

COMPONENT INSPECTION
~i3ID~liQID
Swirl control valve control
vacuum check sw1tch
I Swirl control valve control vacuum check switch
1. Use vacuum pump to apply vacuum to swirl control valve con-
trol vacuum check switch as shown in figure.
ii'"~
c'"

2. Start engine.
3. Check voltage between terminal ® and engine ground with
CONSULT or tester.
Vacuum pump Pressure Voltage (V) riur
~

SEF378S
More than -18.7 kPa
Engine ground
(-t40 mmHg, -5.51 inHg)
-18.7 to -22.7 kPa
Engine ground or
(-140 to -170 mmHg,
Approx. 4.8
-5.51 to -6.69 inHg)
Less than -22.7 kPa
Approx. 4.8
(-170 mmHg, -6.69 inHg)

4. If NG, replace swirl control valve control vacuum check switch.

Swirl control valve control solenoid valve

Check solenoid valve air passage continuity.

Air passage Air passage

Condition continuity continuity
between @ and @ between ® and ©
12V direct current supply
between terminals <Il Yes No
and®
No supply No Yes
MEC4888

If NG, replace solenoid valve.

EC-255 395
 TROUBLE DIAGNOSIS FOR DTC P1320

Ignition Signal
COMPONENT DESCRIPTION
Ignition coil & power transistor {Built into distributor)
The ignition signal from the EGM is sent to and amplified by the
power transistor. The power transistor turns on and off the ignition
harness connector
coil primary circuit. This on-off operation induces the proper high

~\f
voltage in the coil secondary circuit.

Camshaft position sensor and power

__,-,-transistor harness connector SEF128S

ECM TERMINALS AND REFERENCE VALUE

Specification data are reference values and are measured between each terminal and @ (EGGS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

II Engine is running. I
o.3- o.ev·
L Idle speed
1 w Ignition signal
1Engine is running. I
Approximately 0.8V*
L Engine speed is 2,000 rpm

!Engine is running. I
2 WIG Ignition check Approximately 12V*
L Idle speed

1Engine is running. I
3 w Tachometer Approximately 0.9V*
L Idle speed

*:Average voltage for pulse stgnal (Actual pulse stgnal can be conftrmed by osctlloscope.)

ON BOARD DIAGNOSIS LOGIC

Diagnostic
Check Items
Trouble Malfunction is detected when .
(Possible Cause)
Code No.

P1320 • The ignition signal in the primary circuit is not sent • Harness or connectors
0201 during engine cranking or running. (The ignition primary circuit is open or shorted.)
• Power transistor
• Resistor
• Camshaft position sensor
• Camshaft position sensor circuit

396 EC-256
 TROUBLE DIAGNOSIS FOR DTC P1320
Ignition Signal (Cont'd)
DIAGNOSTIC TROUBLE CODE CONFIRMATION
*:MONITOR * NOFAIL D PROCEDURE
CMPS•RPM(REF) BOO rpm Note: If both DTC P0340 (01 01) and P1320 (0201) are i~Tib\
displayed, perform TROUBLE DIAGNOSIS FOR DTC
P0340 first. (See EC-171.)
fF.i\ 1) Turn ignition switch "ON".
~ 2) Select "DATA MONITOR" mode with CONSULT.
3) Start engine. (If engine does not run, turn ignition switch
to "START" for at least 5 seconds.)
I RECORD I SEF712T t;i)
--------OR-------
1) Turn ignition switch "ON".
a" 2) Start engine. (If engine does not run, turn ignition switch
to "START" for at least 5 seconds.)
3) Select MODE 7 with GST.
--------OR--------
(No\ 1) Turn ignition switch "ON".
~ 2) Start engine. (If engine does not run, turn ignition switch
to "START" for at least 5 seconds.) :gl
3) Turn ignition switch "OFF", wait at least 7 seconds and
then turn "ON".
4) Perform "Diagnostic Test Mode II (Self-diagnostic l~'iY
results)" with ECM.

EC-257 397
 TROUBLE DIAGNOSIS FOR DTC P1320
Ignition Signal (Cont'd)

I BAd]RY I EC-IGN/SG-01

W
E~~BLE
(M47), @j)
- ; Detectable line for OTC
lbjdJ Refer to "El·POWER".
. Non-detectable line for DTC
W/B
•
W/B

m
.---"-T--"--, IGNITION
B/W
ST SWITCH

ON
(M130)
rr!Jl
CONDENSER
B/W

~~~~~~~~~---~:+~-----------------_j~L,
POWER
DISTRIBUTOR
~ ~
TRANSISTOR ~ ·~

1'!'1"~"~
(M56)

U4Jl
WIG

r:::j-----1''
'
''
WIG

m
'
~~ ~---,------
~
B

m
:=-1
W

SPARK IGNCK GND- IGN ECM (EGGS B

PLUG CASE CONTROL ...L.
MODULE) -=-
L-------------------~~ ~

,------------------------~ ,-~-------------1
I
I
1( 1
ffi (M12)
1210 Isla)
~(M13) I
I.ZJ.!l.)
Gv GY
I

1 1
: 1
2
(@)
B
[i]@j) :
l1j B I
'-------------------------' L- _____________ I

AEC316A

398 EC-258
 TROUBLE DIAGNOSIS FOR DTC P1320
Ignition Signal (Cont'd)
DIAGNOSTIC PROCEDURE
INSPECTION START
I I
~ Yes
Turn ignition switch "OFF", and restart
---+ ® (Go to next page.)
~s connector
engine.
:--" Is engine running?

~ ~\[- m
! r I ]\1
_..-r"
I_]_--'- lJ
.._Camshaft position sensor and power
transistor harness connector SEF128S
CHECK POWER SUPPLY.
~No

1. Turn ignition switch "OFF". ~ Repair harness or connec-

tors.
2. Disconnect ignition coil harness con-
m nectar.

~ &5~0
3. Turn ignition switch "ON".
4. Check voltage between terminal 0
and ground with CONSULT or tester.
dfu Voltage: Battery voltage

~OK
m
TI[]Wl
~ ~
CHECK GROUND CIRCUIT.
1. Turn ignition switch "OFF".
2. Disconnect power transistor harness
connector.
NG
1- Repair harness or connec-
tors.

SEF172S 3. Check harness continuity between ter-

minal ® and engine ground.
m Continuity should exist.

~ &)@a If OK, check harness for short.

~OK
Cil2lffll5l6)

[ill
,,s_
CHECK INPUT SIGNAL CIRCUIT.
1. Disconnect ECM harness connector.
2. Check harness continuity between ECM
terminalCD and terminal
Continuity should exist.
CD.
-
NG
Repair harness or connec-
tors.

If OK, check harness for short.

~

SEF173S
~OK

l!J
CHECK COMPONENTS
(Ignition coil, power transistor).
~ Replace malfunctioning
component(s).
Refer to "COMPONENT INSPECTION",

~lo@a
EC~261.

~lo ~OK
II ECM foi' CONNECTOR II (1 /2/@/5/6)
Disconnect and reconnect harness con-
1
nectars in the circuit. Then retest.

~Trouble is not fixed.

fiTI Check ECM pin terminals for damage and

SEF174S
check the connection of ECM harness
connector. Reconnect ECM harness con-
nectar and retest.

+
INSPECTION END

EC-259 399
 TROUBLE DIAGNOSIS FOR DTC P1320
Ignition Signal (Cont'd)
®

CHECK INPUT SIGNAL CIRCUIT. NG Repair harness or connec-

1. Stop engine. tors.
2. Disconnect ignition coil harness con~
nectar.
3. Strip tape covering resistor.
4. Disconnect resistor harness connector.
5. Disconnect ECM harness connector.
EC277A 6. Check harness continuity between ter-
minal @ and terminal G), terminal ®
and ECM terminal @.
Continuity should exist.
If OK, check harness for short.

OK

CHECK COMPONENTS Replace resistor.

(Resistor).
Refer to "COMPONENT INSPECTION''
on next page.

OK
AEC125A

Disconnect and reconnect harness con-

nectors in the circuit. Then retest.

~ioc&a Trouble is not fixed.

II ECM JOI'coNNECTOR\1
Check ECM pin terminals for damage and
2
check the connection of ECM harness
connector. Reconnect ECM harness con-
nector and retest.

L __ _ _ _ _ _ _ _ _ _ _ _ _ _ _
-_-_
-_ s_E_F_17_7_JS
- ________ ,-------------~~-------------,
INSPECTION END

400 EC-260
TROUBLE DIAGNOSIS FOR DTC P1320
Ignition Signal (Cont'd)
COMPONENT INSPECTION
Ignition coil
1. Disconnec1 igni1ion coil harness connec1or.
2. Remove distributor cap.
3. Check resistance as shown in the figure.
Terminal Resistance [at 25'C (77'F)]
0·® Less than 1!1

0-® 7-13 kfl

AEC150A
If NG, replace distributor assembly.

Ignition
coil

Power transistor
1. Disconnect camshaft position sensor & power transistor har-
ness connector and ignition coil harness connector. 1i'IP
2. Check power transistor resistance between terminals ® and
®
Terminals Resistance Result
Except Ofl OK
®and@
on NG

AEC151A If NG, replace distributor assembly.

Resistor
1. Disconnect resistor harness connector.
2. Check resistance between terminals CD and ®.
Resistance: Approximately 2.2 kD
If NG, replace resistor.

SEF180S

EC-261 401
 TROUBLE DIAGNOSIS FOR DTC P1336

Crankshaft Position Sensor (CKPS) (OBD)

(COG)
Cocel
COMPONENT DESCRIPTION
I

.
The crankshaft position sensor (OBD) is located on the transmis-

1!0~~=rc~
sion housing facing the gear teeth (cogs) of the flywheel or drive
plate. It detects the fluctuation of the engine revolution.
The sensor consists of a permanent magnet, core and coil.
When the engine is running, the high and low parts of the teeth
cause the gap with the sensor to change.
SEF956N
The changing gap causes the magnetic field near the sensor to
change.
Due to the changing magnetic field, the voltage from the sensor
changes.
The ECM receives the voltage signal and detects the fluctuation of
the engine revolution.
This sensor is not used to control the engine system.
It is used only for the on board diagnosis of misfire.

Crankshaft position
~sensor (OBD)
harness connector
Front left brake hose SEF124S

ECM TERMINALS AND REFERENCE VALUE

Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

1 Engine is running. I (Warm-up condition)

50 BiG Sensors' ground O.OOt - 0.02V
L Idle speed

Crankshaft position sensor 1 Engine is running.! (AfT: N range, MfT: Neutral) More than 0.2V*
53 R
(OBD) L Idle speed (Air conditioner switch "OFF".) (AC range)
..
. Average voltage for pulse s1gnal (Actual pulse s1gnal can be confirmed by oscilloscope.)

ON BOARD DIAGNOSIS LOGIC

Diagnostic
Check Items
Trouble Code Malfunction is detected when .
(Possible Cause)
No.
P1336 • A chipping of the flywheel or drive plate gear tooth • Harness or connectors
0905 (cog) is detected by the ECM. • Crankshaft position sensor (OBD)
• Flywheel (Drive plate)

402 EC-262
 TROUBLE DIAGNOSIS FOR DTC P1336
Crankshaft Position Sensor (CKPS) (OBD)
(COG) (Cont'd) ~~~
'f,: MONITOR * NOFAIL D DIAGNOSTIC TROUBLE CODE CONFIRMATION
CMPS•RPM(REF) BOO rpm PROCEDURE ill!~
rlf\ 1) Turn ignition switch "ON" and select "DATA MONITOR"
\J!) mode with CONSULT.
2) Start engine and run it for at least 2 minutes at idle li.iltl
speed.
---------OR---------
1) Start engine and run it for at least 2 minutes at idle l©
I RECORD I speed.
SEF712T 2) Select "MODE 7" with GST.
---------OR---------
610\ 1) Start engine and run it for at least 2 minutes at idle
~ speed.
2) Turn ignition switch "OFF", wait at least 7 seconds and li'li.i
then turn "ON".
3) Perform "Diagnostic Test Mode II (Self-diagnostic
results)" with ECM. gl

EC-263 403
 TROUBLE DIAGNOSIS FOR DTC P1336
Crankshaft Position Sensor (CKPS) (OBD)
(COG) (Cont'd)

EC-CKPS-01

CRANKSHAFT
POSITION - : Detectable line for DTC
SENSOR (OBD) : Non-delectable line for DTC
~~------~~~-~
rLp l!4JJ
R G
'
r=
I
-==::::::= -~
I
I
I
I
I
+
I

~&:~~~~~~~~&=----,l
=w=
R
=w=
G
®
(~)

r=
I
I
I
I
I
I
--"'"" -r ·~
I I
~= ---------
--------- _:=.
I

G
•
• - 8/G + To EC-ECTS
I
B/G
•
· - B I G + ToEC-TPS

R 8/G

~ ~
,-,;RG~C;,/!£-S-----;':G~ND:':-_-';;A----, ECM (ECCS
CONTROL
MODULE)
@W
il
B
.,!,.
B
.,!,.
<till> (~)
Refer to last page (Foldout page).
@.ill>

~(@) ~~
~ GY l:W..J GY

~1
0

AEC063A

404 EC-264
 TROUBLE DIAGNOSIS FOR DTC P1336
Crankshaft Position Sensor (CKPS) (OBD)
(COG) (Cont'd)
DIAGNOSTIC PROCEDURE
INSPECTION START

CHECK SHIELD CIRCUIT. NG Repair harness or connec-

1. Turn ignition switch "OFF". tors.
2. Loosen and retighten engine ground
screws.

•
SEF089S 3. Remove joint connector-1.
~==:;::::====::;::=======~ 4. Check the following.
• Continuity between joint connector-1
terminal and ground
• Joint connector-1
(Refer to ""HARNESS LAYOUT" in EL
section.)
Continuity should exist.
If OK, check harness for short. Then
reconnect joint connector-1.
Crankshaft position
~sensor (OBD)
OK
harness connector EJ
Front left brake hose SEF124S ~L....-------"'---------, NG
~==============~ Check the following.
m CHECK INPUT SIGNAL CIRCUIT.
1. Disconnect crankshaft position sensor • Harness connectors
(OBD) harness connector and ECM @.@
harness connector. • Harness for open or short
2. Check continuity between ECM terminal between crankshaft posi-
cfl"0 ECM ]OfCONNECTOR II @ and terminal G). tion sensor (OBD) and
53 Continuity should exist. ECM
If OK. check harness for short. If NG, repair harness or con-
nectors.
OK

CHECK GROUND CIRCUIT. NG Check the following.

SEF126S
1. Turn ignition switch "OFF". • Harness connectors
2. Reconnect ECM harness connector. @@
~ io@a 3. Check harness continuity between ter-
minal ® and engine ground.
• Harness for open or short
between crankshaft posi-
cfl"0 Continuity should exist.
If OK, check harness for short.
tion sensor (OBD) and
ECM
If NG, repair harness or con-
OK
nectors.

Loosen and retighten the fixing bolt of the

crankshaft position sensor (OBD). Then
retest.
L __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _s_E_F_12_7~S L_____________- ,_______________j

Trouble is not fixed.

®
(Go to next page.)

EC-265 405
 TROUBLE DIAGNOSIS FOR DTC P1336
Crankshaft Position Sensor (CKPS) (OBD)
(COG) (Cont'd)
@
~
CHECK COMPONENT
[Crankshaft position sensor (OBD)J. ~ Replace crankshaft posi-
tion sensor (OBD).
Refer to "COMPONENT INSPECTION"
below.

~OK
Disconnect and reconnect harness con-
nectars in the circuit. Then retest.

~ Trouble is not fixed.

Check ECM pin terminals for damage and

check the connection of ECM harness
connector. Reconnect ECM harness con-
nectar and retest.

~Trouble is not fixed.

Visually check for chipping flywheel (drive

plate) gear tooth (cog). ~ Replace the flywheel (drive
plate).

~OK

INSPECTION END

COMPONENT INSPECTION
Crankshaft position sensor (OBD)
1. Disconnect crankshaft position sensor (OBD) harness connec-
tor.
2. Loosen the fixing bolt of the sensor.
3. Remove the sensor.
4. Visually check the sensor for chipping.

SEF960N

5. Check resistance as shown in the figure.

Resistance: Approximately 166-5- 203.5!1 at 20°C
(68°F)

SEF151P

406 EC-266
 TROUBLE DIAGNOSIS FOR DTC P1400

To EGR valve
EGRC-Solenoid Valve
COMPONENT DESCRIPTION
The EGRC-solenoid valve responds to signals from the ECM. ~~l'l
When the ECM sends an ON (ground) signal, the coil in the sole-
noid valve is energized. A plunger will then move to cut the vacuum
signal (from the throttle body to the EGR valve). ~ijJ
When the ECM sends an OFF signal, the vacuum signal passes
through the solenoid valve. The signal then reaches the EGR valve.
[L~~

SEF240PD

ECM TERMINALS AND REFERENCE VALUE

Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

IEngine is running. I (Warm~up condition) BATTERY VOLTAGE

L Engine speed is 2,000 rpm. (11 - 14V)
103 W/L EGRC-solenoid valve
1Engine is running. I (Warm-up condition)
0- tV
L Idle speed

CONSULT REFERENCE VALUE IN DATA MONITOR MODE

Specification data are reference values.
MONITOR ITEM CONDITION SPECIFICATION
• Engine: After warming up
Idle ON
• Air conditioner switch: OFF
EGRC SOLIV
• Shift lever: "N"
Racing up to 1 ,500 - 2,000 rpm OFF
• No-load

ON BOARD DIAGNOSIS LOGIC

Diagnostic
Check Items
Trouble Code Malfunction is detected when ....
(Possible Cause)
No.
P1400 • An improper voltage signal is sent to ECM through • Harness or connectors
1005 EGRC-solenoid valve. (The EGRC-solenoid valve circuit is open or shorted.)
• EGRC-solenoid valve :!iii'

EC-267 407
 TROUBLE DIAGNOSIS FOR DTC P1400
EGRC-Solenoid Valve (Cont'd)
OVERALL FUNCTION CHECK
IEGRC SOL/V CIRCUIT I Use this procedure to check the overall function of the
DOES THE SOLENOID EGRC·solenoid valve circuit. During this check, a 1st trip DTC
might not be confirmed.
VALVE MAKE M 1) Turn ignition switch "ON".
AN OPERATING SOUND ~ 2) Perform "EGRC SOUV CIRCUIT" in "FUNCTION
TEST" mode with CONSULT.
EVERY 3 SECONDS? ------------------OR------------------
1) Turn ignition switch "ON".
I NEXT
II NO II YES I 2) Perform "EGRC SOLENOID VALVE" in "ACTIVE
MEF982D TEST" mode with CONSULT and check the operating
sound, according to ON/OFF switching.
- - - - - - - - - - - - - - - - - OR - - - - - - - - - - - - - - - - -
• ACTIVE TEST • D {NO\ 1) Start engine and warm it up sufficiently.
~ 2) Turn ignition switch "OFF" and wait at least 7 seconds.
EGRC SOL/V ON 3) Start engine again.
4) Check the voltage between ECM terminal @ and
===MONITOR===
CM PS· RPM (REF) Orpm ground at idle speed.
Voltage: 0.04 - O.OBV
5) Check that the voltage changes to battery voltage and
returns to 0.04 · O.OBV when the engine speed
increases to about 2,500 rpm.
I ON lllllll OFF JEF353F

CO~NECT

~ £) 00 ID
II ECM [OJCCNNECTOR )/
103 ~

a -=?'

AEC639

408 EC-268
TROUBLE DIAGNOSIS FOR DTC P1400
EGRC-Solenoid Valve (Cont'd)

EC-EGRCN-01

- : Detectable line for DTC

: Non-detectable line for DTC

B!W
~~

'!?iL

[lj]'jf
EGRC-
SOLENOID
VALVE
@ tc~'IT'
. __ _ B!W~W/L---·

lJ'IF

IF~

[F~

WIL

~
,-----'OE'::G';!R'------, EGM (EGGS M
CONTROL
MODULE)
@ill) [11[:i]

®11

liil:!l

[1111

~~

!;[L

1~;!:1

AEC317A

EC-269 409
 TROUBLE DIAGNOSIS FOR DTC P1400
EGRC-Solenoid Valve (Cont'd)
DIAGNOSTIC PROCEDURE
INSPECTION START

r=--~~----~~-----------,NG
CHECK POWER SUPPLY. Check the following.
1. Turn ignition switch "OFF". • 15A fuse
2. Disconnect EGRC-solenoid valve har- • Harness for open or short
ness connector. between EGRC-solenoid
3. Turn ignition switch "ON". valve and fuse
4. Check voltage between terminal G) and If NG, repair harness or
ground with CONSULT or tester. connectors.
Voltage: Battery voltage

OK
m
~~~----~~--~~----,NG
CHECK OUTPUT SIGNAL CIRCUIT. Repair harness or connec-
1. Turn ignition switch "OFF". tors.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM
terminal @ and terminal @.
Continuity should exist.
If OK, check harness for short.

OK
SEF182S

CHECK COMPONENT NG Replace EGRC-solenoid

~85~ ~iv
(EGRC-solenoid valve). valve.
Refer to "COMPONENT INSPECTION""
below.
II ECM ]O[coNNECTORll cfi'b OK
103
Disconnect and reconnect harness connec-
tors in the circuit. Then retest.

Trouble is not fixed.

Check ECM pin terminals for damage and

check the connection of ECM harness con-
SEF183S
nector. Reconnect ECM harness connector
and retest.

INSPECTION END

COMPONENT INSPECTION
EGRC-solenoid valve
Check air passage continuity.

Air passage Air passage

Condition continuity continuity
between @ and @ between @ and ©
12V direct current supply
between terminals (i) Yes No
and®
No supply No Yes

MEC4BBB If NG, replace solenoid valve.

L-----------------------~

410 EC-270
 TROUBLE DIAGNOSIS FOR DTC P1401

EGR Temperature Sensor

COMPONENT DESCRIPTION
The EGR temperature sensor detects temperature changes in the
EGR passage way. When the EGR valve opens, hot exhaust gases
flow, and the temperature in the passageway changes. The EGR
Gasket temperature sensor is a thermistor that modifies a voltage signal
sent from the ECM. This modified signal then returns to the ECM
as an input signal. As the temperature increases, EGR temperature
sensor resistance decreases.
This sensor is not used to control the engine system. It is used only
SEF599K
for the on board diagnosis.
(Reference data)
10,000
EGR temperature Voltage* Resistance
'C ('F) (V) (M!l)
0 (32) 4.81 7.9- 9.7

1,000 50 (122) 2.82 0.57- 0.70 ,:g[L

Acceptable range
100 (212) 0.8 0.08-0.10

*: These data are reference values and measu~d between ECM termmal @
(EGR temperature sensor) and ECM terminal 1SJ (ECCS ground). ~~~UY

10

0 50 100 150 200

(32) (122) (212) (302) (392)
Temperature oc (°F)

SEF526Q

ON BOARD DIAGNOSIS LOGIC

Diagnostic Trouble Check Items
Malfunction is detected when
Code No. (Possible Cause)

P1401 A) An excessively low voltage from the EGR tern~ • Harness or connectors
0305 perature sensor is sent to ECM, even when (The EGA temperature sensor circuit is shorted.)
engine coolant temperature is low. • EGR temperature sensor
• Malfunction of EGR function, EGRC-BPT valve or
EGRC-solenoid valve

B) An excessively high voltage from the EGR • Harness or connectors

temperature sensor is sent to ECM, even (The EGR temperature sensor circuit is open.)
when engine coolant temperature is high. • EGR temperature sensor
• Malfunction of EGR function, EGRC-BPT valve or
EGRC-solenoid valve

I~JE

EC-271 411
 TROUBLE DIAGNOSIS FOR DTC P1401
EGR Temperature Sensor (Cont'd)
OVERALL FUNCTION CHECK
* MONITOR * NO FAIL D Use this procedure to check the overall function of the EGR tem-
CMPS•RPM (REF) Orpm perature sensor circuit. During this check, a 1st trip DTC might not
COOlAN TEMP/S 20'C be confirmed.
EGR TEMP SEN 4.3V
INT/A TEMP SE 22'C Procedure for malfunctions A and 8
1) Turn ignition switch "ON" and select "DATA MONITOR"
mode with CONSULT.
2) Confirm that engine coolant temperature and intake air
temperature are lower than 40"C (104"F). (II necessary,
wait until the temperatures equal atmospheric tempera-
SEF651R ture.)
3) Confirm that "EGR TEMP SEN" reading is between
3.45V and 5.0V.
Lift up the 4) Start engine and warm it up sufficiently.
EGR valve
5) Run engine at idle for at least 2 minutes.
by hand.
6) Confirm that EGR valve is not lilting. If NG, go to
TROUBLE DIAGNOSES FOR DTC P0400 and P0402.
(See pages EC-176 and 184.)
7) Read "EGR TEMP SEN" at about 1,500 rpm with EGR
valve lilted up to the full position by hand.
Voltage should decrease to less than 1.0V.
If step 7 is OK, perform TROUBLE DIAGNOSES FOR
8)
SEF360Q DTC P0400, P0402 and P1400. (See pages EC-176,
184 and 267.)
----------OR----------

~ £) ~
CONNECT

8 (j)1) Turn ignition switch "ON".

2) Confirm that voltage between ECM terminals @, @
and ground are more than 2.72V. (If necessary, wait
II ECM lofCONNECTOR II c0H until engine coolant temperature and intake air tem-
28 51 62
perature equal atmospheric temperature.)
3) Confirm that voltage between ECM terminal @ and
ground is between 3.45V and 5.0V.
4) Start engine and warm it up sufficiently.
5) Run engine at idle for at least 2 minutes.
SEF652R
6) Confirm that EGR valve is not lifting. If NG, go to
TROUBLE DIAGNOSES FOR DTC P0400 and P0402.
(See pages EC-176 and 184.)

~ i) ~ ro cff'b~H 7) Check voltage between ECM terminal @ and ground at

about 1 ,500 rpm with EGR valve lifted up to the full
position by hand.
ECM JOfcONNECTORil Voltage should decrease to less than 1.0V.
62
8) If step 7 is OK, perform TROUBLE DIAGNOSES FOR
DTC P0400, P0402 and P1400. (See pages EC-176,
184 and 267.)

412 EC-272
 TROUBLE DIAGNOSIS FOR DTC P1401
EGA Temperature Sensor (Cont'd)

EC-EGR/TS-01

- : Detectable line for DTC

- : Non-detectable line for DTC

[p~

lb~

~'il

L~lf

'ill'

~~

I"#\

~i

~il

~J

~~·

~'il
,.c;:L..@
Uill GY

~ffii

!lib

~[Qij'1

AEC065A

EC-273 413
 TROUBLE DIAGNOSIS FOR DTC P1401
EGR Temperature Sensor (Cont'd)
DIAGNOSTIC PROCEDURE
INSPECTION START

Ei.1 ~
~C~HE~C~K~P~O~W=E=R~S~U~P~P~L~~----------,NG Repair harness or connec-
1) Disconnect EGA temperature sensor tors.
harness connector.
2) Turn ignition switch "ON".
3) Check voltage between terminal and CD
ground with CONSULT or tester.
Voltage: Approximately 5V

Check the following.

• Harness continuity
between ECM and EGR
temperature sensor
If NG, repair harness or
connector.
OK

CHECK COMPONENT NG Replace EGR temperature

(EGR temperature sensor). sensor.
Refer to "COMPONENT INSPECTION" on
SEF184S next page.
L __ _ _ _ _ _ _ _ _ _-rO~K~--------~

Disconnect and reconnect harness connec-

tors in the circuit. Then retest

Trouble is not fixed.

Check ECM pin terminals for damage and

check the connection of ECM harness con-
nector. Reconnect ECM harness connector
and retest.

s_E_F_1s_s~s lc_________IN_S_P_E_C_T_I_o_N_E_N__o ________

'----------------------------- _J

414 EC-274
 TROUBLE DIAGNOSIS FOR DTC P1401
EGR Temperature Sensor (Cont'd)
COMPONENT INSPECTION
dro EGR temperature sensor
Check resistance change and resistance value.

(Reference data)
EGR temperature Voltage Resistance
oc (oF) (V) (M!l)
0 (32) 4.81 7.9- 9.7
50 (122) 2.82 0.57- 0.70

•
SEF6430
100 (212) 0.8 0.08-0.10
10,000 If NG, replace EGR temperature sensor.

1,000
Acceptable range

c:
~

•
0
if['
..•
~ 100
~

a:

10

0 50 100 150 200

(32) (122) (212) (302) (392)
Temperature °C (°F)

SEF526Q

EC-275 415
 TROUBLE DIAGNOSIS FOR DTC P1441

Vacuum Cut Valve Bypass Valve

COMPONENT DESCRIPTION
The vacuum cut valve and vacuum cut valve bypass valve are
installed in parallel on the EVAP purge line between the fuel tank
and the EVAP canister.
The vacuum cut valve prevents the intake manifold vacuum from
being applied to the fuel tank.
The vacuum cut valve bypass valve is a solenoid type valve and
generally remains closed. It opens only for on board diagnosis.
The vacuum cut valve bypass valve responds to signals from the
SEF186S
ECM. When the ECM sends an ON (ground) signal, the valve is
opened. The vacuum cut valve is then bypassed to apply intake
manifold vacuum to the fuel tank.

ECM TERMINALS AND REFERENCE VALUE

Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

Vacuum cut valve bypass BATTERY VOLTAGE

117 y
valve
[ignition switch "ON"' I (11 - 14V)

CONSULT REFERENCE VALUE IN DATA MONITOR MODE

Specification data are reference values.
MONITOR ITEM CONDITION SPECIFICATION
VCN BYPASSN e Ignition switch: ON OFF

EVAPORATIVE EMISSION SYSTEM DIAGRAM

EVAP canister
EVAP control system pressure sensor purge control
solenoid valve
Vacuum cut valve bypass valve
EVAP shut valve
p

Fuel lank

EVAP canister~ '-.--_J EVAP canister

vent control purge volume
valve control valve SEF782Q

ON BOARD DIAGNOSIS LOGIC

Diagnostic Trouble Check Items
Malfunction is detected when .
Code No. (Possible Cause)
P1441 A) An improper voltage signal is sent to ECM • Harness or connectors
0801 through vacuum cut valve bypass valve. (The vacuum cut valve bypass valve circuit is
open or shorted.)
• Vacuum cut valve bypass valve

B) Vacuum cut valve bypass valve does not operate • Vacuum cut valve bypass valve
properly. • Vacuum cut valve
• Bypass hoses for clogging
• EVAP shut valve
• EVAP control system pressure sensor

416 EC-276
 TROUBLE DIAGNOSIS FOR DTC P1441
Vacuum Cut Valve Bypass Valve (Cont'd)
DIAGNOSTIC TROUBLE CODE CONFIRMATION !ii~
PROCEDURE
Perform "Procedure for malfunction A" first. If 1st trip DTC ~i&c
cannot be confirmed, perform "OVERALL FUNCTION
CHECK", "Procedure for malfunction B".

Procedure for malfunction A

1< MONITOR 1< NOFAIL 0 1) Turn ignition switch "ON".
CMPS•RPM(REF) BOOrpm 2) Select "DATA MONITOR" mode with CONSULT.
3) Start engine and wait at least 5 seconds.
---------OR---------
1) Start engine and wait at least 5 seconds.
2) Select "MODE 7" with GST.
---------OR---------
1) Start engine and wait at least 5 seconds. fdl'ir
2) Turn ignition switch "OFF", wait at least 7 seconds and
I RECORD I
SEF712T then turn "ON".
3) Perform "Diagnostic Test Mode II (Self-diagnostic &cl'
results)" with ECM.

OVERALL FUNCTION CHECK

Procedure for malfunction B
1) Remove vacuum cut valve and vacuum cut valve bypass valve ~fii
as an assembly.
2) Apply vacuum to port ® and check that there is no suction
from port @. !11
3) Apply vacuum to port @ and check that there is suction from
port@.
4) Blow air in port@ and check that there is a resistance to flow [:t~
out of port @.
5) Supply battery voltage to the terminal.
6) Blow air in port ® and check that air flows freely out of port @1
@.

.
Fuel tank stde
7) Blow air in port @ and check that air flows freely out of port
EVAP canister
@. ~
s1de

SEF530Q

EC-277 417
 TROUBLE DIAGNOSIS FOR DTC P1441
Vacuum Cut Valve Bypass Valve (Cont'd)

EC-BYPSN-01
- : Detectable line for DTC
Refer to "EL-POWER". : Non-detectable line for DTC
15A
0

i8/W

lrfll~
'-i-'@
8/W

IBIW

~
VACUUM CUT VALVE
BYPASS VALVE
@)
l!4Jl
y

I
~@
y

I~I(M108)
y

I ECM (ECCS
CVBV
CONTROL

L-------------~~ I
MODULE)

[J
345678~ 12345@
9 011 21314 w 6 7 8 9 10 w

~
~ 38 '39 I40I4il I53I54T55l ~
101 102 103 104 105 106 20212223
I 23
5678910 2425262 728 42143 44 45 46 57 58 59 60 61
107 108 109 110 Ill 112
11 12 13 14 19 29303132 331 fglfo' 47 48 62 63 64 65 70
113 114 115 116 117 118 .J1.J 16 17 18 34 35 36 37 L.:.::. ~ 66676869

AEC318A

418 EC-278
 TROUBLE DIAGNOSIS FOR DTC P1441
Vacuum Cut Valve Bypass Valve (Cont'd)
DIAGNOSTIC PROCEDURE

~HJ, ~f)r\
Procedure for malfunction A
INSPECTION START
I
15:1: ~h ~ 1F r.:.1 l
~\ ~
CHECK POWER SUPPLY. Check the following.
\_ Vacuum cut( valve bypa.ss
" valve- 1. Turn ignition switch "OFF". • Harness connectors
0 harness connector ')--I 2. Disconnect vacuum cut valve bypass @,<@>
")......_....-- valve harness connector. • 15A fuse
SEF187S 3. Turn ignition switch "ON". • Harness for open or short
4. Check voltage between terminal CDand between vacuum cut valve
m ground with CONSULT or tester.
Voltage: Battery voltage
bypass valve and fuse
If NG, repair harness or con~

~~0~ §
l OK
nectars.

cffl:J CHECK OUTPUT SIGNAL CIRCUIT. NG Check the following.

1. Turn ignition switch "OFF". f----> • Harness connectors
2. Disconnect ECM harness connector. @,<@>
3. Check harness continuity between ECM • Harness for open or short

~
terminal @ and terminal @. between vacuum cut valve
1'!11'/
Continuity should exist. bypass valve and ECM
SEF503R If OK, check harness for short. If NG, repair harness or con-
nectors.
+OK
§
CHECK COMPONENT NG
.______.. Replace vacuum cut valve
~IO@a~io (Vacuum cut valve bypass valve).
Refer to "COMPONENT INSPECTION" on
bypass valve.

II ECM for CONNECTOR II diD

next page.

+OK
"'
Disconnect and reconnect harness connec-
tors in the circuit. Then retest.

1ID +Trouble is not fixed.

SEF504R Check ECM pin terminals for damage and
check the connection of ECM harness con-
nector. Reconnect ECM harness connector
and retest.

.j.
INSPECTION END

EC-279 419
 TROUBLE DIAGNOSIS FOR DTC P1441
Vacuum Cut Valve Bypass Valve (Cont'd)
DIAGNOSTIC PROCEDURE
Procedure for malfunction B
INSPECTION START

Pertorm "OVERALL FUNCTION CHECK",

EC-277.
NG
-OK Check EVAP shut valve
EVAP purge line hoses
between EVAP canister and
fuel tank for clogging or dis-
connection.
Refer to "EVAPORATIVE
EMISSION (EVAP) SHUT
VALVE" and "Evaporative
Emission Line Drawing",
EC-21 and EC-22.

CHECK COMPONENT NG Replace malfunctioning

(Vacuum cut valve, vacuum cut valve [----+ parts.
bypass valve).
Refer to "COMPONENT INSPECTION"
below.

~OK
Check bypass hoses for clogging. NG Repair or replace hoses.

~OK
Go to "TROUBLE DIAGNOSIS FOR DTC
P0450", "EVAP Control System Pressure
Sensor", EC-212.

~OK
INSPECTION END

COMPONENT INSPECTION
Vacuum cut valve bypass valve
Check air passage continuity.

Air passa~ continuity

Condition
between ~ and ®
12V direct current supply between terminals Yes
No supply No

SEF351Q
If NG, replace vacuum cut valve bypass valve.

Vacuum cut valve Vacuum cut valve

EVAP canister Check vacuum cut valve as follows:
1. Plug port © and @ with fingers.
2. Apply vacuum to port @ and check that there is no suction
from port@.
3. Apply vacuum to port ® and check that there is suction from
port@.
4, Blow air in port ® and check that there is a resistance to flow
out of port @.
5. Open port © and @.
6. Blow air in port@ check that air flows freely out of port ©.
7. Blow air in port® check that air flows freely out of port @,

420 EC-280
 TROUBLE DIAGNOSIS FOR DTC P1445

Evaporative Emission (EVAP) Canister Purge

Volume Control Valve
SYSTEM DESCRIPTION
Engine speed
Camshaft position sensor
I

Amount of intake air

Mass air flow sensor
I

Engine coolant temperature

Engine coolant temperature sen-
sor

Start signal ECM

Ignition switch (ECCS
I EVAP canister
control purge volume
module) control valve
Throttle position
Throttle position sensor fJJir
I

Density of oxygen in exhaust gas

Front heated oxygen sensor
I (Mixture ratio feedback signal)

Fuel temperature in fuel tank

Tank fuel temperature sensor
I

Vehicle speed
Vehicle speed sensor
I

This system controls flow rate of fuel vapor from the EVAP canister. The opening of the vapor by-pass pas-
sage in the EVAP canister purge volume control valve changes to control the flow rate. A built-in step motor
moves the valve in steps corresponding to the EGM output pulses. The opening of the valve varies for opti-
mum engine control. The optimum value stored in the EGM is determined by considering various engine con-
ditions. When the engine is operating, the flow rate of fuel vapor from the EVAP canister is regulated as the
air flow changes.

ECM TERMINALS AND REFERENCE VALUE

Specification data are reference values and are measured between each terminal and @ (EGGS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

5 R

6 UG Engine is running. I 0- 0.4V or

EVAP canister purge val- 1

BATIERY VOLTAGE
16 G ume control valve L Idle speed (11 - 14V)
17 y

EC-281 421
 TROUBLE DIAGNOSIS FOR DTC P1445
Evaporative Emission (EVAP) Canister Purge
Volume Control Valve (Cont'd)
CONSULT REFERENCE VALUE IN DATA MONITOR MODE
Specification data are reference values.
MONITOR ITEM CONDITION SPECIFICATION
• Engine: After warming up
Vehicle stopped 0 step
• Air conditioner switch: OFF
PURG VOLCN
• Shift lever "N"
Vehicle running -
• No-load

COMPONENT DESCRIPTION
The EVAP canister purge volume control valve uses a step motor
to control the flow rate of fuel vapor from the EVAP canister. This
motor has four winding phases. It operates according to the output
pulse signal of the ECM. Two windings are turned ON and OFF in
sequence. Each time an ON pulse is issued, the valve opens or
closes, changing the flow rate. When no change in the flow rate is
needed, the ECM does not issue the pulse signal. A certain volt-
age signal is issued so that the valve remains at that particular
opening.
SEF249P

ON BOARD DIAGNOSIS LOGIC

Diagnostic Trouble Check Items

Malfunction is detected when .
Code No. (Possible Cause)
P1445 A) An improper voltage signal is sent to ECM • Harness or connectors
1008 through the valve. (The valve circuit is open or shorted.)
• EVAP canister purge volume control valve

B) The canister purge flow is detected during the • EVAP control system pressure sensor
specified driving conditions, even when EVAP • EVAP canister purge volume control valve (The
canister purge volume control valve is completely valve is stuck open.)
closed. • EVAP canister purge control valve
• Hoses
(Hoses are connected incorrectly.)

422 EC-282
 TROUBLE DIAGNOSIS FOR DTC P1445
Evaporative Emission (EVAP) Canister Purge
Volume Control Valve (Cont'd) Cll
DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE i~~?\
Perform "Procedure for malfunction A" first. If the 1st trip DTC
~f J
cannot be confirmed, perform "Procedure for malfunction B".
2
Procedure for malfunction A
M 1) Lift up vehicle.
~ 2) Turn ignition switch "ON" and select "DATA MONITOR" l©
mode with CONSULT.
3) Start engine and let it idle for at least 90 seconds.
4) Move selector/gearshift lever to "1" range (AfT) or "1st"
gear (MIT).
5) Rev engine from idle to 2,000 to 3,000 rpm more than
10 times. m
-=---------OR----------
~ 1) Lift up vehicle.
2) Start engine and let it idle for at least 90 seconds.
3) Move selector/gearshift lever to "1" range (AfT) or "1st"
gear (MIT).
4) Rev engine from idle to 2.000 to 3,000 rpm more than 8iU1
10 times.
5) Select "MODE 3" with GST.
-=---------OR---------
@ 1) Lift up vehicle.
2) Start engine and let it idle for at least 90 seconds.
3) Move selector/gearshift lever to "1" range (AfT) or "1st'' '[f'
gear (MIT).
4) Rev engine from idle to 2,000 to 3,000 rpm more than
10 times.
5) Turn ignition switch "OFF", wait at least 7 seconds and
then turn "ON".
6) Perform "Diagnostic Test Mode II (Self-diagnostic I'JC
results)" with ECM.
Procedure for malfunction 8
1) Lift up vehicle.
1>: MONITOR 1>: NOFAIL 2) Turn ignition switch "ON" and select "DATA MONITOR"'
mode with CONSULT.
CMPSoRPM (POS) 2000rpm 3) Start engine and warm it up sufficiently.
COOLAN TEMP/S sooc 4) Check that tank fuel temperature is above O'C (32,F).
VHCL SPEED SE 65km/h
22,C
5) Turn ignition switch "OFF" and wait at least 7 seconds.
TANK F/TMP SE
6) Turn ignition switch "ON" and wait at least 12 seconds. :0'1'
7) Start engine and let it idle for at least 70 seconds.
8) Maintain the following conditions for at least 25 sec·
onds.
I RECORD I
SEF816T
Gear position:
"2" or "D" range (AfT)
"3rd" or "4th" gear (MIT)
Vehicle speed:
50 - 70 km/h (31 - 43 MPH)
Engine speed:
1,500 - 2,500 rpm
Coolant temperature:
Less than 1OO'C (212'F)

EC-283 423
 TROUBLE DIAGNOSIS FOR DTC P1445
Evaporative Emission (EVAP) Canister Purge
ENGINE SPD ..... ... 825RPM
Volume Control Valve (Cont'd)
COOLANT TEMP ............. 69'C -=--------OR---------
~
VEHICLE SPD ......... OMPH
IGN ADVANCE ...................... 8.0' t) Lift up vehicle.
CALC LOAD ...................... 28.2% 2) Turn ignition switch "ON" and select "MODE t" mode
MAP .......................... .... 36KPaA
MAF ............................. 5.20gm/s with GST.
THROTILE POS ................ 0.0% 3) Start engine and warm it up sufficiently.
INTAKE AIR . 27'C
FUEL SYS #1 ............... OLDRIVE 4) Check that voltage between ECM terminal @ and
FUEL SYS #2 ............... UNUSED ground is less than 4.2V.
SHORT FT #1 ...... .. .. 0.8%
LONG FT #1 .... 0.0% 5) Turn ignition switch "OFF" and wait at least 7 seconds.
028 81 S1 ....................... 0.200V
02FT 81 S1 ......................... 0.8% 6) Turn ignition switch "ON" and wait at least 12 seconds.
028 81 82 ....................... 0.010V SEF519R 7) Start engine and let it idle for at least 70 seconds.
8} Maintain the following conditions for at least 25 sec-
onds.
~i) Gear position:
"2" or "D" range (AfT)
rr====E==c==M=='iJOff:c'='oN==N==Ec""r='oR=j]l
"3rd" or "4th" gear (MIT)
63
Vehicle speed:
50 - 70 km/h (31 - 43 MPH)
Engine speed:
1 ,500 - 2,500 rpm
Coolant temperature:
Less than 1oooc (212°F)
SEF817T 9) Select "MODE 3" with GST.
-=---------OR----------
'@1) Lift up vehicle.
2) Turn ignition switch "ON".
3) Start engine and warm it up sufficiently.
4) Check that voltage between ECM terminal @ and
ground is less than 4.2V.
5) Turn ignition switch "OFF" and wait at least 7 seconds.
6) Turn ignition switch "ON" and wait at least 12 seconds.
7) Start engine and let it idle for at least 70 seconds.
8) Maintain the following conditions for at least 25 sec-
onds.
Gear position:
"2" or ~~o" range (AJT)
"3rd" or "4th" gear (MIT)
Vehicle speed:
50 - 70 km/h (31 - 43 MPH)
Engine speed:
1,500 - 2,500 rpm
Voltage between ECM terminal @) and ground:
More than O.BV
9) Turn ignition switch "OFF", wait at least 7 seconds and
then turn "ON".
10) Perform "Diagnostic Test Mode II (Self-diagnostic
results)" with ECM.

424 EC-284
 TROUBLE DIAGNOSIS FOR DTC P1445
Evaporative Emission (EVAP) Canister Purge
Volume Control Valve (Cont'd) ~I

EC-PGCN-01
- : Detectable line for DTC
Refer to "EL-POWER". - : Non-detectable line lor DTC

~ r--------------,EVAP
. .-------R~

..---G/R~
CANISTER
"1!: PURGE
w w -- VOLUME
CONTROL
VALVE

[]"~
@
RELAY
@
+
14dl~
LJR G/R

I
•-------~•-•-
--

R UG y

SSOFF VB VB CRTN
ffi
EVP EVP
rm
EVP
~
EVP ECM(ECCS
CONTROL
#1 #3 • 2 #4 MODULE)
@

,---------------,
~@
~GY
:me
ltn:Ilw
~@>:
tl:lG I
I I
l---------------~

AEC067A

EC-285 425
 TROUBLE DIAGNOSIS FOR DTC P1445
Evaporative Emission (EVAP) Canister Purge
- (I~ Volume Control Valve (Cont'd)
~ EVAP canister purge DIAGNOSTIC PROCEDURE
~~ /;_ volume control valve~
, ~~sscon~ I INSPECTION START
I
l
~ ~~~ B
1
NG
CHECK POWER SUPPLY. ___. Check the following.

c~\
/ A i r cleaner 1. Turn ignition switch "OFF". e ECCS relay
housing 2. Disconnect EVAP canister purge vof- • BR fusible link
ume control valve harness connector. • Harness for open or
SEF188S 3. Turn ignition switch "ON". short between EVAP
4. Check voltage between terminals ®, canister purge volume
m ® and engine ground with CONSULT control valve and fusible
,...--
~ or tester.
Voltage: Battery voltage
link
• Harness for open or

~i5~
•
short between EVAP
OK
canister purge volume
6 control valve and ECM
,...-- If NG, repair harness or
connectors.
['l] I;]
~ NG
=
SEF578Q
CHECK OUTPUT SIGNAL CIRCUIT.
1. Turn ignition switch "OFF". r---- Repair harness or connec-
tors.
2. Disconnect ECM harness connector.
I;] 3. Check harness continuity between
ECM terminal ~ and terminal ~·
ECM terminal 17 and terminal 4 ,

~iv ~ ~18 ECM terminal 5 and terminal 3 ,

II
5
ECM
6 16
]OfCONNECTOR II
17
a: /
ECM terminal 6 and terminal 6 .
Continuity should exist.
If OK, check harness for short.

-
+OK
[ID CHECK COMPONENT
NG Replace EVAP control sys-
(EVAP control system pressure sensor) tern pressure sensor.
(For malfunction B only).

PL Refer to "COMPONENT INSPECTION" in

"TROUBLE DIAGNOSIS FOR DTC
P0450", EC-216.

~l
+OK

~
CHECK COMPONENT
(EVAP canister purge volume control
~ Replace EVAP canister
purge volume control
valve). valve.
[QJ Reier to "COMPONENT INSPECTION"
on next page.
~

+OK
SEF189S
Disconnect and reconnect harness con-
nectars in the circuit. Then retest.

Trouble is not fixed.

+
Check ECM pin terminals for damage and
check the connection of ECM harness
connector. Reconnect ECM harness con-
nectar and retest.

+
INSPECTION END

426 EC-286
 TROUBLE DIAGNOSIS FOR DTC P1445
Evaporative Emission (EVAP) Canister Purge
Volume Control Valve (Cont'd)
COMPONENT INSPECTION
~0
i5~ EVAP canister purge volume control valve

r--~ 6 5 4
~
~
1. Disconnect EVAP canister purge volume control valve
harness connector.
2. Check resistance between the following terminals.
terminal 0 and terminals G), ®
terminal ® and terminals @, ®
[ill Resistance:
~
- Approximately 30!1 [At 25°C (77°F)]
3. Reconnect EVAP canister purge volume control valve
harness connector.
4. Remove EVAP canister purge volume control valve
from intake manifold collector and disconnect hoses
from the valve. i'l"
(Plug the purge hoses. The EVAP canister purge vol-
ume control valve harness connector should remain
connected.) !'i'L
5. Turn ignition switch "ON".
6. Perform "PURG VOL CONTN" in "ACTIVE TEST"
mode with CONSULT. Check that EVAP canister purge
volume control valve shaft moves smoothly forward and
SEF353Q
backward according to the valve opening.
If NG, replace the EVAP canister purge volume control
• ACTIVE TEST • 0 valve.
----------OR----------
PURG VOL CONTN 20Step 1. Disconnect EVAP canister purge volume control valve Ire
========== MONITOR ========== harness connector.
CMPS•RPM(REF) Orpm 2. Check resistance between the following terminals.
FR02 MNTR
AIF ALPHA
RICH
100%
terminal 0 and terminals G), ® [)'!?
THRTL POS SEN 0.4BV terminal ® and terminals @, ®
Resistance:
Approximately 30!1 [At 25oC (77"F)] f'[L,
laull UP II owN lladl SEF507R
3. Reconnect EVAP canister purge volume control valve
harness connector.
4. Remove EVAP canister purge volume control valve
from intake manifold collector and disconnect hoses
from the valve.
(Plug the purge hoses. The EVAP canister purge vol- ~Ji!
ume control valve harness connector should remain
connected.)
5. Turn ignition switch "ON" and "OFF". Check that EVAP 181
canister purge volume control valve shaft moves
smoothly forward and backward according to the igni-
tion switch position.
If NG, replace the EVAP canister purge volume control
SEF763P valve.

li'.ll

Air cleaner
0-

f housmg
(r// ~
1
( SEF141S

EC-287 427
 TROUBLE DIAGNOSIS FOR DTC P1447

Evaporative Emission (EVAP) Control System

Purge Flow Monitoring
EVAP canister
EVAP control system pressure sensor purge control
solenoid valve
Vacuum cut valve bypass valve
EVAP shut valve
p

,-'----'---, EVAP canister

purge control valve
Vacuum EVAP
Fuel tank
cut valve canister
EVAP canister~'-.--' EVAP canister-
vent control purge volume
valve control valve SEF7820

SYSTEM DESCRIPTION
In this evaporative emission (EVAP) control system, purge flow
occurs during non-closed throttle conditions. Purge volume is
related to air intake volume. Under normal purge conditions (non-
closed throttle), the EVAP canister purge volume control valve and
EVAP canister purge control valve are open. Purge flow exposes
the EVAP control system pressure sensor to intake manifold
vacuum.

ON BOARD DIAGNOSIS LOGIC

Under normal conditions (non-closed throttle), sensor output volt-
age indicates if pressure drop and purge flow are adequate. If not,
a fault is determined.

Diagnostic
Check Items
Trouble Code Malfunction is detected when .
(Possible Cause)
No.
P1447 • EVAP control system does not operate properly. • EVAP canister purge volume control valve stuck
0111 • EVAP control system has a leak between intake closed
manifold and EVAP control system pressure sensor. • EVAP canister purge control valve stuck closed
• EVAP control system pressure sensor
• Loose or disconnected rubber tube
• Blocked rubber tube
• EVAP canister purge control solenoid valve
• Blocked or bent rubber tube to MAP/BARO switch
solenoid valve
• Cracked EVAP canister
• Absolute pressure sensor
• MAP/BARO switch solenoid valve

428 EC-288
 TROUBLE DIAGNOSIS FOR DTC P1447
Evaporative Emission (EVAP) Control System
Purge Flow Monitoring (Cont'd) (~I
1>: MONITOR 1>: NO FAIL D OVERALL FUNCTION CHECK
CMPS•RPM(REF) 787rpm
COOLAN TEMP/S 86•C Use this procedure to check the overall monitoring function of the
VHCL SPEED SE Okm/h EVAP control system purge flow. During this check, a 1st trip DTC
CLSDTHUPSW ON might not be confirmed.
B/FUEL SCHDL 1.1msec
PURGVOLCN Ostep fF.i\ 1) Lift up vehicle. ~[@
EVAP SYS PRES 3.36V \_llV 2) Start engine.
VENTCONTN OFF 3) Select "EVAP SYS PRES" in "DATA MONITOR" mode
VCNBYPASSN OFF
with CONSULT. LG
I RECORD I
SEF508R
4) Check EVAP control system pressure sensor value at
idle speed.
5) Select "PURG VOL CONTN" in "ACTIVE TEST" mode
with CONSULT and set "PURG VOL CONTN" to 20
• ACTIVE TEST • D steps by touching "UP" or "Qu".
PU RG VOL CONTIV 20Step 6) Maintain the following conditions for at least 30 sec- If'~
:::::::::: MONITOR :::::::::: ends. Verify that EVAP control system pressure sensor
CMPS•RPM(REF) 712rpm value ("EVAP SYS PRES") stays O.IV less than the
VHCL SPEED SE Okm/h value at idle speed for at least 2 seconds. Gl
BIFUEL SCHDL 1.1msec
EVAP SYS PRES 3.36V Engine speed:
PURGCONT SN ON Approx. 2,000 rpm
Gear position (for Mff models): uil"J
~I UP I OWN I~SEF509R Any position other than "Neutral" or "Reverse"
CAUTION:
Do not run vehicle at speeds greater than 80 km/h (50 i(J'
MPH).

~i)~ ID ---------OR---------
1) Lift up vehicle. 115
2) Start engine and warm it up sufficiently.
I lol
ECM CONNECTOR II 3) Turn ignition switch "OFF", wait at least 7 seconds.
6' 43
4) Start engine and wait at least 70 seconds. p[c]
5) Set voltmeter probes to ECM terminals @ (EVAP con-
trol system pressure sensor signal) and @ (ground).

~=
6) Check EVAP control system pressure sensor value at 1Cc
idle speed.
=-= SEF510R 7) Establish and maintain the following conditions for at
least 30 seconds. ~ffi,
Air conditioner switch: ON
Steering wheel: Fully turned
Headlamp switch: ON ~~:.
Engine speed: Approx. 3,500 rpm
Intake manifold vacuum:
-73.3 to -60.0 kPa (-550 to -450 mmHg, ~T
-21.65 to -17.72 inHg, -10.63 to -8.70 psi)
Gear position:
Mrr models 1':!0
Any position other than "Neutral" or "Reverse"
Arr models
Any position other than "P", "N" or "R". ~w·
Return all conditions to normal. Repeat this procedure
at least 5 times.
Verify that EVAP control system pressure sensor value llffi\
stays 0.1 V less than the value at idle speed for at least
2 seconds.
CAUTION: ~1
Do not run vehicle at speeds greater than 80 km/h (50
MPH).

EC-289 429
 TROUBLE DIAGNOSIS FOR DTC P1447
Evaporative Emission (EVAP) Control System
Purge Flow Monitoring (Cont'd)
DIAGNOSTIC PROCEDURE
INSPECTION START

CHECK EVAP CANISTER. Replace EVAP canister.

Check EVAP canister for cracks.

OK

CHECK EVAP PURGE LINE. Repair it.

Check EVAP purge line for improper con-
nection.
Refer to "EVAPORATIVE EMISSION
SYSTEM", EC-22.

OK

NG
CHECK COMPONENT Replace EVAP canister
(EVAP canister purge volume control purge volume control
valve). valve.
Refer to "COMPONENT INSPECTION",
EC-292.

OK
~==;:::====:::;:::=====~ ,-----------~-----------,NG
IS]
CHECK COMPONENT Replace EVAP canister
(EVAP canister purge control solenoid purge control solenoid
valve). valve.
Refer to "COMPONENT INSPECTION",
EC-293.

OK
/~
~~~
[!]
~C-H-EC
__K_C_O_M_P_O_N_E~NLT------------, Replace EVAP canister
\f(-~ (EVAP canister purge control valve). purge control valve.
Refer to "COMPONENT INSPECTION",
SEF142S EC-293.

OK
(!]
,-----------~~-----------,NG
CHECK COMPONENT Replace EVAP control sys-
(EVAP control system pressure sensor). tem pressure sensor.
Refer to "COMPONENT INSPECTION",
EC-293.

OK
I!
~----------~-----------,NG
CHECK COMPONENT Replace absolute pressure
(Absolute pressure sensor). sensor.
Refer to "COMPONENT INSPECTION",
EC-294.

OK

®
(Go to next page.)

SEF191S

430 EC-290
TROUBLE DIAGNOSIS FOR DTC P1447
Evaporative Emission (EVAP) Control System
Purge Flow Monitoring (Cont'd) ·!il~
@

/,
li
CHECK COMPONENT
1 NG Replace MAP/BARO
Air cleane-r/ (MAP/BARO switch solenoid valve). switch solenoid valve.

! housing /

\\
Refer to "COMPONENT INSPECTION",
EC-294.

SEF146S OK

CHECK EVAP PURGE LINE. NG Replace it.

Inspect EVAP purge line (pipe and rubber
tube). Check for evidence of leaks.

OK

Clean EVAP purge line (pipe and rubber

tube) using air blower.

Disconnect and reconnect harness connec-

tors in the circuit. Then retest.

Trouble is not fixed.

Check ECM pin terminals for damage and

check the connection of ECM harness con-
nector. Reconnect ECM harness connector
and retest.

INSPECTION END

EC-291 431
 TROUBLE DIAGNOSIS FOR DTC P1447
Evaporative Emission (EVAP) Control System
Purge Flow Monitoring (Cont'd)
COMPONENT INSPECTION
~" EVAP canister purge volume control valve

,--* 6 5 4
(if\
~
1) Disconnect EVAP canister purge volume control valve
harness connector.
2) Check resistance between the following terminals.
terminal ® and terminals CD, ®
terminal® and terminals@, ®
[QJ Resistance:
--.!: i-- Approximately 30!1 [At 25°C (77°F)]
3) Reconnect EVAP canister purge volume control valve
harness connector.
4) Remove EVAP canister purge volume control valve
from intake manifold collector and disconnect hoses
from the valve.
(Plug the purge hoses. The EVAP canister purge vol-
ume control valve harness connector should remain
connected.)
5) Turn ignition switch "ON".
6) Perform "PURG VOL CONTN" in "ACTIVE TEST"
mode with CONSULT. Check that EVAP canister purge
volume control valve shaft moves smoothly forward and
SEF353Q
backward according to the valve opening.
If NG, replace the EVAP canister purge volume control
• ACTIVE TEST • D valve.
---------OR---------
PURG VOL CONT/V 20Step 1) Disconnect EVAP canister purge volume control valve
========== MONITOR ========== harness connector.
CMPS•RPM(REF) Orpm 2) Check resistance between the following terminals.
FR02 MNTR
NFALPHA
RICH
100%
terminal ® and terminals CD, ®
THRTL POS SEN 0.48V terminal ® and terminals @, ®
Resistance:
Approximately 30!1 [At 25°C (77°F)]
IQ!ill uP II owN llodl SEF507R
3) Reconnect EVAP canister purge volume control valve
harness connector.
4) Remove EVAP canister purge volume control valve
from intake manifold collector and disconnect hoses
from the valve.
(Plug the purge hoses. The EVAP canister purge vol-
ume control valve harness connector should remain
connected.)
5) Turn ignition switch "ON" and "OFF". Check that EVAP
canister purge volume control valve shaft moves
smoothly forward and backward according to the igni-
tion switch position.
If NG, replace the EVAP canister purge volume control
SEF763P valve.

Air cleaner
'l

f housmg
(,//
I(
-...._
'
SEF1418

432 EC-292
 TROUBLE DIAGNOSIS FOR DTC P1447
Evaporative Emission (EVAP) Control System
Purge Flow Monitoring (Cont'd) !ilu
EVAP canister purge control valve
Check EVAP canister purge control valve as follows:
1. Plug the port @.
2. Apply pressure [80.0 kPa (600 mmHg, 23.62 inHg, 11.60 psi)]
to port @. Then keep it for 15 seconds, and check there is no ~i:i
leakage.
3. Repeat step 2 for port ©.

SEF285PA

EVAP canister purge control solenoid valve

Check air passage continuity.

Air passage Air passage

Condition continuity continuity
between @ and @ between @ and @
12V direct current supply
Yes No
between terminals
No supply No Yes

SEF313Q
If NG, replace solenoid valve.

~ ''""' ~ f!r:o. EVAP control system pressure sensor

l-41£)0~
- ~
EVAP control system
pressure sensor
I 1.

2.
3.
Remove EVAP control system pressure sensor with its har-
ness connector connected.
Remove hose from EVAP control system pressure sensor.
Use pump to apply vacuum and pressure to EVAP control
[J[] system pressure sensor as shown in figure. 6:1"
4. Check output voltage between terminal ® and engine ground.
Pressure (Relative to atmospheric pressure) Voltage (V)
Pump
0 kPa (0 mmHg, o inHg, o psi) 3.0- 3.6
SEF400S -9.3 kPa (-70 mmHg, -2.76 inHg. -1.35 psi) 0.4 - 0.6

CAUTION:
Always calibrate the vacuum pump gauge when using it.
5. If NG, replace EVAP control system pressure sensor.

EC-293 433
 TROUBLE DIAGNOSIS FOR DTC P1447
Evaporative Emission (EVAP) Control System
Purge Flow Monitoring (Cont'd)
Absolute pressure sensor
1. Remove absolute pressure sensor with its harness connector
Absolute pressure
connected.
2. Remove hose from absolute pressure sensor.
3. Turn ignition switch "ON" and check output voltage between
terminal ® and engine ground.
The voltage should be 3.2 to 4.8 V.
4. Use pump to apply vacuum of -26.7 kPa (-200 mmHg, -7.87
inHg, -3.87 psi) to absolute pressure sensor as shown in fig-
SEF098S ure and check the output voltage.
The voltage should be 1.0 to 1.4 V lower than the value
measured in step 3.
CAUTION:
Always calibrate the vacuum pump gauge when using it.
5. If NG, replace absolute pressure sensor.

MAP/BARO switch solenoid valve

• ACTIVE TEST •
1. Start engine and warm it up sufficiently.
MAPIBARO SWIV MAP 2. Perform "MAP/BARO SWN" in "ACTIVE TEST" mode
with CONSULT.
J==oo======o MONITOR ===oo=====oi 3. Check the following.
CMPS•RPM(REF) 800rpm
MAP/BARO SWIV MAP • When "MAP" is selected, "ABSOL PRES/SE" indi-
ABSOL PRES/SE 1 .3V cates approximately 1.3V.
• When "BARO" is selected, "ABSOL PRES/SE" indi-
cates approximately 4.3V.
4. If NG, replace solenoid valve.
---------OR---------
1. Remove MAP/BARO switch solenoid valve.
2. Check air passage continuity.
• ACTIVE TEST • D
Air passage Air passage
MAP/BARD SWIV BARD
Condition continuity continuity
========== MONITOR ========== between @ and @ between @ and ©
CMPS•RPM(REF) 800rpm
MAP/BARO SWN BARO 12V direct current supply
ABSOL PRES/SE 4.3V between terminals CD Yes No
and®
No supply No Yes
BARO MAP
SEF714T
3. If NG, replace solenoid valve.

MEC488B

434 EC-294
 TROUBLE DIAGNOSIS FOR DTC P1550

Torque Converter Clutch Solenoid Valve

SYSTEM DESCRIPTION
I Engine coolant temperature sensor 1 Engine coolant temperature

ECM Torque
(ECCS converter
control clutch sole-
j Throttle position sensor j Throttle position
module) noid valve

The ECM controls torque converter clutch solenoid

valve to cancel the lock-up condition of AfT. When
the solenoid valve is turned on, lock-up is cancelled.
When the solenoid valve is turned off, AfT lock-up is
operational.
Conditions for lock-up cancel:
• Throttle valve is fully closed (idling or decelera-
tion)
• Engine coolant temperature is below 40°C
(104°F)

ECM TERMINALS AND REFERENCE VALUE

Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TER·
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

1Engine is running. I

t Idle speed
Engine coolant temperature is below 40°C
Approximately OV

(104'F)
Torque converter clutch
t14 UY
solenoid valve II Engine is running.!
- After warming up BATTERY VOLTAGE
- Engine coolant temperature is above 40°C (11 • 14V)
(104'F)
L,_ Engine speed is 2,000 rpm

CONSULT REFERENCE VALUE IN DATA MONITOR MODE

Specification data are reference values
MONITOR ITEM CONDITION SPECIFICATION
• Engine speed: Idle
ON
• Engine coolant temperature below 40°C (104°F)
TCC SOLN • Engine: After warming up
• Engine coolant temperature 2,000 rpm OFF
above 40"C (t04"F)

EC-295 435
 TROUBLE DIAGNOSIS FOR DTC P1550
Torque Converter Clutch Solenoid Valve
(Cont'd)
ON BOARD DIAGNOSIS LOGIC
Diagnostic Trouble Check Items
Malfunction is detected when .
Code No. (Possible Cause)
P1550 • An excessively low voltage from the solenoid is sent • Harness or connectors
0904 to ECM. (The circuit is open or shorted.)
• AfT torque converter slip is occurred in lock-up con- • Torque converter clutch solenoid valve
dition. • AfT hydraulic control system
• Torque converter

DIAGNOSTIC TROUBLE CODE CONFIRMATION

PROCEDURE
@ 1) Turn ignition switch "ON".
\.!!) Select "DATA MONITOR" mode with CONSULT.
2)
Start engine and warm it up sufficiently.
3)
4) Perform test drive in "D" position for at least 20 seconds
continuously under the following conditions.
Engine speed: 2,000-2,700 rpm
Vehicle speed: 75- 95 kmlh (45- 60 MPH)
----------OR----------
(~ 1) Start engine and warm it up sufficiently.
'® 2) Perform test drive in "D" position for at least 20 seconds
continuously under the following conditions.
Engine speed: 2,000- 2,700 rpm
Vehicle speed: 75 - 95 km/h (45 - 60 MPH)
3) Select MODE 7 with GST.
---------OR---------
@ 1) Start engine and warm it up sufficiently.
2) Perform test drive in "D" position for at least 20 seconds
continuously under the following conditions.
Engine speed: 2,000- 2,700 rpm
Vehicle speed: 75 - 95 km/h (45 - 60 MPH)
3) Stop the vehicle, turn ignition switch "OFF", wait at least
7 seconds and then turn "ON".
4) Perform "Diagnostic Test Mode II (Self-diagnostic
results)" with ECM.

436 EC-296
 TROUBLE DIAGNOSIS FOR DTC P1550
Torque Converter Clutch Solenoid Valve
(Cont'd) @I

Refer to "EL~POWER".
10A
[!]]
W/B

[5~

©l

,----'=t="-----, SOLENOID DATA

D
TORQUE VALVE LINK !,i'f
CONVERTER UNIT CONNECTOR
CLUTCH
SOLENOID
<>ill> FOR
CONSULT
VALVE <§3> L~'iJ'
L;J
UY
11"

l"t!J

?!A

~lffi\
UY

0
EGM
(EGGS ~[gl
CONTROL
MODULE)
(~)
:91

[pj~

~('ill) 0 1 2 3 4 5 6 7 (§j)
GY 8 9 10 11 12 13 14 GY ~11

w ~&

~
101 102 103 104 105 106 ~ ~ 1201211221231 38~
l4ol4il f53l54l5sl
44 45 46 57158 59 601 61 ~
107 108 109 110111112115 6 7 8 9110 , 42 43
11 12 13 14 19 1291301311321: foliii 47 48 62 63 64 65 70 Ill
113 114 115 116117 i18fll§J 1617 181 l.§.1.lgJ 66 67 68 691

[IQJ%1

AEC320A

EC-297 437
 TROUBLE DIAGNOSIS FOR DTC P1550
Torque Converter Clutch Solenoid Valve
(Cont'd)
Solenoid valve lit IV @a DIAGNOSTIC PROCEDURE
unit harness
connector@ II ECM ioi' CONNECTOR II I INSPECTION START
I
114

UY B r
CHECK GROUND CIRCUIT.
1~ Repair or replace harness
1. Turn ignition switch to OFF position. r-------- between ECM and torque
2. Disconnect ECM harness connector and converter clutch solenoid
SEF623T
torque converter clutch solenoid valve valve.
harness connector.
3. Check resistance between solenoid
Solenoid valve
valve unit harness terminal No. @ and
unit harness
connector@ ECM harness terminal No. @.
Resistance:
~ Approximately 0!1

W/8 Yes

CHECK POWER SOURCE CIRCUIT. ~ Check the following items:

1. Turn ignition switch to ON position. • Ignition switch and fuse
2. Check voltage between solenoid valve Refer to EL section
SEF624T unit harness terminal No. G) and ("POWER SUPPLY
ground. ROUTING'").
8
[i
v
Solenoid valve unit connector
Voltage:
Battery voltage
• Harness continuity
between fuse and torque

~~l P¥~~
o<OD"
converter clutch solenoid
Yes
valve

CHECK TORQUE CONVERTER CLUTCH NG _ Replace torque converter

/=~
1
SOLENOID VALVE ~ clutch solenoid valve.
'W'
~ ~~v
(RESISTANCE).
Check resistance between torque con-
AAT845 verter clutch solenoid valve terminal Nos.
CD and@.

Solenoid valve unit connector 8 Resistance:

Approximately 25!1
Gft:J OK

CHECK TORQUE CONVERTER Replace torque converter

CLUTCH SOLENOID VALVE clutch solenoid valve.
(OPERATION).
1. Remove torque converter clutch sole-
noid valve. Refer to "ONNEHICLE
SERVICE" in AT section.
AAT846
2. Check torque converter clutch solenoid
valve operation.

~OK
®
(Go to next page.)

438 EC-298
TROUBLE DIAGNOSIS FOR DTC P1550
Torque Converter Clutch Solenoid Valve
(Cont'd) @

~
CHECK CONTROL VALVE. NG Repair control valve.
1. Disassemble control valve assembly.
Refer to "REPAIR FOR COMPONENT
PARTS" in AT section.
2. Check torque converter clutch control
valve.
• Valve, and sleeve slide along valve
bore under their own weight.
SAT740H
• Valve, and sleeve are free from burrs,
dents and scratches.
• Control valve springs are free from
damage, deformation and fatigue.
Ill
• Hydraulic line is free from obstacles.

OK

Is malfunction eliminated? Check control valve again.

Repair or replace control
Yes
valve assembly.

INSPECTION END

EC-299 439
 TROUBLE DIAGNOSIS FOR DTC P1900

Overheat
Note: Since this diagnosis does not meet P1900 of SAEJ2012, it is indicated only by CONSULT.
ON BOARD DIAGNOSIS LOGIC
If the cooling fan or another component in the cooling system malfunctions, the engine coolant temperature
will rise.
When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction is
indicated.
Diagnostic trouble Check Items
Malfunction is detected when ...
code No. (Possible Cause)
OVERHEAT (P1900) • Engine coolant temperature reaches an abnormally • Cooling fan
0208 high temperature. • Radiator hose
• Radiator
• Radiator cap
• Water pump
• Thermostat
For more information, refer to "MAIN 12
CAUSES OF OVERHEATING"", (EC-302).

CAUTION:
When a malfunction is indicated, be sure to replace the coolant following the procedure in the MA
section ("Changing Engine Coolant", "ENGINE MAINTENANCE"). Also, replace the engine oil.
a. Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute like pour-
ing coolant by kettle. Be sure to use coolant with the proper mixture ratio. Refer to MA section
("Anti-freeze Coolant Mixture Ratio", "RECOMMENDED FLUIDS AND LUBRICANTS").
b. After refilling coolant, run engine to ensure that no water-flow noise is emitted.

OVERALL FUNCTION CHECK

WARNING:
Never remove the radiator cap when the engine is hot. Serious
burns could be caused by high pressure fluid escaping from

MAX.

MIN.
I OK
the radiator.
Wrap a thick cloth around cap. Carefully remove the cap by
turning it a quarter turn to allow built-up pressure to escape.
Then turn the cap all the way off.
1) Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
AEC640 If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following step and go to "DIAGNOS-
TIC PROCEDURE" on next page.
2) Confirm whether customer filled the coolant or not. If customer
filled the coolant, go to "DIAGNOSTIC PROCEDURE" on next
page.

440 EC-300
 TROUBLE DIAGNOSIS FOR DTC P1900
Overheat (Cont'd)
DIAGNOSTIC PROCEDURE
INSPECTION START

CHECK COOLING SYSTEM FOR LEAK. NG Check the following for

Apply pressure to the cooling system with leak.
a tester, and check if the pressure drops. • Hose
Testing pressure: • Radiator
157 kPa (1.6 kg/em'. 23 psi) • Water pump
Pressure should not drop. Refer to LC section
SLC754A
CAUTION: ('"Water Pump").
Higher than the specified pressure
may cause radiator damage.
OK
m
~--~----~~-----------,NG
CHECK RADIATOR CAP. Replace radiator cap.
Apply pressure to cap with a tester.
Radiator cap relief pressure:
78- 98 kPa (0.8 • 1.0 kg/em', 11 • 14
psi)
OK
[!)
~----------~-----------,NG
EG17650301 CHECK THERMOSTAT. Replace thermostat.
(J33984-A) SLC755A 1. Check valve seating condition at nor-
mal room temperatures.
It should seat tightly.
2. Check valve opening temperature and
valve lift.
Valve opening temperature:
76.SOC (170°F) [s1andard]
Valve lift:
More than 10 mm/90°C
(0.39 in/194°F)
3. Check if valve is closed at soc (9"F)
below valve opening temperature.
For details, refer to LC section ("Thermo-
stat").
SLC343 L.__ _ _ _ _ _ _ _ _ _ _ _.,-;O"'K:;---------__j

~~--~--~~----------,NG
Check engine coolant temperature sen~ Replace engine coolant
sor. Refer to '"COMPONENT temperature sensor.
INSPECTION", EC·117.
OK

If the cause cannot be isolated, go to

'"MAIN 12 CAUSES OF OVERHEATING"
on next page.

INSPECTION END

Perform FINAL CHECK by the following procedure alter repair :gJ'u"

is completed.
1. Warm up engine. Run the vehicle for at least 20 minutes. Pay
attention to engine coolant temperature gauge on the instrument t~b\
panel. If the reading shows an abnormally high temperature,
another part may be malfunctioning.
2. Stop vehicle and let engine idle. Check the intake and exhaust ~l
systems for leaks by listening for noise or visually inspecting the
components.
3. Allow engine to cool and visually check for oil and coolant leaks. ~)JJZC
Then, perform "OVERALL FUNCTION CHECK".

EC-301 441
 TROUBLE DIAGNOSIS FOR DTC P1900
Overheat (Cont'd)
MAIN 12 CAUSES OF OVERHEATING
Engine Step Inspection item Equipment Standard Reference page

OFF 1 • Blocked radiator • Visual No blocking ~

• Blocked condenser
• Blocked radiator g~ille
• Blocked bumper
2 • Coolant mixture • Coolant tester 50 - 50% coolant mixture See "RECOMMENDED
FLUIDS AND LUBRI-
CANTS" in MA section

3 • Coolant level • Visual Coolant up to MAX level See "Changing Engine

in reservoir tank and Coolant", "ENGINE
radiator filler neck MAINTENANCE" in MA
section

4 • Radiator cap • Pressure tester 78- 98 kPa See "System Check"

(0.8- 1.0 kg/em 2 , 11- 14 "ENGINE COOLING
psi) 59 - 98 kPa SYSTEM" in LC section
(0.6- 1.0 kg/em 2 , 9- 14
psi) (Limit)
ON*2 5 • Coolant leaks • Visual No leaks See "System Check"
"ENGINE COOLING
SYSTEM" in LC section

ON* 2 6 • Thermostat • Touch the upper and Both hoses should be hot See "Thermostat" and
lower radiator hoses ''Radiator'', "ENGINE
COOLING SYSTEM" in
LC section

ON* 1 7 • Cooling fan • Visual Operating See "Cooling Fan"

"ENGINE COOLING
SYSTEM" in LC section.

OFF 8 • Combustion gas leak • Color checker chemical Negative ~

tester 4 gas analyzer

ON* 3 9 • Coolant temperature • Visual Gauge less than 3/4 ~

gauge when driving

• Coolant overilow to resM • Visual No overilow during driving See "Changing Engine
ervoir tank and idling Coolant", "ENGINE
MAINTENANCE" in MA
section
OFF•4 10 • Coolant return from res- • Visual Should be initial level in See "ENGINE MAINTE-
ervoir tank to radiator reservoir tank NANCE" in MA section

OFF 11 • Cylinder head • Straight gauge feeler 0.1 mm (0.004 in) Maxi- See "Inspection", "CYL-
gauge mum distortion (warping) INDER HEAD" in EM
section

12 • Cylinder block and pis- • Visual No scuffing on cylinder See "Inspection", "CYL-
tons walls or piston INDER BLOCK" in EM
section
. ..
1. Turn the 1Qn1t1on sw1tch ON .
*2: Engine running at 3,000 rpm for 10 minutes.
*3: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes.
*4: After 60 minutes of cool down time.
For more information, refer to "OVERHEATING CAUSE ANALYSIS" in LC section.

442 EC-302
 TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS

Injector

EC-INJECT-01

- : Detectable line for DTC

: Non-detectable line for DTC

Refer to "El-POWER".

~~

©lb

IGNITION
ST SWITCH
~Til!
<§g)

,%1
8MI

I -- • •I
mi'

•I
8MI
I 8MI BMI 8MJ
~[ill

~ ~ ~ ~
INJECTOR INJECTOR INJECTOR INJECTOR ~L~~
N0.1 N0.2 NO.3 NO.4
@1) <&llii> @ @
lbjdl lbjdl lbjdl l6jdJ ~ffi\
Wl8 WIL WIR WIG
I
Wl8
I
WIL
I
WIR
I
WIG
[!)~
~ ~ ~ ~
INJ#1 INJ#2 INJ#3 INJ#4 ECM (EGGS
CONTROL
MODULE) 1J1(
<fillY
~~

:-~-------------~
~u
: 1 (f,j£) [ii]@) :
I 2 B
L- _ - - - ____ -
llJ B l
_ _ _ _I

~f~

101102 103 104 105 106

[il[L
107108 109 110 111 112
113 114 115

j[j}Z

AEC068A

EC-303 443
 TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS
Injector (Cont'd)
Terminal COMPONENT DESCRIPTION
The fuel injector is a small, precise solenoid valve. When the ECM
supplies a ground to the injector circuit, the coil in the injector is
energized. The energized coil pulls the needle valve back and
allows fuel to flow through the injector into the intake manifold. The
amount of fuel injected depends upon the injection pulse duration.
Pulse duration is the length of time the injector remains open. The
ECM controls the injection pulse duration based on engine fuel
needs.

SEF596K

ECM TERMINALS AND REFERENCE VALUE

Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

102 W/B Injector No. 1

104 W/R Injector No. 3 BATTERY VOLTAGE

IEngine is running. I
107 W/L Injector No. 2 (11 - 14V)

109 WIG Injector No. 4

DIAGNOSTIC PROCEDURE
• ACTIVE TEST • D
INSPECTION START
••• POWER BALANCE •••

=CMPS·RPM(REF)
= = MONITOR =737rpm
= =
MAS AIR/FL SEN 0 98V
CHECK OVERALL FUNCTION. INSPECTION END
IACV-AAC/V 41%
1. Start engine.
M 2. Perform "'POWER BALANCE" in
.[2]0[3]~ ~ "ACTIVE TEST" mode with
CONSULT.

DDDD~EF354F 3. Make sure that each circuit pro-

duces a momentary engine
speed drop.
f - : : - - - - - OR - - - - - - !

~~t
~ 2. Listen to each injector operating
?~
~)~
~ sound.
Clicking noise should be
Click heard.
At idle
c,,.c" NG

®
(Go to next page.)

-/I
Suitable tool

SEF730L

444 EC-304
 TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS
Injector (Cont'd)
Injector harness Engine front @
connector (No.1) ¢
-
---(IS\_
I' )1 ----o::::- -~ . X-~
/'
CHECK POWER SUPPLY.
1 Repair harness or connec-
1
o\~~~ Ck::l{ 1.Stopengine. tors.
,~ •'-of"'~' 'l;;::r ~--s\. _'tl!\ 2. Disconnect injector harness connector.
~ ~v ~ ~ r=-::,~ 1 3. Turn ignition switch "ON".
~ ~~: >'~
)j ~ F'. 4. Check voltage between terminal and ®
~

'-:/1 ''
\ Jr
~
~ "J' ~~"'- -
tr.fVJ "\ /
I ground with CONSULT or tester.
Voltage: Battery voltage
------,JO"'Kc-----_j
SEF193S L...

m e:~ •
NG... Repair harness or connec-
CHECK OUTPUT SIGNAL CIRCUIT.

r:i~ID~0
1. Turn ignition switch "OFF". -tors.
2. Disconnect ECM harness connector.
3. Check harness continuity between termi-
cffu nal CD and ECM terminals@,@,
@>.@).
Continuity should exist.

N]Jl
...... ~
~ '=" SEF515R
If OK, check harness for short.

CHECK COMPONENT
~OK
~Replace injector.
(Injector).
[!] Reier to "COMPONENT INSPECTION""

~ ID~ r:t~lo below.

~OK
II ECM lof CONNECTORJI oJ'b Disconnect and reconnect harness connec-
102 - 104 - 107 - 109
tors in the circuit. Then retest.

+ Trouble is not fixed.

Check ECM pin terminals for damage and

check the connection of ECM harness con-
nector. Reconnect ECM harness connector
L __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _SEF195S
_ _ __j and retest.

INSPECTION END

COMPONENT INSPECTION
Injector
1. Disconnect injector harness connector.
2. Check resistance between terminals as shown in the figure.
Resistance: 10- 140 at 25°C (77°F)
If NG, replace injector.

AEC559

EC-305 445
 TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS

Start Signal

EC-S/SIG-01

- : Detectable line for DTC

- : Non-detectable line for DTC

IGNITION SWITCH
STAAT
I
8/Y

~[ffi
Refer to "EL-POWER".

OR

OR

l@oll
STSW ECM(ECCS
CONTROL
MODULE)
@W
L __ _ _ _ _______J I

AEC069A

446 EC-306
 TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS
Start Signal (Cont'd)
SYSTEM DESCRIPTION
If the ECM always receives a start signal, the ECM will judge the start signal "OFF" when engine speed is
above 1,000 rpm. This prevents extra enrichment. After the engine speed is below 200 rpm, start-up enrich-
ment will be allowed until the engine speed reaches 1,000 rpm.

ECM TERMINALS AND REFERENCE VALUE

Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

IIgnition switch "ON" I Approximately OV

20 OR Start signal
BATIERY VOLTAGE
pgnition switch "START" I
(11 - 14V)

CONSULT REFERENCE VALUE IN DATA MONITOR MODE

Specification data are reference values.
MONITOR ITEM CONDITION SPECIFICATION
START SIGNAL e Ignition switch: ON ----t START----tON OFF -+ ON -+ OFF

EC-307 447
 TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS
Start Signal (Cont'd)
m • START SIGNAL CKT •
DIAGNOSTIC PROCEDURE

INSPECTION START
1 CLOSE THROTILt. SHIFT II
~
TO P OR N RANGE
2 TOUCH START AND
START ENGINE m
IMMEDIATELY CHECK OVERALL FUNCTION. 0~ INSPECTION END
I
1. Turn ignition switch "ON".
® 2. Pertorm "START SIGNAL CKT""
in "FUNCTION TEST" mode with
I NEXT II START I CONSULT.
SEF191L OR

m *:MONITOR *:NO FAIL D

® 1. Turn ignition switch "ON".
2. Check "START SIGNAL"" in
"DATA MONITOR'' mode with
CONSULT.
START SIGNAL OFF
CLSDTHIPSW ON
IGN "ON" OFF
AIR CONDSIG OFF IGN "START" ON
P/N POSI SW ON I
OR

® 1. Turn ignition switch to "START".

2. Check voltage between ECM
terminal @ and ground.
I RECORD
lEF111P
Voltage:
Ignition switch "START''
Battery voltage
m Except above

I ECM 19 CONNECTOR I [1ti) Approximately OV

J_NG
20

[YJ Check the following.

• 10A fuse
'-~ • Harness for open or short between ECM

@i]ID ~.! ~ =

SEF109P
and ignition switch
If NG, repair harness or connectors.

+
Disconnect and reconnect harness connec-
tors in the circuit. Then retest.

+Trouble is not fixed.

Check ECM pin terminals for damage and
check the connection of ECM harness con~
nectar. Reconnect ECM harness connector
and retest.

+
INSPECTION END

448 EC-308
 TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS

Fuel Pump
SYSTEM DESCRIPTION
Engine speed
I Camshaft position sensor
I ECM
(ECCS
Fuel
pump
control
Start signal relay
!Ignition switch module)
I

The ECM activates the fuel pump for several sec-

Condition Fuel pump operation
onds after the ignition switch is turned on to improve
engine startability. If the ECM receives a 180" sig- Ignition switch is turned to ON.
Operates for
nal from the camshaft position sensor, it knows that 5 seconds
the engine is rotating, and causes the pump to per- Engine running and cranking Operates
form. If the 180° signal is not received when the
When engine is stopped Stops in 1 second
ignition switch is on, the engine stalls. The ECM
stops pump operation and prevents battery Except as shown above Stops
discharging, thereby improving safety. The ECM
does not directly drive the fuel pump. It controls the
ON/OFF fuel pump relay, which in turn controls the
fuel pump.
ECM TERMINALS AND REFERENCE VALUE
Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

I ignition switch ""ON"" I

L For 5 seconds after turning ignition switch

Approximately 1V
'"ON"
8 W/R Fuel pump relay I Engine is running. I

I Ignition switch "ON" 1 BATTERY VOLTAGE

L 5 seconds after turning ignition switch "ON" (11 - 14V)

CONSULT REFERENCE VALUE IN DATA MONITOR MODE

Specification data are reference values
MONITOR ITEM CONDITION SPECIFICATION

• Ignition switch is turned to ON (Operates for 5 seconds)

• Engine running and cranking ON
FUEL PUMP RLY • When engine is stopped (Stops in 1.0 seconds)

• Except as shown above OFF

COMPONENT DESCRIPTION [j'f

The fuel pump with a fuel damper is an in-tank type (the pump and
damper are located in the fuel tank). l~'j'

SEF476P

EC-309 449
 TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS
Fuel Pump (Cont'd)

EC-F/PUMP-01

- : Detectable line for DTC

: Non-detectable line for DTC

WIL
1m1@
.... @Q§)
WIL
B/W B!W

ffim

C
FUEL PUMP
RELAY
(!§:)

lbjdllbfJJ
W/R W/L

WIR
lrbl
FPR ECM (ECCS
CONTROL
MODULE)

L-----------------------~
I
@W

D
345678(~) 12345@) ~@
9 1011 1 13 14 L 6 7 8 9 10 w \:tllli::J GY

AEC340A

450 EC-310
 TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS
Fuel Pump (Cont'd)
DIAGNOSTIC PROCEDURE
INSPECTION START

CHECK OVERALL FUNCTION. OK INSPECTION END

1. Turn ignition switch "ON".
2. Pinch fuel feed hose with fingers.
Fuel pressure pulsation should be felt
on the fuel feed hose for 5 seconds
SEF196S after ignition switch is turned "ON".
~===::;;;::::::;~::;:==:~
CHECK POWER SUPPLY.
NG

1. Turn ignition switch "OFF".

2. Disconnect fuel pump relay.
3. Turn ignition switch "ON".
NG Check the following.
• 10A fuse
• Harness for open or short
between fuse and fuel
•
4. Check voltage between terminals G), pump relay
@) and ground with CONSULT or tester. If NG, repair harness or
Voltage: Battery voltage connectors.
OK iil'r
SEF197S ,=(!]=..._______.________---,
~==============~ CHECK GROUND CIRCUIT. NG Check the following.
m ~- DISCONNOCT 1. Turn ignition switch "OFF". • Harness connectors
~ ~ I() 2. Disconnect fuel pump harness connec- @.@
~~J ~~-eck
• Harness connectors
3. harness continuity between termi· @.@
nal ® and body ground, relay termi- • Harness for open or short
nal ® and terminal ®. between fuel pump and
Continuity should exist. body ground
If OK, check harness for short. • Harness for open or short
between fuel pump and
OK
fuel pump relay
If NG, repair harness or con-
SEF479P nectors.

~==========~~!]
~~~~~~~~~-,
CHECK OUTPUT SIGNAL CIRCUIT. NG Repair harness or connec-
1. Disconnect ECM harness connector. tors.
2. Check harness continuity between ECM
terminal @ and terminal ®.
Continuity should exist.
If OK. check harness for short.
OK

®
(Go to next page.)

SEF200S

EC-311 451
 TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS
Fuel Pump (Cont'd)
I!J ®
[itDi()T ~D~()T

19 II
1!!1 l ~Replace fuel pump relay.
II ECM
8
CONNECTOR CHECK COMPONENT
(Fuel pump relay). I

~ ®
1. Reconnect fuel pump relay, fuel
pump harness connector and
ECM harness connector.
[ill 2. Turn ignition switch "ON".

00 J
SEF482P
3. Turn fuel pump relay "ON" and
"OFF" in "ACTIVE TEST" mode
with CONSULT and check oper-
ating sound.
1!!1 • ACTIVE TEST • D
OR

FUEL PUMP RELAY ON ® Refer to "COMPONENT INSPEC-

TION" below.

tOK
===MONITOR
CMPS·RPM(REF)
===
Orpm CHECK COMPONENT NG_J Replace fuel pump.
(Fuel pump).
I
Refer to "COMPONENT INSPECTION"
below.

I ON lamll OFF I
MEF309F
tOK

Disconnect and reconnect harness connec-

tors in the circuit. Then retest.

+Trouble is not fixed.

Check ECM pin terminals for damage and
check the connection of ECM harness con-
nectar. Reconnect ECM harness connector
and retest.

+
INSPECTION END

COMPONENT INSPECTION

2 Fuel pump relay

Check continuity between terminals ® and ®.
3
Conditions Continuity
12V direct current supply
Yes
between terminals G) and ®
No current supply No

If NG, replace relay.

SEF511P

Fuel pump
1. Disconnect fuel pump harness connector.
2. Check resistance between terminals ® and @.
Resistance: 0.2 - 5.011 at 25°C (77°F)
If NG, replace fuel pump.

SEF402S

452 EC-312
 TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS

Power Steering Oil Pressure Switch

EC-PST/SW-01

- Detectable line lor DTC

- : Non-detectable line for DTC

I'~

rg!,

~n

ff\11

11!'

I'll

?&,

~~

~IT2)

!)'['

~@
~

~@ ~11
~B

[~~

~~

m9llZ

AEC071A

EC-313 453
 TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS
Power Steering Oil Pressure Switch (Cont'd)
COMPONENT DESCRIPTION
The power steering oil pressure switch is attached to the power
steering high-pressure tube and detects a power steering load.
When a power steering load is detected, it signals the EGM. The
EGM adjusts the IAGV-AAG valve to increase the idle speed and
adjust for the increased load.

ECM TERMINALS AND REFERENCE VALUE

Specification data are reference values and are measured between each terminal and @ (EGGS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

II Engine is running.j
ov
Power steering oil pres- L Steering wheel is being turned.
25 G
sure switch ' 1 Engine is running.j
Approximately 5V
L Steering wheel is not being turned.

CONSULT REFERENCE VALUE IN DATA MONITOR MODE

Specification data are reference values
MONITOR ITEM CONDITION SPECIFICATION
Steering wheel in neutral position
• Engine: After warming up, idle OFF
PW/ST SIGNAL (forward direction)
the engine
The steering wheel is turned ON

454 EC-314
 TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS
Power Steering Oil Pressure Switch (Cont'd)
m • PW/ST SIGNAL CIRCUIT.
DIAGNOSTIC PROCEDURE
INSPECTION START
HOLD STEERING WHEEL I
IN A FULL

LOCKED
THEN
POSITION
m
CHECK OVERALL FUNCTION. OK~ INSPECTION END
TOUCH START

NEXT II START
@ 1. Turn ignition switch "ON".
2. Pertorm "PW/ST SIGNAL CIR-
I I
CUlT"" in "FUNCTION TEST""
MEF023E mode with CONSULT.
OR
m -::rMON!TOA

PW/ST SIGNAL
UNO FAIL

OFF
D ® 1. Start engine.
2. Check "PW/ST SIGNAL"" in
""DATA MONITOR"" mode with
CONSULT.
Steering is neutral position: OFF
Steering is turned: ON
OR

I RECORD I
® 1. Start engine.
2. Check voltage between ECM
terminal @ and ground.
SEF5911 Voltage:
When steering wheel is
m turned quickly.
Approximately OV
i;O~NECT

II ECM flCONNECTORII [11 £) Except above

Approximately SV

l ['lJ
+
«l9 !;)
NG

~ID ~
CHECK GROUND CIRCUIT.
1. Turn ignition switch "OFF".
NG Repair harness or connec-
tors.
2. Disconnect power steering oil pressure
SEF126P
switch harness connector.
3. Check harness continuity between termi-

ifr;[t.lL\~~ nal® and engine ground.

l~ '·~-
Continuity should exist.
Ccoo<
If OK, check harness for short.

~OK

1£~~" *':""" ,,:W~

";;;
~ pressure switch
harne~~n,n:_ctor
---
..-
®
(Go to next page.)

,~pressure Power steering oil

sw;tch ~rr:~F203S /

!;)

~&)@a
ffi

911 SEF204S

EC-315 455
 TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS
Power Steering Oil Pressure Switch (Cont'd)
[!1 @

~ID~ ~lo [!1

1
II ECM !of CONNECTOR II
ffi CHECK INPUT SIGNAL CIRCUIT. NG
r-------
Check the following.
25 1. Disconnect ECM harness connector. • Harness connectors
2. Check harness continuity between ECM @,@>
terminal @ and terminal G). • Harness for open or short
[ill Continuity should exist. between ECM and power
If OK, check harness for short. steering oil pressure switch
SEF205S
If NG, repair harness or con-
OK
nectars.

CHECK COMPONENT
(Power steering oil pressure switch).
Refer to "COMPONENT INSPECTION"
below.
-NG Replace power steering oil
pressure switch.

OK

Disconnect and reconnect harness connec-

tors in the circuit. Then retest.

Trouble is not fixed.

Check ECM pin terminals for damage and

check the connection of ECM harness con-
nectar. Reconnect ECM harness connector
and retest.

INSPECTION END

COMPONENT INSPECTION
Power steering oil pressure switch
1. Disconnect power steering oil pressure switch harness con-
nector then start engine.
2. Check continuity between terminals G) and ®.
Conditions Continuity
Steering wheel is being turned Yes
Steering wheel is not being turned No
SEF622T If NG, replace power steering oil pressure sw1tch.

456 EC-316
 TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS

IACV-FICD Solenoid Valve

EC-FICD-01

·------. - : Detectable line for DTC

~ffi ~ffi
Refer to "EL-POWER". : Non-detectable line for DTC

G/R G/W

m
,---------'LT--"-----,AIR

OFF
ON

OFF
CONDITIONER
ON SWITCH
(M120)
•
lbjdJ G/W
GIB G/L

~~-NG . . G/BJ
!@
<MW

t ~•~em SOLENOID
VALVE
Cii§Ql)
-
G/L G/W G/W
I

II]
BIW-·
AIR
CONDITIONER
RELAY
(f,ill)
I
B/W

rep lI@§Qj)
bjdl@
t B
lb'jdll4dJ

~
B

-
G/R B/W
©THERMAL
PROTECTOR JOINT
CONNECTOR-2
~-1
CMlli>
B lb'jdJ

~
G/R B
I

i-il
D
NG
COMPRESSOR
EGM (EGGS
CONTROL (M14)-2
MODULE)
B B B
@ill> ..L ...L oo:b-
(~) (~) (M49)

@®
cffuc~>
GY
ct) (M14)-1
GY
ITJ(M14)-2
w +@ L
d&J<~>
w
@W
Refer to last page (Foldout page).

PU CM02)ill

~
=
~ ~~~61
20212223
101 102 103 104 105 106
I 2 3
5 6 7 8 9 10 2425262728 ~1?
42#
107 108 109 110111112 1112 13 14
19 29 30 31 32 33 49 ~ l4i 70
113 114 115 116 117 118 l.1EJ 16 17 18 34 35 36 37 l2!JgJ

AEC319A

EC-317 457
 TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS
IACV-FICD Solenoid Valve (Cont'd)
COMPONENT DESCRIPTION
The idle air adjusting (IAA) unit is made up of the IACV-AAC valve,
IACV-FICD solenoid valve and idle adjusting screw. It receives the
signal from the ECM and controls the idle speed at the preset
value.

ECM TERMINALS AND REFERENCE VALUE

Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC voltage)
NO.

II Engine is running.!
L Both air conditioner switch and blower switch Approximately 1V

15 G/R Air conditioner relay are "ON".

1Engine is running. I BATTERY VOLTAGE

L Air conditioner switch is "OFF". (11 - 14V)

1 Engine is running. I

L Both air conditioner switch and blower switch Approximately OV

21 G/R Air conditioner switch are "ON". (Compressor operates)

1Engine is running. I BATTERY VOLTAGE

L Air conditioner switch is "OFF". (11 - 14V)

458 EC-318
 TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS
IACV-FICD Solenoid Valve (Cont'd)
eli I
m DIAGNOSTIC PROCEDURE

00 :{0 INSPECTION START

~
~7
~)~2
..
M'\~111\1111/111'/tJ,,

6
C~H
1:<~.

m
CHECK OVERALL FUNCTION.
~ INSPECTION END
~0
>1000 r/m1n
8
§ .. [§ 1. Start engine and warm it up sufficiently.
2. Check idle speed.
MIT: 800±50 rpm
MEF634E A/T: 800±50 rpm (in "N" position)
If NG, adjust idle speed.
151
~15@aiD
3. Turn air conditioner switch and blower
fan switch "ON".
4. Recheck idle speed.

dJb ~c~~H MIT: 900 rpm or more

AfT: 900 rpm or more (in "N" posi-
tion)

l
~Wl
NG

Check if air conditioner compressor func- ~Refer to HA section.

tions normally.
SEF722T
OK
[!)
~15~ 151
CHECK POWER SUPPLY. NG Check the following.
~
cf$ 1. Stop engine.
2. Disconnect IACV-FICD solenoid valve
• Harness connectors,
@.@I>
harness connector. • Harness for open or

__ IIDLfl_ 3. Restart engine and turn air conditioner

switch and blower fan switch "ON".
4. Check voltage between terminal G)
short between IACV-
FICO solenoid valve and
air conditioner relay
and ground with CONSULT or tester. If NG, repair harness or
SEF723T
Voltage: Battery voltage connectors.

OK

[!)
CHECK GROUND CIRCUIT.
1. Turn ignition switch "OFF".
2. Check harness continuity between ter-
minal® and body ground.
Continuity should exist.
--
NG Check the following.
• Harness connectors,
@.@I>
• Joint connector-2
• Harness for open or
If OK, check harness for short. short between IACV-
FICO solenoid valve and
OK
body ground
If NG, repair harness or
connectors.

CHECK COMPONENT
(IACV-FICD solenoid valve).
Refer 1o '"COMPONENT INSPECTION'"
on next page.
--
NG Replace IACV-FICD sole-
noid valve.

~OK
®
(Go to next page.)

EC-319 459
 TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS
IACV-FICD Solenoid Valve (Cont'd)
®
l
Disconnect and reconnect harness con-
nectars in the circuit. Then retest.

l Trouble is not fixed.

Check ECM pin terminals for damage and

check the connection of ECM harness
connector. Reconnect ECM harness con-
nectar. Then retest.

l
INSPECTION END

COMPONENT INSPECTION
IACV-FICD solenoid valve
Disconnect IACV-FICD solenoid valve harness connector.
• Check for clicking sound when applying 12V direct current to
terminals.

• Check plunger for seizing or sticking.

• Check for broken spring.

SEF199S

460 EC-320
 TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS

~~]
MIL & Data Link Connectors

EC-MIUDL-01
1 BAt!r 1

rn
r~~~BLE
(~).@)
W/B Refer to "EL-POWER"
iki=!l
w
1m1~
'-r' @£) - : Detectable line for DTC

~~
- : Non-detectable line for DTC
W/B <:£): AfT models
I
•· BIW-------., RIG
I
I
WIB
To EL-INT/L + RIG-.
I
IF2'im JOINT w
CONNECTOR-2
@ill) r1'sl DATA LINK
CONNECTOR
cyJ FORGST
W/B

1ren1<MW
I
L-----~~~07~~
DATA LINK I 7 I I 5 I I 4 I
I(~)

'-r'@ CONNECTOR ........ ~ !......y--1

I.
W/B FOR CONSULT R B B

I
L-~~~~~~~~~~~(~)
~Li-Jli-JL';J~
METER
(MALFUNCTION
INDICATOR LAMP) Y R G UY B

~a...___
®
~
R

1$1®
@§)
RIW e-uv+ To AT-Afr

LEO-A SCIRX SCITX SCICL

t
LKUP KLINE ECM(ECCS B B B B B
CONTROL ..L ..L ..L ..L ..L
MODULE)
@ill) <~i§l (M1s) (M~60) (M~05) <rY\49>

.--------------. Refer to last page (Foldout page) .

(r@o)
: ~(fMZ) ~(E21) I ~([ill§)
I
I
1
2
B 1 B I
I
w (M142)
~-------------J @.®
\1213456781@2)
\ 9 10 11 12 13 14 15 16/ w
IIO 81 2 3 4 5 6 7
9 10 11J1?Ji3l14
@ig)
GY ~161151 -114113~ (M~2)~
I
~
101 102 103 104 105 106 rTT2T3l ~ 12 0212223 '38
r.:; 39 44[40J4il 53 54155
107108109 110111112 56 7 B gJitO 24 25 26 27 28 45 46 57 58!59 60 61
11 12 13 14 19 12930313233 ~~
~50 47 48 62 63 64 65 70
113 114115 116117 1181112.1 161171181 34 35 36 37 l21.illJ 66 67168 69

AEC321A

EC-321 461
 TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS
MIL & Data Link Connectors (Cont'd)
ECM TERMINALS AND REFERENCE VALUE
Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC Voltage)
NO.

IIgnition switch "ON'' I 0- 1V

18 R/W Malfunction indicator !amp Engine is running. I

1
BATTERY VOLTAGE
L Idle speed (11 - 14V)

Data link connector for 1Engine is running. I

58 R Approximately 9V
GST L Idle speed (GST is disconnected.)

64 y Approximately 0.1V
1 Engine is running.j
Data link connector for
65 R
CONSULT L Idle speed (Connect CONSULT and select Approximately 4 - 9V

68 G DATA MONITOR mode.) Approximately 3.5V*

..
. Average voltage for pulse s1gnal (Actual pulse s1gnal can be confirmed by oscilloscope.)

462 EC-322
 SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications
PRESSURE REGULATOR

Fuel pressure at idling

kPa (kg/cm 2 , psi)

Approximately
Vacuum hose is connected
235 (2.4, 34)

Approximately
Vacuum hose is disconnected
294 (3.0, 43)

Inspection and Adjustment

---------,.-------
Idle speed*1

No-load*2

Air conditioner: ON
rpm

(in "N" position)

{in "N" position)

800±50

900 or more
EGR TEMPERATURE SENSOR
EGR temperature
'C CF)

0 (32)

50 (122)
Voltage
(V)

4.81

2.82
Resistance
(Mll)

7.9- 9.7

0.57- 0.70
•
Ignition timing 10"±2" BTDC 100 (212) 0.8 0.08-0.10
Throttle position touch speed rpm 1,000±150
*1. Feedback controlled and needs no adjustments
*2: Under the following conditions:
• Air conditioner switch: OFF FUEL PUMP
• Steering wheel: Kept in straight-ahead position
• Electrical load: OFF (Lights, heater fan & rear window defog- Resistance [at 25°C (7rF}] 0.2-5.0
ger)

IGNITION COIL IACV-AAC VALVE

Primary voltage v Battery voltage (11 - 14)
Resistance [at 25°C (7JOF)] n Approximately 10.0

Primary resistance
Less than 1.0
[at 25,C (7TF)] !l

Secondary resistance
7- 13
INJECTOR
[at 25'C (77'F)] kll
Resistance [at 25°C (7JOF)] 10- 14

MASS AIR FLOW SENSOR

RESISTOR
Supply voltage v Battery voltage (11 - 14)
Resistance [at 25°C (7rF)] kD Approximately 2.2
Output voltage at idle v 1.3- 1.7

1.8 - 6.5 at idle* (2WD)

Mass air flow
2.1 - 6.0 at idle* (4WD)
(Using CONSULT or GST)
g·m/sec
7.7- 15.0 at 2,500 rpm* (2WD) THROTTLE POSITION SENSOR
6.8- 13.3 at 2,500 rpm* (4WD)
Throttle valve conditions Resistance [at 25°C {7rF)]
Eng1ne IS warmed up suff1c1ently and runnmg under no-load.
Completely closed Approximately 0.5 kfl

Partially open o.5- 4.0 kn

ENGINE COOLANT TEMPERATURE Completely open Approximately 4.0 kn

SENSOR
Resistance

20 (68) 2.1 - 2.9 kn CALCULATED LOAD VALUE

50 (122) 0.68 - 1.00 k!l Calculated load value %
0.236 - 0.260 k!! (Using CONSULT or GST)
90 (194)
16.8 - 34T {2WD)
At idle
15.9 - 33.2' (4WD)

14.1 - 27.6' (2WD)

At 2,500 rpm
13.3 - 26.1' (4WD)
*: Engme 1s warmed up suff1c1ently and runmng under no-load.

EC-323 463
 SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont'd)
INTAKE AIR TEMPERATURE SENSOR REAR HEATED OXYGEN SENSOR HEATER
Temperature oc (°F) Resistance Resistance [at 25°C (7JOF)] U I 11.4- 17.4

20 (68) 2.1-2.9 kH

80 (176) 0.27 - 0.38 kH

CRANKSHAFT POSITION SENSOR (OBD)
Resistance [at 20°C (68°F)] n I 166.5 - 203.5
FRONT HEATED OXYGEN SENSOR
HEATER
Resistance [at 25°C (7JOF)] !1 I 2.3 - 4.3

464 EC-324
 ACCELERATOR CONTROL, FUEL & Ill
EXHAUST SYSTEMS

SECTION FE

ACCELERATOR CONTROL SYSTEM ........................... 2

CONTENTS
FUEL SYSTEM ..............................................................3
II
(;[b
Adjusting Accelerator Wire .......................................... 2 Fuel Tank ................................................................... 3
Fuel Pump and Gauge .. ................ ..... 6
EXHAUST SYSTEM ... ....... .. .... ............ .. ............. .. ........ 7 mj1J

465
 ACCELERATOR CONTROL SYSTEM

CAUTION:
• When removing accelerator wire, mark initial position of lock nut.
• Check that throttle valve opens fully when accelerator pedal is fully depressed. Check that throttle
valve returns to idle position when accelerator pedal is released.
• Check accelerator control parts for improper contact with any adjacent parts.
• When connecting accelerator wire, do not twist or scratch the inner wire.
• For adjustment of AfT throttle wire, refer to AT section ("Throttle Wire Adjustment", "ON-VEHICLE
SERVICE").

SEC. 180

'"·~~
J
I~ 3 • 4 N•m (0.3 - 0.4 kg·m, 26.0 - 34.7 ln-lb)
MFE027A

(Lock nut
Adjusting Accelerator Wire
\Throttle drum

1
~8 -11 N-m CAUTION:
{0.8- 1.1 kg-m,
69 - 95 in-lb) • Make sure the ASCD wire is not pulling the throttle drum.

~~or
• For ASCD wire adjustment, refer to EL section ["AUTO-
MATIC SPEED CONTROL DEVICE (ASCD)"].
1. Loosen lock nut, and tighten adjusting nut until throttle drum
\ Accelerator wire
",. starts to move.
\ Adjusting nut 2. Loosen adjusting nut 1.5 to 2 turns and tighten lock nut.
\\,, i
~
SFE248AB

466 FE-2
 FUEL SYSTEM

Fuel Tank ~[
WARNING:
When replacing fuel line parts, be sure to observe the following: GiJI'c
• Put a "CAUTION: FLAMMABLE" sign in workshop.
• Do not smoke while servicing fuel system. Keep open flames and sparks away from work area.
• Furnish workshop with a C0 2 fire extinguisher. eeoc
IS~<Ji
CAUTION:
• Before removing fuel line parts, carry out the following procedures:
a. Put drained fuel in an explosion-proof container and put the lid on securely.
b. Release fuel pressure from fuel line. Refer to EC section ("Fuel Pressure Release", "BASIC SER·
VICE PROCEDURE").
c. Disconnect battery ground cable.
• When installing fuel check valve, install it in the correct direction. Refer to EC section ("EVAPO·
RATIVE EMISSION SYSTEM").
• Always replace 0-ring with a new one .
• Do not kink or twist tubes and hoses during installation .
• To avoid damaging hoses, do not tighten hose clamps excessively.
rc
• After installing tubes, run engine and check for fuel leaks at connections. ~!'ls
• Use only a genuine fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL
may turn on.
• For inspection of EVAP shut valve, refer to EC section ("EVAPORATIVE EMISSION SYSTEM").
SEC. 172

11!]2.0. 2.5 (0.2- 0.26, 17.4- 22.6) \

Filler protector
~EVAP '""' valve

EVAP canister

@< "@-)

Fuel gauge

Fuel tank protector

(4WD)

\ ~ 27 - 35 (2.8 • 3.6, 20 - 26)

ljJ: N·m (kg·m, in-lb)
~: N·m (kg-m, tt-lb)
AFE065

FE-3 467
 FUEL SYSTEM
Fuel Tank (Cont'd)
REMOVAL
CAUTION:
• Do not disconnect any fuel line unless absolutely neces-
sary.
• Plug hose and pipe openings to prevent entry of dust or
dirt.

1. Release fuel pressure. Refer to EC section ("Fuel Pressure

Release"', "BASIC SERVICE PROCEDURE").
2. Disconnect battery ground cable.
3. Drain fuel from fuel tank.
4. Disconnect electrical connector.
5. Remove filler protector.
6. Disconnect filler tubes, fuel supply tube and fuel return tube.

7. Remove fuel tank protector.

Fuel tank protector bracket (4WD)

Fuel tank protector

(4WD)

8. Remove six fuel tank mounting bolts while supporting fuel tank.

468 FE-4
 FUEL SYSTEM
Fuel Tank (Cont'd)
9. Remove rear fuel tank mounting bracket.

10. Remove fuel tank.

II

INSTALLATION
To install, reverse the removal procedure.
CAUTION:
• Do not kink or twist hoses and tubes during installation.
• To avoid damaging hoses, do not tighten hose clamps
excessively.
• Tighten bolts to specified torque.
• After installation, run engine and check for leaks at con-
nections.

FE-5 469
 FUEL SYSTEM

Fuel Pump and Gauge

REMOVAL
1. Remove fuel tank. Refer to FE-4.
2. Disconnect fuel supply tube, fuel return tube and electrical
connector.
3. Remove the six screws.

4. Remove fuel pump and gauge.

AFE052

INSTALLATION
To install, reverse the removal procedure.
CAUTION:
• Tighten bolts to specified torque.
II'J: 2.0- 2.5 N·m (0.20- 0.26 kg-m, 17.4- 22.6 in-lb)
• Always replace 0-ring with a new one.
• After installation, run engine and check for leaks at con-
nections.

470 FE-6
 EXHAUST SYSTEM

CAUTION:
• Replace exhaust gaskets with new ones when reassem-
bling.
If gasket remains on flange surface, scrape off completely
as shown at left.
• With engine running, check all tube connections for
exhaust gas leaks, and entire system for unusual noises.
• Check to ensure that mounting brackets and mounting
insulators are installed properly and are free from undue
stress. Improper installation could result in excessive lo©
SFE180A
noise or vibration.
• Discard any heated oxygen sensor dropped from a height
of more than 0.5 m (19.7 in) onto a hard surface such as II':©
a concrete floor; use a new one.
2WDmodel
SEC. 200•208

~~"" (1.3-1.6,9-12) ©l

i!u'ii
1/
e:PI l~~r
Three way catalytic
converter
ttJ:l13 ·16 (1.3 ·1.6, 9 ·12)
Rear heated
oxygen sensor J.~

~[]

~Gasket
lf&

~i

~~

~u

1'113

1111i

lilY\

~l

~ : N · m (kg-m, in-lb)
ttJ:l ' N · m (kg·m, ft·lb) I[ill':
~ :Always replace after every
disassembly AFE049

FE-7 471
 EXHAUST SYSTEM

4WDmodel ~ 13-16
SEC. 200•208 ~ 13-16 (1.3 -1.6,
(1.3- 1.6,
9-12)1:1

'l~
kJ /I
. $
I

~43-45
4.4. 5.6, 32- 41)

( '
~ 13-16
(1.3- 1.6,
9 -12)

Rear heated
oxygen sensor

~ 40-60 - ---1
(4.1- 6.1, ~.
30·44)

~~ /~13-16

'
~.-..~43-50 (1.3-1.6,
(4.4-5.1, 9·12)
""'
. 32-37) I ~ Three way catalytic

'DM~>
<
[ ~ b::f . . ~ ~' converter

:
~
]' ~~43-55
-~-/'--:::---, (4.4-5.6,32-41)

~ !Si§L':'- ~

II) : N · m (kg-m, In-Ib)

~' N-m (kg-m. ft-lb)
t!' :Always replace after every
disassembly
~5-7
(0.5-0.7,43-61)
,,A"-" (1.3-1.6,9-12)

AFEOSO

472 FE-8
 CLUTCH @~

SECTION CL
CONTENTS
PRECAUTIONS AND PREPARATION ........ .................. 2 HYDRAULIC CLUTCH CONTROL ................................. ?
Precautions................................................ ..2 Clutch Master Cylinder ................................................ 7
Special Service Tools ........................ 2 Operating Cylinder .......................................................8
Commercial Service Tools ........................................... 2 Clutch Damper .............................................................9
CLUTCH SYSTEM ........................................................... 3 CLUTCH RELEASE MECHANISM ............................... 10
Clutch Pedal ............................................................... .4 CLUTCH DISC AND CLUTCH COVER ............... ......... 12 IIJ1J
INSPECTION AND ADJUSTMENT .............................. ... 5 Clutch Disc... .................................................... 12
Adjusting Clutch Pedal ............................................... 5 Clutch Cover and Flywheel ....................................... 13 &,U'
Bleeding Procedure .................................................. 6 SERVICE DATA AND SPECIFICATIONS (SDS) .......... 14
General Specifications ............................................... 14
Inspection and Adjustment ........................................ 14 1JI"

473
 PRECAUTIONS AND PREPARATION

Precautions
• Recommended fluid is brake fluid "DOT 3".
• Never reuse drained brake fluid.
• Be careful not to splash brake fluid on painted areas.
• When removing and installing clutch piping, use a suit-
able tool.
• Use new brake fluid to clean or wash all parts of master
cylinder, operating cylinder and clutch damper.
• Never use mineral oils such as gasoline or kerosene. They
Commercial service tool
will ruin the rubber parts of the hydraulic system.
SBR686C WARNING:
After cleaning the clutch disc, wipe it with a dust collector. Do
not use compressed air.
Special Service Tools
The actual shapes of Kent-Moore tools may differ from those of special seiVice tools illustrated here.

Tool number
(Kent-Moore No.) Description
Tool name

ST20630000 Installing clutch cover and clutch disc

(J26366)
Clutch aligning bar
a: 15.9 mm (0.626 in) dia.
b: 22.8 mm (0.898 in) dia.
NT405 c: 55 mm (2.17 in)

ST20050240 Adjusting unevenness of clutch cover dia-

( - ) phragm spring
Diaphragm spring
adjusting wrench
a: 150 mm {5.91 in)
NT404 b: 25 mm (0.98 in)

Commercial Service Tools

Tool name Description

CD Flare nut crowfoot Removing and installing clutch piping

® Torque wrench

NT223 a: 10 mm (0.39 in)

Bearing puller Removing release bearing

NT077

Bearing drift Installing release bearing

NT063 a: 50 mm (1.97 in) dia.

474 CL-2
 CLUTCH SYSTEM

SEC. 300•305•306·465
Iii 8- 11 (0.8 - 1.1, 69 - 95)

Clutch master
cylinder

Clutch pedal

Air bleeder valve

Clutch disc
~6- 10
Clutch damper \ (0.6 - 1.0, 52 - 87)
Clutch cover
1111
Flare nut
~15 -18 (1.5 -1.8,
11 - 13) ffilli
~)
~ 17- 20
(1.7 - 2.0,
12 - 14) ~1-6.5 (0.52- 0.66,
1'11'

45.1- 57.5} I'~

Clutch tube
Release
bearing
'\ ~ 17- 20 (1.7- 2.0, 12- 14) [f~

\ li]a- 11 (o.s- 1.1, 69- 95)

Dust cover _ _ _ _ _ _ _ _ _ ___j ~&
D ® : Contact surface to transmission Clutch hose
case and withdrawal lever
(4WD model) Withdrawal lever - ~ 30 - 40 (3.1 - 4.1, 22 - 30) llil~
Clutch operation cylinder
Air bleeder valve
~-----2_w_o_m_o_d_e_I____.J[il].,•"--6-,· 10 (0.6- 1.0, 52 - 87) ~lr
4WD model
Clutch hose
Eye bolt ~~
~ 17- 20
(1.7 - 2.0,
12 - 14) @)lf
Air bleeder valve
li']6- 10
~ N·m (kg-m, ft-lb) (0.6 - 1.0, li-GL~
52 - 87)
ljl : N•m (kg-m, in-lb)

~ ® :Apply anaerobic liquid gasket

~I,
Loctite PIN 51813 or equivalent
I!Ei!l (b) :Apply lithium-based grease including molybdenum disulphide

~[Li)JZ

ACL033

CL-3 475
 CLUTCH SYSTEM

Clutch Pedal
SEC. 465 Pedal bracket

~ 16- 22 (1.6- 2.2.

ASCD clutch switch

Assist spring l!f!

Clutch spring
~ : N• m (kg-m, ft-lb)
~ : N·m (kg-m, in-lb)
EEi!l : Should be lubricated with gree:c~toso

476 CL-4
 INSPECTION AND ADJUSTMENT

Lock nut Adjusting Clutch Pedal

•Pedal stopper
~ 12- 22 1. Adjust pedal height with pedal stopper bolt or ASCD clutch
(1.6 - 2.2, switch.
12 - 16) Pedal height "H":
• ASCD clutch 236 - 246 mm (9.29 - 9.69 in)
switch
~ 12 - 15
(1.2 - 1.5,
9 - 11)
Pedal stopper
bolt or ASCD
clutch switch

Pad
;,.a

Dash lower panel

~ : N•m (kg-m, ft-lb)
ACL051

2. Adjust pedal tree play by turning master cylinder push rod. I1J
Then tighten lock nut.
Lock nut Pedal free play "A":
II] 8 - 11 N·m
9 - 16 mm (0.35 - 0.63 in)
(0.8 ~ 1.1 kg·m,
69 - 95 ln-lb) Pedal free play, measured at pedal pad includes the following:
• Free play due to clevis pin and clevis pin hole, push rod
and master cylinder. ~IJJ
3. Make sure that clevis pin can rotate smoothly.
It not, readjust pedal tree play with master cylinder push rod. f'ft\
0

Push rod~ ~-'-L. . . ,-1/1~ 1

L Clevis pin
rPedal pad

SCL440-A

CL-5 477
 INSPECTION AND ADJUSTMENT
Adjusting Clutch Pedal (Cont'd)
4. Adjust clearance "C" shown in the figure while fully depress-
ing clutch pedal.
Clearance "C":
0.3- 1.0 mm (0.012- 0.039 in)

~T"'ii-~-Pedal stopper bracket

1\\\fr~h:t--- Clutch interlock
switch

ACLOSS

Bleeding Procedure
• Carefully monitor fluid level at clutch master cylinder dur-
ing bleeding operation.
1. Bleed air from clutch operating cylinder according to the fol-
lowing procedures a through f.
a. Fill reseNoir with recommended brake fluid.
b. Connect a transparent vinyl tube to air bleeder valve.
c. Fully depress and release clutch pedal several times.
d. While holding clutch pedal in the depressed position, open
bleeder valve to release air.
SCL208 e. Close bleeder valve, then release clutch pedal.
f. Repeat steps c through e above until brake fluid flows from air
bleeder valve without air bubbles.
2. Bleed air from clutch damper by using the above procedures
a through f.
3. Repeat the above bleeding procedures 1 and 2 several times.

478 CL-6
 HYDRAULIC CLUTCH CONTROL

Clutch Master Cylinder

SEC. 305

Return spring Piston cup 1!8! ®

~iston assembly B 0
Reservoir _
cap
__________r-)
- ~ Lock nut ~ 8 - 11 (0.8 - 1.1, 69 - 95)

Reservoir

Dust cover JiU

1!i5!1 @ Rubbing surface
to push rod

Stopper ring ~ /Z~'jj

Cylinder body Push rod

B@Rubbing I!'Ei!l @ Contact surface to piston assembly
surface
to piston
1!21!1 (!) : Apply rubber lubricant.
~ 8- 11 (0.8- 1.1, 69- 95)
assembly I!'Ei!l @ : Apply silicone grease.
I!'Ei!!l ® : Apply rubber grease.
~ : N•m (kg-m, in-lb)

SCL686

DISASSEMBLY AND ASSEMBLY

• Use a screwdriver to remove stopper ring while pushing push lliJFi
rod into cylinder.
• When installing stopper ring, tap in lightly while pushing push
rod into cylinder. ~1

INSPECTION
Check the following items, and replace as necessary.
• Rubbing surface of cylinder and piston, for uneven wear, rust
or damage
• Piston with piston cup, for wear or damage
• Return spring, for wear or damage
• Dust cover, for cracks, deformation or damage
• Reservoir, for deformation or damage

CL-7 479
 HYDRAULIC CLUTCH CONTROL

Operating Cylinder
r [ C . l 1 7 _ 20 (1.7 • 2.0. 12 • 14)
SEC. 306 1 Clutch hose

Operating cylinder
l!2i!l (!) Rubbing surfaces to piston assembly 0 Copper washer

Piston spring

') ~ Mbleede<valve

·~ iii • - .. '"·' - '·"· ~ -"'

Piston assembly

~ ,._ . "·'- .,, ,_'"'

Dust cover

Push rod
.
EEi!l (!) :Apply rubber lubricant

liJ : N•m (kg-m, in-lb)

[C.l : N•m (kg-m, ft-lb)

ACL052

INSPECTION
Check the following items, and replace as necessary.
• Rubbing surface of cylinder and piston, for uneven wear, rust
or damage
• Piston with piston cup, for wear or damage
• Piston spring, for wear or damage
• Dust cover, for cracks, deformation or damage

480 CL-8
 HYDRAULIC CLUTCH CONTROL

@]
Clutch Damper
\Cylinder body
SEC. 306

Plate
B (f) Contact surface to piston assembly

l!j3!l (f) : Apply rubber lubricant l!Ili'

~ : N·m (kg-m, in-lb)

ACL038

INSPECTION
Check the following items, and replace as necessary. Tl'
• Rubbing surface of cylinder and piston, for uneven wear, rust
or damage
• Piston with piston cup, for wear or damage i~JD;
• Damper rubber and plate for cracks, deformation or damage
• Piston spring, for wear or damage

CL-9 481
 CLUTCH RELEASE MECHANISM

Oust cover ~ ~
SEC. 321
(4WD model r,;j ® SI!!'Ei!''-"~
Dust cover chp ~):::;pply recommended sealant /u -;:-~
(4WD model) -"A;:/
to contact surface of transmiSSion ~-~~ _
case aod Wlt~dmwallevec ~~~:>~~ } 3:
~ (:, ~'/\ ~. \"· \~ ~
'\
Withdcawal m ©; I(JJ(Y?V ~
i \ ( \1l?\ I 10
1

levee / :J' •~-;.:,~~ec ~~~~ ( / 1) ~~~\\~\ /1 ;"

Q

~
.J.
!>
)~
1 I ' ;v
~I If"'/ \~
\C~J
I;

~ \~:jl
~ ~~
~ Holder spring

1!53!(Q : Apply
Release beacin~
lithium-based grease including molybdenum disulphide
Release sleeve
ACL039

REMOVAL AND INSTALLATION

• Install retainer spring and holder spring.

SCL217

• Remove release bearing using a suitable puller.

CL145

• Install release bearing using a suitable drift.

SCL222

482 CL-10
 CLUTCH RELEASE MECHANISM

INSPECTION
Check the following items, and replace as necessary.
• Release bearing, to see that it rolls freely and is free from
noise, cracks, pitting or wear
• Release sleeve and withdrawal/ever rubbing surface, for wear,
rust or damage

LUBRICATION
• Apply recommended grease to contact surface and rubbing
surface.
• Too much lubricant might damage clutch disc facing .

l!i:i!l (b) : Apply lithium-based grease including molybdenum disulphide.

SCL676 rF

WATERPROOF - for 4WD model

• Apply recommended sealant to contact surface of transmission
Withdrawal lever case dust cover and withdrawal lever, then install dust cover 1!£1~
clip.
Recommended sealant: Nissan genuine part (KP115-00100) or
equivalent. !J1i'

Transmission
case

Dust cover~

Dust cover clip t!-4

~ @ : Apply recommended sealant

ACL040

CL-11 483
 CLUTCH DISC AND CLUTCH COVER

SEC. 300 Flywheel

0
0

Clutch cover

• Do not clean clutch disc surface with solvent. IEi!l (b) : Apply
lithium-based grease including
• When installing, be careful that grease from molybdenum disulphide.
main drive shaft does not adhere to clutch disc. ~ : N·m (kg-m, ft-lb)
ACL041

Clutch Disc
; I
'''' INSPECTION
''
''" Check the following items. and replace as necessary.
• Clutch disc, for burns, discoloration, oil or grease leakage
• Clutch disc, for wear of facing
Wear limit of facing surface to rivet head:
0.3 mm (0.012 in)

• Clutch disc, for backlash of spline and runout of facing

Maximum backlash of spline (at outer edge of disc):
1.0 mm (0.039 in)
Runout limit:
1.0 mm (0.039 in)
Distance of runout check point (from hub center):
115 mm (4.53 in)

0 0

SCL221-A

INSTALLATION
• Apply recommended grease to contact surface of splines.
• Too much lubricant may damage clutch disc facing.

484 CL-12
 CLUTCH DISC AND CLUTCH COVER

Clutch Cover and Flywheel

ST20050240 ( - ) INSPECTION AND ADJUSTMENT
• Check clutch cover, installed on vehicle, for uneven diaphragm
spring toe height.
Uneven limit:
0.7 mm (0.028 in)
• If out of limit, adjust the height using Tool.

SCL466

FLYWHEEL INSPECTION
CAUTION:
Dial gauge Do not allow any magnetic materials to contact the ring gear f'l1'
teeth.
• Inspect contact surface of flywheel for slight burns or discol·
oration. Clean flywheel using emery paper.
• Check flywheel runout.
Maximum allowable runout:
Refer to EM section ("Inspection", "CYLINDER 1!1111
BLOCK").

INSTALLATION
• Insert Tool into clutch disc hub while installing clutch cover and
disc. f[S
• Be careful not to allow grease to contaminate clutch facing.
• Tighten bolts in numerical order, in two steps.
First step: l'l!GJ
to:J: 10- 20 N·m (1.0- 2.0 kg-m, 7- 14 ft-lb)
Final step:
to:J: 22- 29 N·m (2.2- 3.0 kg-m, 16- 22 f!-lb) !'m
ACL009

CL-13 485
 SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications
CLUTCH MASTER CYLINDER CLUTCH DISC
Inner diameter mm (in) 15.87 (5/8) Model 240
Engine KA24E
CLUTCH OPERATING CYLINDER
Fac1ng size
240 X 150 X 3.5
(Outer dia. x inner dia. x thickness)
Inner diameter mm (in) 17.46 (11/16) (9.45 X 5.91 X 0.138)
mm (in)

7.8- 8.2
CLUTCH DAMPER Thickness of disc assembly (0.307 - 0.323)
With load mm {in) with 4,413 N
Inner diameter mm (in) 19.05 (3/4) (450 kg, 992 lb)

CLUTCH COVER

Model 240

Engine KA24E

Set-load N (kg, lb) 4,413 {450, 992)

Inspection and Adjustment

CLUTCH PEDAL CLUTCH DISC
Unit" mm (in) Unit· mm (in)

Pedal height "H"* 236 - 246 (9.29 - 9.6g) Model 240

Pedal free play "A" Wear limit of facing surface to rivet head 0.3 (0.012)
9- 16 (0.35- 0.63)
(at pedal pad)
Runout limit of facing 1.0 (0.039)
Clearance "C" between pedal
Distance of runout check point
stopper bracket and dutch pedal 115 (4.53)
0.3 - 1.0 (0.012 - 0.039) (from hub center}
position switch (with clutch pedal
fully depressed) Maximum backlash of spline
1.0 (0.039)
•: Measured from surface of dash lower panel to pedal pad. (at outer edge of disc}

CLUTCH COVER
Unit· mm (in)

Model 240
37.5- 39.5
Diaphragm spring height
(1.476 - 1.555)

Uneven limit of diaphragm spring

0.7 (0.028)
toe height

486 CL-14
 MANUAL TRANSMISSION @I

SECTION MT
CONTENTS
PREPARATION ......................... ...................................... 2 INSPECTION ..................................................... ............ 15
Special Service Tools .................. .......... ..... . ............. 2 Shift Control Components .................. . ............. 15
Commercial Service Tools .......................................... 3 Gear Components ......................................... ........... 15 ©1
ON-VEHICLE SERVICE ................................................ .4 Gears And Shafts........... .. ........ 15
Replacing Rear Oil Seal - 2WD Model .................... .4 Synchronizers .................................................... 15 •
Position Switch Check ................................................ .4 Bearings .......... ............ ... .. ................. 16
REMOVAL AND INSTALLATION .................................... 5 ASSEMBLY........................... .. ........................... 17
MAJOR OVERHAUL ................................................. ..... 7 Gear Components ..................................................... 17
Case Components....................... .. ...................... 7 Shift Control Components ......................................... 23 ffilf
Gear Components- 2WD Model ............................. 8 Case Components ................................................... 24
Gear Components- 4WD Model ............................. 9 SERVICE DATA AND SPECIFICATIONS (SDS) .......... 27 '['["
Shift Control Components ....................................... 10 General Specifications .............................................. 27
DISASSEMBLY ....................................................... ..... 11 Inspection and Adjustment ........................................ 28
Case Components ................................................... 11
Shift Control Components ..... ............................... 11
Gear Components .................................................... 12

487
 PREPARATION

Special Service Tools

The actual shapes of Kent~Moore tools may differ from those of special service tools illustrated here.

Tool number Description

(Kent-Moore No.)
Tool name

ST23810001 Fixing adapter plate with gear assembly

( )
Adapter setting plate

a
a: 166 mm (6.54 in)
NT407 b: 270 mm (10.63 in)

KV32101330 Removing overdrive mainshaft bearing

(See J26349-A)
Puller

a: 447 mm (17.60 in)

NT408 b: 100 mm (3.94 in)

KV31100401 Pressing counter gear and mainshaft

( )
Transmission press stand

NT068

ST22520000 Tightening mainshaft lock nut

(J26348)
Wrench

a: 100 mm (3.94 in)

NT409 b: 41 mm (1.61 in)

ST23540000 Removing and installing fork rod retaining pin

(J25689-A)
Pin punch
a: 2.3 mm (0.091 in) dia.
NT442 b: 4 mm (0.16 in) dia.

ST30031000 Removing and installing 1st gear bushing

(J22912-01) Removing main drive gear bearing
Puller

a: 90 mm (3.54 in) dia.

NT411 b: 50 mm (1.97 in) dia.

ST23860000 Installing counter drive gear

( )
Drift

a a: 38 mm (1.50 in) dia.

NT065 b: 33 mm (1.30 in) dia.

ST22360002 Installing counter gear front and rear end

(J25679-01) bearings
Drift

a a: 29 mm (1.14 in) dia.

NT065 b: 23 mm (0.91 in) dia.

ST22350000 Installing OD gear bushing

(J25678-01)
Drift

a a: 34 mm (1.34 in) dia.

NT065 b: 28 mm (1.10 in) dia.

488 MT-2
 PREPARATION
Special Service Tools (Cont'd)
Tool number Description
(Kent-Moore No.)
Tool name

ST23800000 Installing front cover oil seal

(J25691-01)
Drift

a a: 44 mm (1.73 in) dia.

NT065 b: 31 mm (1.22 in) dia.

ST33400001 Installing rear oil seal

(J26082)
Drift

a: 60 mm (2.36 in) dia.

NT086 b: 47 mm (1.85 in) dia.

ST33290001 Removing rear oil seal

(J34286)
Puller

ST30720000
(J25405)
Drift
NT414
a: 250 mm (9.84 in)
b: 160 mm (6.30 in)

Installing mainshaft ball bearing •

a: 77 mm (3.03 in) dia.
NT115 b: 55.5 mm (2.185 in) dia.

ST30613000 Installing main drive gear bearing

~
(J25742-3)
Drift

a: 71.5 mm (2.815 in) dia.

NT073 a b: 47.5 mm (1.870 in) dia.

ST33200000 Installing counter rear bearing

(J26082)
Drift

a
a: 60 mm (2.36 in) dia.
NT091 b: 44.5 mm {1.752 in) dia.

Commercial Service Tools

Tool name Description

Puller Removing counter bearings, counter drive

and OD gears

NT077

Drift Installing countershaft rear end bearing

(FS5W71 C-4WD model)

a: 40 mm (1.57 in) dia.

NT074 b: 30 mm (1.18 in) dia.

MT-3 489
 ON-VEHICLE SERVICE

Replacing Rear Oil Seal - 2WD Model

REMOVAL
1. Remove the propeller shaft Refer to PD section ("Removal
and Installation", "PROPELLER SHAFT").
2. Remove rear oil seal using Tool.
• Always replace with a new seal once it has been removed.

INSTALLATION
1. Install new oil seal until it stops.
• Apply multi-purpose grease to seal lip of oil seal before
installing.
2. Install any part removed.

Position Switch Check

• Check continuity
Switch Gear position Continuity
Reverse Yes
Back-up lamp switch
Except reverse No
Neutral Yes
Neutral position switch
Except neutral No

' '
jJ~ ·~ '-/
\
~~. r::~~/~
.H'!~"'v>-~.c~"'~
~ r
Back-up lamp
\ switch
OISCONNECl \

E8 \. Neutral position switch

SMT451 88

490 MT-4
REMOVAL AND INSTALLATION

Removal
CAUTION:
Before separating the transmission from the engine, remove
the crankshaft position sensor (OBD) from the transmission.
Be careful not to damage sensor edge or ring gear teeth.

2WD MODEL
1. Remove battery negative terminal.
2. Remove crankshaft position sensor (OBD) from transmission L·V
upper side.
3. Remove clutch operating cylinder from transmission.
4. Remove back-up switch and neutral position switch harness 15:(;
connectors.
5. Remove starter motor from transmission.
6. Remove propeller shaft. Refer to PD section ("Removal and IJO"l'
Installation", "PROPELLER SHAFT").
• Insert plug into rear oil seal after removing propeller shaft.
• Be careful not to damage spline, sleeve yoke and rear oil :Ql
seal when removing propeller shaft.

7. Remove control lever.

8. Support engine by placing a jack under oil pan.
• Do not place jack under oil pan drain plug.
9. Separate transmission from engine.
WARNING:
Support manual transmission while removing it.

SMT099A

4WD MODEL
1. Remove battery negative terminal.
2. "1""'
Remove crankshaft position sensor (OBD) from transmission L0Lf'J
upper side.
3. Remove clutch operating cylinder from transmission.
4. Remove back-up switch and neutral position switch harness ~I
connector.
5. Remove starter motor from transmission.
6. Remove front and rear propeller shafts. Refer to PD section J:i:C::
("Removal and Installation", "PROPELLER SHAFT").
SMT478A • Insert plug into front and rear oil seals of transfer after
removing propeller shafts. ~l

• Be careful not to damage splines, sleeve yokes and front

and rear oil seals of transfer when removing propeller
shafts.
7. Remove torsion bar springs. Refer to FA section ("Torsion Bar
Spring", "FRONT SUSPENSION"). Then remove second
crossmember. 2'6

MT-5 491
 REMOVAL AND INSTALLATION
Removal (Cont'd)
8. Remove transmission and transfer control levers.
9. Support engine by placing a jack under oil pan.
• Do not place jack under oil pan drain plug.
10. Separate transmission with transfer from engine.
WARNING:
Support manual transmission with transfer while removing it.

\
Installation
1. Apply sealant to areas shown below: - 4WD model

Engine block

Engine block

Engine rear plate

Transmission case

45 (1.77)

Gasket

Mating surface of engine block Mating surface of engine rear

and engine rear plate plate and transmission case
Do not apply sealant in this range.

/}Sealant GJ : Apply recommended sealant

(Nissan genuine part·
TransmiSSIOn q ; E n g m e rear plate KP510-00150) or equivalent.
case
~ : Apply anaerobic liquid
Engme block
gasket Loctite PIN 51813
or equivalent
Umt mm (1n) Engine rear plate
AMT080

2. Tighten bolts securing transmission.

Bolt No. Tightening torque N·m {kg-m, ft-lb) r mm (in)

CD 39 - 49 (4.0 - 5.0. 29 - 36) 65 (2.56)

® 39 - 49 (4.0 - 5.0. 29 - 36) 58 (2.28)

®· 16-22 (1.6- 2.2. 12- 16) 25 (0.98)

@) 16-22 (1.6- 2.2. 12- 16) 16 (0.63)
•. W1th nut
0 MIT to engine
0 Engine rear plate to MIT 3. Tighten clutch operating cylinder to the specified torque. Refer
c __ _ _ _ _ _ _ _ _ _ _A_M_To~97 to CL section ("CLUTCH SYSTEM").

492 MT-6
 SEC. 320o321
!2wo model I
Neutral posit"10

~
~

@\)~Dust
" switch
20
tc!)19 - 25 ... - 29 (2.0 • 3.0, 14
(1.9 _ Y Threads • 22) cover

2 .5, 14- 18) "'-,"-- ~ ~Oil seal~~!!!:!!! Seal lip

~
Pnl
.-..
ack·up 1
amp SWitCh
20 - 29 (2 , 0 - 3.0, 14 - 22)
... Th
'~ ~~ -

Y reads X~
tc!)16 - 20 (La- 2.0, 12 - 14)
"--- fX'-. , _I,
Rear extension
Transmission case
r',l Mating surface to Bearing retainer 3:
0
~
engine rear plate
(4WD model- Ill
Ill
Refer to "REMOVAL
(II 0
and INSTALLATIOW, lJ
3: MT-6.)
,. 0
-;-1 ~ Mating surface to transmission case and
0 0
..... .~' rear extension (or overdrive gear case) 3 <
m
"C
I Filler plug 0 lJ
tc!)16- 21 i tc!)25 - 34 (2.5 - 3.5, 18 - 25) ::3 :I:

- >
(II
(1.6 . 2.1, 12 . 15)
~ r:;!i Threads Overdrive gear case ::3 c:
J:"l Threads Drain plug I ll r-
tc!)25 - 34
l~sealing grommet (2-5 - 3,5, 18 - 25)
~ (4WD model) ~Threads

Gasket~ "

r
lll]6,3 . 8,3

Oil seal ~ I!EIII Seal lip fb ~~!· _- 7~~~-

~~ \2

,.
[j]: N·m (kg-m, in-lb)
tc!)' N,m (kg-m, ft·lb)
..... <M •.•.•.•, Il Baffle plate I'"".,~~ ·-- ....._
. - 2.0, 12 - 14)
.-.,.16 - 20 (1 6

r:;l : Apply anaerobic liquid gasket Loctite PIN 51813 or equivalent

"::i
0
00
lEi:!! : Should be lubricated with grease
493

~ @I) ~ :r-~ :s-)) ND F ~~

©!
~.:g
JjjjjJ
IF
5S
2:0 9
djj]
!1@ 9
(@]
221
;!ID
~-')
""
~
""'
IQJ "iijJ 9 IF
CiiJ
Uliil rs-» eo
[ljjj]
~
~J
~
20 '~
 MAJOR OVERHAUL

Gear Components - 2WD Model

SEC. 322

Snap ring*~

l Snap ring~\
Main drive gear

_::;;,~•f:lJ
Main drive gear
/

(
~

Overdrive & reverse

synchronizer hub 1:f

r / Shifting insert

k"
d Woodruff key -4if CS'i2.:.!);
Counter dnve '""\. ·
'--Spreadspnng i:f \
Needle bearingSub·geru- spnn:: ~ b"lY'"""
Reveosema,ngea' ~\JJ~~
~f~J~~ Sub·gea:::~:::
Bushing

. --Q~
Sh'm * ring*~ \_Snap Apply gear oil to gears, shafts, synchronizers
Countershaft front bearing
*:
and bearings when assembling.
Select proper thickness
-ff : Pay attention to its direction
~' N· m (kg·m, ft·lb)
1!E!!1 : Should be lubricated with grease
AMT105

494 MT-8
 MAJOR OVERHAUL

Gear Components - 4WD Model

SEC. 322

Snap ring*~

Pilot bearing l!i:i!l

Snap ring t:1----.
Main drive gear \

Sna:a::n::;~ 7 l ~~
;~\0·
~ )
Main drive gear
/

AMT106

MT-9 495
496

SEC. 328 Return spring plug r'1

R Y Threads

. .
~ j
Lock pin IJ I~r
PBushing
unger
Stnkong rod~~ ~Striking lever
Malin
eturn spring
Select check

0
~

g surtace to control lever

I
20 . 29 (2.0 . 3

iP-:11
,....
.o. 14 . 22)
D- Shift knob

~~ ~~~~~rhse check plug

~ ~ reads
Control lever
@~"9"' ~
~

~Return
@ ·3&(2.7-3
'-"' 26
ij] 9 . 12 (0.9 • 1.2, 78 • 104) _ _ / spring .7, 20 . 27)
-~
Select check plunger ~~ Check ball
eturn 5 .
Return spring R Thre~~~~g plug
1(_/---...__ 1!"4 Snap ring~

Ch ck spring ~ 20 - 29 (2.0 . 3.0, 14 • 22)

Washer

~ '\io/ VCCheckball

~ ~eck
Rubber
seat ;;;< at o)> en
3:
)>

v
ball plug :::r c..

pin~__/ ~/ / ~:;r~~:s
111 .. c: -·
~ < -l ;::t 0
:!) =
tl :;;o- JJ

tst&2ndtorkrod~ d~ti~a
3: ___l._ Socket 1!!!:1!1
;:;:~c.a:~.. (")
,._,,,._., ~
Retaining " . Upper boot retainer
_ Mat 1ng surface
-;-1 0 0
.... to housing and
control lever ·' "" .. ::I <
m

fork~ ~-,
0 "'3
g... -
0
~-Spring ~ -.. cc
111
- JJ
:I:

y"-·-· "'.. :;; (")

1st & 2nd shift )>

ffi
~ 0
3 c:
g: r-
rl1l
"' :I
111

~
Interlock plunger 'C
Retaining pin~
Check spring
3 iil 0
~0 0"0 ::I
~ ~ <Diii

-
CD
: ) Lower boot retainer fl. !:!. ::I

1'L\
:I
cc Ill
Control housong
"'
~

Check ball
-~ 14. 18 (1.4. 1.8. 10 _ 13) =
""0
:I
Gasket~
3rd & 4th shift fork
OD & reverse bracket
~ : Apply anaerobic liquid gasket ?"
Loctite P/N 51813 or equivalent ~

~: N·m (kg-m, in-lb) 111

3
~' N-m (kg·m, ft-lb) 0
<
111
n
~
j
<: -
0
:I
~

2.
 DISASSEMBLY

@I
Case Components
1. Remove rear extension.
a. Remove control housing, check ball, return spring plugs, select
check plungers and return springs. Also remove reverse check
plug, check spring and check ball.
• Be careful not to lose check balls.

SMT982

b. Drive out striking lever retaining pin.

c. Remove striking lever from striking rod.
d. Remove rear extension by lightly tapping on it.

2. Remove front cover, gasket, countershaft front bearing shim ffi\11

and main drive gear ball bearing snap ring.
3. Separate transmission case from adapter plate by lightly tap- l'IP
ping on it.

4. Remove oil seal from front cover.

• Be careful not to damage mating surface of front cover.

(
1
SMT035

Shift Control Components

1. Set up Tool on adapter plate.
2. Remove striking rod from adapter plate.
3. Remove check ball plugs, check springs, and check balls.

MT-11 497
 DISASSEMBLY
Shift Control Components (Cont'd)
4. Drive out retaining pins. Then drive out fork rods and remove
interlock balls.

-End pl•y Gear Components

' r 1.
•
Before disassembly, measure the end play of each gear.
If end play is not within the specified limit, disassemble and
inspect the parts.
Mamshaft or
• Replace any part which is worn or damaged.
Gear end play:
Refer to SDS, MT-28.

2. Mesh 2nd and reverse gear, then remove countershaft front

bearing using a suitable puller.
3. Remove snap ring, then remove sub-gear bracket, sub-gear
spring and sub-gear.

SMT174A

4. Remove counter drive gear together with main drive gear

assembly using a suitable puller.
• When removing main drive gear assembly, be careful not
to drop pilot bearing or baulk ring.
5. Remove snap ring, then remove 3rd & 4th synchronizer
assembly and 3rd main gear.

6. Disassemble parts at rear of adapter plate as follows:

a. Release staking on both countershaft and mainshaft nuts, then
loosen both nuts.
Mainshaft nut: Left-hand thread

SMT546A

498 MT-12
 DISASSEMBLY
Gear Components (Cont'd)
b. Remove overdrive counter gear together with countershaft rear ~~
end bearing using a suitable puller.
c. Remove reverse counter gear and spacer.
d. Remove snap rings from reverse idler shaft, then remove
reverse idler gear, thrust washers and reverse idler gear bear-
ing.

e. Remove snap ring and pull out overdrive mainshaft bearing, ~©

then remove snap ring. (2WD model}
f. Remove mainshaft nut.
g. Remove speedometer drive gear and steel ball. (2WD model} I'~
h. Remove thrust washer, steel roller, roller bearing and washer.
i. Remove overdrive main gear, needle bearing and baulk ring
(overdrive). ©ll
j. Remove counter gear by tapping on rear end of counter gear.
k. Press out overdrive gear bushing and overdrive & reverse
synchronizer assembly.
I. Remove reverse main gear and needle bearing.
m. Press out reverse gear bushing.

SMT554A

7. Remove thrust washer, steel ball, 1st main gear and needle rRl&
bearing.
• Be careful not to lose steel baiL

!81'[]'
8. Press out 1st gear bushing together with 2nd main gear using
Tool.
Remove 2nd gear needle bearing.

MT-13 499
 DISASSEMBLY
Gear Components (Cont'd)
9. Remove main drive gear ball bearing.
a. Remove snap ring.
b. Remove main drive gear ball bearing.
ST30031000
{J22912-01)

SMT420A

500 MT-14
 INSPECTION

Shift Control Components

• Check contact and sliding surfaces of fork rods for wear,
scratches, projections and other damage.

*
~
*

Mainshaft and gear

SMT075C

Gear Components
GEARS AND SHAFTS
•
• Check shafts for cracks, wear and bending.
• Check gears for excessive wear, chips and cracks.

Counter gear

SMT550A

Shifting insert
SYNCHRONIZERS
• Check spline portion of coupling sleeves, synchronizer hubs
and gears for wear, chips and cracks. IIi!\
• Check baulk rings for cracks and deformation.
• Check shifting inserts for wear and deformation.
• Check insert spread springs for deformation. !l~

MT-15 501
 INSPECTION
Gear Components (Cont'd)
Baulk ring to • Measure baulk ring wear.
gear clearance a. Measure clearance between baulk ring and gear.
Clearance between baulk ring and gear:
Refer to SDS, MT-28.
• If the clearance is less than the wear limit, replace baulk ring.

SMT140

Inner baulk ring • Measure 2nd baulk ring wear--4WD model.

'd)F:-··· ...
\2nd 1nner baulk ring a.
b.
Place baulk rings in position on synchronizer cone.
While holding baulk rings against synchronizer cone as far as
possible, measure dimensions "A" and "8".
Standard:
Inner "A": 0.7- 0.9 mm (0.028- 0.035 in)
1\~P· Outer "B"': 0.6 - 1.1 mm (0.024 - 0.043 in)
ST30031000
(J22912-01)
~o; ~
Wear limit:
D•al indicator 0.2 mm (0.008 in)
ST30031000 c. If dimension "A" or "B" is less than the wear limit, replace
(J22912-01) baulk ring.
SMT041B

Outer baulk ring

Synchronizer cone
2nd outer baulk ring

Feeler gauge

o:GT=+·
l!!'::__s~_nchronim cone
2nd outer baulk ring
SMT042B

BEARINGS
• Make sure all bearings roll freely and are free from noise,
cracks, pitting or wear.

502 MT-16
 ASSEMBLY

Gear Components
Malnshaft ball bearing In adapter plate

'(1'~ /
"
ST30720000
(J25405)

Install until flush with front surface

of overdrive gear case.

Counter rear bearing In adapter plate

1.
2.
•
Install bearings into case components.
Assemble adapter plate parts.
Install oil gutter on adapter plate and expand on rear side.
AMT085

•
• Install bearing retainer.
a. Insert reverse idler shaft, then install bearing retainer.

b. Tighten each screw, then stake each one at two points.

SMT674C

3. Install main drive gear ball bearing.

a. Press main drive gear ball bearing.
ST30613000
IJ25742-31

MT-17 503
 ASSEMBLY
Gear Components (Cont'd)
b. Select and install proper main drive gear snap ring to achieve
proper clearance of groove.
Allowable clearance of groove:
0-0.13 mm (0- 0.0051 in)
Main drive gear snap ring:
Refer to SDS, MT-28.

4. Assemble synchronizers.
• 1st and 2nd (2WD model) synchronizer

SMT054C

• Check coupling sleeve and synchronizer hub orientation.

~
~~
~ Coupling slee'e

Frontsy ~arside

Synchronizer hub

SMT206C

• 2nd double baulk ring type synchronizer (4WD model)

Inner
baulk ring

SMT046B

504 MT-18
 ASSEMBLY
Gear Components (Cont'd)

• 3rd & 4th synchronizer

Spread spring
• The three synchronizer gutters should be at the rear.
Shifting i n s /

/6-DV \
J K"--Sync~;~~~er
l~ Couphng"

I
~
'
hub
5

9 8
(0.35) (0.31)
Ill
HH

Front. Front.
•
2WD 4WO
Unit: mm (in)
SMT306C

• Overdrive & reverse synchronizer

..
Front

Shifting
insert
SMT207CA

MT-19 505
 ASSEMBLY
Gear Components (Cont'd)
5. Assemble front side components to mainshaft.
a. Install 2nd main gear. needle bearing and 1st & 2nd synchro-
nizer assembly, then press 1st gear bushing on mainshaft.
b. Install 1st main gear.

c. Install steel ball and 1st gear washer.

• Before installation, apply multi-purpose grease to steel
ball and to both sides of the 1st gear washer.

TM358

6. Install mainshaft and counter gear on adapter plate and main

drive gear on mainshaft as follows:
a. Press mainshaft assembly into adapter plate using Tool.

KV31100401
I - I

b. Press counter gear into adapter plate using Tool.

c. Install 3rd main gear and needle bearing, then press 3rd & 4th
synchronizer assembly onto mainshaft.
• Pay attention to the direction of 3rd & 4th synchronizer.

SMT750

d. Install front mainshaft snap ring.

Select proper front mainshaft snap ring to achieve proper
clearance of groove.
Allowable clearance of groove:
0-0.18 mm (0- 0.0071 in)
Mainshaft front snap ring:
Refer to SDS, MT-28.
e. Apply gear oil to mainshaft pilot bearing and install it on main-
shaft.

TM441

506 MT-20
 ASSEMBLY
Gear Components (Cont'd)
f. Press counter drive gear together with main drive gear using @I
Tool.
• Pay attention to the direction of counter drive gear.
ST23860000
I I
Front

![)
SMT412C

g. Install sub-gear components.

(1) Install sub-gear and sub-gear bracket on counter drive gear,
then select proper snap ring to achieve proper clearance of
groove. ~L~
Allowable clearance of groove:
0- 0.18 mm (0- 0.0071 in)
Counter drive gear snap ring:
Refer to SDS, MT-28.

•
(2) Remove snap ring, sub-gear bracket and sub-gear from
counter gear.
(3) Reinstall sub-gear, sub-gear spring and sub-gear bracket
SMT528A

h. Install selected counter drive gear snap ring.

TM366

i. Press countershaft front bearing onto counter gear using Tool. [fib\

KV31100401
I - I
TM443

~~~
7. Install rear side components on mainshaft and counter gear as
follows:
a. Install reverse idler gear to reverse idler shaft along with l~b\
spacers, snap rings and reverse idler gear bearing.

TM451

MT-21 507
 ASSEMBLY
Gear Components (Cont'd)
b. Install bushing, reverse main gear and overdrive & reverse
synchronizer to mainshaft.
• Pay attention to the direction of synchronizer hub.

Shifting
msert 7r1111
I!

..
Front

ShiftingJ
insert
SMT207CA

c. Install overdrive gear bushing to mainshaft using Tool.

d. Install overdrive main gear and needle bearing to mainshaft.
e. Install spacer, reverse counter gear and overdrive counter gear
to countershaft.
• OD main gear and OD counter gear should be handled as
a matched set.
f. Install washer, roller bearing, steel roller and thrust washer.
g. Tighten mainshaft lock nut temporarily.
• Always use new lock nut.

SMT531

ST22360002 h. Install countershaft rear end bearing using Tool.

IJ25679-01 I

SMT043

8. Mesh 2nd and reverse gears, then tighten mainshaft lock nut
using Tool.
• Always use new lock nut.
Mainshaft lock nut:
~: 137- 167 N·m (14.0- 17.0 kg-m, 101 - 123 ft-lb)

SMT003A

508 MT-22
 ASSEMBLY
Gear Components (Cont'd)
c • Use the chart shown at left to determine the proper reading @~
Torque wrench torque.
(Length of torque wrench vs. setting or reading torque)
9. Tighten countershaft lock nut. !~;!,
• Always use new lock nut.
Countershaft lock nut:
to.J:98- 127 N·m (10.0- 13.0 kg-m, 72- 94 ft-lb) 11!1~

(801

(2.0) (2.5) (ft)

L: Length of torque wrench

SMT004A

Countershatt 10. Stake mainshaft Iock nut and countershaft lock nut using a 1~1
punch.
11. Measure gear end play. Refer to "Gear Components", ""
"DISASSEMBLY", MT-12. u~

Shift Control Components

Fork rod 1. Install fork rods, interlock plunger, interlock balls and check
(1st & 2nd) balls. lliilii
Fork rod
(3rd & 4th)
~-+-Interlock plunger

iJfj~?;J)!..-rnterlock
baH

SMT992-A

2. Install 1st & 2nd shift fork, then drive in retaining pin.

SMT989

MT-23 509
 ASSEMBLY
Shift Control Components (Cont'd)
3. Install 3rd & 4th shift fork, then drive in retaining pin.

4. Install overdrive & reverse shift fork, then drive in retaining pin.

Case Components
1. Install front cover oil seal using Tool.
• Apply multi-purpose grease to seal lip.

SMT036

2. Apply sealant to mating surface of transmission case as shown

at left.
• Use anaerobic liquid gasket Loctite P/N 51813 or
equivalent.

SMT061C

3. Slide gear assembly onto adapter plate by lightly tapping it

using a soft hammer.

SMT013

510 MT-24
 ASSEMBLY
Case Components (Cont'd)
4. Install main drive gear ball bearing snap ring.

\o
Jo
SMT672A

5. Apply sealant to mating surface of adapter plate as shown at ~!"!;;

left.
• Use anaerobic liquid gasket Loctite P/N 51813 or
equivalent. [5[:;

Sealant
SMT062C

__________ Striking rod

6. Place shift forks in neutral position.
~ 7. Install striking lever and rod onto adapter plate and align strik-
ing lever with shift brackets.
Shift bracket

SMT801B

8. Install rear extension.

9. Fit main drive bearing snap ring.

SMT802B

10. Install striking rod lock pin.

~ '

SMTSOOB

MT-25 511
 ASSEMBLY
Case Components (Cont'd)
A A: Distance from bearing
11. Select countershaft front bearing shim.
surface to transmission Countershaft front bearing shim:
case Refer to SDS, MT-29.
12. Install gasket and front cover.

[ ) Transmission case
® Countershaft front bearing
@ Counter gear
AMT092

13. Install return spring plugs, check ball, return springs and select
check plungers.
14. Install control housing and gasket.

512 MT-26
 SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications
Applied model 2WD 4WD
Transmission FS5W71C

Number of speed 5

1 3 5
Shift pattern
~·_j
2
II
4 A

Synchromesh type Warner

Gear ratio

1st 3.321 3.985

2nd 1.902 2.246

3cd 1.308 1.415

4th 1.000 1.000

OD 0.838 0.821
Reverse 3.382 3.657
Number of teeth

Mainshaft

Drive 22 21
1st 33 34
2nd 27 28
3cd 26 26
OD 22 21
Reverse 36 36
Countershaft

Drive 31 32
1st 14 13
2nd 20 19
3cd 28 28
OD 37 39
Reverse 15 15
Reverse idler gear 21 21
Oil capacity
2.0 (4-1/4, 3-1/2) 4.9 (10-3/8, 8-518)
I' (US pt, Imp pt)

Reverse synchronizer

Remarks 2nd double baulk

- ring type synchro-
nizer

MT-27 513
 SERVICE DATA AND SPECIFICATIONS (SDS)

Inspection and Adjustment

GEAR END PLAY AVAILABLE SNAP RINGS
Unit: mm (in)
Main drive gear bearing
1st gear 0.31 • 0.41 (0.0122. 0.0161)

2nd gear 0.11 • 0.21 (0.0043 ~ 0.0083) Allowable clearance 0-0.13 mm (0- 0.0051 in)

3rd gear 0.11 - 0.21 (0.0043- 0.0083) Thickness mm (in) Part number

Overdrive gear 0.24-0.41 (0.0094- 0.0161) 1.87 (0.0736) 32204-78001

1.94 (0.0764) 32204-78002
2.01 (0.0791) 32204-78003
CLEARANCE BETWEEN BAULK RING AND
GEAR
Unit: mm (in)
Mainshaft front
Standard Allowable clearance 0-0.18 mm {0- 0.0071 in)
1st & 2nd {2WD) 1.20 - 1.60 (0.0472 - 0.0630} Thickness mm (in) Part number
3rd & main drive 1.20- 1.60 (0.0472- 0.0630) 2.4 (0.094) 32263-V5200
Overdrive 1.20- 1.60 (0.0472- 0.0630) 2.5 (0.098) 32263-V5201

Reverse 1.10- 1.55 (0.0433- 0.0610)

Wear limit
Mainshaft rear end bearing (2WD model)
1st & 2nd (2WD) 0.80 (0.0315) Allowable clearance 0-0.14 mm (0- 0.0055 in)
3rd & main drive 0.80 (0.0315) Thickness mm (in) Part number
Overdrive 0.80 (0.0315) 1.1 (0.043) 32228-20100
Reverse 0.70 (0.0276) 1.2 (0.047) 32228-20101
1.3 (0.051) 32228-20102
1.4 (0.055) 32228-20103
2nd baulk ring (4WD model)
Unit: mm (in)
Counter drive gear
Allowable clearance 0-0.18 mm (0- 0.0071 in)

Thickness mm (in) Part number

1.4 (0.055) 32215-E9000

1.5 (0.059) 32215-E9001
1.6 (0.063) 32215-E9002

Synchronizer cone

Inner baulk ring

SMT733C

Dimension Standard Wear limit

0.7-0.9
A
(0.028 - 0.035)
0.2 (0.008)
0.6 - 1.1
B
(0.024 - 0.043)

514 MT-28
 SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont'd)
AVAILABLE SHIMS
Countershaft front bearing
Unit mm (in)

A A: Distance from bearing

surface to transmission
case

G) Transmission case
@ Countershaft front bearing
@ Counter gear

AMT092

Thickness of
"A" Part number
shim

4.52-4.71 (0.1780- 0.1854) Not necessary

4.42-4.51 (0.1740- 0.1776) 0.1 (0.004) 32218-VSOOO

4.32-4.41 (0.1701- 0.1736) 0.2 (0.008) 32218-V5001

4.22-4.31 (0.1661- 0.1697) 0.3 (0.012) 32218-V5002

4.12-4.21 (0.1622- 0.1657) 0.4 (0.016) 32218-V5003

4.02-4.11 (0.1583- 0.1618) 0.5 (0.020) 32218-V5004

3.92-4.01 (0.1543- 0.1579) 0.6 (0.024) 32218-VSOOS

MT-29 515
 AUTOMATIC TRANSMISSION

SECTION AT
CONTENTS
PREPARATION AND PRECAUTIONS ...................... ..... 2 REMOVAL AND INSTALLATION . ............................... .40
Special Service Tools ............................................... 2 Removal. ................................................................ .40
Precautions For Supplemental Restraint System Installation .............................................................. .41
(SRS) "AIR BAG"................ .............................. .4 MAJOR OVERHAUL........ .. ................ .. .......... 42
Precautions ............................................................... .4 Oil Channel ..............................................................44
OVERALL SYSTEM ........................................................ 5 Locations of Needle Bearings, Thrust Washers
Circuit Diagram... ............................. .. .... 5 and Snap Rings ...................................................... 45
Wiring Diagram... .. .... 6 DISASSEMBLY ................................................... ........ .46
Cross-Sectional View ................................................ 8 Disassembly ........................................... 46
Hydraulic Control Circuits ............................................ 9 REPAIR FOR COMPONENT PARTS.... .. ................ 57
Shift Mechanism ................................................. ....... 10 Oil Pump........................................ .. .......... 57
TROUBLE DIAGNOSIS - Basic Inspection ........... ... 12 Control Valve Assembly ........................................... 61
Remarks.................... .. ......................... 12 Control Valve Upper Body..... .. ........................ 66
AfT Fluid Check.. .. .. ......... .......... .. .................... 12 Control Valve Lower Body .. .. .. .. .. .. .. .. ... .. .. .. .. ... 70
Road Test.. .............. .. .. ............ 12 Governor Valve Assembly .. .. ........ .. ..... 72
Shift Schedule .... .. .. 14 Parking Gear...................... .. ................. 72
TROUBLE DIAGNOSIS - General Description ........ 16 Reverse Clutch ...... .. ..... .. ..... .. ..................... 73
Symptom Chart............ .. ................................... 16 High Clutch ... .. .................. .... ................. .. ... 77
TROUBLE DIAGNOSIS FOR DTC P1550 ............. ...... 20 Forward and Overrun Clutches ................................ 79
Torque Converter Clutch Solenoid Valve .................. 20 Low & Reverse Brake ................ . ........ 83
TROUBLE DIAGNOSES ....................................... 22 Forward Clutch Drum Assembly.. .. ........ 86
Component Inspection............................... ...22 Rear Internal Gear and Forward Clutch Hub ........... 88
Final Check................................................ ... 25 Band Servo Piston Assembly.. .. ................. 90
TROUBLE DIAGNOSES- AfT Shift Lock Parking Pawl Components ..... .. ...... ....... ............ .. ... 94
System .......................................................... .............. 30 ASSEMBLY ................................................................96
Description ................................................................30 Assembly (1) ... .. .. 96
Shift Lock System Electrical Parts Location .... 30 Adjustment ............................................................ 104
Wiring Diagram..................... .. ..................... 31 Assembly (2) .. ........... .. .................... 106
Diagnostic Procedure ...................... . .. .............. 32 SERVICE DATA AND SPECIFICATIONS (SDS) ........ 113
Key Interlock Cable ....................... .. .. .............. 34 General Specifications....................... .. .... 113
Component Check .. .. .. ............. 35 Specifications and Adjustment................... .. .. 113
ON-VEHICLE SERVICE . . ........... 37 Vehicle Speed When Shifting Gears ................. 113
Control Valve Assembly and Accumulators Vehicle Speed When Pertorming And
Inspection ................................................................. 37 Releasing Lock-Up.............. .. .................. 113
Rear Oil Seal Replacement.. .................................... 37 Stall Revolution ..... .. .............. .. .................. 113
Parking Components Inspection ............................... 38 Line Pressure........ ............. .. .................. 113
Governor Valve ........................................................38 Return Springs.... .................. .. ...... 114
Throttle Wire Adjustment ................ 38 Accumulator 0-Ring ........ ...... .. .................. 114
Inhibitor Switch Adjustment ..................................... 39 Clutches And Brakes.............. .. .................. 115
Manual Control Linkage Adjustment.. ....................... 39 Oil Pump And Low One-Way Clutch .................. 116

516
 CONTENTS <cont'd.)
Total End Play .................................................... 116 Reverse Clutch Drum End Play .......................... 116
Parking Gear. .................................. . """"""""116 Removal And Installation .................................... 116 u:o!J',

When you read wiring diagrams:

• Read Gl section, "HOW TO READ WIRING DIAGRAMS". il'f:il
• See EL section, "POWER SUPPLY ROUTING" for power distribution circuit.
When you perform trouble diagnoses, read Gl section, "HOW TO FOLLOW FLOW
CHART IN TROUBLE DIAGNOSES". lc©

517
 PREPARATION AND PRECAUTIONS

Special Service Tools

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number
(Kent-Moore No.) Description
Tool name

(J34301-C) Measuring line pressure and governor

Oil pressure gauge set pressure
G) (J34301-1)
Oil pressure gauge
® (J34301-2)
Hose
® (J34298)
Joint pipe
@) (J34282-2)
Adapter
@ (790-301-1230-A)
60' Adapter
® (J34301-15)
Square socket

AAT546

ST07870000 a Disassembling and assembling AfT

(J37068)
Transmission case stand
d a: 182 mm (7.17 in}
b: 282 mm (11.10 in)
c: 230 mm (9.06 in)
NT421 d: 100 mm (3.94 in)

KV31102100 Checking one-way clutch in torque converter

(J37065)
Torque converter one-way
clutch check tool

NT098

ST25850000 Removing oil pump assembly

(J25721-A)
Sliding hammer

a: 179 mm (7.05 in)

b: 70 mm (2.76 in)
c: 40 mm (1.57 in) dia.
NT422 d: M12 x 1.75P

KV31102400 Removing and installing clutch return springs

(J34285 and
J34285-87)
Clutch spring compressor

a: 320 mm (12.60 in)

NT423 b: 174 mm (6.85 in}

518 AT-2
 PREPARATION AND PRECAUTIONS
Special Service Tools (Cont'd)
Tool number
(Kent-Moore No.) Description
Tool name

ST33200000 Installing oil pump housing oil seal

(J26082) Installing rear oil seal
Drift

a: 60 mm (2.36 in) dia.

NT091 b: 44.5 mm (1.752 in) dia.

ST30720000 Installing rear oil seal

(J34331)
Drift

a: 77 mm (3.03 in) dia.

NT115 b: 55.5 mm (2.185 in) dia.

(J34291) Selecting oil pump cover bearing race and oil

Shim setting gauge set pump thrust washer

NT101

AT-3 519
 PREPARATION AND PRECAUTIONS

Precautions For Supplemental Restraint

System (SRS) "AIR BAG"
The Supplemental Restraint System "Air Bag", used along with a
seat belt, helps to reduce the risk or severity of injury to the driver
in a frontal collision. The Supplemental Restraint System consists
of an air bag module (located in the center of the steering wheel),
a diagnosis sensor unit, warning lamp, wiring harness, a crash
zone sensor (4WD models) and spiral cable. Information necessary
to service the system safely is included in the RS section of this
Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could
increase the risk of personal injury or death in the event
of a collision which would result in air bag inflation, all
maintenance must be performed by an authorized NISSAN
dealer.
• Improper maintenance, including incorrect removal and
installation of the SRS, can lead to personal injury caused
by unintentional activation of the system.
• Do not use electrical test equipment on any circuit related
to the SRS unless instructed to in this Service Manual.
SRS wiring harnesses are covered with yellow insulation
either just before the harness connectors or for the com-
plete harness, for easy identification.

Precautions
• Before proceeding with disassembly, thoroughly • Properly installed valves, sleeves, plugs, etc.
clean the outside of the transmission. It is impor- will slide along their bores in the valve body
tant to prevent the internal parts from becoming under their own weight.
contaminated by dirt or other foreign matter. • Before assembly, apply a coat of recommended
• Disassembly should be done in a clean work ATF to all parts. Apply petroleum jelly to protect
area. 0-rings and seals, or hold small bearings and
• Use lint-free cloth or towels lor wiping parts washers in place during assembly. Do not use
clean. Common shop rags can leave fibers that grease.
could interfere with the operation of the trans- • Extreme care should be taken to avoid damage
mission. to 0-rings, seals and gaskets when assembling.
• Place disassembled parts in order lor easier and • Replace ATF cooler if excessive foreign material
proper assembly. is found in oil pan or clogging strainer.
• All parts should be carefully cleaned with a gen- • Alter overhaul, refill the transmission with new
eral purpose, non-flammable solvent before ATF.
inspection or reassembly. • When the AfT drain plug is removed, only some
• Gaskets, seals and 0-rings should be replaced of the fluid is drained. Old AfT fluid will remain
anytime the transmission is disassembled. in torque converter and ATF cooling system.
• The valve body contains precision parts and Always follow the procedures under "Changing
requires extreme care when parts are removed AfT Fluid" in the MA section when changing AfT
and serviced. Place removed parts in order, on fluid.
a parts rack, so they can be put back in the
valve body in the same positions and
sequences. Care will also prevent springs and
small parts from becoming scattered or lost.

520 AT-4
 OVERALL SYSTEM

Circuit Diagram

I IGNITION SWITCH
ON or- START
®'" th ASCD

7""
COMBINATION MCTCR
(0/D 011 INDICATOR
LAMP)~

'-V

!
'
~
~OVERDRIVE
~
mORQUE

~
CONVERTER CANCEL
CLUTCH SOLENOID
SOLENOID VALVE
VALVE
r--@----- To ASCD control unit

INHIBITOR
SWITC~I
p R· N ~--~ ullf
I
2 2 -" 4 s 6 I DATA LINK
jo ~ COI\NECTOR
91011121 14 FOR CONSULT ON/- OFF
A/T DEVICE
( OVERDRIVE
CONTROL
SWITCH)

~
BID ~ PARK AND
NEUTRAL
POSITION
18 1 CNGINC
COOLANT
1

TCMPCRATURE
SCNSOR
~~ THROTTUO
POSIT ION
SENSOR
~

RELAY 1

"- I l-
22 114 51 50 23 49 -

..
ECM CECCS CONTROL MOLJULE)
-

AAT031A

~-J

AT-5 521
 OVERALL SYSTEM

Wiring Diagram
AT-A!T-01
Refer to "EL-POWER".
10A
~:WithASCD
@)

JOINT
CONN ECTOR-2
I
W/B

(~) ;;'i\.WIB _ _. . . _ _ . _ _ _ _. . . . . , _ _ _ _ .1'::---._ Ne><t

~ W/B -v--- page
I
W/B

~ ~--;====[1Jl
1
===:;----lsOLENOID DATA

D
I VALVE LINK
UNIT CONNECTOR
(Mgi) FOR
CONSULT
<!illj)
r"-TJ'--,cOMBI NATION
METER
(0/D OFF ~
INDICATOR W~G UY UY
LAMP)
@ Q~ToEL-ASCD
~

~ ~
GLY ~~E
@ (i;jill} GY
GY~Gv:..e
GY• UY

ffi

0
~"-;--"-----,AfT

OFF --- DEVICE fE~~s

ON (OVERDRIVE CONTROL
CONTROL SWITCH) MODULE)
(~) @Y

l!4JlB

I
_.__
B

(~)
Refer to last page (Foldout page).
@£)
D @ill),@
~(M27) 1112 3 4 5 (M156)
GY 1617 8 9 10 L

101 102 103 104 105 106

107108 109 110111112 11 12 1314
113 114 115 116117118 15 1617 18

AAT032A

522 AT-6
 OVERALL SYSTEM
Wiring Diagram (Cont'd)

AT-A/T-02

Preceding~
page ~W/B
• - - - - - - - - - - - - - - - - - - - - - - - - - - - -. .

.------"";="--------,INHIBITOR
SWITCH
1 c;;w>
,_R 2'
- ----
- N D A

--
f:
I
I
I
:•-
I
+

._____.I
I
I
I
I
I
I
I
--
n+ Jf
p p p
+
~ IT~ilff~illi'11
I
-
I I JOINT
CONNECTOR-1
I <~>
'-;,1--,t':"'!---;lr~f--r.l +
p B

= w
r ·~~--------------~~~:O~I~I~;~s~l--~~~~~l~ls;~,c.l ECM
I· r'=fI
1 i-il
TW GND-A TV01 AVCC NEUT (ECCS
•
CONTROL
MODULE) B B
B B B
@W _.___.__ ~ ~ _._
L---------------------------------------~ (M1~(M1~ <0'49> (MtQ5) (~)
Refer to last page (Foldout page).
(~)

cffrl(M1B)
GY
cill5:D (M23)
BR
~(M28)
w
~(~)
L

<M~,>~

~
101 102 103 104 105 106 liT2T3l ~ 1211221231 '38 39 l4ol4il 53 54 55 ~
107 108 109 110111 112
5 6 7 8 91 10 ~If, 44 45 46 57 58 59 601 61
1112 13 14 19 1301311321331 ~Ito 474862636465 70
113 114 115 116117 1181lllJ ~ 341351361<
~
~ 66 67 68 691

AAT790-8

AT-7 523
524

Torque converter clutch piston

Torque converter

Converter housing
Front planetary gear

Rear planetary gear

Transmission case
Forward clutch
Brake band
Forward one-way clutch
Low & reverse brake
Overrun clutch

(')
0
<
a
Ill
m
:tJ
Ill )>
~ '
en r-
'
OQ

-
(D
0
0
j
!!!.
r-
en
-<
en
-1
m
$
(D
s::
==

~ Control valve Output shaft

~

~
 OVERALL SYSTEM

Hydraulic Control Circuits

'Ei!l

ill
Jb<,
aE J]
b
:::;
~
'"'
shift f= ==: 11!¥'
''
i ' ""'

IIIII
"II"
~ 'i i
~g w: .
'"'l",l i [Ql[Q)
~
~l
"''' i.
''II Jr' '1!'""
=
~ ~
~
v>
ISP.
1~1
b
'~ lfi3~
~'
=
~~
II
F= ~~

~~

AAT033A

AT-9 525
 OVERALL SYSTEM

Shift Mechanism
The RL4R01A automatic transmission uses compact, dual planetary gear systems to improve power-trans-
mission efficiency, simplify construction and reduce weight.
It also employs an optimum shift control and superwide gear ratios to improve starting performance and
acceleration during medium and high-speed operation.
Two one-way clutches are also employed: one is used for the forward clutch and the other for the low clutch.
These one-way clutches, combined with four accumulators, reduce shifting shock to a minimum.

CONSTRUCTION

·~
I

4 9 (jJ) -~ JJ) I @
CD Torque converter clutch piston ® Front sun gear @ Forward one-way clutch
® Torque converter @ Front internal gear @ Overrun clutch
@ Oil pump ([j) Front planetary carrier @ Low one-way clutch
@ Input shaft @ Rear sun gear
® Low & reverse brake
@ Brake band @ Rear pinion gear @ Parking pawl
@ Reverse clutch ·j}) Rear internal gear
© Parking gear
(j) High clutch @ Rear planetary carrier @ Output shaft
@ Front pinion gear @ Forward clutch

SAT026HA

526 AT-10
 OVERALL SYSTEM
Shift Mechanism (Cont'd)
FUNCTION OF CLUTCH AND BRAKE
Clutch and brake
Abbr. Function
components
® Reverse clutch RIC To transmit input power to front sun gear ®.
(j) High clutch HIC To transmit input power to front planetary carrier @.
@ Forward clutch FIG To connect front planetary carrier@ with forward one-way clutch @.
@ Overrun clutch OIC To connect front planetary carrier @ with rear internal gear@.
®Brake band BIB To lock front sun gear®.
When forward clutch @ is engaged, to stop rear internal gear @ from rotating in
@ Forward one-way clutch FIO.C
opposite direction.
@ Low one-way clutch UO.C At D1 position, to prevent rear internal gear @ from rotating in opposite direction.
To lock rear internal gear@ (2, 12 and 11 ), to lock front planetary carrier@
@ Low & reverse brake L & RIB
(A position).

OPERATION OF CLUTCH AND BRAKE

Band servo Forward Low Low &
Reverse High Forward Overrun
Shift one-way one-way reverse
clutch clutch clutch clutch Lock-up Remarks
position 2od 3cd 4th clutch clutch brake
® (j) @ @ apply release apply @ @ @
p PARK POSITION

REVERSE
R
0 0 POSITION

NEUTRAL
N
POSITION

D
1st

2od
0
0 .1
@)
IVJ 0 •• • Automatic shift
'4
3cd

4th
0
0
0
@
IVJ '2@

'3@
@

@ 0 • ·sO
0
1f--t2f--t3H4

2
1st

2od
0
0
@)
0 0 •• • Automatic shift
1H2

1
1st

2od
0
0
0
0 0 •• 0 Locks (held
stationary) in 1st
speed 1 f - 2

*1 :Operates when overdrive control switch is set in OFF position.

*2 ·Oil pressure is applied to both 2nd ·'apply" side and 3rd "release'' side of band servo piston. However, brake band does not contract because oil
pressure area on the "release" side is greater than that on the "apply" side.
*3 :Oil pressure is applied to 4th "apply" side in condition *2 above, and brake band contracts.
'4 :AfT will not shift to 4th when overdrive control switch is set to OFF position.
'5 :Operates when overdrive control switch is set to OFF position.
Q: Operates.

~:Operates when throttle opening is less than 1/16, activating engine brake.

e: Operates during "progressive'' acceleration.

@:Operates but does not affect power-transmission.

@:Operates when throttle opening is Jess than 1/16 but does not affect engine brake.

AT-11 527
 TROUBLE DIAGNOSIS - Basic Inspection

Remarks
ATF COOLER SERVICE
II the oil pan contains large quantities of foreign matter or the
strainer is excessively clogged, replace the ATF cooler.
• ATF cooler is not serviceable separately from the radiator. If
service is required, replace radiator assembly.

Fluid leakage AfT Fluid Check

FLUID LEAKAGE CHECK
1. Clean area suspected of leaking, - tor example, mating sur-
lace of converter housing and transmission case.
2. Start engine, apply loot brake, place selector lever in "D" posi-
tion and wait a lew minutes.
3. Stop engine.
4. Check lor fresh leakage.

SAT288G

FLUID CONDITION CHECK

Fluid color Suspected problem
Dark or black with burned odor Wear of frictional material

Water contamination
Milky pink - Road water entering through filler
tube or breather
Oxidation
Varnished fluid, light to dark brown
- Over or under filling
and tacky
- Overheating
SAT638A

FLUID LEVEL CHECK

Refer to MA section ("Checking AfT Fluid", "CHASSIS AND BODY
MAINTENANCE").

Road Test
Pertorm road tests using "Symptom" chart. Refer to AT-16.

"P" POSITION
1. Place selector lever in "P" position and start the engine. Stop
the engine and repeat the procedure in all positions, including
"N" position.
2. Stop vehicle on a slight upgrade and place selector lever in "P"
position. Release parking brake to make sure vehicle remains
locked.

"R" POSITION
1. Manually move selector lever from "P" or "R", and note shift
quality.
2. Drive vehicle in reverse long enough to detect slippage or
other abnormalities.

528 AT-12
 TROUBLE DIAGNOSIS - Basic Inspection
Road Test (Cont'd)
"N" POSITION @[
1. Manually move selector lever from "R" and "D"" to "N" and
note shift quality.
2. Release parking brake with selector lever in "N" position.
Lightly depress accelerator pedal to make sure vehicle does
not move. {When vehicle is new or soon after clutches have
been replaced. vehicle may move slightly. This is not a
problem.)
l©

"D" POSITION
1. Manually shift selector lever from "N" to "D" position, and note

2.
shift quality.
Using the shift schedule as a reference, drive vehicle in "D"
15~
position. Record, on symptom chart, respective vehicle speeds
at wbhich up-shifting andff down-shhiftin g occur. The(slehspehedfs a red ©t
to e read at three di erent t rott 1e pos1t1ons 1g I, a1 an
full), respectively. Also determine the timing at which shocks
are encountered during shifting and which clutches are lfil
Drive in different
engaged.
throttle conditions.
AAT797 3. Determine, whether lock-up properly occurs while driving •
vehicle in proper gear position and at proper speeds. 1
4. Check to determine if shifting to overdrive gear cannot be
made while overdrive control switch is OFF.
5. Drive vehicle at 65 to 80 km/h (40 to 50 MPH) with half to light fiP
throttle position {D 3 position). Fully depress accelerator pedal
to make sure transmission downshifts from 3rd to 2nd gear.
6. Drive vehicle at 35 to 45 km/h (22 to 28 MPH) with half to light
throttle position (D 2 position). Fully depress accelerator pedal lolg
to make sure transmission downshifts from 2nd to 1st gear.

"2" POSITION
1. Shift to "2" position and make sure vehicle starts in 1st gear.
2. Increase vehicle speed to make sure transmission upshifts from 1st to 2nd gear. ~~
3. Further increase vehicle speed. Make sure transmission does not upshift to 3rd gear.
4. Drive vehicle at 35 to 45 km/h (22 to 28 MPH) with throttle at half to light position {2 2 position). Fully depress
accelerator pedal to make sure transmission downshifts from 2nd to 1st gear. gj"j
5. Drive vehicle at idle in "2" position to make sure that transmission downshifts to 1st gear.
6. Move selector lever to "D" position and drive vehicle at 40 to 50 km/h {25 to 31 MPH). Then, move
selector lever to "2" position to make sure transmission downshifts to 2nd gear. I~®

"1" POSITION
1. Place selector lever in "1" position and accelerate. Make sure transmission does not shift from 1st to 2nd ~f
gear although vehicle speed increases.
2. While driving vehicle in "1" position, release accelerator pedal to make sure that engine compression
acts as a brake. 1{[1,
3. Place selector lever in "D" or "2" position and drive vehicle at 20 to 30 km/h (12 to 19 MPH). Then move
selector lever to "1" position to make sure transmission downshifts to 1st gear.

AT-13 529
 TROUBLE DIAGNOSIS - Basic Inspection

Shift Schedule
VEHICLE SPEED WITH SHIFTING GEARS
This check should be carried out when ATF temperature is between
50 and aooc (122 and 176°F) after the vehicle has been driven
approx. 10 minutes.

Vehicle speed when shifting gears

Throt11e Vehicle speed km/h (MPH)
position o, ---4 02 02 --4 03 03---? 04 04 _,. 03 03 _,. 02 02 .....;. 01 12 --7 1,
53-57 100- 108 147- 157 91 -99 47-51 41-45
Fult throttle
(33. 35) (62. 67)
- (91 . 98) (29. 32) (25. 28)
(57. 62)
32-36 57-65 114--124 65- 75 28-36 12- 16 41 -45
Half throttle
(20. 22) (35. 40) (71. 77) (40. 47) (17. 22) (7. 10) (25. 28)

Vehicle speed when performing and

releasing lock-up
D,
Throttle position Vehicle speed km/h (MPH)

Lock-up ON Lock-up OFF

Full throttle - -
Half throttle 71-79(44-49) 71 . 79 (44 . 49)

530 AT-14
 TROUBLE DIAGNOSIS - Basic Inspection

NOTES ill~

li:!lb\

~iii!

l~

~~

I'~

~L

lfiJ

•
111'

i'l~

~~

~liil

~7

~@

~'[]'

~I !'I

];!,

~iij)j;\

AT-15 531
 TROUBLE DIAGNOSIS - General Description

Symptom Chart
ON VEHICLE

Numbers are arranged in order of probability.

Perform inspections starting with number one and work up.
Numbers in the OFF VEHICLE columns indicate that the transmission
must be removed from the vehicle to perform the inspection. rn
0
•> •> •
-@ •>
:§
eE • "
.£ >

B : Valve expected to be malfunctioning

"·a, TI TI
•• •> "" > >
>

•
~ •
c
~

•rn •
~
~

"
> ,rn ~

•> •> •>

0 "•> -5
• -~ ~ "rn ~, •> TIs0
'6 0 0
0
E
~ ""c
TI 0
c ~

•• :g " > •w·" ~ E

"" "
~

•• " "
.§ > > >
:gc :0B" • •c "~ ~
, ,~
,E 0 £~
s
•
•c ~ " ""~ ""~ " " "
>
i' ~
~ ~ ~

."'w
~ ~

"i5 " " " .,. ~

0
TI

u
0 c ~
u
0
!j ')'
"' ')' 0

Sharp shocks in shifting from "N" to "D" position

B r- ::J

"
a_ a_
"' '
"' "' "'
<(

;
1 2 5 3 4 8 I~~ ·t

When shifting from 1st to 2nd or 2nd to

3rd
1 2 4 3 7 ~ 1' 1;,:
In•¥ I!~
When shifting from 3rd to 4th 1 2 4 3 6 ~ :' ~"~' I:,
Shift shocks
When shifting from "D" to "2" and "1"
position.
I** in*
! ::
1 2 4 3 5
When overdrive control switch is set from
ON to OFF ; ~ :, !i i
~
~
When shifting from 2nd to 1st in ''1" posi- ' u
lion
1 2 4 3 5
~ ~· ~: '
When shifting from 1st to 2nd 1 2 4 3 6
:: :'
Shift slippage when upshifting When shifting from 2nd to 3rd 1 2 4 3 6 '' '
When shifting from 3rd to 4th 1 2 4 3 6
' '
'~ ;,
$4

"
When shifting from 4th to 2nd 1 2 5 3 7 ~
c '*
a
Shift slippage with accelerator When shifting from 4th to 3rd 1 2 4 3 6 ·'
pedal depressed
When shifting from 4th to I st and shifting ',. ''• u
"'
'
" ':
1 2 5 3 7
from 3rd to 1st

When vehicle starts 1 2 5 3 10 .'

.; ' it')
Poor power/acceleration ',. ' rtl *
When upshifting 1 2 4 3 8
" In~
:; " u ;
When shifting from "D" to "2" and "1"
position
1 2 4 3 6
1: t :. ' .
~

No engine braking
When overdrive control switch is set from
1 2 4 3 8
"" *
ON to OFF 't +
*
: ' .
uu' I''
When shifting from 2nd to 1st in "1" posi- F 1'
1 2 4 3 6
lion 01 ¥ 4

Too low a gear change point from 2nd to

1 4 2 5
''
''
3rd and from 3rd to 2nd. ~:,
Too high a gear change point from 2nd to
1 4 2 5
., 1' I;,' u u
3rd and from 3rd to 2nd. ': I~*
Shift quality
Too low a gear change point from 2nd to
1 4 2 5
::·:; n u
1st in "1" position. 11 t 1

Too high a gear change point from 2nd to

" ''
1 4 2 5
1st in "1" position.

532 AT-16
 4-2 relay valve

Torque converter clutch control valve

I:::': 1:~~ ~ 'l:;;:: :J;I 1:::! 1:: t;; ~: 'z '

,% ,~,

:: : ::,~::::
** Throttle valve & detent valve

Manual valve
,, v
1::'. v::. ~~ !:_;_ 'v 1: ~ . ' I•
#

1~: Kickdown modifier valve

~~~,, It~" I::; ;: 1::: 1st reducing valve

1!:47 :.~ F t :::::::2 ~ Overrun clutch reducing valve

lz! I::;; 3-2 timing valve -1

::0
Torque converter relief valve
0
lv: c:
" " " " . .. .. 4-2 sequence valve

Governor pressure
0
z
<
Ill
r-
m
ro ro ::: m
"' "' "' "' Governor valve
I
c
l:::j 1~:;; L:_:: : ::w :: ~~'.~!! ~~ Primary governor valve
(j
r
m )>
1::::1:::;: r;~;; ,:::: :: 1:::: =~ Secondary governor valve G) CJ)C)
1:::'1:::::.: 1_;;:~ ::;:~ :; ~=~= :: Secondary governor valve ® '<
3 0
z
~
Overdrive cancel solenoid valve
"9.~
~ Torque converter clutch solenoid valve o en
.....' Accumulator N-0 3 I
..... "' "'
~ ~ ~
~ ro

m
~ ~ Accumulator 1-2 9c;,
Ill (I)
"' "' "' ~
"' Accumulator 2-3
... :I
~ ~ ~ ~ ~ Accumulator 3-4 (N-R) .........
-(I)

0111
Ignition switch and starter motor
0 -
t :I c
"' overdrive control switch and wiring
"'t(l)
;;; Torque converter Q,(/1
._.(')
w
r
m Oil pump ::::!.
:;;: m Reverse clutch "9.
c;·
~ m 0 <i; "' "' ~ High clutch
0
:I
Forward clutch -n
"' "'
::: "';;; Forward one-way clutch
-n
<
m
I
~ m ~ ;;; <0 ro Overrun clutch (j
r
m
"0
"' Low one-way clutch

w"

l
ro ~ Low & reverse clutch

0 ::: " Brake band

"'
~ ~ ~
"' "
Parking components
533

w rm ~J
~ [ljjjJ IF [ljjjJ
~
l9
?~
M
IF
2S
20
IQ2J
co[
~
IC~?l 9 ~
~
25-'-' ~ ""9 "" 9
<Ij)
IF iiilil C(j © ~ ;b:o
C':£21
 TROUBLE DIAGNOSIS - General Description
Symptom Chart (Cont'd)
ON VEHICLE

Numbers are arranged in order of probability.

Pertorm inspections starting with number one and work up.
Numbers in OFF VEHICLE columns indicate that the transmission must be
removed from the vehicle to perform the inspection. ~ m
c m m
m -"m >
Q: Valve expected to be malfunctioning q ·§ -"m
>
>

"
>
" >

"
-
TI TI
m m > 2 m
0 > .m
~
c >
rr m m -~ c0
0 m
~
~
~
~

~
"
>
0 '60 m m m u ""
> 0

"2 "
B m
m
•• ••
~ ~ > > >
~ E
~
~
TI > u
c .0 0 ~ E
"~ :2" ":§
~
m ~
> > > ~ m
:§ ~
:2 TI c
• ~
~
>
•>
.91
2 2 m
c0 :c:0 ~ .,
m
c
m
~
~

c0
m
m
~
~
~
0
~
~
~
0
~
~ ~ ~ ~
3
E
0
u
0
TI £

Failure to change gear from 4th to 2nd

i5 ()
"
~
f-
c
w
c
::J ()
~

"
~
Q_
~
Q_
- '"
':' M
1"
M
u

"'
':'
M
'?
"'
1 4 2 5
with accelerator pedal depressed.

Failure to change gear from 3rd to 2nd

with accelerator pedal depressed.
1 4 2 5
qq
::
Failure to change gear from 1st to 2nd in
"D" and "2" position.
1 4 2 5 "+
Vehicle does not start from 1st in "D" and
1 4 2 5 ~·~
Shift quality "2" position. u

Failure to change gear to 3rd to 4th in ,. I+' ~·

~
1 4 2 7
"D" position. '+1+••,
h \)

Changes gear to 1st directly when selec-

1 4 2 5
tor lever is set from "D" to "1" position.

I~: '1+
Changes gear to 2nd in "1"' position. 1 4 2 5
'
Too high or low a change point when I"" I; :
lock-up operates.
1 4 2 5 I~: 1:: ~
1! k 1i u
Lock-up point is extremely high or low. 1 4 2 5
Q "
' ~
++
+
Torque converter does not lock-up. 1 4 2 5
Lock-up quality ''
Lock-up is not released when accelerator
1
pedal is released.

Engine does not start in "P" and "N" positions, or

2 3
engine starts in positions other than "P" and "N" positions.

Vehicle moves with selector lever in "P" position. 1

534 AT-18
 ~l~' 4-2 relay valve
e:: Torque converter clutch control valve
:::~

'""' lw~! 1¥+~

Throttle valve & detent valve

Manual valve

1~: : i! Kickdown modifier valve

~'!~'! 1::: 1st reducing valve

Overrun clutch reducing valve

3-2 timing valve -1

:ll
Torque converter relief valve
0
l•u 4-2 sequence valve c:
w w w w w w w w w w 0 m
Governor pressure z r
0> 0> 0> 0> 0>
"' 0> 0> 0> 0> Governor valve
<
m m
1,;; 18w ~::;~; : :::~= ~ ±m*' Primary governor valve
I
0
r
c
• ' m )>
0 Secondary governor valve G) enG>
'< z
=· 1!: u ·~!!' i,~ *~'!::: Secondary governor valve ®

~
.....'
<0
"'
0> Overdrive cancel solenoid valve

Torque converter clutch solenoid valve

Accumulator N-D
--
3
3 0
"Cen
o en
I
Accumulator 1-2 gG>
Ill (I)

-- ...
Accumulator 2-3
~::J
Accumulator 3-4 (N-R) (I)
~
Ignition switch and starter motor O!ll
0 -
"' Overdrive control switch and wirmg ::J c
'"':(I)
" Torque converter C. Ill
'-"O
...-·
r
Oil pump

Reverse clutch '9.

(5'
High clutch
0
::J
Forward clutch -n
-n
Forward one-way clutch <
m
I
Overrun clutch 0
r
m
Low one-way clutch

Low & reverse clutch

1
Brake band
N
Parking components
535

[nftJ 2S @Til ~ Q'!JI) §JJ

~ 'B 9
~
C[~
l9
"" IFJiJ ,~
WiJ ~
~
IF 2-'> ~ (:;0; co[ 20 J_<o:~ [g) CiiJ F lrihl ~ ~-?! §; ;!lo-o
~
 TROUBLE DIAGNOSIS FOR DTC P1550

Fuse
Torque Converter Clutch Solenoid Valve
Ignition~
switch 1 ~ When the malfunction indicator lamp indicates DTC P1550 (0904),
perform "Final check" after inspecting components. If DTC P1550
(0904) is indicated again on "Final check", recheck control valve.
~~
Torque
converter
clutch Repair or replace control valve assembly as necessary.
solenoid

-
valve
~
CHECK GROUND CIRCUIT. No Repair or replace harness
114 I 1. Turn ignition switch to OFF position. between ECM and torque
I ECM {ECCS control module)
2. Disconnect ECM harness connector and converter clutch solenoid
AAT842
torque converter clutch solenoid valve valve.
harness connector.
~ 3. Check resistance between solenoid
Solenoid valve unit valve unit harness terminal No. ® and
connector@
ECM harness terminal No. @.
Resistance:
~ II ECM @coNNECTOR II
Approximately 00
OISCQN~fCT ~
114
Yes
IV lJY lJY

CHECK POWER SOURCE CIRCUIT. No ~ •Check the following items:

1
1. Turn ignition switch to ON position. ~ Ignition switch and fuse
2. Check voltage between solenoid valve Refer to EL section
AAT843 unit harness terminal No. G) and ("POWER SUPPLY
ground. ROUTING"").
Voltage: • Harness continuity
Battery voltage between fuse and torque
~ Solenoid valve
converter clutch solenoid
l..Ll..1) unit connector Yes
@ valve.
W/B

CHECK TORQUE CONVERTER CLUTCH NG ~ Replace torque converter

+ 1

SOLENOID VALVE ~ clutch solenoid valve.

(RESISTANCE).
-=? Check resistance between torque conM
AAT844 verter clutch solenoid valve terminal Nos.

~========:::;::.:;;:::::==~
[!) Solenoid valve unit connector@)
G) and@.
Resistance:

~~;-~A~';;r':J)~~~-o~~~ Approximately 25!1

OK

~ ~:
-+=- ~
if$kiill
~
I!]
CHECK TORQUE CONVERTER Replace torque converter
).'1 J3.<1illlllo."""""""""'l"'w"' '" CLUTCH SOLENOID VALVE clutch solenoid valve.
'®J'Y (OPERATION).
I•Q 1 ~ ol:8co~ 1. Remove torque converter clutch sole-
~ V noid valve. Refer to AT-37.
2. Check torque converter clutch solenoid
AAT845
valve operation.

Solenoid valve unit connector @) tOK

Gft) ®
(Go to next page.)

AATB46

536 AT-20
 TROUBLE DIAGNOSIS FOR DTC P1550
Torque Converter Clutch Solenoid Valve
(Cont'd) @I

CHECK CONTROL VALVE. Repair control valve.

1. Disassemble control valve assembly.
Refer to AT-61.
2. Check torque converter clutch control
valve.
• Valve, and sleeve slide along valve
SAT740H bore under their own weight.
'-----------------------' • Valve, and sleeve are free from burrs,
dents and scratches.
• Control valve springs are free from
damage, deformation and fatigue.
• Hydraulic line is free from obstacles.

OK

Is malfunction eliminated? Check control valve again.

Repair or replace control
Yes
valve assembly.

INSPECTION END

Final check
1) Erase the diagnostic test mode II (Self-diagnostic results) memory from
ECM. Refer to EC section ["Malfunction Indicator Lamp (MIL)", "ON
BOARD DIAGNOSTIC SYSTEM DESCRIPTION""].

® 2) Turn ignition switch ON.

3) Select "ENGINE" system, "DATA MONITOR" mode with
CONSULT.
4) Start engine and warm it up sufficiently.
5) Perform test drive in "D" position for at least 20 seconds
continuously under the following conditions.
Engine speed: 2,000 - 2,700 rpm
Vehicle speed: 75- 95 km/h (47- 59 MPH)
OR

r6v 2) Start engine and warm it up sufficiently.

3) Select MODE 7 with GST.
4) Perform test drive in "D" position for at least 20 seconds
continuously under the following conditions.
Engine speed: 2,000 - 2,700 rpm
Vehicle speed: 75- 95 km/h (47- 59 MPH)
OR

@s 2) Start engine and warm it up sufficiently.

3) Pertorm test drive in "D" position for at least 20 seconds
continuously under the following conditions.
Engine speed: 2,000- 2,700 rpm
Vehicle speed: 75 - 95 kmlh (47 - 59 MPH)
4) Stop the vehicle, turn ignition switch OFF and wait at least 3
seconds. Then turn ignition switch ON.
5) Pertorm "Diagnostic Test Mode II (Self-diagnostic results)" with
ECM.

AT-21 537
 TROUBLE DIAGNOSES

Component Inspection
Fuse
Ignition switch OVERDRIVE CONTROL SWITCH AND OVERDRIVE
CANCEL SOLENOID VALVE
0/D OFF
indicator
Overdrive lamp
cancel
solenoid OK
valve CHECK OlD OFF INDICATOR LAMP CIRCUIT.
Go lo [!]
1. Turn ignition switch to ON.
OFF ON (Do not start engine.)
2. Set overdrive control switch to OFF position.
OlD OFF indicator lamp should come on.
AAT034A L - - - - - - - - - , N : ; : G ; ; - - - - - - _ _ j

~m;============~ Check the following items:

• 0/D OFF indicator lamp
Refer to EL section {"METER AND

........
GAUGES").
• Ignition switch and fuse
Refer to EL section ("POWER SUPPLY
ROUTING") .

t OK

NG Replace overdrive control

CHECK OVERDRIVE CONTROL SWITCH.
Check continuity between overdrive control switch.
AAT836 switch terminals G) and @.

~'='============~
~ device (overdrive control switch)
AfT Overdrive
9 connector control switch
position
Continuity

ON No
I I
OFF Yes

OK
[!]
r=~----------~------------,NG
CHECK OVERDRIVE CANCEL SOLENOID Replace overdrive cancel
VALVE. solenoid valve.
Check resistance between overdrive cancel
AAT035A
solenoid valve terminals G) and ®.
Resistance:
Approximately 250

OK
Check the following items:
• Harness continuity between fuse and over-
drive cancel solenoid valve
• Harness continuity between overdrive cancel
solenoid valve and overdrive control switch
• Condition of diode

OK
AAT838 INSPECTION END

538 AT-22
 TROUBLE DIAGNOSES
Component Inspection (Cont'd)
INHIBITOR SWITCH
Ignition switch
~
7~ r.i.1
Eli,
CHECK INHIBITOR SWITCH CIRCUIT.
1. Turn ignition switch to ON position. ~ INSPECTION END

~
(Do not start engine.)
2. Check voltage between ECM terminal
22 @ and ground while moving selector
ECM (ECCS lever through each position.
control module)
.,c "P", "N" position: OV
"R", "0", "2", "1" position:

.•
AAT839
Approx. 5V
r.i.1
0 0----- NG

·'"'-. - - - - -. a
.'i>
/

\/c;;: ----'·---) •
\ )-~~-~~I:"'..'-,
i, 'Iii' ·-.,~, ~~~---
\ ~-...: r. . -j!;-:.:--, •
1--~ '~ ,......,if·''
I,'~-+{ '' •
00
CHECK POWER SUPPLY FOR INHIBI-
TOR SWITCH.
1. Disconnect inhibitor switch harness
connector.
-
No Check 10A fuse (No. [j] ,
located in the fuse block),
harness and conntector.
Refer to EL section ("Wir·

~~!~
. /,' '/
2. Turn ignition switch to ON position.
(Do not start engine.)
ing Diagram", "POWER
SUPPLY ROUTING").
Do approx. 12 volts exist between inhibitor

[at switch harness terminal No. (j) and body

ground?
CONNECT
II ECM ~CONNECTOR II
() 22
Yes
!!l
CHECK INHIBITOR SWITCH. ~ Replace inhibitor switch.
[YJ • Check continuity in "N", "P" and "R" I
positions.
,----Q_g}f--
• With manual lever held in each
position, turn manual shaft 1.5"' in both
~ directions. (When manual lever is in
each position, continuity normally exists
within 1.5° range.) If continuity does not
AAT840
exist equally in either direction, properly
adjust inhibitor switch. Refer to AT-39.
00
ctlD connector@
Inhibitor switch ~ 1000 Position
Terminal No.

W/B
CD ® CD ®
Park/neutral ~ ~
position
[YJ R
+

~OK
~ Reconnect inhibitor switch harness con-
AAT859
nector.

:~~~ =-~o~
1
~~
~~~
l ® ',
£L
®
t
(Go to next page.)

/.-~ SWitCh

[ill~
" AAT841

AT-23 539
 TROUBLE DIAGNOSES
Component Inspection (Cont'd)
I!] Park and neutral position relay
®
connector@
l:j
I
15 CHECK POWER SUPPLY FOR PARK
AND NEUTRAL POSITION RELAY.
1. Disconnect park and neutral position
~ Disconnect inhibitor switch
I .... harness connector. Check
circuit continuity between

00 relay harness connector.

2. Put selector lever in "P" or "N" position.
inhibitor switch harness
terminal No. ® and park
Do approx. 12 volts exist between park and neutral position relay
AAT868
and neutral position relay harness terminal harness terminal No. @.
No. @ and body ground? Continuity should exist.
If OK, check harness for
Yes
short.

Park and
neutral position
relay connector @ Inhibitor switch CHECK BODY GROUND CIRCUIT FOR Repair harness or

,[&\~!:1--c--J-f3 PARK AND NEUTRAL POSITION

RELAY.
Does continuity exist between park and
neutral position relay terminal Nos. (!),
® and body ground?
connector.

Continuity should exist.

AAT869 c _ - - - - - - - - r = , - - - - - - - - _ j
~======~~~;=;=~ OK
IJ Parl< and ~ :i~ ~
neutral position l.a ~V ~ CHECK PARK AND NEUTRAL POSI- NG Replace park and neutral
relay connector @
TION RELAY. ~ position key.
cn:Jp- B Check continuity between terminals ®
and®.
B

Condition Continuity

~2V direct current s_!::I.Pply

between terminals (!) and Yes
®
AAT870
No current supply No

OK

Check circuit continuity between ECM

harness terminal No. @ and park and
neutral position relay harness terminal
No.®.
Continuity should exist.
-
NG Repair harness or
connector.

5 If OK, check harness for short.

Replace ECM.

II ECM JO[coNNEcroRII neutral position

relay connector
22
@~
UB
UB

AAT873

540 AT-24
 TROUBLE DIAGNOSES

Final Check
STALL TESTING
Stall test procedure
1. Check AfT and engine fluid levels. If necessary, add fluid.
2. Drive vehicle for approx. 10 minutes or until engine oil and ATF ~[01
reach operating temperature.
ATF operating temperature:
50 - 80°C (122 - 176°F)

SAT647B

3. Set parking brake and block wheels. ~!(;

4. Install a tachometer where it can be seen by driver during test.
• It is good practice to put a mark on point of specified !'~
engine speed on indicator.

•
SAT513G

5. Start engine, apply foot brake, and place selector lever in "D"
position.

AAT817

6. Accelerate to wide open throttle gradually while applying foot

brake.
• During test, never hold throttle wide-open for more than 5 ~iFB
seconds.
7. Quickly note the engine stall revolution and immediately
release throttle. ~'I
Stall revolution standard:
2,100 - 2,300 rpm

8. Shift selector lever to "N" position.

9. Cool off ATF.
• Run engine at idle for at least one minute. iilffil
10. Repeat steps 5 through 9 with selector lever in "2", "1" and "R"
positions.

SAT453H

AT-25 541
 TROUBLE DIAGNOSES
Final Check (Cont'd)
JUDGEMENT OF STALL TEST

Selector lever position Judgement

D L D H

0 : Stall revolution is normal.

H : Stall revolution is higher
L 0 0 than specified
L : Stall revolution is lower
R L H H
than specified.

Damaged components

Forward clutch

Forward ane·way clutch

Engine Low & reverse brake

Hydraulic circuit for

line pressure control
(Line pressure is low.)

Torque converter one-way clutch

Reverse clutch

Clutches and brakes except

high clutch and brake band
are OK. (Condition of high
clutch and brake band can
not be confirmed by stall
test.)
D

R 0 0 H 0
Selector lever position Judgement

SAT161GA

542 AT-26
 TROUBLE DIAGNOSES
Final Check (Cont'd)
Front
PRESSURE TESTING
• Location of line pressure test port
• Line pressure plugs are hexagon-headed bolts .
• Always replace line pressure plugs as they are self-
sealing bolts.
Front

II
Lrest port for D,
2 and 1 positions

SAT176G

Line pressure test procedure [:';(~

1. Check AfT and engine fluid levels. If necessary. add.
2. Drive vehicle for approx. 10 minutes or until engine oil and ATF
11 ,
reach operating temperature.
ATF operating temperature:
50- 80°C (122- 176°F) (;;L

•
SAT6478

3. Install pressure gauge to line pressure port.

- D, 2 and 1 positions -

(J34301-C)

AAT809

- R position -

(J34301-C)

AAT810

4. Set parking brake and block wheels.

• Continue to depress brake pedal fully while performing
line pressure test at stall speed.

SAT513G

AT-27 543
 TROUBLE DIAGNOSES
Final Check (Cont'd)
5. Start engine and measure line pressure at idle and stall speed.
• When measuring line pressure at stall speed, follow the
stall test procedure.
Line pressure:
Engine speed Line pressure kPa (kg/cm 2 , psi)
rpm D, 2 and 1 positions R position

422 - 461 667- 706

Idle
(4.3- 4.7. 61 - 67) (6.8 - 7.2. 97 - 1 02)
SAT494G 883- 961 1,393- 1.471
Stall
(9.0- 9.8. 128- 139) (14.2 - 15.0, 202 - 213)

JUDGEMENT OF LINE PRESSURE TEST

Judgement Suspected parts
At idle Line pressure is low in all positions. • Oil pump wear
• Control piston damage
• Pressure regulator valve or plug sticking
• Spring for pressure regulator valve damaged
• Fluid pressure leakage between oil strainer and
pressure regulator valve
• Clogged strainer
Line pressure is low in particular position. • Fluid pressure leakage between manual valve and
particular clutch.
• For example, line pressure is:
-Low in "R" and "1" positions, but
- Normal in "D" and "2" positions.
Therefore, fluid leakage exists at or around low &
reverse brake circuit.
Refer to OPERATION OF CLUTCH AND BRAKE,
AT-11.

Line pressure is high. • Maladjustment of throttle position sensor

• Fluid temperature sensor damaged
• Line pressure solenoid valve sticking
• Short circuit of line pressure solenoid valve circuit
• Pressure modifier valve sticking
• Pressure regulator valve or plug sticking
At stall speed Line pressure is low. • Maladjustment of throttle position sensor
• Control piston damaged
• Line pressure solenoid valve sticking
• Short circuit of line pressure solenoid valve circuit
• Pressure regulator valve or plug sticking
• Pressure modifier valve sticking
• Pilot valve sticking

544 AT-28
TROUBLE DIAGNOSES
Final Check (Cont'd)
i(j]
Governor pressure testing
1. Check AfT and engine fluid levels. It necessary, add fluid.
2. Drive vehicle tor approx. 10 minutes or until engine oil and ATF
reach operating temperature.
ATF operating temperature:
50- SO"C (122- 176"F)
3. Install pressure gauge to governor pressure port.

L©

4. Jack up front and rear wheels.

5. Set selector lever in "D" position and gradually depress
accelerator pedal.
• Be careful of rotating wheels.

Governor pressure:
• Governor pressure is not generated when vehicle is
stopped. riC
• Governor pressure rises gradually in response to vehicle
speed.
Vehicle speed Governor pressure kPa (kg/cm 2 psi)
0 km/h (0 MPH) 0 (0, 0)
29 km/h (18 MPH) 102.4-141.6 (1.22 -1.26. 17 -18)
57 km/h (35 MPH) 233.5 . 284.5 (2.40 - 2.90, 34 - 41)
86 km/h (53 MPH) 350.6 . 409.4 (3.58 . 4.18, 51 - 60)

It not, check governor valve assembly. Refer to AT-72.

AT-29 545
 TROUBLE DIAGNOSES - AfT Shift Lock System

Description
• The mechanical key interlock mechanism also operates as a shift lock:
With the key switch turned to ON, the selector lever cannot be shifted from "P" (park) to any other posi-
tion unless the brake pedal is depressed.
With the key removed, the selector lever cannot be shifted from "P" to any other position.
The key cannot be removed unless the selector lever is placed in "P".
• The shift lock and key interlock mechanisms are controlled by the ON-OFF operation of the shift lock
solenoid and by the operation of the rotator and slider located inside the key cylinder, respectively.

Shift Lock System Electrical Parts Location

ASCD brake switch

Stop lamp switch

Steering column

Key interlock cable

AfT device harness

connector

Park position switch Shiff lock solenoid

harness connector AAT036A

546 AT-30
 TROUBLE DIAGNOSES -AfT Shift Lock System

Wiring Diagram

AT-SHIFT-01
Refer to "EL-POWER" ~:WithASCD
1DA
[DJ
WIB

~
JOINT
CONNECTOR-2
(illij)

~
W/B

ffi
,-------~~RE_L_E-AS_E_o'ASCD
.... - - BRAKE
SWITCH
DEPRESSED (~n

lbjdJ

-
UB
•

•
To EL-ASCD ... UB ~Q
•
UB B

m m A!f
w 8 DEVICE
SHIFT
LOCK
SOLENOID B
I ~

c II QJARK
SWITCH
POSITION

8 ®®:Dj
.._s•'!QJIL

Refer to last page (Foldout page)

@B)

AAT037A

AT-31 547
 TROUBLE DIAGNOSES - AfT Shift Lock System

Diagnostic Procedure
SYMPTOM 1:
• Selector lever cannot be moved from "P" position with
key in ON position and brake pedal applied.
• Selector lever can be moved from "P'" position with key in
ON position and brake pedal released.
• Selector lever can be moved from "P" position when key
is removed from key cylinder.
SYMPTOM 2:
Ignition key cannot be removed when selector lever is set to
"P" position. It can be removed when selector lever is set to
any position except "P".

Check key interlock cable for damage.

OK
b Repair key interlock cable.
Refer to "Key Interlock
Cable", AT-34.

Check selector lever position for damage.

~ Check selector lever. Refer
to "ON-VEHICLE SER-
OK
VICE - Inhibitor Switch
and Manual Control Link-
age Adjustment", AT-39.

fi.1
fi.1 CHECK POWER SOURCE. NG Check the following items:
f---+
~ f) 00
CONNECT
1. Turn ignition switch to ON position. (Do • 1OA fuse (No. [l] .
not start engine.) located in the fuse block)
2. Check voltage between ASCD brake • Harness for short or

~
ASCD brake switch switch harness connector terminal No. open between fuse and
harness connector § ®and ground. ASCD brake switch har-
Voltage: Battery voltage ness connector terminal
W/8
®
ll_CYJ OK
No.
• Ignition switch (Refer to
EL section.)
""'" Q..§lt--
AAT038A • Joint connector-2

IS) IS)
~i) CHECK INPUT SIGNAL
~ Check the following items:
A/T device (ASCO CANCEL SWITCH). • Harness for short or

~ ~ harness connector @ill) 1. Turn ignition switch to ON position. (Do open between AfT
device harness connec-
rcf(l}g not start engine.)
®
nj]LIB
2. Check voltage between AfT device har- tor terminal No. and
ness connector terminal No. ®and ASCD brake switch har-
ground. ness connector terminal
No. G)
ccea ~
Brake pedal Voltage • ASCD brake switch
(Refer to "Component
SAT3201 Depressed ov
Released Battery voltage Check". AT-36.)

+OK

®
(Go to next page.)

548 AT-32
 TROUBLE DIAGNOSES - AfT Shift Lock System
Diagnostic Procedure (Cont'd)
[!J ®
~ eJ
DISCONNECT

AfT device
harness connector @ill)
[!J
1
[BI FYJ1 I
CHECK GROUND CIRCUIT.
1. Turn ignition switch to OFF position. ~ Repair harness or
connector.

fl--5]8 ~
2. Disconnect AfT device harness
connector.
3. Check continuity between AfT device
harness connector terminal No. ® and
AATBOO ground.
Continuity should exist.

TOK

CHECK PARK POSITION SWITCH. NG Replace park position

(Re1er 1o "Componen1 Check", AT-36.) f---. switch.

l OK

CHECK SHIFT LOCK SOLENOID. ~ Replace shift lock solenoid.

(Reier 1o "Componen1 Check", AT-35.)

10K

Reconnect AfT device harness connector.

l
Turn ignition switch from OFF to ON
position. (Do not start engine.)

1
Recheck shift lock operation.
~ Recheck harness
connector connection.
lOK

INSPECTION END

AT-33 549
 TROUBLE DIAGNOSES - AfT Shift Lock System

Key Interlock Cable

Lock plate

Snap pin

Steering column

Adjuster holder

Rod

Key interlock
cable
Bracket
AAT803

CAUTION:
• Install key interlock cable in such a way that it will not be
damaged by sharp bends, twists or interference with
adjacent parts.
• After installing key interlock cable to control device, make
sure that casing cap and bracket are firmly secured in
their positions. If casing cap can be removed with an
external load of less than 39.2 N (4.0 kg, 8.8 lb), replace
key interlock cable with new one.

REMOVAL
Unlock slider from adjuster holder and remove rod from cable.

550 AT-34
 TROUBLE DIAGNOSES - AfT Shift Lock System
Key Interlock Cable (Cont'd)
INSTALLATION Iilli
1. Set key interlock cable to steering lock assembly and install
lock plate.
2. Clamp cable to steering column and fix to control cable with
band.
3. Set control lever to "P'' position.

Steering
lock
AATBOS

4. Insert interlock rod into adjuster holder.

~~L

if['

5. Install casing cap to bracket.

6. Move slider in order to fix adjuster holder to interlock rod.

7. Install snap pin.

Component Check
~iD
AfT device
~i5
Shift lock solenoid
SHIFT LOCK SOLENOID
lFDffii
harness connector~ harness connector@ • Check operation by applying battery voltage to AfT device and

~
shift lock solenoid harness terminal.
II msD
W B

AAT802

AT-35 551
 TROUBLE DIAGNOSES - AfT Shift Lock System
Component Check (Cont'd)
PARK POSITION SWITCH
• Check continuity between AfT device harness connector termi-
nal ® and park position switch harness connector terminal ®
AfT device harness Park position switch
connector@) harness connector@
Condition Continuity
6
2 When selector lever is set in "P" position and selec-
Yes
tor lever button is released
8 Except above No
L

AAT799

ASCD BRAKE SWITCH

ASCD brake switch
harness connector
• Check continuity between terminals CD and ®
Condition Continuity
When brake pedal is depressed No
When brake pedal is released Yes

Check ASCD brake switch after adjusting brake pedal. Refer to

BR section ("Adjustment", BRAKE PEDAL AND BRACKET")-
AAT039A

552 AT-36
 ON-VEHICLE SERVICE

i§JI
Control Valve Assembly and Accumulators
Inspection
1. Drain ATF from drain plug.
2. Remove oil pan and gasket.
3. Remove oil strainer.
4. Disconnect harness connector.

SAT103C

5. Remove control valve assembly by removing fixing bolts.

Front

0 Bolt length and location

Bolt symbol
~I
I
® ® cg, r' mm (in)

33 (1.30)

® 45 (1.77)
®
® Be careful not to drop manual valve out of valve body.
(B) 6. Remove solenoids and valves from valve body if necessary.

•
7. Remove terminal cord assembly if necessary.
®
®
(a)
®
@

®
@: ®
SAT714C

~Ji
8. Remove accumulators @, @, © and @ by applying com-
pressed air if necessary.
Hold each piston with rag.
9. Reinstall any part removed.
Always use new sealing parts.

Rear Oil Seal Replacement

ST33200000
(J26082) 1. Remove propeller shaft from vehicle. Refer to PD section
("Removal and Installation", "PROPELLER SHAFT").
2. Remove rear oil seal.
3. Install rear oil seal.
• Apply ATF before installing.
4. Reinstall any part removed.

AT-37 553
 ON-VEHICLE SERVICE

Parking Components Inspection

1. Remove propeller shaft from vehicle. Refer to PO section
("Removal and Installation", "PROPELLER SHAFT").
2. Support AfT assembly with a jack.
3. Remove rear engine mounting member.
4. Remove rear extension from transmission case.
5. Replace parking components if necessary.
6. Reinstall any part removed.
• Always use new sealing parts.

Governor Valve
1. Remove propeller shaft from vehicle. Refer to PO section
("Removal and Installation", "PROPELLER SHAFT").
2. Support AfT assembly with a jack.
3. Remove rear engine mounting member from AfT assembly.
4. Remove rear extension from transmission case.
5. Remove governor valve assembly.
6. Inspect and repair governor valve assembly. Refer to REPAIR
FOR COMPONENT PARTS, AT-72.

SAT108C

Throttle Wire Adjustment

1. Turn ignition switch OFF.
2. While pressing lock plate, move adjusting tube in Direction T.
3. Release lock plate. (Adjusting tube is locked at this time.)
4. Move throttle drum from P2 (Idling position) to P1 (Full throttle
position) quickly and release.
5. Ensure that throttle wire stroke "L" is within the specified
range, between full throttle and idle.
Throttle wire stroke "L":
38-42 mm (1.50- 1.65 in)
• Adjust throttle wire stroke after accelerator wire is
installed and adjusted.
• When connecting throttle wire to throttle drum, do not use
tools. Manually hook wire.
Engine side Adjusting tube
• Put mark on throttle wire for measuring wire stroke.
bracket

LReturn
spring

SAT551D

Nominal kickdown range If throttle wire stroke is improperly adjusted, the following problems
4/4 ..-r------,------,-- may arise.
• When the throttle drum fully-open position "P 1 " is too far
toward Direction T, the shift schedule will be as shown by ®
in the figure, and the kickdown range will greatly increase.
• When the throttle drum fully-open position "P 1 " is too far
toward Direction U, the shift schedule will be as shown by CD
in the figure, and kickdown will not occur.

OL___L __ _ _ _ _ _ _ _ _ _ _ __
Vehicle speed
SAT411

554 AT-38
 ON-VEHICLE SERVICE

~I
Inhibitor Switch Adjustment
1. Remove manual control linkage from manual shaft of AfT
assembly.
2. Set manual shaft of AfT assembly in "N" position.
3. Loosen inhibitor switch fixing bolts.
4. Use a 4 mm (0.157 in) pin for this adjustment.

\\ a.
b.
Insert the pin straight into the manual shaft adjustment hole.
Rotate inhibitor switch until the pin can also be inserted straight
into hole in inhibitor switch.
--\1 5. Tighten inhibitor switch fixing bolts.
SAT081B 6. Remove pin from adjustment hole after adjusting inhibitor
switch.
7. Reinstall any part removed.
8. Adjust control linkage. Refer to "Manual Control Linkage
Adjustment".
9. Check operation of inhibitor switch. Refer to AT-23.

Manual Control Linkage Adjustment

Move the selector lever from the "P'' position to "1" position. You
should be able to feel the detents in each position. "Ill'
If the detents cannot be felt or the pointer indicating the position is
improperly aligned, the linkage needs adjustment.
1. Place selector lever in "P" position. l'l!D
2. Loosen lock nuts.

"P'" position 3. Tighten lock nut ® until it touches trunnion, pulling selector
lever toward "R" position side without pushing button.
4. Back off lock nut ® 1 turn and tighten lock nut CJ) to the
specified torque. ~~
Lock nut:
!:OJ: 11 - 15 N·m
(1.1 - 1.5 kg-m, 8- 11 ft-lb)
5. Move selector lever from "P" position to "1" position. Make
sure that selector lever can move smoothly.
lock nut®
Lock nut@
SAT033G

AT-39 555
 REMOVAL AND INSTALLATION

Removal
CAUTION:
Before separating the AfT assembly from engine, remove the
crankshaft position sensor (OBD) from the AfT assembly. Be
careful not to damage sensor.
1. Disconnect battery negative terminal.
2. Remove fluid charging pipe from AfT assembly and plug
opening.
3. Remove oil cooler pipe from AfT assembly and plug opening.
4. Remove propeller shaft.
Refer to PD section ("Removal and Installation'",
"PROPELLER SHAFT').
• Insert plug into rear oil seal after removing rear propeller
shaft.
• Be careful not to damage spline, sleeve yoke and rear oil
seal.
5. Remove AfT control linkage from selector lever.
6. Disconnect AfT harness connectors.

7. Remove starter motor.

B. Remove bolts securing torque converter to drive plate.
• Rotate crankshaft to gain access to securing bolts.

9. Support AfT assembly with a jack.

10. Remove rear mounting bracket from body and AfT assembly.
Refer to EM section ("ENGINE REMOVAL'").
11. Remove bolts securing AfT assembly to engine.
12. Pull AfT assembly backwards.
• Secure torque converter to prevent it from dropping.
• Secure AfT assembly to a jack.

13. Slant and lower AfT assembly.

556 AT-40
REMOVAL AND INSTALLATION

Installation
1. Check drive plate runout.
CAUTION:
Do not allow any magnetic materials to contact the ring gear
teeth.
Maximum allowable runout: ~~[L
Refer to EM section ("Inspection", "CYLINDER
BLOCK").
If this runout is out of specification, replace drive plate with ring ;~,~
gear.

2. When connecting torque converter to transmission, measure IC;!!'i

distance "A" to be certain that they are correctly assembled.
Distance "A":
26.0 mm (1.024 in) or more P~

©L

3. Install converter to drive plate.

• With converter installed, rotate crankshaft several turns to
check that transmission rotates freely without binding.

4. Tighten bolts securing transmission.

Tightening torque Bolt length "£"
N·m (kg-m, ft-lb) mm (in)
CD 39- 49 (4.o- 5.o. 29- 36) 43 (1.69)
® 3 - 4 (0.3 . 0.4, 2.2 - 2.9) 16 (0.63)
@ 16-22 (1.6- 2.2, 12- 16) 16 (0.63)

5. Reinstall any part removed.

6. Adjust manual control linkage. Refer to AT-39.
7. Adjust throttle wire. Refer to AT-38.
8. Adjust inhibitor switch. Refer to AT-39.
9. Refill transmission with ATF and check fluid level.
10. Move selector lever through all positions to be sure that ~l
transmission operates correctly.
With parking brake applied, allow engine to idle. Move
selector lever through "N" to "D", to "2", to "1" and to "R". A
slight shock should be felt through the hand gripping the l!l?1
selector each time the transmission is shifted.
SAT638A
11. Perform road test. Refer to "ROAD TEST", AT-12.
AT-41 557
 MAJOR OVERHAUL

SEC. 311•313•315
to.J ' N·m (kg·m. ft·lb)
~ : Apply anaerobic liq "d

~' "'equivalent
gasket Loctite PIN 51813
Ul

~~~ Sode seal

I
-----.__----=>~'
Apply ATF Sode seal

~ ;&~
EI!@·A Povotpon

*.
· pply petroleum -811
S I 1 y
· e ect with proper thickness C
antral PISton

~
Oil pump housin
0-ring
.I
g o1 seal ~(®
f...9l.
~~

one-way clutch

End bearing

ring

Forward clutch hub

Thrust washer I!Ei! ®
Rear internal gear

Bearing race I!Ei!l ®

AAT811

558 AT-42
 MAJOR OVERHAUL

SEC. 311•315•317

~ · N•m (k g-m, in-lb)

~ 'N•m (kg-m, ft-lb)
~-.
~-Apply ATF

*:
!!'Ell @ APP IY petroleum
.
jelly.

*: . Select with
Adjustment ~roper
IS
thickness
required. .

AAT041A

AT-43 559
 MAJOR OVERHAUL

Oil Channel

2 accumulator drain

3 -+ 4 & N -+ R accumulator shoulder pressure 2 -+ 3 accumulator back pressure

3 -+ 4 & N -+ R accumulator back pressure 1 -+ 2 accumulator back pressure

Servo 2nd apply chamber pressure j+O~~==;=~=~~~~~~~~;t~~~~~~~~-- N -+ D accumulator back pressure

Servo 3rd release chamber pressure --l--c-hf:r'1r'l\t~ 'l~ii!J~\fi.I-}1H---
~ 2 -+ 3 accumulator shoulder pressure

Oil pump feedback pressure -H~~~~~1Jl~~~I::J:

Servo 4th apply chamber pressure _j,-f-r;"\~~

Oil pump discharge pressure

Overrun clutch pressure
Front lubricating hole Governor pressure
High-clutch pressure
Forward clutch pressure
Torque converter pressure (lock-up released)
Reverse clutch pressure
Torque converter pressure (lock-up applied) r--------------------------l
1* Accumulator back and
Oil pump suction hole : shoulder pressure are shown below. i
1

: Back pressure Shoulder pressure i

' ' I
Accumulator
piston

High-clutch pressure
Front lubricating hole
Oil pump discharge hole
r Torque converter pressure (lock-up released)
Reverse clutch pressure
'
'
'
'
'
:'
~~~~
Torque converter pressure
pressure
{lock-up applied) I _____ - - - - - - - - - - - - - - - - - - - -

pressure

High-clutch pressure

Torque converter NessuceJ

Reverse clutch pressure
(lock-up released)
Forward clutch pressure
Overrun clutch pressure

Governor
pressure

Oil cooler tube (IN) hole

Forward clutch pressure pressure

Servo 3rd chamber pressure

SAT173C

560 AT-44
 <D ® @ ® ® (j)
Outer diameter of snap rings
®
Item Outer diameter
number mm (in)
2! I 161.0 (6.341
3! I 140.1 (5.521
4! I 156.4 (6.161
·s) 1 142.o (5.591
7) I 159.2 (6.271

Inner diameter of thrust washers

Item Inner diameter
Color
number mm (in)
Black 52.8 (2.08)
5 White 84.5 (3.33)

111r s::
:I 0 l>
~
Q.(')
Ill 0
Ul:: ll
~ :I 0
Ill:~ 0
~' "CIJJ <
C1l Outer diameter of needle bearings
m
nem
number
uuter diameter
mm (in) -·-
:Do
:::~z
IC<D
ll
::J:
8 47 (1.85) l>
® 9 53 (2.09)
1/J<D c:
10 53 (2.09)
a. r
<D
1 78 (3.07)
1 53 (2.09) m
<D
.13 78 (3.07) Ill
57 (2.24) :::!.
:I
78 (3.07) IC
64 (2.52) Ill
53 (2.09)
-1
Installation of one-piece bearings
...
:T
Item
number
I Bearur~ rat;t::
(black) location
Front
Rear side
Rear side
Inner diameter of bearing races
Item
number
Outer diameter
mm (in)
-
s:::
Ill

~
Ill

~
__@ 58 (2.28) :T
Rear side
Q3) 58.8 (2.315) ...
<D
Ill

"")
561

§ lJLn} ~-~ @0 ~'21 (0/J IQ6J ~ w

~J ~~ ~~ ~ CCiJ liiiil :c- mru 5 \<!i")
~
"" d~ c-C (@ 2CJ 0 ~
~ :F ITTiil l?;-,>) (Q)
~ 2~
 DISASSEMBLY

Disassembly
1. Removing torque converter by holding it firmly and turning
while pulling straight out.

KV31102100
2. Check torque converter one-way clutch.
(J37065) {Rotate) a. Insert Tool into spline of one-way clutch inner race.
Wire (Hold) b. Hook bearing support unitized with one-way clutch outer race
with suitable wire.
c. Check that one-way clutch inner race rotates only clockwise
with Tool while holding bearing support with wire.

SAT019BA

3. Remove inhibitor switch from transmission case.

SAT021B

4. Remove oil pan.

a. Drain ATF from drain plug.
b. Raise oil pan by placing wooden blocks under converter
housing and adapter case.
c. Separate the oil pan and transmission case.
• Always place oil pan straight down so that foreign par-
ticles inside will not move.

5. Place transmission into Tool with the control valve facing up.

562 AT-46
 DISASSEMBLY
Disassembly (Cont'd)
6. Check foreign materials in oil pan to help determine cause of ~I
malfunction. If the fluid is very dark, smells burned, or contains
foreign particles, the frictional material (clutches, band) may
need replacement. A tacky film that will not wipe clean
indicates varnish buildup. Varnish can cause valves, servo,
and clutches to stick and may inhibit pump pressure.
• If frictional material is detected, replace radiator after
repair of AfT. Refer to LC section ("Radiator", "ENGINE
COOLING SYSTEM").

SAT1718

Connectors 7. Remove torque converter clutch solenoid valve and overdrive ::;~~
cancel solenoid valve connectors.

B.
a.
Remove oil strainer.
Remove oil strainer from control valve assembly.
Then remove O·ring from oil strainer. •
b. Check oil strainer screen for damage.

SAT025B

9. Remove control valve assembly.

a. Straighten terminal clips to free terminal cords then remove
terminal clips.

SAT3071

AT-47 563
 DISASSEMBLY
Disassembly (Cont'd)

•
Front b. Remove bolts® and@, and remove control valve assembly
from transmission .

@ @ ® ® Bolt f mm (in)

® 33 (1.30)

(B) ® 45 (1.77)

c. Remove manual valve from control valve assembly.

10. Remove terminal cord assembly from transmission case while

pushing on stopper.
• Be careful not to damage cord.
• Do not remove terminal cord assembly unless it is
damaged.

11. Remove converter housing.

a. Remove converter housing from transmission case.
b. Remove traces of sealant.
• Be careful not to scratch converter housing.

564 AT-48
 DISASSEMBLY
Disassembly (Cont'd)
12. Remove 0-ring from input shaft.

SAT995A

13. Remove oil pump assembly.

a. Attach Tool to oil pump assembly and extract it evenly from
transmission case.

itur

b. Remove 0-ring from oil pump assembly.

c. Remove traces of sealant from oil pump housing.
• Be careful not to scratch pump housing.

FL~
d. Remove needle bearing and thrust washer from oil pump
0+ assembly.

SAT1088

14. Remove input shaft and oil pump gasket.

SAT988A

AT-49 565
 DISASSEMBLY
Disassembly (Cont'd)
15. Remove brake band and band strut.
a. Loosen lock nut and remove band servo anchor end pin from
transmission case.

b. Remove brake band and band strut from transmission case.

c. Hold brake band in a circular shape with clip.

Check brake band facing for damage, cracks, wear or burns.

Clip

SAT655

16. Remove front side clutch and gear components.

a. Remove clutch pack (reverse clutch, high clutch and front sun
gear) from transmission case.

b. Remove front bearing race from clutch pack.

c. Remove rear bearing race from clutch pack.

Front

Rear

SAT3741

566 AT-50
 DISASSEMBLY
Disassembly (Cont'd)
d. Remove front planetary carrier from transmission case. rllJ~

IL©

e. Remove front needle bearing from front planetary carrier.

f. Remove rear bearing from front planetary carrier.

g. Remove rear sun gear from transmission case.

•
17. Remove rear extension case.
a. Remove rear extension case from transmission case.
b. Remove rear extension gasket from transmission case.

c. Remove oil seal from rear extension case.

• Do not remove oil seal unless it is to be replaced.

AT-51 567
 DISASSEMBLY
Disassembly (Cont'd)
18. Remove output shaft and parking gear.
a. Remove governor valve assembly.

SAT120C

b. Remove rear snap ring from output shaft.

c. Slowly push output shaft all the way forward.

• Do not use excessive force.
d. Remove snap ring from output shaft.

e. Remove output shaft and parking gear as a unit from

transmission case.
f. Remove parking gear from output shaft.

g. Remove needle bearing from transmission case.

~1J~\~\C_j

\\:2: /
~ ----- / SAT033B

568 AT-52
 DISASSEMBLY
Disassembly (Cont'd)
19. Remove rear side clutch and gear components.
a. Remove front internal gear.

L©

b. Remove bearing race from front internal gear.

c. Remove needle bearing from rear internal gear.

d. Remove rear internal gear, forward clutch hub and overrun M

clutch hub as a set from transmission case.

SAT951A

e. Remove needle bearing from overrun clutch hub.

f. Remove overrun clutch hub from rear internal gear and
forward clutch hub.

SAT682H

AT-53 569
 DISASSEMBLY
Disassembly (Cont'd)
g. Remove thrust washer from overrun clutch hub.

0
h. Remove forward clutch assembly from transmission case.

20. Remove band servo and accumulator components.

a. Remove band servo retainer from transmission case.

b. Apply compressed air to oil hole until band servo piston comes
out of transmission case.
• Hold piston with a rag and gradually direct air to oil hole.
c. Remove return springs.

SAT0398

d. Remove springs from accumulator pistons @, © and @.

e. Apply compressed air to each oil hole until piston comes out.
• Hold piston with a rag and gradually direct air to oil hole.
Identification of accumulator pistons ® @ © @
Identification of oil holes @ ® @ @

SAT0408A

570 AT-54
 DISASSEMBLY
Disassembly (Cont'd)
Front c) f. Remove 0-ring from each piston.
(2--?-3) (3-+4, N-+A)
Accumulator Accumulator

E fi ~··"S
Accumulator Accumu~ator
piston (ii;J piston ©
SAT618GA

21. Remove throttle wire components if necessary.

a. Remove throttle wire from AfT assembly.

SAT135C

b. Remove throttle lever shaft E-ring.

c. Remove return spring.
d. Remove throttle lever.

SAT136C

Retaining pin e. Remove throttle lever shaft retaining pin and throttle lever Iilii,
shaft.

SAT137C

22. Remove manual shaft components, if necessary.

a. Hold width across flats of manual shaft (outside the transmission
case) and remove lock nut from shaft.

SAT04i8

AT-55 571
 DISASSEMBLY
Disassembly (Cont'd)
b. Remove retaining pin from transmission case.
Manual plate
Retaining pin
Oil seal
Manual shaft

SAT042B

c. While pushing detent spring down, remove manual plate and

parking rod from transmission case.

d. Remove manual shaft from transmission case.

e. Remove spacer and detent spring from transmission case.

f. Remove oil seal from transmission case.

SAT044B

572 AT-56
 REPAIR FOR COMPONENT PARTS

Oil Pump
SEC. 313 ~ : N•m (kg·m, lt·lb)
Control piston Side seal EEi!l :~) @V: Apply ATF.
Ei3!l (f'J : Apply petroleum jelly.
Pivot pin Side seal EEi!l C'--"~

Oil pump housing

Friction ring m ~I

Vane ring

return spnng Reverse clutch seal ring - I:Ql

~ E:i!l (i:'_" High clutch seal ring

Pivot pin ~m®

Oil seal~~ Rotor Cam ring

AAT812

DISASSEMBLY
1. Loosen bolts in numerical order and remove oil pump cover.
•
2. Remove rotor, vane rings and vanes.
Inscribe identification mark.
• Inscribe a mark on back of rotor for identification of fore-
aft direction when reassembling rotor. Then remove rotor.

3. While pushing on cam ring remove pivot pin.

• Be careful not to scratch oil pump housing.

AT-57 573
 REPAIR FOR COMPONENT PARTS
Oil Pump (Cont'd)
4. While holding cam ring and cam ring return spring, lift out cam
ring return spring.
• Be careful not to damage oil pump housing.
• Hold cam ring return spring to prevent it from jumping.

5. Remove cam ring and cam ring return spring from oil pump
housing.

6. Remove pivot pin from control piston and remove control

piston assembly.

7. Remove oil seal from oil pump housing.

• Be careful not to scratch oil pump housing.

INSPECTION
Oil pump cover, rotor, vanes, control piston, side seals, cam
ring and friction ring
• Check for wear or damage.

SAT656A

574 AT-58
 REPAIR FOR COMPONENT PARTS
Oil Pump (Cont'd)
Dial Indicator Side clearances
• Measure side clearances between end of oil pump housing
Straight edge and cam ring, rotor, vanes and control piston in at least four
places along their circumferences. Maximum measured values
should be within specified ranges.
• Before measuring side clearance, check that friction rings, C:iJ
0-ring, control piston side seals and cam ring return
piston spring are removed.
Cam ring Standard clearance (Cam ring, rotor, vanes and
Vane control piston):
SAT657A Refer to SDS, AT-116.
• If not within standard clearance, replace oil pump assembly !§(;
except oil pump cover assembly.
Seal ring clearance
• Measure clearance between seal ring and ring groove .
Standard clearance:
0.10- 0.25 mm (0.0039- 0.0098 in)
Wear limit:
0.25 mm (0.0098 in)
• If not within wear limit, replace oil pump cover assembly.

•
SAT658A

ASSEMBLY
1. Drive oil seal into oil pump housing.
• Apply ATF to outer periphery and lip surface.

2. Install cam ring in oil pump housing by the following steps.

a. Install side seal on control piston.
• Pay attention to its direction- Black surface goes toward ,g,;i
control piston.
• Apply petroleum jelly to side seal.
b. Install control piston on oil pump. 'BiT

c. Install 0-ring and friction ring on cam ring.

• Apply petroleum jelly to 0-ring.

AT-59 575
 REPAIR FOR COMPONENT PARTS
Oil Pump (Cont'd)
d. Assemble cam ring, cam ring return spring and spring seat.
Install spring by pushing it against pump housing.

e. While pushing on cam ring install pivot pin.

3. Install rotor, vanes and vane rings.

• Pay attention to direction of rotor.

SAT662A

4. Install oil pump housing and oil purnp cover.

a. Wrap masking tape around splines of oil pump cover
assembly to protect seal. Position oil pump cover assembly in
oil pump housing assembly, then remove masking tape.
b. Tighten bolts in a criss-cross pattern.

5. Install seal rings carefully after packing ring grooves with

petroleum jelly. Press rings down into jelly to a close fit.

0
Small dia.
• Seal rings come in two different diameters. Check fit
carefully in each groove.
Small dia. seal ring:
No mark
Large dia. seal ring:
Yellow mark in area shown by arrow
• Do not spread gap of seal ring excessively while installing.
It may deform ring.
SAT663A

576 AT-60
 REPAIR FOR COMPONENT PARTS

Control Valve Assembly Clll

SEC. 317

Lower body

I I ~Orifice check spring

~Orifice check valve
I I

J
·-~ e
e
~ J,
e "" a
e
e
e e
ee

e
e Separator plate
e
e
e

{?J!a 61 0"
.,.,.e/S3
=
CJe
I
~Support plates

Side plate~ Steel ball

Upper body

~---' J,
~ Reamer bolt

0-ring~C@)
Lamer bolt
~ Torque converter clutch
solenoid valve

~ : N•m (kg-m, in-lb)

~ : Apply ATF.
~ 10. 13 (1.0 • 1.3. 87 . 113)

AAT813

AT-61 577
 REPAIR FOR COMPONENT PARTS
Control Valve Assembly (Cont'd)
DISASSEMBLY
1. Remove solenoids.
a. Remove overdrive cancel solenoid valve and side plate from
lower body.
b. Remove 0-ring from solenoid.

Overdrive cancel
solenoid valve
AAT814

c. Remove torque converter clutch solenoid valve from upper

body.
d. Remove 0-ring from solenoid valve.

SAT144G

2. Disassemble upper and lower bodies.

a. Place upper body facedown, and remove bolts, reamer bolts
and support plates.
b. Remove lower body, separator plate and separate gasket as
a unit from upper body.
• Be careful not to drop orifice check valve, spring and steel
balls.

SAT138C

c. Place lower body facedown, and remove separator plate.

d. Remove orifice check valve and orifice check spring.

SAT874C

e. Check to see that steel balls are properly positioned in upper

body and then remove them from upper body.

SAT726C

578 AT-62
 REPAIR FOR COMPONENT PARTS
Control Valve Assembly (Cont'd)
INSPECTION
Lower and upper bodies
• Check to see that there are pins and retainer plates in lower iluli\
body.

SAT139C

• Check to see that there are pins and retainer plates in upper l"i©
body.
• Be careful not to lose these parts .

SAT140C

Tube bracket • Check to make sure that oil circuits are clean and free from
damage.
• Check tube brackets and tube connectors for damage .
Tube

SAT141C

Separator plates
• Check to make sure that separator plate is free of damage and
not deformed and oil holes are clean. iiliPl
Overdrive cancel solenoid valve and torque converter
clutch solenoid valve
• Check that filter is not clogged or damaged. :1!1
• Measure resistance. Refer to "Component Inspection", AT-22.

SAT151G

ASSEMBLY
1. Install upper and lower bodies.
a. Place oil circuit of upper body face up. Install steel balls in their Ill~
proper positions.

SAT726C

AT-63 579
 REPAIR FOR COMPONENT PARTS
Control Valve Assembly (Cont'd)
b. Install reamer bolts from bottom of upper body and install
Reamer bolt Reamer separate gaskets.
{Long) ~"'--'..---...--..----... bolt
"'"' "' ... "'(Short)

•g

SAT147H

c. Place oil circuit of lower body face up. Install orifice check
spring, orifice check valve.
D: mm (in)
2.0 (0.079)

d. Install separator plate on lower body.

L: 25 (0.98)
e. Install and temporarily tighten support plates and tube brackets.

0
0 00
8 =
0
0
0

00
Unit: mm (in)
SAT3121

f. Temporarily assemble lower and upper bodies, using reamer

bolt as a guide.
• Be careful not to dislocate or drop steel balls, orifice
check spring and orifice check valve.

SAT198B

580 AT-64
 REPAIR FOR COMPONENT PARTS
Control Valve Assembly (Cont'd)
g. Install and temporarily tighten bolts and tube brackets in their iiilJ
proper locations.
Bolt length and location:
Bolt symbol

Bolt length mm (in) 45 (1.77) 33 (1.30)

~Side plate
2. Install solenoids.
a. Attach 0-ring and install overdrive cancel solenoid valve and
~ ' Overdrive cancel
solenoid valve
side plate onto lower body.

b. Attach 0-ring and install torque converter clutch solenoid valve

onto upper body.
3. Tighten bolt.

SAT144G

AT-65 581
 REPAIR FOR COMPONENT PARTS

Control Valve Upper Body

Plug~
1 '' r
SEC. 317
Pon
~ TO"!Ue converte• clutch con,ol valve

~- r@Retumspnng
Retaining plate

1 '-@Retumspnng '1/ii-~

Pl:~nl ~2::valve ~ '/

Plug\ ~~ ~') /
~~ ~- /
0~ ~ /

ItPiu~~-3
.,_");,~ /}:/
~(
-- ~~-~-
3~4shlftJ ~ -~
shift plug/ .( (' ........_ o 4th speed cut valve

,( [-
plug ~;~t" ~:~. ca '--_ ~ ----.____ (.\1)Ret:r:1::ring
@ Retum spnng _jfr ~· ~----._ -~ ~ ~ Pin
~~v:hlft o~~ oa ~. ~®Ret_urn flnrro...._~ \r
• ~0~ #!.; , "-
~- Q{U
spnng 0
2·3 throttle _ ~ :jl" - ~ ----._ . <li/rll>- _ ~lug
modifiervalvey ~~ )/ / / . Sfnngseat~,
. <.,., 1 (]) Return spnng ~Sieeveplug
@ Return spring \ _ / / C{Q"Qj Pressure -.
)§>"> /. //· (. modifier valve -...- fl
Retaining plate~ 1$) ~ / . / C[Q-rr'i:ifr,. :~~v~ntrol ~lugPin~
CJ ~ / / ''f'---rfrtn.._._ Sleeve plug
, 3-2downshlft ./ <(__ @)Retu~ ~ ~v:hlft- n

it Dl.
Plug
0 valve/<-
4in /
~-
~-::~-ash>~ ~Plug
valve ~ rr-
Lp;n

Pin
'--._ ----..____ . ~ Plug
~~leeve ~ 3 tshoft
il4 '
~ ~alve Q--- Pin

~Plug
\ (!) Retum spnng ~II{) _
"'r~ ~Pm
~~~u~ulator Q-(CJ-,_ ~{[) ~
valve '\__ Plug Pin

Apply ATF to all components before their installation.

AAT040A

Numbers preceding valve springs correspond with those shown in Return Springs Chart on SDS. AT-114.

582 AT-66
 REPAIR FOR COMPONENT PARTS
Control Valve Upper Body (Cont'd)
DISASSEMBLY @I
1. Remove valves at parallel pins.
• Do not use a magnetic hand.

SAT140C

a. Use a wire paper clip to push out parallel pins.

SAT822A

b. Remove parallel pins while pressing their corresponding plugs

and sleeves.
• Remove plug slowly to prevent internal parts from liP
jumping out.

~~l
c. Place mating surface of valve facedown, and remove internal
parts.
• If a valve is hard to remove, place valve body facedown
and lightly tap it with a soft hammer.
~~I

• Be careful not to drop or damage valves and sleeves .

Soft hammer

SAT824A

2. Remove valves at retainer plates.

a. Pry out retainer plate with wire paper clip.

Wire paper clip

1~:>!
Retainer plate
SAT825A

AT-67 583
 REPAIR FOR COMPONENT PARTS
Control Valve Upper Body (Cont'd)
b. Remove retainer plates while holding spring.
Spring

Retainer plate

SAT826A

c. Place mating surface of valve facedown, and remove internal

parts.
• If a valve is hard to remove, lightly tap valve body with a
soft hammer.
• Be careful not to drop or damage valves, sleeves, etc.

Soft hammer

SAT827A

INSPECTION
Valve springs
• Measure free length and outer diameter of each valve spring.
Also check for damage or deformation.
Inspection standard:
Refer to SDS, AT-114.
• Replace valve springs if deformed or fatigued.
~ : Free length
Control valves
• Check sliding surfaces of valves, sleeves and plugs.
SAT829A

ASSEMBLY
1. Lubricate the control valve body and all valves with ATF Install
control valves by sliding them carefully into their bores.
• Be careful not to scratch or damage valve body.

Valve~

SAT830A

• Wrap a small screwdriver with vinyl tape and use it to insert the
valves into proper position.

SAT831A

584 AT-68
REPAIR FOR COMPONENT PARTS
Control Valve Upper Body (Cont'd)
Accumulator control plug ®I
• Align protrusion of accumulator control sleeve with notch in
plug. 1111~
• Align parallel pin groove in plug with parallel pin, and install
accumulator control valve.

J
SAT833A

2. Install parallel pins and retainer plates.

SAT140C

• While pushing plug, install parallel pin.

• Insert retainer plate while pushing spring.
'TF

['l[Q)

IF£'\
SAT449E

~~1

§11

!'%:§)

~11

ill'\

~ib

I[Q)l:l

AT-69 585
 REPAIR FOR COMPONENT PARTS

Control Valve Lower Body

SEC. 317

p;n
] [
a@ Plug

Retum 'Pt;ng
3-2 timing valve
Plug
P;n~
U ,[ @Return spring

'0
· { 4-2 •equence valve

./

Manual \})l/
~etent oalve

valve ~
/ G) Return sprmg

P;n\ ..--A-Thmttlevalve

Wa'h"'\~
P~~")\ / Sleeve plug

Apply ATF to all components before their Installation.

SAT752GA

Numbers preceding valve springs correspond with those shown in Return Springs Chart on SDS. AT-114.

586 AT-70
 REPAIR FOR COMPONENT PARTS
Control Valve Lower Body (Cont'd)
DISASSEMBLY
1. Remove valves at parallel pins.
2. Remove valves at retainer plates.
For removal procedures, refer to "DISASSEMBLY", "Control
Valve Upper Body," AT-67.

SAT139C

INSPECTION

\ \ Valve springs
• Check each valve spring for damage or deformation. Also I"~
measure free length and outer diameter.
Inspection standard:
.:Lf- Refer to SDS, AT-114. ©~
• Replace valve springs if deformed or fatigued.
2 : Free length
Control valves U:,!'u
• Check sliding surfaces of control valves, sleeves and plugs for
SAT829A
damage. •
ASSEMBLY '
• Install control valves.
For installation procedures, refer to "ASSEMBLY", "Control 111'
Valve Upper Body," AT-68.

SAT139C

AT-71 587
 REPAIR FOR COMPONENT PARTS

Governor Valve Assembly

SEC. 317 f Governor body

/ ~ -........_ -~ Retammg
~ plate

Primary valve

·~
~ tf~
Retaining plate
\

\_CD
\_ Retaining plate

Return spring
~:ID Return spring

1 ) Secondary governor valve II

Apply ATF to all components
before their Installation. ~· SAT450EB

INSPECTION
Valve springs
• Measure free length and outer diameter of each valve spring.
Also check for damage or deformation.
Inspection standard:
Refer to SDS, AT-114.
Q : Free length Governor valves and valve body
• Check governor valves and valve body for indication of burn-
ing or scratches.
SAT829A

Parking Gear
INSPECTION
• Check contacting surface of parking gear and ring groove
areas for wear.
• Measure clearance between seal ring and ring groove.
Standard clearance:
0.15-0.40 mm (0.0059- 0.0157 in)
Wear limit:
0.40 mm (0.0157 in)
SAT152G

588 AT-72
 REPAIR FOR COMPONENT PARTS

Reverse Clutch
SEC. 315
Cill): Apply ATF. [fu'Uffi),
* :Select with proper thickness.
Driven plate Cill) ~r;,_r.l
!Suo!J

Dish plate ~ Drive plate (®

Snap ring~
Spring retainer

Piston

Oilseai@D~

i plate
Retaining plate
Snap ring

SAT841BB

DISASSEMBLY
1. Check operation of reverse clutch.
a. Install seal ring onto oil pump cover and install reverse clutch. 1111lil
Apply compressed air to oil hole.
b. Check to see that retaining plate moves to snap ring.
c. If retaining plate does not contact snap ring. @I
• D-ring might be damaged.
• Oil seal might be damaged.
• Fluid might be leaking past piston check ball. }il@

2. Remove drive plates, driven plates, retaining plate, dish plate

E'C'
and snap ring.

AT-73 589
 REPAIR FOR COMPONENT PARTS
Reverse Clutch (Cont'd)
3. Remove snap ring from clutch drum while compressing clutch
r K¥31102400
(J34285 and
J34285-87)
•
springs.
Do not expand snap ring excessively.
4. Remove spring retainer and return spring.

SAT620G

5. Install seal ring onto oil pump cover and install reverse clutch
drum. While holding piston, gradually apply compressed air to
oil hole until piston is removed.
• Do not apply compressed air abruptly.
6. Remove D-ring and oil seal from piston.

INSPECTION
Reverse clutch snap ring and spring retainer
• Check for deformation, fatigue or damage.

Reverse clutch return springs

• Check for deformation or damage. Also measure free length
and outside diameter.
Inspection standard:
Refer to SDS, AT-114.

ll : Free length

SAT829A

Thickness Reverse clutch drive plates

• Check facing for burns, cracks or damage.
• Measure thickness of facing.
Facing
Thickness of drive plate:
Standard value 1.90 - 2.05 mm (0.0748 - 0.0807 in)
Wear limit 1.80 mm (0.0709 in)
• If not within wear limit, replace.
Core plate
Reverse clutch dish plate
• Check for deformation or damage.
SAT845A

590 AT-74
 REPAIR FOR COMPONENT PARTS
Reverse Clutch (Cont'd)
No air leakage Air leakage is present. Reverse clutch piston
Check ball Check ball
• Shake piston to assure that balls are not seized.
~~-~I I~'------c';}::-- • Apply compressed air to check ball oil hole opposite the return
spring to assure that there is no air leakage.
• Also apply compressed air to oil hole on return spring side to
assure that air leaks past ball.

SAT846A

ASSEMBLY
1. Install D-ring and oil seal on piston.
• Apply ATF to both parts_

SAT847A

2. Install piston assembly by turning it slowly and evenly.

• Apply ATF to inner surface of drum.

SAT848A

3. Install return springs and spring retainer.

4. Install snap ring while compressing clutch springs.

AT-75 591
 REPAIR FOR COMPONENT PARTS
Reverse Clutch (Cont'd)
• Do not align snap ring gap with spring retainer stopper.

5. Install drive plates, driven plates, retaining plate and dish plate.
6. Install snap ring.

7. Measure clearance between retaining plate and snap ring. If

not within allowable limit, select proper retaining plate.
Specified clearance:
Standard
0.5 - 0.8 mm (0.020 - 0.031 in)
Allowable limit
1.2 mm (0.047 in)
Retaining plate:
Refer to SDS, AT-115.

8. Check operation of reverse clutch.

Refer to "DISASSEMBLY", "Reverse Clutch", AT-73.

592 AT-76
 REPAIR FOR COMPONENT PARTS
-
F~r 1
~~;~;::_":"9~h~~C"'IU~tc~h~---------====
@I

SEC. 315
the number of
H" ~~

driven plate), refer ~~u~~~ ~~~=:: {drive plate and

clutch dru ~ss-sectlon. ~Retaining plate*
m~

D-ring (Large) ~
~~r.=, I - Snap ring
D-ring (Small) ~@D Driven plate
Clutch piston

Drive plate ~
~

Driven plate
Snap ring~

Return spring

@D:
*:
Apply ATF
Select With
· · proper thickness.
Drive plate
Retaining plate

SAT576HA
•
DISASSEMBLY AN
Service proced D ASSEMBLY
those for revers~es for high clutch
• Check of highc~~tch,
utch with the
operation foll~re
Wingessentially
exception:the same as

KV31102400
(J34285 and
• Removal an d.1nstallafIOn of return spring
J34285-87)

SAT621G

AT-77 593
 REPAIR FOR COMPONENT PARTS
High Clutch (Cont'd)
• Inspection of high clutch return springs
Inspection standard:
Refer to SDS, AT-114.

!l : Free length

SAT829A

Thickness • Inspection of high clutch drive plate

Thickness of drive plate:
Standard
Facing 1.52 - 1.67 mm (0.0598 - 0.0657 in)
Wear limit
1.40 mm (0.0551 in)

Core plate

SAT845A

• Measurement of clearance between retaining plate and snap

Feeler gauge ring
Specified clearance:
Standard
1.8 - 2.2 mm (0.071 - 0.087 in)
Allowable limit
2.8 mm (0.110 in)
Retaining plate:
Refer to SDS, AT-115.

SAT858A

594 AT-78
 REPAIR FOR COM PONE NT PARTS

Forward and 0 verrun Clutches

SEC. 315
For the numbe
driven plate), refer
r of clutch
to th e sheet .
b elows (dnve plate and
cross-section.

Snap ring
Retaining plate*
Drive plate C®
Driven plate

Dish plate

""-~
----------·
•
Direction of 01.1 seal
Driven plate

@) : Apply ATF
* :Select w·.
lth proper thickness

SAT3141

AT-79 595
 REPAIR FOR COMPONENT PARTS
Forward and Overrun Clutches (Cont'd)
DISASSEMBLY AND ASSEMBLY
Service procedures for forward and overrun clutches are
essentially the same as those for reverse clutch, with the following
exception:
• Check of forward clutch operation.

SAT860A

• Check of overrun clutch operation.

• Removal of forward clutch drum

Remove forward clutch drum from transmission case by
holding snap ring.

• Removal of forward clutch and overrun clutch pistons

1. While holding overrun clutch piston, gradually apply
compressed air to oil hole.

2. Remove overrun clutch from forward clutch.

SAT863A

596 AT-80
 REPAIR FOR COMPONENT PARTS
Forward and Overrun Clutches (Cont'd)
(~]
• Removal and installation of return springs

KV3~102400
(J34285 and
J34285-87)
SAT148H

• Inspection of forward clutch and overrun clutch return springs ~©

Inspection standard:
Refer to SDS, AT-114.

Q : Free length

•
SAT829A

Thickness • Inspection of forward clutch drive plates

Thickness of drive plate:
Standard
Facing 1.52 - 1.67 mm (0.0598 - 0.0657 in)
Wear limit
1.40 mm (0.0551 in)

Core plate

SAT845A

Thickness • Inspection of overrun clutch drive plates

Thickness of drive plate:
Standard
Facing 1.90 - 2.05 mm (0.0748 - 0.0807 in)
Wear limit
1.80 mm (0.0709 in)

Core plate

SAT845A

• Installation of forward clutch piston and overrun clutch piston

1. Install forward clutch piston by turning it slowly and evenly.
• Apply ATF to inner surface of clutch drum.

SAT741G

AT-81 597
 REPAIR FOR COMPONENT PARTS
Forward and Overrun Clutches (Cont'd)
• Align notch in forward clutch piston with groove in
forward clutch drum.
2. Install overrun clutch by turning it slowly and evenly.
• Apply ATF to inner surface of forward clutch piston.

SAT153G

• Measurement of clearance between retaining plate and snap

ring of overrun clutch
Specified clearance:
Standard
1.0 - 1.4 mm (0.039 - 0.055 in)
Allowable limit
2.0 mm (0.079 in)
Retaining plate:
Refer to SDS, AT-115.

• Measurement of clearance between retaining plate and snap

ring of forward clutch
Specified clearance:
Standard
0.35 - 0.75 mm (0.0138- 0.0295 in)
Allowable limit
1.85 mm (0. 728 in)
Retaining plate:
Refer to SDS, AT-115.

598 AT-82
 REPAIR FOR COMPONENT PARTS

Low & Reverse Brake

SEC. 315 Low & reverse brake piston
Low one~way
Snap ring clutch 1nner race

Dish plate
Needle bearing
Retaining plate*
~1!55!®
Driven plate

~1!55!® ~
L1 21 • 26 N·m
(2.1 • 2.7 kg·m.
15 • 20 tt-lb)

Drive plate @)
Driven plate
Direction of oil seal

Direction of
dish plate

~:App~ATF.
1!!8!1 ® : Apply petroleum jelly. 1i'IF
* :Select with proper thickness. Drive plate
Dish plate
SAT849BB

DISASSEMBLY
1. Check operation of low and reverse brake.
a. Install seal ring onto oil pump cover and install reverse clutch.
Apply compressed air to oil hole.
b. Check to see that retaining plate moves to snap ring.
c. If retaining plate does not contact snap ring,
• D-ring might be damaged.
• Oil seal might be damaged.
• Fluid might be leaking past piston check ball.

SATB72A

~1i'
2. Remove snap ring, low & reverse brake drive plates, driven
plates and dish plate.

AT-83 599
 REPAIR FOR COMPONENT PARTS
Low & Reverse Brake (Cont'd)
3. Remove low one-way clutch inner race, spring retainer and
return spring from transmission case.
4. Remove seal rings from low one-way clutch inner race.
5. Remove needle bearing from low one-way clutch inner race.

SATi54G

6. Remove low & reverse brake piston using compressed air.

7. Remove oil seal and D-ring from piston.

INSPECTION
Low & reverse brake snap ring and spring retainer
• Check for deformation, or damage.

Low & reverse brake return springs

• Check for deformation or damage. Also measure free length
and outside diameter.
Inspection standard:
Refer to SDS, AT-114.

!l : Free length

SAT829A

Thickness Low & reverse brake drive plates

• Check facing for burns, cracks or damage.
• Measure thickness of facing.
Facing
Thickness of drive plate:
Standard value
1.52 - 1.67 mm (0.0598 - 0.0657 in)
Wear limit
Core plate 1.8 mm (0.071 in)
• If not within wear limit, replace.

SAT845A

600 AT-84
 REPAIR FOR COMPONENT PARTS
Low & Reverse Brake (Cont'd)
Low one-way clutch inner race @u

Clearance • Check frictional surface of inner race for wear or damage .

~Seal ring • Install new seal rings onto low one-way clutch inner race.
u:lili\1
• Be careful not to expand seal ring gap excessively.
" • Measure seal ring-to-groove clearance .

B
Inspection standard: igu:li]
Standard value 0.10 - 0.25 mm (0.0039 - 0.0098 in)
Allowable limit 0.25 mm (0.0098 in)
• If not within allowable limit, replace low one-way clutch inner ~©
race.
SAT155G

~©

Q-m® ASSEMBLY
1. Install needle bearing onto one-way clutch inner race.
• Pay attention to its direction - Black surface goes to rear IF~
... side.
• Apply petroleum jelly to thrust washers .
©!o

~~1J

SAT112B

2. Install oil seal and D-ring onto piston.

Oil seal~ • Apply ATF to oil seal and D-ring .

D-ring~
SAT879A

3. Install piston by rotating it slowly and evenly.

• Apply ATF to inner surface of transmission case.

~1J
4. Install return springs, spring retainer and low one-way clutch
inner race onto transmission case.
5. Install dish plate, low & reverse brake drive plates, driven
plates and retaining plate.
6. Install snap ring on transmission case.

AT-85 601
 REPAIR FOR COMPONENT PARTS
Low & Reverse Brake (Cont'd)
7. Check operation of low & reverse brake clutch piston. Refer to
"DISASSEMBLY", AT-83.

8. Measure clearance between retaining plate and snap ring. If

not within allowable limit, select proper retaining plate.
Specified clearance:
Standard
0.8 - 1.1 mm (0.031 - 0.043 in)
Allowable limit
2.3 mm (0.091 in)
Retaining plate:
Refer to SDS, AT-115.

9. Install low one-way clutch inner race seal ring.

• Apply petroleum jelly to seal ring.
• Make sure seal rings are pressed firmly into place and
held by petroleum jelly.

Forward Clutch Drum Assembly

SEC. 315

Forward clutch drum assembly

Needle bearing
Snap ring
Low one-way clutch
Side plate

Snap ring

---

SAT886AA

602 AT-86
REPAIR FOR COMPONENT PARTS
Forward Clutch Drum Assembly (Cont'd)
DISASSEMBLY
1. Remove snap ring from forward clutch drum.
2. Remove side plate from forward clutch drum.
3. Remove low one-way clutch from forward clutch drum.
4. Remove snap ring from forward clutch drum.
5. Remove needle bearing from forward clutch drum.

INSPECTION
Forward clutch drum
• Check spline portion for wear or damage .
• Check frictional surfaces of low one-way clutch and needle
bearing for wear or damage.

SAT892A

Needle bearing and low one-way clutch

• Check frictional surface for wear or damage.

ASSEMBLY
1. Install needle bearing in forward clutch drum.
2. Install snap ring onto forward clutch drum.

'IDIJ'
3. Install low one-way clutch onto forward clutch drum by
pushing the roller in evenly.

AT-87 603
 REPAIR FOR COMPONENT PARTS
Forward Clutch Drum Assembly (Cont'd)
• Install low one-way clutch with flange facing rearward.
4. Install side plate onto forward clutch drum.
5. Install snap ring onto forward clutch drum.

SAT895A

Rear Internal Gear and Forward Clutch Hub

SEC. 315
Rear internal gear (with forward one-way clutch inner race}

Thrust washer l!2i!l ®

Forward clutch hub (with forward one-way clutch outer race)

Snap ring

Forward one-way clutch

Snap ring

Ei3!l (~): Apply petroleum jelly.

SAT896AA

DISASSEMBLY
1. Remove rear internal gear by pushing forward clutch hub
forward.
2. Remove thrust washer from rear internal gear.
3. Remove snap ring from forward clutch hub.
4. Remove end bearing.

5. Remove forward one-way clutch and end bearing as a unit

UEndbeanng
from forward clutch hub.
6. Remove snap ring from forward clutch hub.

f!~~~~:w~~
~'\-.. clutch

/ ~1 End beanng

r~~~ SAT287G

604 AT-88
 REPAIR FOR COMPONENT PARTS
Rear Internal Gear and Forward Clutch Hub

.. (Cont'd)
INSPECTION
Rear internal gear and forward clutch hub
·ill~

..• • Check gear for excessive wear, chips or cracks .

• Check frictional surfaces of forward one-way clutch and thrust
washer for wear or damage .
@:~~

• Check spline for wear or damage .

SAT902A

Snap ring and end bearing

00 • Check for deformation or damage.

00 SAT903A

ASSEMBLY
1. Install snap ring onto forward clutch hub.
2. Install end bearing.

SAT901A

3. Install forward one-way clutch onto clutch hub.

• Install forward one-way clutch with flange facing rearward.
4. Install end bearing.
5. Install snap ring onto forward clutch hub.

6. Install thrust washer onto rear internal gear.

• Apply petroleum jelly to thrust washer.
• Securely insert pawls of thrust washer into holes in rear [llffij
internal gear.

Hole for thrust washer pawl

SAT906A

AT-89 605
 REPAIR FOR COMPONENT PARTS
Rear Internal Gear and Forward Clutch Hub
(Cont'd)
7. Position forward clutch hub in rear internal gear.

SAT907A

8. After installing, check to assure that forward clutch hub rotates

clockwise.
Direction of

SAT905A

Band Servo Piston Assembly

SEC. 315
r Flelurn spring @ Return spring ©
D·ring~c&"D
Return spring @ Servo piston spring retainer
Gasket~
Piston stem

00 servo
D·ring~c&"D O·ring~c&"D

D-ring~@)

Servo piston retainer

Band servo piston @f): Apply ATF.

Servo cushion spring retainer
SAT908AC

DISASSEMBLY
1. Block one oil hole in OD servo piston retainer and the center
hole in OD band servo piston.
2. Apply compressed air to the other oil hole in piston retainer to
remove OD band servo piston from retainer.
3. Remove D-ring from OD band servo piston.

606 AT-90
 REPAIR FOR COMPONENT PARTS
Band Servo Piston Assembly (Cont'd)
4. Remove band servo piston assembly from servo piston Jlill
retainer by pushing it forward.

5. Place piston stem end on a wooden block. While pushing ~~

servo piston spring retainer down, remove E-ring.

6. Remove servo piston spring retainer, return spring © and •

piston stem from band servo piston.

SAT912A

7. Remove E-ring from band servo piston.

8. Remove servo cushion spring retainer from band servo piston.
9. Remove D-rings from band servo piston.
10. Remove 0-rings from servo piston retainer.

SAT914A

..
-----
Piston stem INSPECTION
Pistons, retainers and piston stem

..... ...
• Check frictional surfaces for abnormal wear or damage .

Servo cushion spring retainer SAT A

915

AT-91 607
 REPAIR FOR COMPONENT PARTS
Band Servo Piston Assembly (Cont'd)
Return springs
Spring@)
• Check for deformation or damage. Measure free length and
outer diameter.
Inspection standard:
Refer to SDS, AT-114.

SAT916AA

ASSEMBLY
1. Install 0-rings onto servo piston retainer
• Apply ATF to 0-rings.
• Pay attention to position of each 0-ring.

2. Install servo cushion spring retainer onto band servo piston.

3. Install E-ring onto servo cushion spring retainer.

4. Install D-rings onto band servo piston.
• Apply ATF to D-rings.

5. Install servo piston spring retainer, return spring © and piston

stem onto band servo piston.

SAT912A

608 AT-92
REPAIR FOR COMPONENT PARTS
Band Servo Piston Assembly (Cont'd)
6. Place piston stem end on a wooden block. While pushing '!li~
servo piston spring retainer down, install E-ring.

SAT921A

7. Install band servo piston assembly onto servo piston retainer li"i©
by pushing it inward.

8. Install D-ring on OD band servo piston.

• Apply ATF to D-ring.

SAT923A

9. Install OD band servo piston onto OD servo piston retainer by M

pushing it inward.

SAT924A

AT-93 609
 REPAIR FOR COMPONENT PARTS

Parking Pawl Components

SEC. 311·314
Parking rod
Parking pawl spacer

Parking pawl

Parking pawl

Parking gear

AAT816

DISASSEMBLY
1. Slide return spring to the front of rear extension flange.

2. Remove return spring, pawl spacer and parking pawl from rear
extension.
3. Remove parking pawl shaft from rear extension.

4. Remove parking actuator support from rear extension.

610 AT-94
 REPAIR FOR COMPONENT PARTS
Parking Pawl Components (Cont'd)
INSPECTION
Parking pawl Parking actuator
support Parking pawl and parking actuator support
• Check contact surface of parking rod and parking gear for iii"'
wear.

AATBBB

ASSEMBLY
1. Install parking actuator support onto rear extension.
2. Insert parking pawl shaft into rear extension.

3. Install return spring, pawl spacer and parking pawl onto park-
ing pawl shaft.

4. Bend return spring upward and install it onto rear extension.

AT-95 611
 ASSEMBLY

Assembly (1)
1. Install manual shaft components.
a. Install oil seal onto manual shaft.
• Apply ATF to oil seal.
• Wrap threads of manual shaft with masking tape.
b. Insert manual shaft and oil seal as a unit into transmission
case.
c. Remove masking tape.

d. Push oil seal evenly and install it onto transmission case.

e. Align groove in shaft with drive pin hole, then drive pin into
position as shown in figure at left.

I. Install detent spring and spacer.

g. While pushing detent spring down, install manual plate onto

manual shaft.

612 AT-96
 ASSEMBLY
Assembly (1) (Cont'd)
h. Install lock nuts onto manual shaft.

iL©
I\ SAT936A

2. Install throttle lever components. 1':©

a. Install throttle lever shaft.
b. Align groove in shaft with drive pin hole, then drive pin into
position as shown in figure at left. l'l':

c. Install throttle lever, return spring, spring retainer and E-ring.

d. Install throttle wire.

SAT135C

• Apply ATF to 0-ring.

6 //:
jl--/
I
0-ring_j
<@)

SAT150C

AT-97 613
 ASSEMBLY
Assembly (1) (Cont'd)
3. Install accumulator piston.
Front . . a. Install 0-rings onto accumulator piston.

'b ~,.E
Accumulator Accumulator • Apply ATF to 0-rings.
Accumulator piston 0-rings:

? Refer to SDS, AT-114.

Accumulator Accumulator
piston @ piston ©
SAT937AA

b. Install return spring for accumulator @ onto transmission

case.
Free length of return spring:
Refer to SDS, AT-114.

c. Install accumulator pistons @, @, © and @.

• Apply ATF to transmission case.

,~

/1 r-5
SAT939AA

4. Install band servo piston.

a. Install return springs onto band servo piston.

b. Install band servo piston onto transmission case.

• Apply ATF to 0-ring of band servo piston and transmission
case.
c. Install gasket for band servo onto transmission case.

614 AT-98
 ASSEMBLY
Assembly (1) (Cont'd)
1
d. Install OD servo piston retainer onto transmission case. ~1

SAT940A

5. Install rear side clutch and gear components.

a. Place transmission case in vertical position.
0' --0\@

~~
~i'ii

ST07870000
(J3706B)
li:JJi"
[ J
"" SAT943A

Forward clutch drum b. Slightly lift forward clutch drum assembly and slowly rotate it •
clockwise until its hub passes fully over the clutch inner race
inside transmission case.

Inner
I race

SAT944A

c. Check to be sure that rotation direction of forward clutch W~

assembly is correct.

SAT945A

d. Install thrust washer onto front of overrun clutch hub.

~Ei!® •
•
Apply petroleum jelly to the thrust washer.
Insert pawls of thrust washer securely into holes in
~Pawl overrun clutch hub.
Hole for
pawl

SAT946A

AT-99 615
 ASSEMBLY
Assembly (1) (Cont'd)
e. Install overrun clutch hub onto rear internal gear assembly.

SAT947A

e.
l!'il!(P)
f.
•
Install needle bearing onto rear of overrun clutch hub.
Apply petroleum jelly to needle bearing .

~r~
'~~
~J SAT697H

g. Check that overrun clutch hub rotates as shown while holding

forward clutch hub.

SAT949A

h. Place transmission case into horizontal position.

i. Install rear internal gear, forward clutch hub and overrun clutch
hub as a unit onto transmission case.

SAT156G

j. Install needle bearing onto rear internal gear.

• Apply petroleum jelly to needle bearing.
k. Install bearing race onto rear of front internal gear.
• Apply petroleum jelly to bearing race.
• Securely engage pawls of bearing race with holes in front
internal gear.

616 AT-100
 ASSEMBLY
Assembly (1) (Cont'd)
I. Install front internal gear on transmission case.

ll,©

6. Install output shaft and parking gear.

a. Insert output shaft from rear of transmission case while slightly
lifting front internal gear.
• Do not force output shaft against front of transmission 1'1':
case.

SAT956A

b. Carefully push output shaft against front of transmission case.

Install snap ring on front of output shaft.
• Check to be sure output shaft cannot be removed in rear !fi'
direction.

c. Install needle bearing on transmission case.

• Pay attention to its direction - Black side goes to rear.
• Apply petroleum jelly to needle bearing.

d. Install parking gear on transmission case.

AT-101 617
 ASSEMBLY
Assembly (1) (Cont'd)
e. Install snap ring on rear of output shaft.
• Check to be sure output shaft cannot be removed in
forward direction.

Governor valve-----.,\
assembly '

SAT120C

7. Install rear extension case.

a. Install oil seal on rear extension case.
• Apply ATF to oil seal.

b. Install rear extension gasket on transmission case.

c. Install parking rod on transmission case.

618 AT-102
 ASSEMBLY
Assembly (1) (Cont'd)
d. Install rear extension case on transmission case. Tighten bolts ~I
to specified torque.
tc:J: 20 - 25 N·m (2.0 - 2.5 kg-m, 14 - 18 ft-lb)

8. Install front side clutch and gear components.

a. Install rear sun gear on transmission case.
• Pay attention to its direction.

b. Install needle bearing on front of front planetary carrier.

• Apply petroleum jelly to needle bearing.
c. Install needle bearing on rear of front planetary carrier.
• Apply petroleum jelly to needle bearing.
• Pay attention to its direction - Black side goes to front .

[f:]0
d. While rotating forward clutch drum clockwise, install front ~'
planetary carrier on forward clutch drum.

lli!l'
• Check that portion A of front planetary carrier protrudes
Front planetary carrier approximately 2 mm {0.08 in) beyond portion B of forward
clutch assembly. i'iJ!i\

SAT970A

AT-103 619
 ASSEMBLY
Assembly (1) (Cont'd)
e. Install bearing races on front and rear of clutch pack.
I!Ci!® • Apply petroleum jelly to bearing races.
• Securely engage pawls of bearing races with holes in
clutch pack.
f. Place transmission case in vertical position.

Front Rear

SAT971A

g. Install clutch pack into transmission case.

SAT973A

Adjustment
When any parts listed in the following table are replaced, total end
play or reverse clutch end play must be adjusted.
Item
Part name Reverse clutch
Total end play
end play
Transmission case • •
Low one-way clutch inner race
• •
Overrun clutch hub • •
Rear internal gear • •
Rear planetary carrier • •
Rear sun gear • •
Front planetary carrier • •
Front sun gear • •
High clutch hub • •
High clutch drum • •
Oil pump cover • •
Reverse clutch drum - •

Oil pump . Oil pump

1. Adjust total end play.
assembly
7 1 gasket Total end play "T1 ":
~ 0.25 - 0.55 mm (0.0098 - 0.0217 in)

'-,--~~~,~~::::l#=f T,
Clutch pack Bearing Needle bearing
race SAT975A

620 AT-104
 ASSEMBLY
Adjustment (Cont'd}
(J34291-5) a. With needle bearing installed, place J34291-1 (bridge), i!J
V Lock
(J34291-2)
J34291-2 (legs) and the J34291-5 (gauging cylinder) onto oil
pump. The long ends of legs should be placed firmly on
machined surtace of oil pump assembly and gauging cylinder
should rest on top of the needle bearing. Lock gauging
cylinder in place with set screw.

SAT976A

b. Install J34291-23 (gauging plunger) into gauging cylinder.

{J34291-23)
SAT977A

c. With original bearing race installed inside reverse clutch drum,

place shim selecting gauge with its legs on machined surtace
of transmission case (no gasket) and allow gauging plunger to 1!'1'
rest on bearing race. Lock gauging plunger in place with set
screw.

SAT978A

d. Remove Tool and use feeler gauge to measure gap between ~lffi\
gauging cylinder and gauging plunger. This measurement
should give exact total end play.
Total end play "T1 ":
0.25 - 0.55 mm (0.0098 - 0.0217 in)
• If end play is out of specification, decrease or increase
thickness of oil pump cover bearing race as necessary. ~.']]'

Available oil pump cover bearing race:

Refer to SDS, AT-116.
Feeler gauge

SAT979A

2. Adjust reverse clutch drum end play.

Reverse clutch drum end play "T2':
0.55 - 0.90 mm (0.0217 - 0.0354 in)

AT-105 621
 ASSEMBLY
Adjustment (Cont'd)
a. Place J34291-1 (bridge), J34291-2 (legs) and J34291-5 (gaug-
ing cylinder) on machined surface of transmission case (no
gasket) and allow gauging cylinder to rest on front thrust sur-
face of reverse clutch drum. Lock cylinder in place with set
screw.

b. Install J34291-23 (gauging plunger) into gauging cylinder.

SAT982A

c. With original thrust washer installed on oil pump, place shim

setting gauge legs onto machined surface of oil pump assem-
bly and allow gauging plunger to rest on thrust washer. Lock
plunger in place with set screw.
Lock

SAT983A

d. Use feeler gauge to measure gap between gauging plunger

and gauging cylinder. This measurement should give you exact
reverse clutch drum and play.
Reverse clutch drum end play "T2 ":
0.55 - 0.90 mm (0.0217 - 0.0354 in)
• If end play is out of specification, decrease or increase
thickness of oil pump thrust washer as necessary.
Available oil pump thrust washer:
Refer to SDS, AT-116.
Feeler gauge
SAT984A

Assembly (2)
1. Place transmission case into horizontal position.
2. Install brake band and band strut.
a. Install band strut on brake band.
• Apply petroleum jelly to band strut.

SAT985A

622 AT-106
 ASSEMBLY
Assembly (2) (Cont'd)
@[
b. Place brake band around reverse clutch drum, and insert band
strut into end of band servo piston stem.
u111Ji,

rgrra

L:G

c. Install anchor end bolt on transmission case. Then, tighten lllC:

anchor end bolt just enough so that reverse clutch drum (clutch
pack) will not tilt forward.
~PiE

©l

u~TI

3. Install input shaft on transmission case.

•
4.
Pay attention to its direction- 0-ring groove side is front .
Install gasket on transmission case. 111"

~·[g)

'Po'\
SAT988A

~~
5. Install oil pump assembly.
a. Install needle bearing on oil pump assembly.
•b. Apply petroleum jelly to the needle bearing .
Install selected thrust washer on oil pump assembly.
~[~j

• Apply petroleum jelly to thrust washer.

®'I

Wj§
""'
SAT989A

~Jli
c. Carefully install seal rings into grooves and press them into the
Seal ring
petroleum jelly so that they are a tight fit.
m® 1~5\

lllL

WAI
SAT990A

AT-107 623
 ASSEMBLY
Assembly (2) (Cont'd)
d. Install 0-ring on oil pump assembly.
• Apply petroleum jelly to 0-ring.

a-ring m®
SAT991A

e. Apply petroleum jelly to mating surface of transmission case

and oil pump assembly.

f. Install oil pump assembly.

• Install two converter housing securing bolts in bolt holes
in oil pump assembly as guides.

SAT993A

case Oil assembly • Insert oil pump assembly to the specified position in
transmission, as shown at left.

6. Install 0-ring on input shaft.

• Apply ATF to 0-rings.

624 AT-108
 ASSEMBLY
Assembly (2) (Cont'd)
7. Install converter housing.
a. Apply anaerobic liquid gasket Loctite PiN 51813 or equivalent
around bolt holes in converter housing.
• Do not apply too much sealant.

SAT397C

b. Apply anaerobic liquid gasket Locite PiN 51813 or equivalent ~©

to seating surfaces of bolts that secure front of converter
housing.
c. Install converter housing on transmission case.

SAT158G

8. Adjust brake band.

a. Tighten anchor end bolt to specified torque.
Anchor end bolt:
~: 4- 6 N·m (0.4- 0.6 kg-m, 35- 52 in-lb)
b. Back off anchor end bolt two and a half turns.

c. While holding anchor end pin, tighten lock nut.

9. Install terminal cord assembly.

a. Install 0-ring on terminal cord assembly.
• Apply petroleum jelly to 0-ring.
b. Compress terminal cord assembly stopper and install terminal
cord assembly on transmission case.

AT-109 625
 ASSEMBLY
Assembly (2) (Cont'd)
10. Install control valve assembly.
a. Install accumulator piston return springs @, © and @.
Free length of return springs:
Refer to SDS, AT-114.

b. Install manual valve on control valve.

• Apply ATF to manual valve.

SAT005B

c. Install control valve assembly on transmission case.

d. Install connector tube brackets and tighten bolts ® and @.
• Check that terminal assembly harness does not catch.

Bolt f mm(in) ~£

® 33 (1.30)
@ 45 (1.77)

e. Install 0-ring on oil strainer.

• Apply petroleum jelly to 0-ring.
f. Install oil strainer on control valve.

g. Securely fasten terminal harness with clips.

SAT3071

626 AT-110
 ASSEMBLY
Assembly (2) (Cont'd)
H. Install oil pan.
a. Attach a magnet to oil pan.

b. Install new oil pan gasket on transmission case.

c. Install oil pan and bracket on transmission case.
• Always replace oil pan bolts; they are self-sealing bolts. !Pii'i
• Before installing bolts, remove traces of sealant and oil
from mating surface and thread holes.
• Tighten four bolts in a criss-cross pattern to prevent ©IL
dislocation of gasket.
d. Tighten drain plug.

12.
a.
b.
c.
Install inhibitor switch.
Check that manual shaft is in "1" position.
Temporarily install inhibitor switch on manual shaft.
Move manual shaft to "N".
•
d. Use a 4 mm (0. 157 in) pin for this adjustment.
1) Insert the pin straight into the manual shaft adjustment hole.
2) Rotate inhibitor switch until the pin can also be inserted straight
~~
into hole in inhibitor switch.
e. Tighten inhibitor switch fixing bolts.
f. Remove pin from adjustment hole after adjusting inhibitor "'il
\
switch. "'
I
\I
-\I
SAT014B

13. Install torque converter.

) a. Pour ATF into torque converter.
• Approximately 2 liters (2-1/8 US qt, 1-3/4 Imp qt) of fluid
are required for a new torque converter.
• When reusing old torque converter, add the same amount
of fluid as was drained.

SAT015BA

AT-111 627
 ASSEMBLY
Assembly (2) (Cont'd)
b. Install torque converter while aligning notches and oil pump.

c. Measure distance A to check that torque converter is in proper

position.
Distance "A":
26.0 mm (1.024 in) or more

628 AT-112
 SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications 1:£1

Automatic transmission model RL4R01A

Transmission model code number 49X10
Stall torque ratio 2.0: 1
Transmission gear ratio
1st 2.785
2nd 1.545
Top 1.000
OD 0.694
Reverse 2.272
Nissan Matic "D" (Continental
U.S. and Alaska) or Genuine
Recommended fluid
Nissan Automatic Transmission
Fluid {Canada)*1
Fluid capacity .: (US qt, Imp qt) 7.9 (8-3/8, 7)

*1: Refer to MA sect1on ("Fiu1ds and Lubncants", "RECOMMENDED

FLUIDS AND LUBRICANTS").

Specifications and Adjustment

VEHICLE SPEED WHEN SHIFTING GEARS
Vehicle speed km/h (MPH)

•
Throttle position
D, --+ 0 2 02--+ 03 03-+ 04 04-+ 03 03 -7 02 0 2 -+ D, 12--+ 11
53-57 100- 108 147-157 91.99 47-51 41.45
Full throttle
(62. 67)
- (91 • 98) (57. 62) (29. 32) (25. 28)
(33. 35)
32.36 57-65 114- 124 65- 75 28-36 12- 16 41-45
Half throttle (25. 28)
(20. 22) (35. 40) (71. 77) (40 . 47) (17. 22) (7. 10)

VEHICLE SPEED WHEN PERFORMING LINE PRESSURE

AND RELEASING LOCK-UP Line pressure kPa (kg/cm 2 , psi)
Engine speed
D, rpm 0, 2 and 1 positions R position
Throttle position Vehicle speed km/h (MPH) 667- 706
422 - 461
Lock-up ON Lock-up OFF Idle (6.8. 7.2,
(4.3. 4.7, 61 . 67)
97. 102)
Full throttle - -
883. 961 1 ,393 - 1,471
Halt throttle 71 . 79 (44 . 49) 71 - 79 (44. 49) Stall (9.0. 9.8, (14.2. 15.0,
128-139) 202- 213)

STALL REVOLUTION
Stall revolution 2,100 - 2,300

AT-113 629
 SERVICE DATA AND SPECIFICATIONS (SDS)
Specifications and Adjustment (Cont'd)
RETURN SPRINGS
Unit· mm (in)

Item
Parts
Part No. Free length Outer diameter

CD 4th speed cut valve spring 31756·48X09 23.5 (0.925) 7.0 (0.276)

® Pressure regulator valve spring 31742-48X16 48.5 (1.909) 12.1 (0.476)

® Pressure modifier valve spring 31742-48X13 40.83(1.6075) 8.0 (0.315)

@) 1-2 shift valve spring 31762-48XOO 43.4 (1.709) 6.0 (0.236)

® 2-3 shift valve spring 31762-48X01 42.7 (1.681 I 9.0 (0.354)

Upper body ® 3-4 shift valve spring 31762-48X06 44.03 (1.7335) 8.0 (0.315)
(j) Accumulator control valve spring 31742-48X02 29.3 (1.154) 8.0 (0.315)
- 3-2 downshift valve spring - - -
® 2-3 throttle modifier valve spring 31742-41X21 33.0 (1.299) 6.5 (0.256)

Control valve ® 4-2 relay valve spring 31756-41XOO 29.1 (1.146) 6.95 (0.2736)
Torque converter clutch control valve
@ spring
31742-48X07 20.0 (0.787) 5.45 (0.2146)

CD Throttle valve & detent valve spring 31802-4BX02 34.23 (1.3476) 11.0 (0.433)

® Kickdown modifier valve spring 31756-48X01 45.3 (1.783) 7.0 (0.276)

® 1st reducing valve spring 31756-48X08 29.7 (1.169) 7.2 (0.283)

@) 31742-48X21 33.2 (1.307) 7.7 (0.303)
Lower body Overrun clutch reducing valve spring
I@ 31742-48X05 31.0 (1.220) 5.2 (0.205)

® 3-2 timing valve spring 31742-48X15 23.0 (0.906) 7.0 (0.276)

(j) Torque converter relief valve spring 31742-41X23 38.0 (1.496) 9.0 (0.354)

® 4-2 sequence valve spring 31756-41 xoo 29.1 (1.146) 6.95 (0.2736)

CD Primary valve spring 31742-48X11 19.1 (0.752) 9.05 (0.3563)

Governor valve ® Secondary governor valve I spring 317 42-48X09 30.58 (1.2039) 9.2 (0.362)

® Secondary governor valve II spring 31742-4BX10 16.79 (0.6610) 9.0 (0.354)

Reverse clutch 16 pes 31505-41X02 19.69 (0.7752) 11.6 (0.457)
High clutch 16 pes 31505-21X03 22.06 (0.8685) 11.6 (0.457)
Forward clutch 3152i-41XOO
20 pes 35.77 {1.4083) 9.7 (0.382)
(Overrun clutch) (Assembly)

Low & reverse brake 18 pes 31505-41X05 22.3 (0.878) 11.6 (0.457)
Spring@ 31605-41X05 45.6 (1.795) 34.3 (1.350)
Band servo Spring@ 31605-41XOO 53.8 (2.118) 40.3 (1.587)
Spring© 31605-41X01 29.0 (1.169) 27.6 (1.087)
Accumulator @ 31605-41X02 43.0 (1.693) 18.0 (0.709)
Accumulator ® 31605-41X15 66.0 (2.598) 20.8 (0.819)
Accumulator
Accumulator © 31605-41X09 45.0 (1.772) 29.3 (1.154)
Accumulator @ 31605-41X06 58.4 (2.299) 17.3 (0.681)

ACCUMULATOR 0-RING
Diameter mm (in)
Accumulator
® ® © @
28.6 31.5 28.6
Small diameter end 44 (1.73)
(1.13) (1.24) (1.13)
48.8 48.8
Large diameter end 44 (1.73) 44 (1.73)
(1.92) (1.92)

630 AT-114
 SERVICE DATA AND SPECIFICATIONS (SDS)
Specifications and Adjustment (Cont'd)
CLUTCHES AND BRAKES Cill
I 4. Overrun clutch I
Code number 49X10 Number of drive plates 3

I 1. Reverse clutch
I Number of driven plates 5
Number of drive plates 2 1.90- 2.05
Thickness of Standard
drive plate (0.0748 - 0.0807)
Number of driven plates 2
mm (in) Wear limit 1.80 (0.0709)
Thickness of 1.90- 2.05
Standard
drive plate (0.0748- 0.0807) Standard 1.0 - 1.4 (0.039 - 0.055)
Clearance
mm (in) Wear limit 1.80 (0.0709) mm (in) Allowable limit 2.0 (0.079)

Clearance Standard 0.5- 0.8 (0.020- 0.031) Thickness

Part number
mm (in) Allowable limit 1.2 (0.047) mm (in)

4.2 (0.165) 31537-41X80

Thickness Thickness of retaining plate
Part number 4.4 (0.173) 31537-41X81
mm (in)
4.6 (0.181) 31537-41X82
4.8 (0.189) 31537-42X02 4.8 (0.189) 31537-41X83
Thickness of retaining plate 5.0 (0.197) 31537-42X03 5.0 (0.197) 31537-41X84
5.2 (0.205) 31537-42X04
5.4
5.6
(0.213)
(0.220)
31537-42X05
31537-42X06
I 5. Low & reverse brake I
Number of drive plates 6

I 2. High clutch
I Number of driven plates 6
Number of drive plates 5 1.52-1.67
Thickness of Standard
Number of driven plates drive plate (0.0598 - 0.0657)
5

•
mm(in) Wear limit 1.80 (0.0709)
Thickness of 1.52-1.67
Standard
drive plate (0.0598 - 0.0657) Standard 0.8 - 1.1 (0.031 - 0.043)
Clearance
mm (in) Wear limit 1.40 (0.0551 I mm (in) Allowable limit 2.3 (0.091)

Clearance Standard 1.8 - 2.2 (0.071 - 0.087) Thickness

Part number
mm (in) Allowable limit 2.8 (0.110) mm (in)

Thickness 7.0 (0.276) 31667-41X12

Part number 7.2 (0.283) 31667-41X13
mm (in)
7.4 (0.291) 31667-41X14
3.4 (0.134) 31537-41X71 7.6 (0.299) 31667-41X07
3.6 (0.142) 31537-41X61 Thickness of retaining plate 7.8 (0.307) 31667-41 XOB
Thickness of retaining plate 3.8 (0.150) 31537-41X62 8.0 (0.315) 31667-41 xoo
4.0 (0.157) 31537-41X63 8.2 (0.323) 31667-41X01
4.2 (0.165) 31537-41X64 8.4 (0.331) 31667-41X02
4.4 (0.173) 31537-41 X65 8.6 (0.339) 31667-41X03
4.6 (0.181) 31537-41X66 8.8 (0.346) 31667-41X04
4.8 (0.189) 31537-41X67 9.0 (0.354) 31667-41X05
9.2 (0.362) 31667-41 X06
I 3. Forward clutch I
Number of drive plates 5 I 6. Brake band I
Anchor end bolt tightening torque
Number of driven plates 5 4 - 6 (0.4 - 0.6, 35 - 52)
N·m (kg-m, in-lb)
Thickness of 1.52 - 1.67
Standard Number of returning revolutions for
drive plate (0.0598 - 0.0657) 2.5
anchor end bolt
mm (in) Wear limit 1.40 (O.oss1 1

0.35- 0.75
Clearance Standard
(0.0138 - 0.0295)
mm (in)
Allowable limit 1.85 (0.0728)

Thickness
Part number
mm (in)

8.0 (0.315) 31537-41XOO

8.2 (0.323) 31537-41X01
Thickness of retaining plate 8.4 (0.331) 31537-41X02
8.6 (0.339) 31537-41X03
8.8 (0.346) 31537-41X04
9.0 (0.354) 31537-41X05
9.2 (0.362) 31537-41X06

AT-115 631
 SERVICE DATA AND SPECIFICATIONS (SDS)
Specifications and Adjustment (Cont'd)
OIL PUMP AND LOW ONE-WAY CLUTCH REVERSE CLUTCH DRUM END PLAY
Oil pump clearance mm (in) Reverse clutch drum 0.55 - 0.90 mm
end play "T2 " (0.0217- 0.0354 in)
Cam ring- oil pump housing
Thickness
Standard 0.01 • 0.024 (0.0004 • 0.0009) Part number
mm (in)
Rotor, vanes and control piston
0.9 (0.035) 31528-21X01
- oil pump housing Thickness of oil pump 1.1 (0.043) 31528-21X02
thrust washer 1.3 (0.051) 31528-21X03
Standard 0.03. 0.044 (0.0012. 0.0017)
1.5 (0.059) 31528-21X04
Seal ring clearance mm (in) 1.7 (0.067) 31528-21X05
Standard 0.10. 0.25 (0.0039. 0.0098) 1.9 (0.075) 31528-21X06

Allowable limit 0.25 (0.0098)

REMOVAL AND INSTALLATION
TOTAL END PLAY Manual control linkage

0.25 - 0.55 mm Number of returning revolutions

Total end play "T," 2
(0.0098 - 0.0217 in) for lock nut

Thickness Lock nut tightening torque

Part number 11 • 15 (1.1. 1.5, 8. 11)
mm (in) N·m (kg-m, tt-lb)

0.8 (0.031) 31435-41X01 Distance between end of clutch

1.0 (0.039) 31435-41X02 housing and torque converter 26.0 (1.024) or more
Thickness of oil pump
1.2 (0.047) 31435-41X03 mm(in)
cover bearing race
1.4 (0.055) 31435-41X04
1.6 (0.063) 31435-41X05
1.8 (0.071) 31435-41X06
2.0 (0.079) 31435-41X07

PARKING GEAR
Seal ring- ring groove mm (in)

Standard 0.15-0.40 (0.0059- 0.0157)

Allowable limit 0.40 (0.0157)

632 AT-116
 TRANSFER@~

SECTION TF
CONTENTS
PREPARATION ...............................................................2 REPAIR FOR COMPONENT PARTS ....................... .... 15
Special Service Tools .................................................. 2 Mainshaft ................................................................... 15
Commercial Service Tools ........................................... 3 Front Drive Shaft ...................................................... 17 ©l
Replacing Oil Seal ...................................................... .4 Counter Gear ............................................................. 18
Center Case Oil Seal ............................................. .4 Main Gear .................................................................. 18
Shift Shaft Oil Seal. ................................................ .4 Front Case .................................................................20 1!/l'il
Rear Oil Seal ...........................................................5 Shift Shaft Oil Seal. ............................................... 20
REMOVAL AND INSTALLATION .................................... 6 Front Case Cover ...................................................... 20
TRANSFER GEAR CONTROL ...................................... 7 Cover Oil Seal ....................................................... 20 bill
MAJOR OVERHAUL ....................................................... 8 Bearing Retainer ........................................................ 21
Case Components ....................................................... 8 Oil Catcher ............................................................21
Gear Components ....................................................... 9 Rear Case ..................................................................21
Shift Control Components ......................................... 10 Rear Oil Seal .........................................................21
DISASSEMBLY .............................................................. 11 Air Breather ...........................................................21 [§l[Q)
Shift Control Components ......................................... 22
ASSEMBLY ....................................................................23
SERVICE DATA AND SPECIFICATIONS (SDS) .......... 30 !Pb\
General Specifications ............................................... 30
Inspection and Adjustment ........................................ 30

633
 PREPARATION

Special Service Tools

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number
(Kent-Moore No.) Description
Tool name

ST38060002 Removing companion flange nut

(J34311) Installing companion flange nut
Flange wrench

a: 480 mm (18.90 In)

b: Pitch dia.: 75 mm (2.95 in)
NT428 Pin dia.: 10 mm (0.39 in)

ST30021000 Removing counter gear front bearing

(J22912-01) (Use with ST3671 001 0)
Puller Removing L & H hub

a: 110 mm (4.33 in) dia.

NT411 b: 68 mm (2.68 in) dia.

ST30031000 Removing counter gear rear bearing

(J22912-01) (Use with ST3671 001 0)
Puller

a: 90 mm (3.54 in) dia.

NT411 b: 50 mm (1.97 in) dia.

ST33290001 Removing center case oil seal

(J34286) Removing rear oil seal
Puller

a: 250 mm (9.84 in)

NT414 b: 160 mm (6.30 in)

ST33051001 a Removing companion flange

(J22888)
Puller
c
a: 135 mm (5.31 in)
b: 100 mm (3.94 in)
NT429 c: 130 mm (5.12 in)

ST30720000 CD Installing center case oil seal

CD (J25273J ® Installing rear oil seal
® (J25405)
Drift
a: 77 mm (3.03 in) dia.
NT115 b: 55.5 mm (2.185 in) dia.

ST36710010 Removing counter gear front bearing

( ) (Use with ST30021 000)

~
Drift Removing counter gear rear bearing
(Use with ST30031000)

NT063 a: 34.5 mm {1.358 in) dia.

634 TF-2
 PREPARATION
Special Service Tools (Cont'd)
Tool number
{Kent~Moore No.) Description
Tool name

ST33061000 Removing main gear bearing

~
(J8107-2)
Drift
a: 28.5 mm (1.122 in) dia.
NT116 b: 38 mm (1.50 in) dia.

ST30613000 G) Installing main gear bearing

~
CD (J25742-3) ® Installing cover oil seal
@ (J34339)
Drift
a: 72 mm (2.83 In) dla.
NT073 b: 48 mm (1.89 in) dia.

(J35864) Installing shift shaft oil seal

~
Drift
a: 26 mm (1.02 in) dia.
b: 20 mm (0.79 in) dia.
NT117 c: 150 mm (5.91 in)

(J26092) Seating counter gear assembly

Drift

b a: 44.5 mm (1.752 in) dia.

a
NT065 b: 38.5 mm (1.516 in) dia.

(J34291) Selecting counter gear rear bearing shim

~-
Shim setting gauge set

PdfYP lt~A2AQA\
NT101

(J34291-20) Selecting counter gear rear bearing shim

Plunger-shim setting gauge

NT118

Commercial Service Tools

Tool name Description

Puller Removing front drive shaft front bearing

Removing front drive shaft rear bearing
Removing main gear bearing

NT077

Drift G) Installing mainshaft rear bearing

@ Installing L & H hub
CD a: 50 mm (1.97 in) dia.
b: 42 mm (1.65 in) dia.
c: 180 mm (7.09 in)
@ a: 60 mm (2.36 in) dia.
b: 50 mm (1.97 in) dia.
NT117 c: 60 mm (2.36 in)

TF-3 635
 PREPARATION

Replacing Oil Seal

CENTER CASE OIL SEAL
1. Remove front propeller shaft. Refer to PD section ("Removal
and Installation", " PROPELLER SHAFT").
2. Remove companion flange nut.

3. Remove companion flange.

4. Remove center case oil seal.

5. Install center case oil seal.
• Before installing, apply multi-purpose grease to seal lip.
6. Install companion flange.

7. Tighten companion flange nut.

to.J: 226-324 N·m (23- 33 kg-m, 166-239 ft-lb)
8. Install front propeller shaft. Refer to PD section ("Removal and
Installation", "PROPELLER SHAFT").

SHIFT SHAFT OIL SEAL

1. Remove front propeller shaft. Refer to PD section ("Removal
and Installation", "PROPELLER SHAFT").
2. Remove companion flange. Refer to "CENTER CASE OIL
SEAL", TF-4.
3. Remove transfer control lever from transfer outer shift lever.
Then remove outer shift lever.

636 TF-4
 PREPARATION
Replacing Oil Seal (Cont'd)
4. Remove shift shaft oil seal. @jJ
• Be careful not to damage cross shaft.

ci "
. \!
"'"'
0;_-_l
; '
~/
Screwdriver
' \
5. Install shift shaft oil seal.
• Before installing, apply multi-purpose grease to seal lip.
6. Install transfer control linkage. !'Ill
7. Install companion flange. Refer to "CENTER CASE OIL
SEAL", TF-4.
8. Install front propeller shalt. Refer to PD section ("Removal and
Installation", "PROPELLER SHAFT").
©IL

REAR OIL SEAL

1. Remove rear propeller shaft. Refer to PD section ("Removal
and Installation", "PROPELLER SHAFT").
2. Remove rear oil seal.

3. Install rear oil seal.

• Before installing apply multi-purpose grease to seal lip.
4. Install rear propeller shaft. Refer to PD section ("Removal and ®~
Installation", "PROPELLER SHAFT").

TF-5 637
 REMOVAL AND INSTALLATION

Removal
1. Drain oil from transfer and transmission.
2. Remove front and rear propeller shaft. Refer to PD section
("Removal and Installation", "PROPELLER SHAFT").
Insert plug into rear oil seal after removing propeller shaft.
• Be careful not to damage spline, sleeve yoke and rear oil
seal, when removing propeller shaft.
3. Remove torsion bar spring. Refer to FA section ("Torsion Bar
Spring", "FRONT SUSPENSION"). Then remove second
crossmember.
4. Remove transfer control lever from transfer outer shift lever.
5. Separate transfer from transmission.
WARNING:
Support transfer while removing it.

Installation
• Apply recommended sealant to mating surface of transfer case
to transmission.
Recommended sealant:
Nissan genuine part (KP61 0·00250) or equivalent

c::l : Apply sealant.

SMT495A

• Tighten bolts securing transfer.

Tightening torque
Bolt No. r mm (in)
N·m (kg·m, ft-lb)
CD 31 . 41 (3.2 . 4.2, 23 . 30) 45(1.77)
31 . 41 (3.2. 4.2, 23. 30) 60 (2.36)

.,
s : M/T to transfer SMT496A

638 TF-6
 TRANSFER GEAR CONTROL

SEC. 333 ~ : N·m (kg-m, in-lb)

to.J : N·m (kg-m, fl·lb)

I!EEI!I 1 Fill multi-purpose grease up.

III:! 2 : Apply multi-purpose grease.
*1 : Securely bend pawls during assembly.
Be careful not to damage boot.
~2 : Do not touch boot with a sharp-pointed
or a hard tool as it breaks easily.

Transfer control lever

T _______-- Bush
Control lever
~ 8. 11 ~Snap ring~ (holder assembly)
(0.8 • 1.1' 69 • 95)
eJ9 Bush
to.l 15.7 • 20-6
(1.6 . 2.1,
11.6. 15.2)
Ball joint linkage

Outer shift lever

Washer

Ball joint linkage

SMT809C

TF-7 639
640

SEC. 331

4WD switch
Rear oil seal ~ l!fl!l Seal lip

a Threads Air breather

~ 15 • 20 (1.5 • 2.~

Breather cover \

~ 4 - 5 (0.4 - 0.5, 35 - 43)\ \

l
Neutral position switch
Oil gutter
~Threads
"-'r-::=:-~~:- \_Filler plug
1

~ 15 . 20 (1.5 . 2.0, 11 . 14)

~ D Threads s::
~ 0
l:0
/ - {l

'l"\. -;::;-- a -~ tCJ 25 • 34 Ill

, -: / / , ~ \~s- -2;;5·

~
(1)
:0
-I 0
pi~
0

~
0
0 0
&: K__Knock . / 26 · 36
(2.7 . 3.7,
3
"0
<
m
~ / 20·27) 0 :0
:I :I:

-
• ~ Rearcase
GQG
~)~~~~~ ~ Matmg
(1) l>
/ ') ~ / "'
tCJ 26 _ 36
surface
to center case
:I c:
< ~ /~ (2.7 . 3.7, 20 - 27)
I ll r-
~>JF=" Center case t1 Mat1ng surface to front case

~ Dram plug ~ Threads

1!i:i! Seal lip ~ ~ 25 - 34 (2.5 - 3.5, 18 - 25)
~- ~
Front case cover
~ Mating surface
to front case __/
~26-36 Iy~
(2.7 - 3.7
20- 27)
--- --_.

--.
---:;-- o2,-
0
/
"-.__ Cent;r case

0
~~
011 seal

rm
IJ!:a!l

.~~-~ 16- 21 (1.6- 2.1, 12- 15)

Seal lip

00
Cover oil seal ~ I!!'E!!I Seal lip • ~---. ill!] N•m (kg m, rn-lb)
Front case ~ Mating surface to transmission Under guard J ~ N•m (kg-m, ft-lb)
] ~ 16- 21
)> tr'.J 26- 36 (2.7- 3.7, 20 - 27) (1.6. 2.1, 12 • 15) D Apply anaerobic liquid gasket

~
Lochte P/N 51813 or equivalent
 SEC. 332 Steel balll!l:i!

L & H Needle bearing:.

hub*7
Mainshaft '-

9
/
l

~:~gear ~ ~"'~~·I, (\.'Q-,_

L & H coupl

"•Cl!;! -
Needle beanng>ng Gleeve ~•• ,

I~~-,.•"
Ma>n gear 0
bearing* I

~ *---0 ~
Spacer

• snapnng)
"""""" * Cl ·
Counter
nap nng
~1
Front sub-gear Rear sub-gear

0 bea~~gar s !m*!H!

~~~-~
Dtsh plate*-........ rear h

-\t.ll~y~~
r:l Counter

'""""'
beanng •• 'rant- lf\ · -ometer- dnve·-gear nng
"' s:
~
C)
"ff!!)V /
l:
~'0~ ~
Co Spacer (]
(I)
Spacer unter gear Baulk nngClutch gear ""
...

~· "~"o"" ~·~--.
~11\r~\J
~ ~ , ,,
Y Ill 0
::tl
-1 Front dnve Shrft>ng >nsert* ft\ C 0
0
~~~o ~ ~--" ·~,.~~·
"TI 0

'l~
cb o·J ___..-
(1.6- 2.1, 12 -15)
Snap rmg L9J.
Seal l i p \
sprocket
r- ~ I
\;J!
2-4 \_
\
coupl>n \
.,.. . Retainer
eanng* ring
3
"D
0
:::1
<
m
::tl
::I:

-
n Spread g sleeve*
(I) )>
[OJ 16- 21 :::1
\ I spnng c
!
I ll r-
"" I I Iii .
"- Needle b . Dnve chain*
eanng
\ Spacer
Bearing reta·1ner Front drive shaft f1

Mainshaft fro
(with snap . nt bearing*

~~
nng)
synchronizers

L Companion flange
\_
[OJ 226 - 324

~
(23 - 33, 166 - 239)

;,-c
641

~ ~ ~ ~
""lB ~
d8l @Til
l@ "iii]
~ ©J IP
~ ~ 9 @i) dW d-"'--, 20 c..:J IP ""
jjjjJ ~ ~" "'"
~
§
JB:·
@;)J
642

SEC. 333
Check plug
~Threads
trli19. 25 (19
. • 2.5, 14 • 18)

'""~-~~
Retaining pin .:•

~
~~
Check ball

rod~
\~'~ • "•• ,•.
-~··
Check plug L & H shift
Inner shift lever
.... " "I
Plug·~~'

I
~Threads
trli
1
9 • 25 (1

Diff. lever
9 'I

~
. --
Che~k
\. L
......,
.
:s:
oil"' \ \ ball
---------o I L -- - ....
C/)
l::
~ IIi'!-·-,, ~. ~ 1.... "··-,,:.;· =
\ \Lock pin ~
Snap ring·~~~Q \~ · I U ' ,. :::T
0

®;;~r
-1 :0
"T1
Thrust washer_/ 0

-... 0
0
......
' E-ring

~ ~
24
0
©@) I'J
. " 2-4 ,hift - 'hift fork
:I <
m
\ '-c. - Aetainin - • rod 0 :0
\ . Interlock pi g P'" ••i 0 :::t
l . 0 :t>
c:
,3
Retaining pin • unger
2-4 shift bracket .... r
0
:I
L11']9 . 12 (0.9 • 1.2. 78 - 104)

Cross shaW ~)
~
\Lock pin'
-
(I)
:I
I ll

[j]9-12(0.9-1.2,78-104)~
~~~ \ \ ,
Spring washer- \ \
Washer j J : If these parts require replacement,
Outer shill lever'
replace them as a set
rtJ: N•m (kg-m, in-lb)
~ : N·m (kg-m, 11-lb)
l: ~ :Apply anaerobic liquid gasket

~
0
Loctite PIN 51813 or equivalent
 DISASSEMBLY

1. Remove companion flange nut.

2. Remove companion flange.

ST33051001
(J22888) SMT434C

3. Remove 4WD switch.

4. Remove rear case.
• Be careful not to damage the mating surface.

J!il'ii'
SMT270A

5. Remove oil cover and oil gutter.

6. Remove snap ring from 2-4 shift rod.

7. Remove bolts securing bearing retainer.

• This step is necessary to remove mainshaft from center
case.

~m
8. Remove bolts securing center case to front case, then separate
center case from front case.

TF-11 643
 DISASSEMBLY

9. Measure low gear end play.

Standard:
0.2 - 0.35 mm (0.0079 - 0.0138 in)
• If end play is not within specification, check low gear and
L & H hub for wear.

10. Disassemble center case assembly.

a. Remove snap ring from mainshaft.

b. Remove low gear with L & H hub.

c. Remove needle bearing from main shaft.

d. Pay attention to the direction of the drive chain before

removing it. (It must be reinstalled in the same direction.)

644 TF-12
 DISASSEMBLV

e. Remove mainshaft, front drive and drive chain as a set by IGJI

tapping front end of mainshaft and front drive shaft alternately.
• Be careful not to bend drive chain .
~~~

~Ill:

l©
SMT279A

11. Disassemble front case assembly. ~©

a. Remove switch, plugs, check springs and balls.
[f!E

©l

i~Jlr'

b. Remove lock pin from outer shift lever, then remove outer shift l~1
lever.

I
I'---'
( I
~!

------
I
/ \I
•·... \ SMT797A

c. Remove lock pin from inner shift lever, then drive out cross i'Jffi\
shaft and plug together.

SMT282A

d. Remove 2-4 shift rod.

TF-13 645
 DISASSEMBLY

e. Remove L & H shift rod and fork assembly with coupling

sleeve.

f. Remove needle bearing from main gear.

g. Remove bolts securing front case cover, then remove case

cover.

Soft hammer h. Remove counter gear by tapping lightly.

i. Remove main gear by tapping lightly.

646 TF-14
REPAIR FOR COMPONENT PARTS

Mainshaft
DISASSEMBLY
1. Check front drive sprocket end play.
Standard:
0.2 - 0.35 mm (0.0079 - 0.0138 in)
• If end play is not within specification, check front drive [1;[1j]
sprocket and clutch gear for wear.

2. Remove retainer ring, speedometer drive gear and steel ball. [1;©
• Be careful not to lose the steel ball.

3. Remove snap ring and spacer.

SMT290A

4. Use a press to remove front drive sprocket with mainshaft rear M-

bearing and clutch gear together.
5. Remove needle bearing.

~'ii'
6. Remove bearing retainer, then remove snap ring and spacer.

TF-15 647
 REPAIR FOR COMPONENT PARTS
Mainshaft (Cont'd)
7. Use a press to remove mainshaft front bearing from mainshaft.

SMT293A

INSPECTION
Gear and shaft
• Check gears for excessive wear, chips or cracks .
• Check shaft for cracks, wear or bending .
• Check coupling sleeve for wear or damage .

Baulk ring
• Check baulk ring for cracks or deformation.

SMT349A

• Measure clearance between baulk ring and clutch gear.

Baulk ring to clutch gear clearance:
Refer to SDS, TF-30.

Bearing
• Make sure bearings roll freely and are free from noise, cracks,

~
pitting or wear.

-~ SMT351A

648 TF-16
 REPAIR FOR COMPONENT PARTS
Mainshaft (Cont'd)
ASSEMBLY
1. Press mainshaft front bearing onto mainshaft.
• Pay attention to its direction.
Shield side

' I
I
f=='--
"
SMT294A

2. Install spacer.
3. Select and install snap ring with proper thickness.
Allowable clearance between snap ring and groove:
0- 0.15 mm (0- 0.0059 in)
Available snap ring for mainshafl front bearing:
Refer to SDS, TF-30.
4. For further procedures, refer to "ASSEMBLY", TF-23.

SMT295A

Front Drive Shaft

DISASSEMBLY
• Using a gear puller, remove front drive shaft front and rear
bearings.

Front bearing Rear bearing SMT c

437

INSPECTION
Sprocket and shaft
• Check sprocket for excessive wear, chips or cracks.
• Check shaft for cracks or wear.

Bearing
• Make sure bearings roll freely and are free from noise, cracks,
pitting or wear. [~]@

SMT357A

ASSEMBLY
• Press front drive shaft front and rear bearings onto front drive
shaft. !lffi'

Front bearing
/ /
SMT438C

TF-17 649
 REPAIR FOR COMPONENT PARTS

~ST300210DOL _ J Counter Gear

\(J22912-0TJ ~(-~<;)
DISASSEMBLY
1. Use a press to remove counter gear front bearing, then remove
front sub-gear, spacer and dish plate.

AMT093

ST300310QO, I
2. Use a press to remove counter gear rear bearing, then remove
IJ22912.0TI ":~q rear sub-gear, spacer and dish plate.

- --ST36710010
I I

SMT301A

INSPECTION
Gear and shaft
• Check gears for excessive wear, chips or cracks.
• Check shaft for cracks or wear.

Bearing
• Make sure bearings roll freely and are tree from noise, cracks,
pitting or wear.

SMT358A

ASSEMBLY
1. Install front sub-gear, dish plate and spacer, then press on
counter gear front bearing.
2. Install rear sub-gear, dish plate and spacer, then press on
counter gear rear bearing.

Main Gear
DISASSEMBLY
Main gear bearing
1. Remove snap ring.

SMT304A

650 TF-18
 REPAIR FOR COMPONENT PARTS
Main Gear (Cont'd)
2. Pull out main gear bearing.

SMT305A

Plug
• Always replace with a new one whenever it has been
removed.

SMT306A

INSPECTION

•
Gear and shaft
• Check gears for excessive wear, chips or cracks.
• Check shaft for cracks or wear.

Bearing
• Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.

SMT359A

ASSEMBLY
- ST30613000
(J25742"3) Main gear bearing
1. Press on main gear bearing. l~l~

r-
1

I
1-----
1

SMT307A

2. Select and install snap ring with proper thickness.

Allowable clearance between snap ring and groove:
0- 0.15 mm (0- 0.0059 in)
Available snap ring for main gear bearing:
Refer to SDS, TF-30.

SMT308A

TF-19 651
 REPAIR FOR COMPONENT PARTS
Main Gear (Cont'd)
Plug
Apply sealant to plug, then install.

Front Case
SHIFT SHAFT OIL SEAL
Removal
• Use a screwdriver to pry out old seal.
• Be careful not to damage case.
• Always replace with a new one whenever it has been removed.

SMT310A

Installation
• Install new shift shaft oil seal until flush with case.
• Before installing, apply multi-purpose grease to seal lip.

Front Case Cover

COVER OIL SEAL
Removal
• Drive out old seal from inside of front case cover.
• Be careful not to damage front case cover.

SMT312A

Installation
ST30613000 • Install new front case cover oil seal until it stops.
(J34339) • Before installing, apply multi-purpose grease to seal lip.

652 TF-20
 REPAIR FOR COMPONENT PARTS

Bearing Retainer
OIL CATCHER
Removal
• Drive out oil catcher from inside of bearing retainer.
• Be careful not to damage bearing retainer.

Installation
• Install oil catcher until it stops.
• Be careful not to damage or distort oil catcher or bearing II'~
retainer.
• Before installing, apply multi-purpose grease to seal lip.

SMT315A

Rear Case
ST33290001
(J34286) REAR OIL SEAL
Removal
• Pull out rear oil seal.

AMT094

Installation
• Install new rear oil seal until it stops.
• Before installing, apply multi-purpose grease to seal lip. ~~

Front AIR BREATHER

t Install as shown in illustration.

SMT799A

TF-21 653
 REPAIR FOR COMPONENT PARTS

Shift Control Components

INSPECTION
• Check contact surface and sliding surface for wear, scratches,
projections or other faulty conditions.

SMT360A

L & H SHIFT ROD & FORK

• Assemble as shown in illustration.

L&H
shift fork

Retaining pin• ~ L& Hshiftrod

• Retaining pin is the same size as the one for 2-4 shift rod.
SMT319A

2-4 SHIFT ROD & FORK

• Assemble as shown in illustration.

2-4 shift rod

2-4 shift bracket

• Retaining pins are the same size.
SMT320A

• Pay attention to the direction of fork guide collar.

2·4 shift fork

j Spring
I

'
Fork guide collar~
Retainer ring~
;/)

SMT321A

654 TF-22
 ASSEMBLY

1. Assemble front case. @I

a. Install main gear assembly by tapping lightly.

I.ITiffil

~[i:j]

l©
SMT323A

b. Apply sealant to the mating surface and bolts of front case ~©

® cover, then attach it to the front case.

• These ten bolts should be coated with sealant.
Bolts A: IP~
~: 16-21 N·m (1.6- 2.1 kg-m, 12- 15 ft-lb)
Bolts B:
~: 19-24 N·m (1.9- 2.4 kg-m, 14- 17 ft-lb)
©l

[i:j]1J

SMT325A

~~ c. Apply gear oil to needle bearing and install it into main gear. 3\11

0_____------------
0 -~ ~
/~
'c'l1
IJIQl

[pffil
SMT326A

d. Install counter gear assembly by tapping lightly.

li'Jb\

~l~

§11

~§

SMT327A

~It
e. Install cross shaft and inner shift lever.
• When replacing cross shaft, outer shift lever or outer shift
lever lock pin, replace them as a set. lilffil

~l

I[[J)IZ

TF-23 655
 ASSEMBLY

f. Apply sealant to plug, then install it into front case.

g. Insert interlock plunger into front case.

h. Install L & H shift rod and fork assembly with coupling sleeve.

i. Install 2-4 shift rod.

j. Install switches, check balls, check springs and plugs.

• Apply sealant to switches and plugs.

656 TF-24
 ASSEMBLY

2. Select counter gear rear bearing shim. @]]

a. Seat counter gear assembly.

SMT590A

b. Place J34291-1 (bridge), J34291-2 (legs) and J34291-5 (gaug- ~©

(J34291-2) ing cylinder) on machined surface of center case, allowing
gauging cylinder to rest on top outer portion of counter gear
rear bearing. Lock gauging cylinder in place. l"il'

I ~

_.. -·- .-_--c.

V\• _ -~IJ34291·51
')~

0) 0/;::.-~0
e;;{__)_,
' ·,_.'!(
u

/~-~~"-:"-~ ..--=; t
(Jc:j' 0

Center case
- I --- //- ' ' SMT591A

c. Insert J34291-20 (gauging plunger) into J34291-5 (gauging $:,11

cylinder).

•
SMT592A

-(J34291·51 d. Place bridge, legs, gauging cylinder and gauging plunger onto
machined surface of front case assembly, allowing gauging
plunger to drop until it contacts counter gear rear bearing mat-
ing surface.

;IH"lL;(-Counter gear
assembly

Front case

(J34291-20)

Counter gear rear-;

bearing
Front case~
~

(J34291-2) ______;
/ SMT593

TF-25 657
 ASSEMBLY

e. Lock gauging plunger in place and use feeler gauge to mea-

sure clearance between gauging cylinder and gauging plunger.
f. Use measured distance to select correct counter gear rear
bearing shim.
Allowable counter gear clearance:
0 - 0.2 mm (0 - 0.008 in)
Available counter gear rear bearing shim:
Refer to SDS, TF-30.

3. Place suitable shim with grease on counter gear rear bearing.

4. Apply gear oil to each part in front case.

5. Assemble center case assembly.

a. Install mainshaft on center case by tapping lightly.
• Apply gear oil to mainshaft front bearing.

b. Install bearing retainer.

~: 16- 21 N·m (1.6- 21 kg-m, 12- 15 ft-lb)

Front drive shaft

c. Put drive chain onto the front drive sprocket and front drive
shaft, and then put them in center case.
• Be sure to install drive chain in same direction as
removed.

Front drive sprocket

SMT408A

658 TF-26
 ASSEMBLY

d. Install front drive shaft by tapping lightly.

Soft hammer • Make sure shafts are aligned in the case.

e. Apply gear oil to needle bearings and install them into front
drive sprocket.
• These needle bearings will be installed more easily if front
drive sprocket is rotated while installing them.

SMT411A

f. Install 2-4 coupling sleeve with 2-4 shift fork.

• Pay attention to the direction of the coupling sleeve.

g. Install shifting inserts and spread spring.

• Pay attention to the direction of shifting inserts.

~IL

Spread spring
SMT353A

TF-27 659
 ASSEMBLY

~Shield
""'side 10--__
1IT¢:;:::-,~
~m
( h. Install baulk ring, then install clutch gear and mainshaft rear
bearing.

©
'- Fco! It:;:::i,hoft
&. / rear bearing
• Place wooden block under mainshaft in order to protect
mainshaft front bearing.

~ Clutch gear

•
Front

SMT413A

i. Install spacer.
j. Select and install snap ring with proper thickness.
Allowable clearance between snap ring and groove:
0-0.15 mm (0- 0.0059 in)
Available snap ring for mainshaft rear bearing:
Refer to SDS, TF-30.

k. Install steel ball, speedometer drive gear and retainer ring.

• Steel ball is the smallest check ball for this unit.

SMT415A

I. Install low gear and bearing onto mainshaft.

• Apply gear oil to needle bearing.

m. Install L & H hub and snap ring onto mainshaft.

• Pay attention to the direction of L & H hub.

SMT760A

660 TF-28
 ASSEMBLY

n. Measure low gear end play.

Standard: 0.2- 0.35 mm (0.0079- 0.0138 in)

6. Apply sealant to mating surface of center case, then attach to ~©

~~~
. \ I front case and tighten bolts.
I I - ---
l;_- ---\.,____1

SMT343A

7. Install snap ring to 2-4 shift rod.

8. Install oil gutter and oil cover.

9. Apply gear oil to each part in center case.

~I]'
~- Soft hammer 10. Apply sealant to mating surface of rear case, then attach it to
', I>
center case and tighten bolts.
11. Install 4WD switch.
• Apply sealant to switch threads .

SMT497C

TF-29 661
 SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications
Transfer model TX10A
High 1.000
Gear ratio
Low 2.020

Main gear 29
Low gear 37

Counter High 38
Number of teeth
gear Low 24
Front drive sprocket 41
Front drive shaft 41
Oil capacity 1 (US qt, Imp qt) 2.2 (2-3/8, 2)

Inspection and Adjustment

GEAR END PLAY AVAILABLE SNAP RING
Unit mm (in)
Mainshaft front bearing
Front drive sprocket 0.2 - 0.35 (0.0079 - 0.0138)
Low gear 0.2- 0.35 (0.0079- 0.0138) Allowable clearance 0-0.15 mm (0- 0.0059 in)

Counter gear 0 - 0.2 (0 - 0.008) Thickness mm (in) Part number

3.1 (0.122) 33138-73?10

3.19 (0.126) 33138-73?11

CLEARANCE BETWEEN BAULK RING AND 3.28 (0.129) 33138-73?12

CLUTCH GEAR
Unit: mm (in)

Standard Wear limit Mainshaft rear bearing

1.0 - 1.5 (0.039 - 0.059) 0.5 (0.020)
Allowable clearance 0-0.15 mm (0- 0.0059 in)
Thickness mm (in) Part number

AVAILABLE SHIM 1.8 (0.071) 33138-73?20

1.89 (0.074) 33138-73?21

Counter gear rear bearing
1.98 (0.078) 33138-73P22
Allowable clearance 0 - 0.2 mm (0 - 0.008 in) 2.07 (0.081) 33138-73P23
Thickness mm (in) Part number 2.16 (0.085) 33138-73P24
0.1 (0.004) 33112-C6900

0.2 (0.008) 33112-C6901

0.3 (0.012) 33112-C6902 Main gear bearing

0.4 (0.016) 33112-C6903
Allowable clearance 0-0.15 mm (0- 0.0059 in)
0.5 (0.020) 33112-33GOO
Thickness mm (in) Part number
0.6 (0.024) 33112-33G01
2.60 (0.102) 33114-73POO

2.69 (0.1 06) 33114-73P01

2.78 (0.109) 33114-73P02

662 TF-30
 PROPELLER SHAFT &
DIFFERENTIAL CARRIER

SECTION PO
CONTENTS
PREPARATION . ..............................................................2 ADJUSTMENT ............................... ............................... 24
Special Service Tools .................................................. 2 Side Bearing Preload ................................................. 24
Pinion Gear Height and Pinion Bearing Preload ....... 25
Propeller shaft Tooth Contact. ............................................................29
ASSEMBLY ....................................................................30
PROPELLER SHAFT....... ................................... ? Extension Tube and Differential Side Shaft .............. 30
On-vehicle Service .......................................................9 Differential Case ........................................................30
Removal and Installation ............................................. 9 Final Drive Housing. ........................................ 31
lnspection ..................................................................... 9
Disassembly ............................................................. 10 H190A
Assembly ................................................................. 11
REAR FINAL DRIVE...................... ....................... 35
Final drive DISASSEMBLY............................................... ........ 36
Pre-inspection ............................................................ 36
ON-VEHICLE SERVICE .......................... ..................... 13 Differential Carrier ...................................................... 36
Front Oil Seal Replacement (Front final drive) ......... 13 Differential Case ........................................................ 38
Front Oil Seal Replacement INSPECTION ................................................................. .40
(Rear final drive: Model H233B) ................................ 13 Ring Gear and Drive Pinion . ...... .................... .40
Rear Cover Gasket Replacement Differential Case Assembly ....................................... .40
(Rear final drive: Model C200) .................................. 14 Bearing ...................................................................... .40
REMOVAL AND INSTALLATION (Front final LIMITED SLIP DIFFERENTIAL ..................................... 41
drive)............. .................................................. 15 Preparation for Disassembly .................................... .41
REMOVAL AND INSTALLATION (Rear final drive) .... 16 Disassembly .............................................................. .42
lnspection ................................................................... 42
Assembly .................................................................. .43
R180A
ADJUSTMENT .............................................................. .46
Side Bearing Preload ................................................ .46
FRONT FINAL DRIVE ................................................... 17 Pinion Gear Height .................................................... 47
DISASSEMBLY .............................................................. 18 Tooth Contact.......... ..................................... 51
Pre-inspection ............................................................ 18 ASSEMBLY..................................... ...................... 52
Final Drive Housing ................................................... 18 Differential Case ........................................................52
Differential Case ........................................................20 Differential Carrier ......................................................53
Extension Tube and Differential Side Shaft .............. 21
INSPECTION ..................................................................23
Ring Gear and Drive Pinion ..................................... 23
Differential Case Assembly ....................................... 23
Bearing ......................................................................23

664
 CONTENTS ccont'd.) @ll

C200 H233B

REAR FINAL DRIVE .................................................... 57 REAR FINAL DRIVE ..................................................... 80

DISASSEMBLY ... ......................................................... 58 DISASSEMBLY ......................................................... .... 8t
Pre-inspection ................. . ...................... 58 Pre-inspection ........................................................... 81
Differential Carrier ................ ................................. .58 Differential Carrier ...................................................... 81
Differential Case .................................................... 60 Differential Case ........................................................83 ~,1:
INSPECTION ............. ................................................ 62 INSPECTION .................................................................. 85
Ring Gear and Drive Pinion ..................................... 62 Ring Gear and Drive Pinion ..................................... 85
Differential Case Assembly ....................................... 62 Differential Case Assembly ........................................ 85 ~©
Bearing.................. .............................. . ....... 62 Bearing ....................................................................... 85
LIMITED SLIP DIFFERENTIAL ......... .......................... 63 LIMITED SLIP DIFFERENTIAL.. ........ ........................... 86
Preparation for Disassembly .................................... 63 Preparation for Disassembly ..................................... 86 IF~
Disassembly. ............. ............................ .63 Disassembly ...............................................................86
Inspection .................................................................. 64 lnspection ...................................................................87 ©fL
Adjustment... ................................................... 65 Adjustment ................................................................88
Assembly .................................................................67 Assembly ...................................................................89
ADJUSTMENT .................................. ............................ 69 ADJUSTMENT .................................................. ............ 92
Side Bearing Preload ................................................ 69 Pinion Gear Height .................................................... 92
Pinion Gear Height.. .............................................. ..70 Tooth Contact. ............................................................95
Tooth Contact... ....................................................... 74 ASSEMBLY ....................................................................96 fo\1[
ASSEMBLY.................... .................................... 75 Differential Case .......................................................96
Differential Case .......................................................75 Differential Carrier ......................................................97
Differential Carrier .....................................................76 SERVICE DATA AND SPECIFICATIONS (SDS) ........ 100 1JF
Propeller Shaft ........................................................ 100
Final Drive ................................................................ 102
General Specifications ........................................ 102
Inspection And Adjustment (R180A) ................... 103
Inspection And Adjustment (H190A) ................... 104 IPb\
Inspection And Adjustment (C200) ..................... 105
Inspection And Adjustment (H233B) ................... 106

665
 PREPARATION

Special Service Tools

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number Unit application

(Kent-Moore No.) Description
Tool name R180A H190A C200 H2338

ST3127SOOO Measuring pinion bearing

(See J25765-A) preload and total preload
Preload gauge
(j) GG91 030000 ~
I
(J25765) 4J.F=U
Torque wrench
@ HT62940000 ®--------§ X X X X

-
~
( )
Socket adapter
@ HT62900000
( - )
Socket adapter NT124

w
KV38100800 a Mounting final drive
(J25604-01 ), (J3431 0) (To use, make a new hole.)
Differential attachment
X - - -
.
NT119 a: 152 mm {5.98 in)

ST06310000
(J25602-01)
Differential attachment

NT140
JV? Mounting final drive

- X - -

ST06340000 Mounting final drive

(J24310)
Differential attachment
~)y - - - X

NT140

ST32580000 Adjusting side bearing pre-

(J34312) load and backlash (ring gear-
Differential side bearing drive pinion)
adjusting nut wrench - - - X

NT141

ST33290001 Removing side bearing outer

~
(J25810-A) race and side oil seal
Side bearing outer race
X - - -
puller

NT076

ST38060002 Removing and installing

~
(J34311) propeller shaft lock nut and
Drive pinion flange drive pinion lock nut
X X X -
wrench

NT113

666 PD-2
 PREPARATION
Special Service Tools (Cont'd)
@~
Tool number Unit application
(Kent-Moore No.) Description
Tool name R180A H190A C200 H233B
WJL~
KV38104700 Removing and installing pro-

~
(J34311) peller shaft Jock nut, and
~~j
Drive pinion flange drive pinion lock nut
X
wrench

NT113 !oiG
ST3090SOOO Removing and installing drive
( ) pinion rear inner cone ~lg

~w
Drive pinion rear inner
race puller set
G) ST30031 000 I'~
(J22912-01)
Puller
X X X X
@ ST30901 000 ©~
(J2601 0-01) a
Base
a: 79 mm (3.11 in) dia.
b: 45 mm {1.77 in} dia. i!u'ii'
NT527 c: 35 mm (1.38 in) dia.

ST3306S001 Removing and installing dif-

Jl'ii'
Differential side bearing terential side bearing inner
puller set cone
G) ST33051 001

0 @!
a 'ill'
(J22888-20)

•
Body X X X X
@ ST33061000
b
(J8107-2)
Adapter
c])
a: 28.5 mm (1.122 in) dia. IPi~\
NT072 b: 38 mm (1.50 in) dia.

ST33230000 Installing side bearing inner

(J25805-01) cone ~Jl
Differential side bearing
drift X X X
a: 51 mm (2.01 in) dia. ~~
b: 41 mm (1.61 in) dia.
NT085 c: 28.5 mm {1.122 in) dia.
@If
ST33190000 Installing side bearing inner
(J25523) cone
Differential side bearing
X ~~
drift
a: 52 mm (2.05 in) dia.
b: 45.5 mm (1.791 in) dia.
NT085 c: 34 mm (1.34 in) dia. ~I]'

ST33081000 Installing side bearing inner

l!
( ) cone
~LS
Side bearing puller
adapter X X
~~
a: 43 mm (1.69 in) dia.
NT431 b: 33.5 mm (1.319 in) dia.

~[Q)j:1

PD-3 667
668 PD-4
 PREPARATION
Special Service Tools (Cont'd)
Tool number Unit application
(Kent-Moore No.) Description
Tool narne R180A H190A C200 H233B

ST33720000 Installing side retainer

~~
(J25817)
Differential side retainer X - - -
guide
NT138

ST33270000 Installing side oil seal

a
(J25809)
Side oil seal drift ~
,w: " X - - -

~~ a: 62 mm (2.44 in) dia.

NT526 b: 28 mm (1.10 in) dia.

(J34309) Adjusting bearing pre-load

Differential shim and gear height
selector

Q ~f$
~<:>'&
X X X X

~
NT134

(J25269-4) Selecting pinion height

Side bearing discs
(2 Req'd)

NT136
@ adjusting washer
X - X -

(J25269-t8) Selecting pinion height

Side bearing discs
(2 Req'd)

NT135
® adjusting washer
- X - X

(J8129)
Spring gauge ~

~ Measuring carrier turning

X X X X

N'f,27 torque

(J35764) Installing side oil seal

~
Gear carrier side oil seal
drift - -
X -

NT120

PD-5 669
 PREPARATION
Special Service Tools (Cont'd)
Tool number Unit application
(Kent-Moore No.) Description
Tool name R180A H190A C200 H233B

KV381051SO Checking differential torque

( - ) on limited slip differential
Rear axle shaft dummy
CD

~~
KV38105110
( - ) - X X -
Torque wrench side
® KV38105120
( - )
Vice side NT142

KV381052SO Checking differential torque

( - ) on limited slip differential
Rear axle shaft dummy

~~
CD KV38105210
( - ) - - - X
Torque wrench side
® KV38105220
( - )
Vice side NT142

670 PD-6
 PROPELLER SHAFT

Front propeller shaft (Model 2F71 H) @I

SEC. 370

Greasing point

l©

<@M! ~

~Joumal
Propeller shaft tube

y (!)

%)
@ I'\"·· "~""
Snap ring* O

\~ 39. 44 (4.0. 4.5, 29- 33)

* Adjustment IS required
~ N•m (kg-m, ft-lbl jj'

SPD724-A •

,R_e_ar__
pr_o_p_e_ll_e_r_sh_a_tt__(M
__od_e_I_2_S_s_o_B_)__________________________________________ 'I

SEC. 370

Propeller shaft tube

\Snap ring* O
\ /Joumal beaclng

~
\ 'kiJ 0

~~\-~ 'kiJ <ZJ

@
\ Journal
I
\_Sleeve yoke

* : Adjustment is required.
~ • N·m (kg-m, ft-lb) l!iliZ
SPD250AA

PD-7 671
 PROPELLER SHAFT

Rear propeller shaft (Model 35808)

Washer
SEC.370 Apply a coat of multi-purpose lithium grease
Center bearing upper containing molybdenum disulfide to the end
mounting bracket face of the center bearing and both sides of
the washer.

Propeller shaft
Locknut~ 2nd tube
tcl: 137. 167
(14 -17,101 -123)
I
Jol'nalbearing

Journal

' ~ 78·88
(8. 9,
58- 65)

Companion flange

Center bearing assembly

Center bearing lower mounting bracket

~ : N -m (kg-m, ft-lb)
Snap ring tr ~ tt : Adjustment is required
APDOO?

Rear propeller shaft (Model 3571 A)

SEC. 370 Washer
Center bearing upper Apply a coat of multi-purpose lithium grease
mounting bracket containing molybdenum disutfide to the end
face of the center bearing and both sides of
the washer.

~16·22
(1.6- 2.2,
12- 16) Locknut~
~ 137·167
{14 -17,101 -123)

-~~z ~39-44
(4.0- 4.5,
29- 33)
~18·25
Compan1on flange (1.8 - 2.5,
13- 18)
Center bearing assembly

Center bearing lower mounting bracket

Propeller shaft
1st tube
~' N -m (kg-m, ft·lb)
APD008

672 PD-8
 PROPELLER SHAFT

@]
On-vehicle Service
PROPELLER SHAFT VIBRATION
If vibration is present at high speed, inspect propeller shaft runout
first.
1. Raise rear end of vehicle until wheels are clear of the ground.
2. Measure propeller shaft runout at several points along propel- ~i)U
ler shaft by rotating final drive companion flange using hands.
3. If runout exceeds specifications, disconnect propeller shaft at
final drive companion flange. Rotate companion flange 180 l~
degrees, then reconnect propeller shaft.
Runout limit: 0.6 mm (0.024 in)
4. Check runout again. If runout still exceeds the limit, replace ~,:;:;
propeller shaft assembly.
5. Periorm road test.

~~7rrf'--r?=' APPEARANCE CHECKING

~~~~~~-~ • Inspect propeller shaft tube suriace for dents or cracks and

180/7
(~[L
replace as necessary.
• Check center bearing for noise or damage and replace as
necessary.

SPD102

Removal and Installation

1. Place matching marks on flanges, then separate propeller
shaft from final drive. llll"'

2. Remove propeller shaft.

• Insert plug into rear oil seal after removing rear propeller
shaft

Plug
SPD359

Inspection
• Inspect propeller shaft runout. If runout exceeds the limit,
replace propeller shaft assembly. ~lil,
Runout limit: 0.6 mm (0.024 in)

SPD106

PD-9 673
 PROPELLER SHAFT
Inspection (Cont'd)
• Inspect journal axial play.
II play exceeds the limit, replace propeller shalt assembly.
Journal axial play:
0.02 mm (0.0008 in) or less

SPD874

Disassembly
CENTER BEARING
1. Place matching marks on flanges, then separate 2nd tube from
,___,_.,...--_____..... 1st tube.

SPD109

2. Place matching marks on the flange and shalt.

SPD110

3. Remove locking nut using Tool.

Tool numbers:
R180A,H190A,C200
ST38060002 (J34311)
H233B

~Cccik}i;
KV38104700 (J34311)
\~ .
A / 4. Remove companion flange using puller.
' /
' ..

~~
~ SPD170A
5. Remove center bearing using Tool and press.
Tool number: ST30031 000 (J22912-01)

SPD113

674 PD-10
 PROPELLER SHAFT
Disassembly (Cont'd)
JOURNAL
NOTE:
1. Place matching marks on propeller shaft and flange or yoke.

2. Remove snap ring.

3. Remove pushed out journal bearing by lightly tapping yoke ,%11

with a hammer, taking care not to damage journal and yoke
hole.

?,%
SPD732

~
4. Remove bearing at opposite side in above operation.
Put marks on disassembled parts so that they can be
reinstalled in their original positions.
~~

!!11

~§)

~f
Assembly
CENTER BEARING
~&
• When installing center bearing, position the "F" mark on cen-
ter bearing toward front of vehicle.
• Apply a coat of multi-purpose lithium grease containing
molybdenum disulfide to the end face of the center bearing
~l

and both sides of the washer.

PD-11 675
 PROPELLER SHAFT
Assembly (Cont'd)
• Stake the nut. Always use new one.
• Align match marks when assembling tubes.

JOURNAL
1. Assemble journal bearing. Apply recommended multi-purpose
grease on bearing inner surface.
When assembling, be careful that needle bearing does not fall
down.

2. Select snap ring that will provide specified play in axial direction
of journal, and install them.
Refer to SDS, PD-1 01.
Select snap rings with a difference in thickness at both sides
within 0.06 mm (0.0024 in).

3. Adjust thrust clearance between bearing and snap ring to zero

by tapping yoke.

4. Check to see that journal moves smoothly and check for axial
play.
Axial play: 0.02 mm (0.0008 in) or less

SPD874

676 PD-12
 ON-VEHICLE SERVICE Final drive I

Front Oil Seal Replacement (Front final drive)

1. Remove front propeller shaft.
2. Loosen drive pinion nut.
Tool number: ST38060002 (J34311)

3. Remove companion flange using puller.

4. Remove front oil seal.

SPD735

5. Apply multi-purpose grease to cavity at sealing lips of oil seal. M

Press front oil seal into carrier.
Tool number:
ST30720000 (J25405)
6. Install companion flange and drive pinion nut.
7. Install propeller shaft.

Front Oil Seal Replacement

(Rear final drive: Model H233B)
CAUTION:
For final drive models using collapsible spacer (H190A, C200),
bearing preload must be adjusted whenever companion flange
is removed. Therefore, final drive overhaul is required. ~IL
1. Remove propeller shaft.
2. Loosen drive pinion nut.
Tool number: KV38104700 (J34311)
PD237

PD-13 677
 ON-VEHICLE SERVICE I Final drive I
Front Oil Seal Replacement
(Rear final drive: Model H233B) (Cont'd)
3. Remove companion flange.

4. Remove front oil seal.

SPD738

5. Apply multi-purpose grease to cavity at sealing lips of oil seal.

Press front oil seal into carrier.
Tool number: KV38100500 (J25273)
6. Install companion flange and drive pinion nut.
7. Install rear propeller shaft.

SPD739

Rear Cover Gasket Replacement

(Rear final drive: Model C200)
1. Drain gear oil.
2. Remove rear cover and rear cover gasket.
3. Install new rear cover gasket and rear cover.
4. Fill final drive with recommended gear oil.

678 PD-14
 REMOVAL AND INSTALLATION (Front final drive) Final drive I

Removal liill
1. Remove front propeller shaft.
2. Remove drive shaft. Refer to FA section ["Drive Shaft", lkU#\
"FRONT AXLE (4WD)"].
3. Remove engine mounting bolts and raise up engine.
4. Remove front final drive together with differential mounting ~U!u
member.

Installation ~©
1. Install front final drive assembly together with differential
mounting member. I'~

2. Tighten front final drive securing bolts and nuts by following the ffi\'j'
procedure to prevent drive train vibration.
a. Temporarily tighten nut @.
b. Temporarily lighten nut @.
c. Tighten bolt (9 to the torque of 68 to 87 N·m (6.9 to 8.9 kg-m,

•
50 to 64 11-lb).
@ d. Tighten bolt @ to the torque of 68 to 87 N·m (6.9 to 8.9 kg-m,
50 to 64 ft-lb).
e. Tighten nut ® to the torque of 68 to 87 N·m (6.9 to 8.9 kg-m,
front 50 to 64 ft-lb). !Pi\
<? f. Tighten nut @ to the torque of 68 to 87 N·m (6.9 to 8.9 kg-m,
50 to 64 ft-lb).
® g. Tighten nut ® to the torque of 68 to 87 N·m (6.9 to 8.9 kg-m, lfufi,
50 to 64 11-lb).
3. Install drive shaft. Refer to FA section ["Drive Shaft", "FRONT
® AXLE (4WD)"]. [8)~
4. Install front propeller shaft.

SPD743

PD-15 679
 REMOVAL AND INSTALLATION (Rear final drive) Final drive I

Removal
• Remove propeller shaft.
Plug front end of transfer.
• Remove axle shalt.
Refer to RA section ("REAR AXLE").
CAUTION:
• Be careful not to damage spline, sleeve yoke and front oil
seal when removing propeller shaft.
• Before removing the final drive assembly or rear axle
assembly, disconnect the ABS sensor harness connector
from the assembly and move it away from the final drive/
rear axle assembly area. Failure to do so may result in the
sensor wires being damaged and the sensor becoming
inoperative.

Installation
• Fill final drive with recommended gear oil.

SPD123

• Pay attention to the direction of gasket (H233B only).

(r~··

~ 1V,';
~[}~·-
Green Gray
""
'"'
"'
''' SPD767

680 PD-16
 SEC. 381
n : Adjustment is required.
* : Using locking agent Pinion mate shaft
[Locktite (stud lock) or equivalent]
Side flange lock nut
tc!J N·m (kg·m. ft-lb)
.,
~: N•m (kg-m, in-lb)
~ · Apply recommended sealant (N1ssan genume lf1=:u
part: KP6i0-00250) or equivalent. \l:)'~

~ ~~
Side gear

rrPJ a1 • 42 (3.2 • 4.3. 23 • 31) @)

\ D1fferenttal case RH ~~ ®
O·rlng ~
Rear cover
Differential

Differential case LH

1a a. .,::c
~
69 • (7. s1 • 581
@@0/~
't:~ I"
o7kf·~ 0
z
,c Ring gear
-1
::!!
....
I z)>
--I
r-
c
::c
Pinion front
<
m
bearing

Side retainer adjusting shim tf

Front oil seal~

Companion flange Differential side shaft

rPJ 167 • 196 (17 • 20, 123 • 145)

~
"'
-u

I
681

en m
~
9
~
~ @'/) ~ ~- s,=()
~s IF
~ 2S (g9_) WI
i§
?:::i; ?~ ~l (0/J 9 d.9 2.0 CjjJ
9 [p mru ({"j © ~ ""'
 DISASSEMBLY I R180A I

Pre-inspection
Before disassembling final drive, perform the following inspection.
• Total preload
a. Turn drive pinion in both directions several times to set bearing
rollers.
b. Check total preload with Tool.
Tool number: ST3127SOOO (J25765-A)
Total preload:
1.2-2.3 N·m
(12- 23 kg-em, 10-20 in-lb)
SPD634

• Ring gear-to-drive pinion backlash

Check backlash of ring gear with a dial indicator at several
points.
Ring gear-to-drive pinion backlash:
0.13-0.18 mm (0.0051 - 0.0071 in)

SPD635

• Ring gear runout

Check runout of ring gear with a dial indicator.
Runout limit:
0.05 mm (0.0020 in)
• Tooth contact
Check tooth contact. Refer to "ADJUSTMENT", PD-29.

Final Drive Housing

1. Using three spacers [20 mm (0. 79 in)], mount final drive
assembly on Tool.
Tool number:
KV38100800 (J34310), (J25604-01)

Tool
SPD637

2. Remove extension tube and differential side shaft assembly.

SPD638

682 PD-18
 DISASSEMBLY R180A

Final Drive Housing (Cont'd)

3. Remove differential side flange.

SPD713

4. Mark side retainers for identification. Remove side retainers.

Be careful not to confuse right and left side retainers and
shims.

5. Extract differential case from final drive housing.

6. Remove side outer races.

Tool number: ST33290001 (J2581 0-A)
Keep the side bearing outer races together with their respec-
~~
tive inner cones - do not mix them up.
7. Remove side oil seal.

8. Loosen drive pinion nut.

Tool number: ST38060002 (J34311)
9. Remove companion flange with puller.

PD-19 683
 DISASSEMBLY R180A

Final Drive Housing (Cont'd)

10. Take out drive pinion together with pinion rear bearing inner
cone, drive pinion bearing spacer and pinion bearing adjusting
washer.
11. Remove front oil seal and pinion front bearing inner cone.

12. Remove pinion front and rear bearing outer races with brass
drift.

13. Remove p1mon rear bearing inner cone and drive pinion
adjusting washer.
Tool number: ST30031000 (J22912-01)

Differential Case
1. Remove side bearing inner cones.
To prevent damage to bearing, engage puller jaws in grooves.
Tool numbers:
@ ST33051001 (J22888-20)
@ ST33061 000 (J81 07-2)

• Shows groove

SPD642

684 PD-20
 DISASSEMBLY I R180A I
Differential Case (Cont'd)
C>ll
Be careful not to confuse the right and left hand parts.

SPD022

2. Loosen ring gear bolts in a criss-cross fashion.

3. Tap ring gear off differential case with a soft hammer.
Tap evenly all around to keep ring gear from binding.

4. Separate differential case LH and RH.

Put match marks on both differential case LH and RH sides
prior to separating them.

Extension Tube and Differential Side Shaft

1. Remove differential side shaft assembly from extension tube.

~'jj'
2. Cut rear axle bearing collar with cold chisel. Be careful not to
damage differential side shaft.

Support with wooden block.

SP0236A

PD-21 685
 DISASSEMBLY I R180A I
Extension Tube and Differential Side Shaft
(Cont'd)
3. Reinstall differential side shaft into extension tube and secure
with bolts. Remove rear axle bearing by drawing out differential
side shaft from rear axle bearing with puller.

Without collar

SPD646

4. Remove grease seal.

SPD647

686 PD-22
 INSPECTION I R180A I

Ring Gear and Drive Pinion

Check gear teeth for scoring, cracking or chipping.
If any damaged part is evident, replace ring gear and drive pinion [i:j]ffi\
as a set (hypoid gear set).

Differential Case Assembly

Check mating surfaces of differential case, side gears, pinion mate
gears, pinion mate shaft and thrust washers.

SPD648

Bearing
1. Thoroughly clean bearing.
2. Check bearing for wear, scratches, pitting or flaking.
Check tapered roller bearing for smooth rotation. If damaged,
replace outer race and inner cone as a set.

SPD715

PD-23 687
 ADJUSTMENT I R180A I

For quiet and reliable final drive operation, the following five
adjustments must be made correctly:
1. Side bearing preload
2. Pinion gear height
3. Pinion bearing preload
4. Ring gear-to-pinion backlash. Refer to "ASSEMBLY", PD-33.
5. Ring and pinion gear tooth contact pattern.

Side Bearing Preload

A selection of carrier side retainer adjusting shims is required
for successful completion of this procedure.
1. Make sure all parts are clean. Also make sure the bearings are
well lubricated with light oil or type "DEXRON™" automatic
transmission fluid.
2. Install differential carrier and side bearing assembly into the
final drive housing.

3. Place all of the original side retainer adjusting shims onto the
side bearing retainer that goes at the ring gear end of the
carrier.

SPD192A

4. Install both bearing retainers onto the final drive housing and
torque the retainer bolts.
Bolt torque specification:
II']: 9- 12 N·m (0.9 -1.2 kg-m, 78- 104 in-lb)

5. Turn the carrier several times to seat the bearings.

6. Measure the carrier turning torque with a spring gauge, J8129,
at the ring gear retainer bolt.
Turning torque specification:
34.3- 39.2 N (3.5- 4.0 kg, 7.7- 8.8 lb)
of pulling force at the ring gear bolt

688 PD-24
 ADJUSTMENT I R180A I
Side Bearing Preload (Cont'd)
7. If the turning torque measured is incorrect, establish the cor- ~I
reel bearing preload by adding to or subtracting from the total
amount of shim thickness.
• Increase shim thickness to decrease turning torque on the JjiJl
carrier.
• Decrease shim thickness to increase turning torque on the
carrier. ~1\!u

8. Record the correct, selected total thickness of the side retainer I"©
adjusting shims, and remove the carrier and bearings from the
final drive housing. Save all shims for later re-use.

SPD195A

Pinion Gear Height and Pinion Bearing Preload

1. Make sure all parts are clean and that the bearings are well
lubricated.
2. Assemble the pinion gear bearings into the pinion pre-load
shim selector tool, J34309. •
• Front Pinion Bearing- make sure the J34309-3 front pinion • 1
bearing seat is secured tightly against the J34309-2 gauge
anvil. Then turn the front pinion bearing pilot, J34309-7, to
lllllllllilllllll n secure the bearing in its proper position.

SPD769

~~~
• Rear Pinion Bearing - the rear plnton bearing pilot,
J34309-8, is used to center the rear pinion bearing only. The
rear pinion bearing locking seat, J34309-4, is used to lock the ~!Pl
bearing to the assembly.

SPD196A

SPD197A

PD-25 689
 ADJUSTMENT I R180A I
Pinion Gear Height and Pinion Bearing Preload
(Cont'd)
3. Place the pinion preload shim selector tool gauge screw,
J34309-1, with the pinion rear bearing inner cone installed, into
the final drive housing.

4. Install the J34309-2 gauge anvil with the front pinion bearing
into the final drive housing and assemble it to the J34309-1
gauge screw. Make sure that the J34309-16 gauge plate will
turn a full 360 degrees, and tighten the two sections by hand.

SP0199A

5. Turn the assembly several times to seat the bearings.

SPD770

6. Measure the turning torque at the end of the J34309-2 shaft

using Tool.
Tool number: ST3127SOOO (J25765-A)
Turning torque specification:
0.6- 1.0 N·m (6- 10 kg-em, 5.2- 8.7 in-lb)
7. Place the J34309-10 "R180A" pinion height adapter onto the
gauge plate and tighten it by hand.
CAUTION:
Make sure all machined surfaces are clean.

SPD234A

PINION BEARING PRELOAD WASHER SELECTION

8. Place the solid pinion bearing adjusting spacer squarely into
the recessed portion of the J34309-2 gauge anvil.

690 PD-26
 ADJUSTMENT I R180A I
Pinion Gear Height and Pinion Bearing Preload
(Cont'd) ~~
9. Select the correct thickness of pinion bearing preload adjust-
ing washer using a standard gauge of 6 mm (0.24 in) and
J34309-101 feeler gauge. The exact total measure you get
with the gauges is the thickness of the adjusting washer
required. Select the correct washer.
Drive pinion bearing adjusting washer:
Refer to SDS, PD-1 03.
/ 10. Set the selected pinion bearing preload adjusting washer aside ~©
for use when assembling the pinion and bearings into the final
drive housing.

PINION HEIGHT ADJUSTING WASHER SELECTION ~©

11. Place the J34309-1 0 pinion height adapter onto the gauge
Pinion height plate and tighten by hand. [!'11;
adapter ~~~ CAUTION:

~
Make sure all machined surfaces are clean.

SP0208A

12. Position firmly the side bearing discs, J25269-4, and arbor into t\\1!
the side bearing bores.

•
~~
13. Select the correct standard pinion height adjusting washer
thickness using a standard gauge of 3 mm (0.12 in) and
J34309-1 01 feeler gauge. Measure the distance between the
~[PJ
J34309-10 "R180A" pinion height adapter and the arbor.

14. Write down your exact total measurement.

SPD77i

PD-27 691
 ADJUSTMENT I R180A I
Pinion Gear Height and Pinion Bearing Preload
(Cont'd)
15. Correct the pinion height washer size by referring to the "pinion
head number".
There are two numbers painted on the pinion gear. The first
one refers to the pinion and ring gear as a matched set and
should be the same as the number on the ring gear. The sec-
ond number is the "pinion head height number", and it refers
to the ideal pinion height from standard for quietest operation.
Use the following chart to determine the correct pinion height
washer.
SPD542
Add or Remove from the Standard
Pinion Head Height Number Pinion Height Washer Thickness
Measurement
-6 Add 0.06 mm (0.0024 in)
-5 Add 0.05 mm (0.0020 in)
-4 Add 0.04 mm (0.0016 in)
-3 Add 0.03 mm (0.0012 in)
-2 Add 0.02 mm (0.0008 in)
-1 Add 0.01 mm (0.0004 in)
0 Use the selected washer thickness
+1 Subtract 0.01 mm (0.0004 in)
+2 Subtract 0.02 mm (0.0008 in)
+3 Subtract 0.03 mm (0.0012 in)
+4 Subtract 0.04 mm (0.0016 in)
+5 Subtract 0.05 mm (0.0020 in)
+6 Subtract 0.06 mm (0.0024 in)
. .
16. Select the correct pimon height washer.
Drive pinion height adjusting washer:
Refer to SDS, PD-103.

17. Remove the J34309 pinion preload shim selector tool from the
final drive housing and disassemble to retrieve the pinion
bearings.

SPD205A

692 PD-28
 ADJUSTMENT I R180A I

Tooth Contact
Gear tooth contact pattern check is necessary to verify correct
relationship between ring gear and drive pinion. ll::lft\
Hypoid gear sets which are not positioned properly may be noisy,
or have short life, or both. With a pattern check, the most desirable
contact for low noise level and long life can be assured. ~11::1

1. Thoroughly clean ring gear and drive pinion teeth.

2. Sparingly apply a mixture of powdered ferric oxide and oil or
equivalent to 3 or 4 teeth of ring gear drive side.

SPD357

3. Hold companion flange steady and rotate the ring gear in both
directions.

!PI'\

~i
Usually the pattern will be correct If you have calculated the shims correctly and the backlash is correct.
However, in rare cases you may have to use trial-and-error processes until you get a good tooth contact pattern.
The tooth pattern Is the best indication of how well a differential has been set up.
~~
Heel contact Face contact Toe contact Flank contact

~~
~11

To correct, increase thickness of pinion ~~

To correct, reduce thickness of pinion
height adjusting washer in order to bring height adjusting washer in order to make
drive pinion close to ring gear. drive pinion go away from ring gear.

____ /V--6
@11

~~

~
~~
When adjustment is completed, be sure to wipe
off completely the ferric oxide and oil or their

~
equivalent.
[[ij)ji
SPD007

PD-29 693
 ASSEMBLY I R180A I

\Bearing
Extension Tube and Differential Side Shaft
1. Measure rear axle bearing end play.
~§I I§J-=fe Rear axle bearing end play (A - B):
0.1 mm (0.0039 in) or less
The end play can be adjusted with bearing adjusting shim.
L Extension tube retainer
Available bearing adjusting shims:

~=tA Refer to SDS, PD-103.

L Extension tube
SPD206A

2. Install grease seal.

Tool number: (J35764)
\--------~~

Tool

SPD654

3. Install extension tube retainer, rear axle bearing and rear axle

•
Press
Tool shaft bearing collar on differential side shaft.
4. Install differential side shaft assembly into extension tube.

SPD655

Differential Case
1. Measure clearance between side gear thrust washer and
differential case.
Clearance between side gear thrust washer
8 and differential case (A - B):
Less than 0.15 mm (0.0059 in)
The clearance can be adjusted with side gear thrust washer.
Available side gear thrust washers:
Refer to SDS, PD-1 03.
2. Apply gear oil to gear tooth surfaces and thrust surfaces and
check to see they turn properly.

SPD656

694 PD-30
 ASSEMBLY I R180A I
Differential Case (Cont'd)
3. Install differential case LH and RH.

4. Place differential case on ring gear.

5. Apply locking agent [Locktite (stud lock) or equivalent] to ring
gear bolts, and install them.
Tighten bolts in a criss-cross fashion, lightly tapping bolt head !'Ill
with a hammer.

SPD746

6. .
Press-fit side bearing inner cones on differential case w1th ~'IT'

Tools.
Tool numbers:
Tool@ ~ ST33230000(J25805-Q1)
@ ST33061000 (J8107-2)

PD353

Final Drive Housing

1. Press-fit front and rear bearing outer races with Tools.
Tool numbers:
Pinion rear
~ ST30611000 (J25742-1)
@ ST30621000 (J25742-5)
@ ST30701000 (J25742-2)

Pinion front
bearing outer race

SPD679

PD-31 695
 ASSEMBLY I R180A I
Final Drive Housing (Cont'd)
2. Select pinion bearing adjusting washer and drive pinion bearing
spacer. Refer to "ADJUSTMENT", PD-25.
3. Install drive pinion height adjusting washer in drive pinion, and
press-fit pinion rear bearing inner cone in it, using press and
Tool.
Tool number: ST30901000 (J26010-01)

4. Place pinion front bearing inner cone in final drive housing.

5. Apply multi-purpose grease to cavity at sealing lips of oil seal.
Install front oil seal.
Tool number: ST30720000 (J25405)

6. Place drive pinion bearing spacer, p1mon bearing adjusting

washer and drive pinion in final drive housing.

7. Insert companion flange into drive p1mon by tapping the

companion flange with a soft hammer.

SPD659

8. Tighten pinion nut to the specified torque.

The threaded portion of drive pinion and pinion nut should be
free from oil or grease.
Tool number: ST38060002 (J34311)

PD466

696 PD-32
 ASSEMBLY I R180A I
Final Drive Housing (Cont'd)
9. Turn drive pinion in both directions several revolutions and iflll
measure pinion bearing preload.
Tool number: ST3127SOOO (J25765-A)
Pinion bearing preload: ITillffil
1.1 -1.7 N·m (11 -17 kg-em, 9.5- 14.8 in-lb)
When pinion bearing preload is outside the specifications,
replace pinion bearing adjusting washer and spacer with a [jjli~
different thickness.

SPD634

10. Select side retainer adjusting shim.

Refer to "ADJUSTMENT", PD-24.
11. Press-fit side bearing outer race into side retainer.
Tool numbers:
@ ST30611000 (J25742-1)
@ ST30621000 (J25742-5)

Tool@
Tool @
SPD332

12. Install side oil seal to side retainer. !'11

Tool number: ST33270000 (J25809)
13. Install differential case assembly.
14. Place side retainer adjusting shims (refer to "ADJUSTMENT", 111'

(
I
PD-24), and 0-ring on side retainer, and install them in final
drive housing.
Tool number: ST33720000 (J25817)
Ill
' I

~
'

1,\
SPD660

M
• Align arrows stamped on side retainer and final drive housing .

~1
15. Measure ring gear-to-drive pinion backlash with a dial indicator.
Ring gear-to-drive pinion backlash:
0.13 - 0.18 mm (0.0051 - 0.0071 in) llffil
• If backlash is too small, decrease thickness of right shim and
increase thickness of left shim by the same amount.
If backlash is too great, reverse the above procedure.
~b
Never change the total amount of shims as it will change the
bearing preload.

SPD635

PD-33 697
 ASSEMBLY I R180A I
Final Drive Housing (Cont'd)
16. Check total preload with Tool.
When checking preload, turn drive pinion in both directions
several times to set bearing rollers.
Tool number: ST3127SOOO (J25765·A)
Total preload:
1.2- 2.3 N·m
(12- 23 kg-em, 10 · 20 in-lb)

SPD634

• If preload is too great, add the same amount of shim to each

side.
• If preload is too small, remove the same amount of shim from
each side.
Never add or remove a different number of shims for each side
as it will change ring gear-to-drive pinion backlash.
17. Recheck ring gear·to·drive pinion backlash because increase
or decrease in thickness of shims will cause change of ring
gear to pinion backlash.

18. Check runout of ring gear with a dial indicator.

Runout limit:
0.05 mm (0.0020 in)
• If backlash varies excessively in different places, the variance
may have resulted from foreign matter caught between the ring
gear and the differential case.
• If the backlash varies greatly when the runout of the ring gear
is within a specified range, the hypoid gear set or differential
case should be replaced.
19. Check tooth contact. Refer to "ADJUSTMENT", PD-29.
20. Install rear cover and gasket.

21. Install extension tube and differential side shaft assembly.

SPD661

698 PD-34
 SEC. 380

~~~ Pinion mate shaft

IJ ®.a Thrust block

~JI~\ ~161
Side gear thrust washer D

Differential case

~~' ,~ * ~132-152(13.5-15.5,98-112)

Plnlonmatege&J?~deC Q ~ ~:L~Jr
ti

•!• .'"'"""''"ben·ng
_,,,,, ~" ~ 't
I @ " r@tVi ~ :oJ 49-59
(5.0 • 6.0, 36 • 43) JJ

~-~ ' I
A ~ . ~,- ..
m
Gear canier
Gasket
, IJ!I!! w
j t{0
)>
JJ
"tl Outec .ace lnnec cone !!
~ 0~~
c z
w' - dJ"usting shim )>
~))
<::<
U1 a Outec .ace r-
bearing~·
Pinion front _ Hypoid gear set

lV/[~
o c
r g~
Drive pinion height JJ
<
ABSsenso,unlt<~nne'~co~·J.' /~;)r
Outer race adjusting washer 11 Side bearing cap
FmntoHseal•!•
Side bearing m

~
~~6ifi} Drive pinion

1\~ ~/'
.ne . \\ washer
•!•
~- ''~J\~ ~5 )'
Companion \ • Collapsible spacer

(~~~~ ~ / /
flange ..

~~.>
:c:J \
8-11
~ :c:Jt6-24(1.6-2 4
· • 11.6 -17)

"" (0.8-11
. ' 58
' - 8.0)

~
~-J 127-294p"(13
Tighten . .0 • 30.0, 94. 217)
,. ~~ 1.2-2.2 N•m {12 until total preload
1mon nut t.t=!J • N· m {kg-m, ft-lb)
u : Adjustment is required

~
m-lb) is obtained. - 22 kg-m, 10. 19

~ * :Using locking agent [Locktite (stud lock)

or equivalent]
699

~
(@ 22) (I@ @0
~
CUjJ
:;;:: ~' ~ ©
~
1M) (F IWiJ ~ ~
©l
~ """"' 9 (!@ 9 22) ~--o 9 9 IF © a ~ d~
 DISASSEMBLY I H190A I

Pre-inspection
Before disassembling final drive, perform the following inspection.
• Total preload
a. Turn drive pinion in both directions several revolutions to seat
bearing rollers correctly.
b. Check total preload with Tool.
Tool number: ST3127SOOO (J25765-A)
Total preload:
1.2-2.2 N·m
(12- 22 kg-em, 10- 19 in-lb)

• Ring gear-to-drive pinion backlash

Check backlash of ring gear with a dial indicator at several
points.
Ring gear-to-drive pinion backlash:
0.13 - 0.18 mm (0.0051 - 0.0071 in)

SPD140

• Ring gear runout

Che.::k runout of ring gear with a dial indicator.
Runout limit:
0.08 mm (0.0031 in)

SPD141

• Tooth contact
Check tooth contact. Refer to "ADJUSTMENT", PD-51.
Feeler
• Side gear-to-pinion mate gear backlash
gauge Measure clearance between side gear thrust washer and
differential case with a feeler gauge.
Clearance between side gear thrust washer and
differential case:
Less than 0.15 mm (0.0059 in)

SPD004

Differential Carrier
1. Mount differential carrier on Tools.
Tool numbers:
@ ST0501 SOOO ( - )
@ ST06310000 (J25602-01)

SPD139

700 PD-36
 DISASSEMBLY I H190A I
Differential Carrier (Cont'd)
2. Put match marks on one side of side bearing cap with paint or @~
punch to ensure that it is replaced in proper position during
reassembly.
Bearing caps are line-bored during manufacture and should
be put back in their original places.

3. Remove side bearing caps.

Match mark
SPD009

4. Remove differential case assembly with a pry bar.

'ii'IP

~
Keep the side bearing outer races together with their respective
inner cones - do not mix them up.

5. Remove drive pinion nut with Tool.

Tool
Tool number: ST38060002 (J34311)
6. Remove companion flange with puller.

SPD213A

PD-37 701
 DISASSEMBLY I H190A I
Differential Carrier (Cont'd)
7. Remove drive pinion with soft hammer.
8. Remove oil seal.

SPD015

9. Remove pinion bearing outer races with a brass drift.

SPD563

10. Pull out rear bearing inner cone with a press and Tool.
Tool number: ST30031000 (J22912-01)

SPOOfS

Differential Case
1. Remove side bearing inner cones.
To prevent damage to bearing, engage puller jaws in groove.
Tool numbers:
@ ST33051001 (J22888-20)
@ ST33061000 (J8107-2)

SPD207A

Be careful not to confuse the left and right hand parts.

SPD022

702 PD-38
 DISASSEMBLY I H190A I
Differential Case (Cont'd)
2. Spread out lock straps and loosen ring gear bolts in a iilll
criss-cross fashion.
3. Tap ring gear off differential case with a soft hammer.
Tap evenly all around to keep ring gear from binding.

SPD024

4. Drive out pinion mate shaft lock pin, with Tool from ring gear ll"©
side.
Lock pin is calked at pin hole mouth on differential case.

SPD025

PD-39 703
 INSPECTION I H190A I

Ring Gear and Drive Pinion

Check gear teeth for scoring, cracking or chipping.
If any damaged part is evident, replace ring gear and drive pinion
as a set (hypoid gear set).

Differential Case Assembly

Check mating surfaces of differential case, side gears, pinion mate
gears, pinion mate shaft, and thrust washers.

SPD239A

Bearing
1. Thoroughly clean bearing.
2. Check bearings for wear, scratches, pitting or flaking.
Check tapered roller bearing for smooth rotation. If damaged,
replace outer race and inner cone as a set.

SPD715

704 PD-40
 LIMITED SLIP DIFFERENTIAL I H190A I

No ol discs and plates (One side)

~del H190A

Friction disc 2
Friction plate 2
Spring disc 1
Spring plate 1

*Adjustment is required.
SPD147AA

CAUTION:
Do not run engine when only one wheel (rear) is off t h e .
ground.

Preparation for Disassembly

CHECKING DIFFERENTIAL TORQUE
Measure differential torque with Tools.
If it is not within the specifications, inspect components of limited
slip differential.
Differential torque:
New parts
69- 118 N·m (7- 12 kg-m, 51 -87 ft-lb)
Used parts
Tool@ 39 - 74 N·m (4 - 7.5 kg-m, 29 - 54 ft-lb)
Tool number:
@ KV38105110 ( )
@ KV38105120 ( )
rul/i)_.,
IJlb-.,

PD-41 705
 LIMITED SLIP DIFFERENTIAL I H190A I

Disassembly
1. Remove couple screws.
2. Separate differential cases A and B. Draw out component parts
(disc and plates etc.).

SPD149A

Inspection
CONTACT SURFACES
1. Clean the disassembled parts in suitable solvent and blow dry
with compressed air.
2. If the following surfaces are found with burrs or scratches,
smooth with oil stone.
G) Differential case A
2 ® Differential case B
3 @ Side gear
@ Pinion mate gear
® Pinion mate shaft
® Thrust block

~
0 Pressure ring
5
7

6
SPD150A

DISC AND PLATE

t~
'

l --==------ -- :~--
1. Clean the discs and plates in suitable solvent and blow dry with
compressed air.
2. Inspect discs and plates for wear, nicks and burrs.
3. Check friction discs or plates for warpage.
Maximum allowable warpage:
0.08 mm (0.0031 in)
If it exceeds limits, replace with a new plate to eliminate
possibility of clutch slippage or sticking.

SPD279

706 PD-42
 LIMITED SLIP DIFFERENTIAL I H190A I
Inspection (Cont'd)
4. Measure frictional surfaces and projected portions of friction @I
discs, plates, spring disc and plate. If any part has worn
beyond the wear limit, replace it with a new one that is the
same thickness as the projected portion.
Wear limit:
0.1 mm (0.004 in) or less

B
A

!T\
-~· ··0·· •
•
• : Measuring points
A : Projected portion
B : Frictional surface

A- B "'Wear limit mm (in)

SP0403

Assembly
~ F'iction plate Prior to assembling discs and plates, properly lubricate them with
limited slip differential oil.
Friction disc 1. Alternately position specified number of friction plates and
friction discs on rear of side gear.

SPD153A

2. Install spring disc.

Spnng disc

SPD154A

3. Install spring plate.

Spring plate

SPD155A

PD-43 707
 LIMITED SLIP DIFFERENTIAL I H190A I
Assembly (Cont'd)
4. Install side gear thrust washer to differential case A.

SPD156A
'

5. Install differential case A over side gear, discs and plates

assembly.

Suitable block

SPD157A

6. Install pinion mate gears, pinion shaft and thrust block to

differential case A.

SPD158A

7. Install side gear to pinion mate gears.

8. Install pressure ring to side gear.
9. Install each disc and plate.
Use same procedures as outlined in steps 1. through 3.

SPD159A

10. Install side gear thrust washer to differential case B.

SPD160A

708 PD-44
 LIMITED SLIP DIFFERENTIAL I H190A I
Assembly (Cont'd)
11. Install differential case B. @I
Position differential cases Band A by correctly aligning marks
stamped on cases.

SPD161A

12. Tighten differential case couple screws.

SPD162A

13. Check if there is a clearance between differential cases B and i~"J

A.
If there is a clearance, use a thinner side gear thrust washer on
both sides. li'IP
Available side gear thrust washers:
Refer to SDS, PD-1 04.

Feeler gauge

SPD163A

14. Check differential torque:

Differential torque:
New parts
69- 118 N·m (7- 12 kg-m, 51 -87 ft-lb)
Used parts
39 - 74 N·m (4 - 7.5 kg-m, 29 - 54 ft-lb)
Tool numbers:
@ KV38105110 ( )
@ KV38105120 ( )
If greater than specification, use a thinner friction disc. If less than ~~
Tool@ specification, use a thicker friction disc.
Available friction discs:
Refer to SDS, PD-1 04.

PD-45 709
 ADJUSTMENT H190A

For quiet and reliable final drive operation, the following five
adjustments must be made correctly:
1. Side bearing preload
2. Pinion gear height
3. Pinion bearing preload. Refer to "ASSEMBLY", PD-55.
4. Ring gear-to-pinion backlash. Refer to "ASSEMBLY", PD·55.
5. Ring and pinion gear tooth contact pattern

Side Bearing Preload

A selection of carrier side bearing preload shims is required
for successful completion of this procedure.

1. Make sure all parts are clean and that the bearings are well
lubricated with light oil or type "DEXRON™'' automatic
transmission fluid.
2. Remove side bearing inner cones.
To prevent damage to bearing, engage puller jaws in grooves.
Groove Tool numbers:
@ ST33051 001 (J22888-20)
@ ST33061000 (J8107-2)

SPD207A

3. Reinstall all of the original side bearing adjusting shims on the

carrier side, away from the ring gear.

--------------
(~~)
~ W10Uo)
~ SPD214A

4. Reinstall the carrier side bearing using Tools J25805·01 and

J8107·2. Press on the bearings.

'"" '
(J25805-01~~
ST33061000
IJB107·2l
SPD145

710 PD-46
 ADJUSTMENT I H190A I
Side Bearing Preload (Cont'd)
5. Install carrier and bearings into the final drive housing. Install "'I
"'"
side bearing caps. Torque the bolts and tap on the caps with
a soft hammer to seat the bearings.
Side bearing cap bolt torque specification: lrliffi,
49 - 59 N·m (5 - 6 kg-m, 36 - 43 ft-lb)

6. After turning the carrier several times to seat the bearings, ~©

measure carrier turning force with spring gauge J8129.
Turning force specification:
34.3- 39.2 N (3.5- 4.0 kg, 7.7- 8.8 lb) li'~
of pulling force at the ring gear bolt

SPD192A

7. If necessary, correct the carrier bearing preload by adding to iiJ

'''I or subtracting from the total amount of shim thickness.
' Add shim thickness to increase turning force on the carrier. J'IP
I
I!..
' "'-.!.JV
Subtract shim thickness to decrease turning force on the
I carrier.
I
----.!....,
-,
L

/
__ _...r f) SPD776

Pinion Gear Height

1. Make sure all parts are clean and that the bearings are well
lubricated. IBJ:J
2. Assemble the pinion gear bearings into the pinion pre-load
shim selector Tool, J34309.

SPD196A
~11
• Front Pinion Bearing- make sure the J34309-3 front pinion
bearing is secured tightly against the J34309 gauge anvil.
Then turn the front pinion bearing pilot J34309-5 to secure the lilflc
bearing in its proper position.
• Rear Pinion Bearing- the rear pinion bearing pilot, J34309-
15, is used to center the rear pinion bearing only. The rear ~!,
pinion bearing locking seat, J34309-4 is used to lock the bear-
ing to the assembly.

SPD197A

PD-47 711
 ADJUSTMENT I H190A I
Pinion Gear Height (Cont'd)
3. Place the pinion pre-load shim selector Tool J34309-1 gauge
screw assembly with the pinion rear bearing inner cone
installed into the final drive housing.

4. Assemble the front pinion bearing inner cone and the J34309-2
gauge anvil together with the J34309-1 gauge screw in the
final drive housing. Make sure that the pinion height gauge
plate, J34309-16, will turn a full 360 degrees, and tighten the
two sections together by hand.

5. Turn the assembly several times to seat the bearings.

6. Measure the turning torque at the end of the J34309-2 gauge

anvil using Tool.
Tool number: ST3127SOOO (J25765-A)
Turning torque specification:
1.0- 1.3 N·m
(10- 13 kg-em, 8.7- 11.3 in-lb)

SPD234A

7. Place the J34309-14 pinion height adapter onto the gauge

plate and tighten it by hand.
CAUTION:
Make sure all machined surfaces are clean.

SPD208A

712 PD-48
 ADJUSTMENT I H190A I
Pinion Gear Height (Cont'd)
PINION HEIGHT ADJUSTING WASHER SELECTION
8. Now, position the side bearing discs, J25269-18, and arbor
firmly into the side bearing bores.
I
'
0 j
\
~'
K1ct(
9. Install the side bearing caps and torque the cap bolts.
Specification:
49 - 59 N·m (5 - 6 kg-m, 36 - 43 11-lb)

10. Select the correct standard pinion height adjusting washer ;1,1
thickness by using J34309-1 01 feeler gauge. Measure the gap
between the J34309-14 pinion height adapter and the arbor.

11. Write down your exact total measurement.

SPD778
~'ij'
12. Correct the pinion height washer size by referring to the "pinion
head number".
There are two numbers painted on the pinion gear. The first tilffi\
one refers to the pinion and ring gear as a matched set and
should be the same as the number on the ring gear. The sec-
ond number is the "pinion head height number," and it refers ~l
to the ideal pinion height from standard for quietest operation.

SPD542

PD-49 713
 ADJUSTMENT I H190A I
Pinion Gear Height (Cont'd)
Use the following chart to determine the correct pinion height
washer
Add or Remove from the Standard
Pinion Head Height Number Pinion Height washer Thickness
Measurement
-6 Add 0.06 mm (0.0024 in)
-5 Add 0.05 mm (0.0020 in)
-4 Add 0.04 mm (0.0016 in)
-3 Add 0.03 mm (0.0012 in)
-2 Add 0.02 mm (0.0008 in)
-1 Add 0.01 mm (0.0004 in)
0 Use the selected washer thickness
+1 Subtract 0.01 mm (0.0004 in)
+2 Subtrac1 0.02 mm (0.0008 in)
+3 Subtract 0.03 mm (0.0012 in)
+4 Subtract 0.04 mm (0.0016 in)
+5 Subtract 0.05 mm (0.0020 in)
+6 Subtract 0.06 mm (0.0024 m)

13. Select the correct pimon height washer.

Drive pinion height adjusting washer:
Refer to SDS, PD-1 04.

14. Remove the J34309 pinion preload shim selector Tool from the
final drive housing and disassemble to retrieve the pinion
bearings.

714 PD-50
 ADJUSTMENT I H190A I

Tooth Contact
Checking of gear tooth contact pattern is necessary to verify
correct relationship between ring gear and drive pinion. f;~Tiffil
Hypoid gear sets which are not positioned properly may be noisy,
or have short life, or both. With a pattern check, the most desirable
contact for low noise level and long life can be assured. !1;1:!~

1. Thoroughly clean ring gear and drive pinion teeth.

2. Sparingly apply a mixture of powdered ferric oxide and oil or
equivalent to 3 or 4 teeth of ring gear drive side.

SPD005

3. Hold companion flange steady and rotate the ring gear in both
directions.

SPD006

Usually the pattern will be correct if you have calculated the shims correctly and the backlash is correct.
However, in rare cases you may have to use trial-and-error processes until you get a good tooth contact pattern.
The tooth pattern Is the best indication of how well a differential has been set up.

Heel contact Face contact Toe contact Flank contact

~~
To correct. increase thickness ot pinion
height adjusting washer in order to bring
To correct, reduce thickness of pinion
height adjusting washer in order to make
drive pinion close to ring gear. drive pinion go away from ring gear.

--··- / &tl---b
When adjustment Is completed, be sure to wipe
off completely the ferric oxide and oil or their
equivalent.
~
~ SPD007

PD-51 715
 ASSEMBLY I H190A I

Differential Case
1. Install side gears, pinion mate gears and thrust washers into
differential case.

SPD552

2. Fit pinion mate shaft to differential case so that it meets lock

Feeler gauge
pin holes.
Feeler gauge 3. Adjust backlash between side gear and pinion mate gear by
selecting side gear thrust washer. Refer to SDS, PD-1 04.
Backlash between side gear and pinion mate gear
(Clearance between side gear thrust washer and dif-
ferential case):
Less than 0.15 mm (0.0059 in)

SPD828

4. Install pinion mate shaft lock pin with a punch.

Make sure lock pin is flush with case.

5. Apply gear oil to gear tooth surfaces and thrust surfaces and
check to see they turn properly.

6. Apply locking agent [Locktite (stud lock) or equivalent] to con-

tacting surfaces of ring gear and differential case, then place
differential case on ring gear.

SPD600

716 PD-52
 ASSEMBLY I H190A I
Differential Case (Cont'd)
7. Apply a small amount of locking agent (described on previous ill~
page) to ring gear bolts.
8. Install new lock straps and ring gear bolts.
• Tighten bolts in a criss-cross fashion, lightly tapping bolt
head with a hammer.
• Then bend up lock straps to lock the bolts in place .

9. Select side bearing adjusting shims.

Refer to "ADJUSTMENT", PD-46.
10. Install the shims behind each bearing and press on side
Tool@ bearing inner cones with Tools. ~~
Tool numbers:
@ ST33230000 (J25805-01)
@ ST33061000 (J8107-2)

Tool@
PD353

~'TI'
Differential Carrier
1. Press-fit front and rear bearing outer races with Tools.
Tool numbers: Ill"
@ ST30611000 (J25742-1)

•
@ ST30621 000 (J25742-5)
@ ST30613000 (J25742-3)

Pinion rear
~"'
Tool@ ~

;:
Tool@

llil~

on front \)1]'
ring outer race

I'll)

SP0580
1!)11
2. Select p1mon height adjusting washer. Refer to
"ADJUSTMENT", PD-47.
3. Install pinion height adjusting washer in drive p1mon, and
press-fit rear bearing inner cone with press and Tool. ~"'
Tool number: ST30901000 (J26010-01)
~IL

~[jjz

PD-53 717
 ASSEMBLY I H190A I
Differential Carrier (Cont'd)
4. Place pinion front bearing inner cone in gear carrier.

SPD58i

5. Apply multi-purpose grease to cavity at sealing lips of oil seal.

Install front oil seal.
Tool numbers:
@ ST30720000 (J25405)
@ KV38102510 ( )

Drive pinion washer 6. Install drive pinion washer, collapsible spacer and drive pinion
Collapsible spacer in gear carrier.

7. Install companion flange and hold it firmly.

Insert pinion into companion flange by tapping its head with a
soft hammer.

8. Temporarily tighten pinion nut until there is no axial play.

Tool
The threaded portion of drive pinion and pinion nut should be
free from oil or grease.
Tool number: ST38060002 (J34311)

718 PD-54
 ASSEMBLY I H190A I
Differential Carrier (Cont'd)
9. Tighten pinion nut by degrees to the specified preload while lllil
lr--- checking the preload with Tools.
When checking preload, turn drive pinion in both directions
several times to seat bearing rollers correctly.
Pinion bearing preload:
1.1 - 1.6 N·m (11 - 16 kg-em, 9.5- 13.9 in-lb)
Tool number: ST3127SOOO (J25765-A)
CAUTION:
The preload is achieved by the permanent setting of the col-
lapsible spacer. So, if an overpreload results from turning of lL~:G
the pinion nut excessively, the spacer should be replaced by
SPD149
new one.
~~:g
10. Install differential case assembly with side bearing outer races
into gear carrier.

SPD01

11. Align mark on bearing cap with that on gear carrier and install J\f
bearing cap on gear carrier.

~t~
12. Measure ring gear-to-drive pinion backlash with a dial indica·
tor.
Ring gear-to-drive pinion backlash:
0.13 - 0.18 mm (0.0051 - 0.0071 in)
• If backlash is too small, decrease thickness of left shim and
increase thickness of right shim by the same amount.
• If backlash is too great, reverse the above procedure.
Never change the total amount of shims as it will change the
bearing preload.

SPD140

13. Check total preload with Tool.

When checking preload, turn drive pinion in both directions
several times to set bearing rollers.
Tool number: ST3127SOOO (J25765-A)
Total preload:
1.2- 2.2 N·m (12- 22 kg-em, 10- 19 in-lb)

SPD149

PD-55 719
 ASSEMBLY I H190A I
Differential Carrier (Cont'd)
• If preload is too great, remove the same amount of shims from
each side.
• If preload is too small, add the same amount of shims to each
side.
Never add or remove a different number of shims for each side
as it will change ring gear-to-drive pinion backlash.
14. Recheck ring gear-to-drive pinion backlash because an
increase or decrease in thickness of shims will cause change
of ring gear-to-pinion backlash.

SPD031

15. Check runout of ring gear with a dial indicator.

Runout limit: 0.08 mm (0.0031 in)
• If backlash varies excessively in different places, the variance
may have resulted from foreign matter caught between the ring
gear and the differential case.
• If the backlash varies greatly when the runout of the ring gear
is within a specified range, the hypoid gear set or differential
case should be replaced.
16. Check tooth contact.
Refer to "ADJUSTMENT", PD-51.
SPD141

720 PD-56
 SEC. 380
trll127 - 294 (13 - 30, 94 - 217)

~~
'1
~
~
)\
L Companion fla.nge
Front oil seal ~
) Inner cone

Side bearing cap Outer race \

trll 88 - 98 (9 - 10 65
trll132 - 152 (13.5 - 15 ' - 72),
~f{
'!/, /
-"""'
.~~\0 _, ,.
~Drive pinion
front bearing

.5, 98 - 112) \ I(( l:J

"tl
cI
en
......
Differential case lnnerc::~~~~~~
~
~
~-

~' \ _
>/ ~ Collapsible spacer ~
Drain plug r:4
trll59 - 98 (6 - 10, 43 - 72)
m
)>
l:J
:!!
z
)>
r-
Carrier cover
Pinion height ad·JUSIIng
. Washer
washern- c
l:J

/ ~(3--Pmron mate thrust washer

<
m
~--Thrust block
~ Set so that round seat direction faces spacer side.
~Side gear
.~--\1

~~ ~Side bearing adjusting shim{!

Side gear thrust

washer f:l Inner coney (d
r ® I
Spacer

Pinion mate shaft Side bearing~uter race (2')

Lock pint:i
trll • N•m (kg-m. ft-lb)
~ : Always replace when

~
""'
disassembled

~
U : Adjustment is required.

II
721

~ liiCl
tr ~
lQ.?J
c--:J
:~.';'}
0Jil
!!!iJ
9
@flJ
29 "-"'
~~
"ml
:0--::>
~
CjjJ ~ ~
9
c"
[p
"liil
!ffiil ~
•F"
·:S-"b
!ffiil
~
~
~~
~
~l
 DISASSEMBLY I C200 I

Pre-inspection
Before disassembling final drive, perform the following inspection.
• Total preload
a. Turn drive pinion in both directions several times to set bearing
rollers.
b. Check total preload with Tool.
Tool number: ST3127SOOO (J25765-A)
Total preload:
1.2-2.3 N·m
Tool (12- 23 kg-em, 10- 20 in-lb)
PD245

• Ring gear-to-drive pinion backlash.

Check backlash of ring gear with a dial indicator at several
points.
Ring gear-to-drive pinion backlash:
0.13-0.18 mm (0.0051- 0.0071 in)

• Ring gear runout

Check runout of ring gear with a dial indicator.
Runout limit: 0.05 mm (0.0020 in)

• Tooth contact
Check tooth contact. Refer to "ADJUSTMENT", PD-74.
• Side gear-to-pinion mate gear backlash
Measure clearance between side gear thrust washer and
differential case with a feeler gauge.
Clearance between side gear thrust washer and differ-
ential case:
Less than 0.15 mm (0.0059 in)

Differential Carrier
1. Remove rear cover and rear cover gasket.
2. Put match marks on one side of side bearing cap with paint or
punch to ensure that it is replaced in proper position during
reassembly.
Bearing caps are line-bored during manufacture and should
be put back in their original places.

722 PD-58
 DISASSEMBLY I C200 I
Differential Carrier (Cont'd)
3. Remove side bearing caps.

SPD202

4. Remove differential case assembly with pry bar.

SPD193

ffil1i'
Keep the side bearing outer races together with their respective
inner cones - do not mix them up.

SPD745
•
5. Remove pinion nut with Tool.
Tool number: ST38060002 (J34311)

~204

6. Remove companion flange with puller.

SPD014

PD-59 723
 DISASSEMBLY I C200 I
Differential Carrier (Cont'd)
7. Remove drive pinion with soft hammer.
8. Remove front oil seal and pinion front bearing inner cone.

Soft hammer
SP0206

9. Remove pinion bearing outer races with a brass drift.

PD349

10. Remove pinion rear bearing inner cone and pinion height
adjusting washer.
Tool number: ST30031 000 (J22912-01)

{Tool

PD179

Differential Case
1. Remove side bearing inner cones.
To prevent damage to bearing, engage puller jaws in grooves.
Tool numbers:
@ ST33051 001 (J22888-20)
@ ST33061 000 (J81 07-2)

Tool Clf;7
,:
;:
;:
//
i ,I

SPD529

724 PD-60
 DISASSEMBLY
Differential Case (Cont'd)
Be careful not to confuse the right and left hand parts.

SPD022

2. Loosen ring gear bolts in a criss-cross fashion.

3. Tap ring gear off the differential case with a soft hammer.
Tap evenly all around to keep ring gear from binding.

SPD024

4. Punch off pinion mate shaft lock pin from ring gear side.
Lock pin is calked at pin hole mouth on differential case.

SPD025

PD-61 725
 INSPECTION I C200 I

Ring Gear and Drive Pinion

Check gear teeth for scoring, cracking or chipping. If any damaged
part is evident, replace ring gear and drive pinion as a set (hypoid
gear set).

Differential Case Assembly

Check mating surfaces of differential case, side gears, pinion mate
gears, pinion mate shaft, thrust block and thrust washers.

SPDSB4

Bearing
1. Thoroughly clean bearing.
2. Check bearings for wear, scratches, pitting or flaking.
Check tapered roller bearing for smooth rotation. If damaged,
replace outer race and inner cone as a set.

SPD715

726 PD-62
 LIMITED SLIP DIFFERENTIAL I C200 I

No. of discs and plates (One side) Differential case

couple bolt
~el ~54 - 64 N•m (5.5 - 6.5 kg-m,~
C200 40 - 47 ft-lb)
Friction disc 6 Lock stcap ~\ \
Friction plate 6
Spring plate 1
->~
,~'
Friction plate* ~~~;~~·.v
~ 'd) gj Differential

~ ~ Th<~ "~' -· •

~ i \_p··
~ 1n1on mate thrust washer

Pinion mate gear

For number of discs or plates,
Side gear refer to table.

Spring plate•

SPD004A

CAUTION:
Do not run engine when only one wheel (rear) is off the
ground.

Preparation for Disassembly

CHECKING DIFFERENTIAL TORQUE
Measure differential torque with Tools.
If it is not within the specifications, inspect components of limited
slip differential.
Differential torque:
88 • 108 N·m
(9.0 • 11.0 kg-m, 65 • 80 ft-lb)
Tool numbers:
Tool@
@ KV38105110 ( )
@ KV38105120 ( )
Disassembly
1. Spread out lock straps.
2. Remove couple bolts using a press.
Tool number: ST33081 000 ( )
3. Separate differential cases A and B.
Draw out component parts (discs and plates, etc.).
Put marks on gears and pressure rings so that they can be
reinstalled in their original positions.

PD-63 727
 LIMITED SLIP DIFFERENTIAL I C200 I

Inspection
CONTACT SURFACES
1. Clean the disassembled parts in suitable solvent and blow dry
with compressed air.
2. If the following sufaces are found with burrs or scratches,
smooth with oil stone.
G) Differential case B
® Differential case A
@ Side gear
@) Pinion mate gear
® Pinion mate shaft
® Thrust block
0 Friction plate guide

SPD291

DISC AND PLATE

1. Clean the discs and plates in suitable solvent and blow dry with
compressed air.
2. Inspect discs and plates for wear, nicks and burrs.

3. Check friction discs or plates for warpage.

Maximum allowable warpage:
0.08 mm (0.0031 in)
If it exceeds limits, replace with a new plate to eliminate
possibility of clutch slippage or sticking.

728 PD-64
 LIMITED SLIP DIFFERENTIAL I C200 I
Inspection (Cont'd)
4. Measure frictional surfaces and projected portions of friction i;Oll
discs, plates and spring plate. If any part has worn beyond the
wear limit, replace it with a new one that is the same thickness
as the projected portion.
Wear limit:
0.1 mm (0.004 in) or less

B
A

fT\
-~· ··0·· •
•
• : Measuring points ©iL
A : Projected portion
B : Frictional surface
A- B "'Wear limit mm (in)

SPD403

Adjustment
FRICTION DISC AND FRICTION PLATE END PLAY
End play of friction disc and friction plate can be calculated by using 1!'1'
the following equation and should be adjusted within the following
range.
Adjustment can be made by selecting friction disc having two
different thicknesses.
End play E:
0.05 - 0.15 mm (0.0020 - 0.0059 in)
SPD761
E =A- (B +C)

A: Length of differential case contact surface

to differential case inner bottom.
B: Total thickness of friction discs, friction plates
and spring plate in differential case
on one side.
C: Length of differential case contact surface to
back side of side gear.

Differential case B Dip caliper Differential 1. Measure values of "A".

case A Standard length A:
49.50 - 49.55 mm (1.9488 - 1.9508 in)

SPD417

PD-65 729
 LIMITED SLIP DIFFERENTIAL I C200 I
Adjustment (Cont'd)
2. Measure thickness of each disc and plate.
Total thickness "B":
19.24- 20.26 mm (0.7575- 0.7976 in)
No. of discs and plates (One side):
Friction disc 6
Friction plate 6
Spring plate 1

SPD420

3. Measure values of "C".

a. Attach a dial indicator to the base plate.
b. Place differential case B on the base plate, and install a master
Suitable block
[master gauge 30 mm gauge on case B.
(1. 18 in)] Then adjust the dial indicator scale to zero with its tip on the
master gauge.

SPD418

c. Install pinion mate gears, side gears and pinion mate shaft in
differential case B.
d. Set dial indicator's tip on the side gear, and read the indication.
Suitable block
[master gauge 30 mm Example:
{1.18 in)]

E=A-D
=A- (B +C)
= 0.05 to 0.15 mm
A= 49.52 mm
B = 19.45 mm
C = 29.7 mm
D=B+C
B ... 19.45
+ c ... 29.7
49.15

E=A-D
A ... 49.52
-0 ... 49.15
0.37

From the above equation, end play of 0.37 mm exceeds the

specified range of 0.05 to 0.15 mm.
Select suitable discs and plates to adjust correctly.

730 PD-66
 LIMITED SLIP DIFFERENTIAL I C200 I
Qll
Assembly
Friction disc Prior to assembling discs and plates, properly lubricate them by
dipping them in limited slip differential oil. 101~
1 . Alternately position specified number of friction plates and
- Friction plate friction discs on rear of side gear.
Always position a friction plate first on rear of side gear. ~i!i

SPD421

2. Install spring plate.

SPD423

3. Install friction plate guides.

Correctly align the raised portions of friction plates, and apply
grease to inner surfaces of friction plate guides to prevent 1i'IP
them from falling.

~L~
4. Install differential case B over side gear, discs, plates and
friction plate guide assembly.
• Install differential case B while supporting friction plate
guides with your middle finger by inserting through oil
~l"l

hole in differential case.

• Be careful not to detach spring plate from the hexagonal
part of the side gear.
~1i'

5. Install pinion mate gears and pinion shaft to differential ~1i'

case B.

SPD426

PD-67 731
 LIMITED SLIP DIFFERENTIAL
Assembly (Cont'd)
6. Install thrust block.

7. Install side gear to pinion mate gears.

8. Install each disc and plate.
Use same procedures as outlined in steps 1. through 3.

9. Install differential case A.

Position differential cases A and B by correctly aligning marks
stamped on cases.

10. Tighten differential case bolts.

~I
11. Place ring gear on differential case and install new lock straps
and bolts.
Tighten bolts in a criss-cross fashion, lightly tapping bolt head
with a hammer.
Then bend up lock straps to lock the bolts in place.
12. Install side bearing inner cone.
13. Check differential torque.

SPD288

732 PD-68
 ADJUSTMENT

For quiet and reliable final drive operation, the following five @~
adjustments must be made correctly.
1. Side bearing preload
2. Pinion gear height ~vlffio
3. Pinion bearing preload. Refer to "ASSEMBLY", PD-77.
4. Ring gear-to-pinion backlash. Refer to "ASSEMBLY", PD-78.
5. Ring and pinion gear tooth contact pattern !ill~

Side Bearing Preload

A selection of carrier side bearing preload shims is required
for successful completion of this procedure.

©lb

1. Make sure all parts are clean. Make sure, also, the bearings fAT
are well lubricated with light oil or type "DEXRON™" automatic
transmission fluid.
2. Place the differential carrier, with side bearings and bearing 1JIF
races installed, into the final drive housing.

3. Put the side bearing spacer in place.

CAUTION:
Side bearing spacer is placed on either the right or left ~:RI
depending upon final drive gear ratio. Be sure to replace it on
the correct side.

llliV
4. Use Tool to place original carrier side bearing preload shims on
the carrier end, opposite the ring gear.
Tool number: KV38100600 (J25267) !ilffio

PD-69 733
 ADJUSTMENT
Side Bearing Preload (Cont'd)
5. Install the side bearing caps in their correct locations and
torque the bearing cap retaining bolts.
Specification:
88-98 N·m
(9.0 - 10.0 kg-m, 65 - 72 ft-lb)
6. Turn the carrier several times to seat the bearings.

SPD526

7. Measure the turning torque of the carrier at the ring gear

retaining bolts with a spring gauge, J8129.
Specification:
34.3- 39.2 N
(3.5- 4.0 kg, 7.7- 8.8 lb)
of pulling force at the ring gear bolt

SPD194A

I 8. If the turning torque is not within the specifications, correct the

I
torque as follows:

am?·g
I
,
I
• If the turning torque is less than the specified range, install
I, washers of greater thickness.
L--
; • If the turning torque is greater than the specification, install
;
; thinner washers.
--z.,\_ • See the SDS section for washer dimensions and part numbers.
'--
9. Record the total amount of washer thickness required for the
correct carrier side bearing preload.

SPD772

10. Remove the carrier from the final drive housing. Save the
Too!
selected preload washers for later use during the assembly of
the final drive unit.

PD344

Pinion Gear Height

1. Make sure all parts are clean and that the bearings are well
lubricated.
2. Assemble the pinion gear bearings into the pinion preload shim
selector Tool, J34309.

11111111111111111

SPD769

734 PD-70
 ADJUSTMENT I C200 I
Pinion Gear Height (Cont'd)
@'[
• Front pinion bearing - make sure the J34309-3 front pinion
bearing seat is secured tightly against the J34309-2 gauge
anvil. Then turn the front pinion bearing pilot, J34309-5, to
secure the bearing in its proper position.
• Rear pinion bearing - the rear pinion bearing pilot,
J34309-8, is used to center the rear pinion bearing only. The ~~JJ
rear pinion bearing locking seat, J34309-4, is used to lock the
bearing to the assembly.

SPD197A

3. Install the pinion rear bearing inner cone into the final drive ~©
housing. Then place the pinion preload shim selector Tool,
J34309-1 , gauge screw assembly.

__/

c
SPD893

4. Assemble the front pinion bearing inner cone and the J34309-2 ffi\1!
gauge anvil. Assemble them together with the J34309-1 gauge
screw in the final drive housing. Make sure that the pinion 1712
height gauge plate, J34309-16, will turn a full 360 degrees. u ~
Tighten the two sections together by hand.

SPD199A
•
5. Turn the assembly several times to seat the bearings.

SPD770

6. Measure the turning torque at the end of the J34309-2 gauge

®7
anvil using Tool.
Tool number: ST3127SOOO (J25765-A)
Turning torque specification:
1.0- 1.3 N·m
(10- 13 kg-em, 8.7- 11.3 in-lb)

SPD234A

PD-71 735
 ADJUSTMENT I C200 I
Pinion Gear Height (Cont'd)
7. Place the J34309-11 pinion height adapter onto the gauge
plate and tighten it by hand.
CAUTION:
Make sure all machined surfaces are clean.

PINION HEIGHT ADJUSTING WASHER

SELECTION
8. Now, position the side bearing discs, J25269-4, and arbor
firmly into the side bearing bores.
Install the side bearing caps and tighten the cap bolts to proper
torque.

9. Select the correct standard pinion height adjusting washer

thickness. Select by using a standard gauge of 3 mm (0.12 in)
and J34309-101 feeler gauge. Measure the distance between
the J34309-11 pinion height adapter including the standard
gauge and the arbor.

10. Write down your exact measurement (the value of feeler

gauge).

SPD775

736 PD-72
 ADJUSTMENT
Pinion Gear Height (Cont'd) w
11. Correct the pinion height washer size by referring to the "pinion "'"
head number".
There are two numbers painted on the pinion gear. The first
one refers to the pinion and ring gear as a matched set. This
number should be the same as the number on the ring gear.
The second number is the "pinion head height number''. It
refers to the ideal pinion height from standard for quietest
operation. Use the following chart to determine the correct
pinion height washer.

SPD542

Use the following chart to determine the correct pinion height rgc;
washer:

Pinion head height Add or remove from the standard pinion height
number washer thickness measurement
-6 Add 0.06 mm (0.0024 in)
-5 Add 0.05 mm (0.0020 in)
-4 Add 0.04 mm (0.0016 in)
-3 Add 0.03 mm (0.0012 in)
-2 Add 0.02 mm (0.0008 in)
-1 Add 0.01 mm (0.0004 in)
0 Use the selected washer thickness
+1 Subtract 0.01 mm (0.0004 in)
+2 Subtract 0.02 mm (0.0008 in)
+3 Subtract 0.03 mm (0.0012 in)
+4 Subtract 0.04 mm (0.0016 in)
+5 Subtract 0.05 mm (0.0020 in)
+6 Subtract 0.06 mm (0.0024 in)

12. Select the correct pinion height washer.

Drive pinion height adjusting washer:
Refer to SDS, PD-1 05.

13. Remove the J34309 pinion preload shim selector Tool from the
i1i1i'
final drive housing. Then disassemble to retrieve the pinion
bearings.

SPD205A

PD-73 737
 ADJUSTMENT C200

Tooth Contact
Checking gear tooth contact pattern is necessary to verify correct
relationship between ring gear and drive pinion.
Hypoid gear set which is not positioned properly may be noisy, or
have short life or both. With the checking or gear tooth contact
pattern, the most desirable contact for low noise level and long life
can be assured.

1. Thoroughly clean ring gear and drive pinion teeth.

2. Sparingly apply a mixture of powdered ferric oxide and oil or
equivalent to 3 or 4 teeth of ring gear drive side.

3. Hold companion flange steady and rotate the ring gear in both
directions.

Usually the pattern will be correct II you have calculated the shims correctly and the backlash Is correct.
However, In rare cases you may have to use trial-and-error processes until you get a good tooth contact pattern.
The tooth pattern Is the best Indication of how well a differential has been set up.

Heel contact Face contact Toe contact Flank contact

~~
To correct. increase thickness of pinion
height adjusting washer in order to bring
To correct, reduce thickness of pinion
height adjusting washer in order to make
drive pinion close to ring gear. drive pinion go away from ring gear.

_____ /V--b
When adjustment Is completed, be sure to wipe
off completely the ferric oxide and oil or their
equivalent.
~
~ SPD007

738 PD-74
 ASSEMBLY

Differential Case
1. Measure clearance between side gear thrust washer and
differential case. IT!uffi'..
Clearance between side gear thrust washer
and differential case (A - B):
Less than 0.15 mm (0.0059 in) l"ull
The clearance can be adjusted with side gear thrust washer.
Refer to SDS, PD-1 05.
2. Apply gear oil to gear tooth surfaces and thrust surfaces and L:C:
check to see they turn properly.

IiiiiI
SPD656

3. Install differential case LH and RH.

•
4. Place differential case on ring gear.
5. Apply locking agent [Locktite (stud lock) or equivalent] to ring
gear bolts, and install them.
~~
Tighten bolts in a criss-cross fashion, lightly tapping bolt head
with a hammer.

SPD746

6. Press-fit side bearing inner cones on differential case with Tool. IIDll
Tool numbers:
@ ST33230000 (J25805-01)
@ ST33061000 (J8107-2)

Tool@
P0353

PD-75 739
 ASSEMBLY I C200 I

Differential Carrier
1. Press-fit front and rear bearing outer races with Tools.
Tool numbers:
Pinion rear
bearing outer race
@ ® @ ST30611 000 (J25742-1)
@ ST30621 000 (J25742-5)
@ ST30613000 (J25742-3)

Pinion front
bearing outer race

2. Select pinion height adjusting washer. Refer to

"ADJUSTMENT'", PD-70.
3. Install pinion height adjusting washer in drive pinion, and
press-fit rear bearing inner cone in it, with press and Tool.
Tool number: ST30901000 (J26010-01)

4. Place pinion front bearing inner cone in gear carrier.

SPD581

5. Apply multi-purpose grease to cavity at sealing lips of oil seal.

Install front oil seal.
Tool
Tool number: KV38100500 (J25273)

SPD557

740 PD-76
 ASSEMBLY I C200 I
Differential Carrier (Cont'd)
6. Place drive pinion bearing spacer, drive p1mon bearing lil'~
adjusting washer and drive pinion in gear carrier.

SPD222

7. Insert companion flange into drive pinion by tapping the ~©

companion flange with a soft hammer.

Soft hammer

SPD708

8. Tighten pinion nut to 127 N·m (13 kg-m, 94 ft-lb).

/
The threaded portion of drive pinion and pinion nut should be
free from oil or grease.
Tool number: ST38060002 (J34311)

9. Tighten the pinion nut by very small degrees until the specified M
preload is achieved. When checking the preload, turn the drive
Pinion in both directions several times to set the bearing rollers. [8)~
Tool number: ST3127SOOO (J25765-A)
Pinion bearing preload:
1.1- 1.7 N·m
(11 - 17 kg-em, 9.5- 14.8 in-lb)
This procedure will have to be repeated if:
• Maximum preload is achieved before the minimum pinion
nut torque is reached. I'J&
Tool
• Minimum preload is not achieved before maximum pinion
SPD241
nut torque is reached.
10. Select side bearing adjusting washer.
Refer to Adjustment.
11. Install differential case assembly with side bearing outer races
into gear carrier.

PD-77 741
 ASSEMBLY C200

Differential Carrier (Cont'd)

12. Insert left and right side bearing adjusting washers in place
between side bearing and carrier.

SPD558

Side bearing spacer 13. Drive in side bearing spacer with Tool.
\ Tool number: KV38100600 (J25267)

14. Align mark on bearing cap with that on gear carrier and install
bearing cap on gear carrier.

15. Measure ring gear-to-drive pinion backlash with a dial indicator.

Ring gear-to-drive pinion backlash:
0.13-0.18 mm
(0.0051 - 0.0071 in)
• If backlash is too small, decrease thickness of right shim and
increase thickness of left shim by the same amount.
If backlash is too great, reverse the above procedure.
Never change the total amount of shims as it will change the
bearing preload.

SPD196

16. Check total preload with Tool.

When checking preload, turn drive pinion in both directions
several times to seat bearing rollers correctly.
Total preload:
1.2- 2.3 N·m
(12- 23 kg-em, 10- 20 in-lb)
Tool number: ST3127SOOO (J25765-A)

Tool
SPD241

742 PD-78
 ASSEMBLY
Differential Carrier (Cont'd)
• If preload is too great, remove the same amount of shim from ®~
each side.
• If preload is too small, add the same amount of shim to each
side.
Never add or remove a different number of shims for each side
as it will change ring gear-to-drive pinion backlash.
17. Recheck ring gear-to-drive pinion backlash because increase
or decrease in thickness of shims will cause change of ring
gear-to-pinion backlash.

18. Check runout of ring gear with a dial indicator.

Runout limit:
0.05 mm (0.0020 in)
• If backlash varies excessively in different places, the variance I"~
may have resulted from foreign matter caught between the ring
gear and the differential case.
• If the backlash varies greatly when the runout of the ring gear ·:GIL
is within a specified range, the hypoid gear set or differential
case should be replaced.
19. Check tooth contact.
Refer to "ADJUSTMENT", PD-74.
20. Install rear cover and gasket.

PD-79 743
744

SEC. 380

~.~J~f[D ~~~-- r P1n10n mate thrust washer

PiniOn mate gear

rtf}@ ~~
1 m::r:~::locH
Pon1on

~ '(9/
~ t ~!/ gearRt1:~u:e:;sher
Sode gear &

/Side

~ ~ Iff} ' / o~
- ~ .tl \ -·-
J' o Oofferential case LH

Gasket i ~"'
6!, £1.
0

~ I.,..,. Side bearing

::D
m
Drive pinion
rear bearing
~ G)
~,._o_ o o
~~ ~
Inner Outer
cone\..(0/
race
Side bearong cap
- ~

"tl ~······[! ~
outer cone ~
.--tn-ner L
Orniv•:e:_I'P:::in::·'o_n--,_ _ __
::D
::!!
c•
CD
0
rae~~ \ Hypoid gear set .
z
~

.~' I '"~'"""e~-
I
Drive pinion
c
" .-"
front bearing
::D
ABS sensor uni/ rker , <
cole ®'
Drive pinion heoght ,...,
~-,; 64 • 74 (6.5 • . '
Inner race 1 · washeru m
Companion flange

.
adjustong
Pinion bearing spacer Ring gear bolt _ _ , 98 _ 112)

I ~~~ ~ 132 - 152 (13.5 15 5

)~./ Drive pinion bearing adjusting shim u

~ / Front oil seal~
~ &?'~
\ \~.- 11 (0.8- 1.1, 69-950

~196- 264 //
(20 - 29, 145 - 210) ~ ~: N•m (kg-m, in-lb)

~Apply
toJ N•m (kg-m. ft-lb)

~
U · Adjustment is required.

lO
differential oil to thread. *: Applied to models equipped
~ 27. 36 (2.8. 3.7. 20. 27) with rear drum brake
§
 DISASSEMBLY H233B

Pre-inspection
Before disassembling final drive, perform the following inspection.
• Total preload i£iZ
a. Turn drive pinion in both directions several times to seat
bearing rollers correctly.
b. Check total preload with Tool. ~~~
Total preload:
1.7-2.5 N·m
(17 - 25 kg-em, 15 - 22 in-lb) ll•i.:
Tool number: ST3127SOOO (J25765-A)
SPD149

• Ring gear-to-drive pinion backlash ~·:(;

Check backlash of ring gear with a dial indicator at several
points.
Ring gear-to-drive pinion backlash: IP~
0.15- 0.20 mm (0.0059- 0.0079 in)

• Ring gear runout

Check runout of ring gear with a dial indicator.
Runout limit:
0.08 mm (0.0031 in)

SPD247

• Tooth contact
Check tooth contact, referring to "ADJUSTMENT", PD-95.
- Feeler
gauge
• Side gear-to-pinion mate gear backlash
Measure clearance between side gear thrust washer and ~!Pl
differential case with a feeler gauge.
Clearance between side gear thrust washer and
differential case:
Less than 0.15 mm (0.0059 in)

SPD004

Differential Carrier
1. Mount final drive assembly on Tool.
Tool numbers:® ST0501SOOO ( )
@ ST06340000 (J24310)

SPD139

PD-81 745
 DISASSEMBLY I H233B I
Differential Carrier (Cont'd)
2. Put match marks on one side of side bearing cap with paint or
punch to ensure that it is replaced in proper position during
reassembly.
Bearing caps are line-bored during manufacture and should
be put back in their original places.

3. Remove side lock fingers and side bearing caps.

4. Remove side bearing adjuster with Tool.

Tool number: ST32580000 (J34312)

5. Remove differential case assembly with a pry bar.

Keep the side bearing outer races together with their respec-
tive inner cones - do not mix them up.

746 PD-82
 DISASSEMBLY H233B

Differential Carrier (Cont'd)

6. Remove drive pinion nut with Tool. (~I
Tool
Tool number: KV381 04700 (J34311)
7. Remove companion flange with puller.
8. Remove ABS sensor.

C2f'
9. Take out drive pinion together with pinion rear bearing inner ""'
cone, drive pinion bearing spacer and pinion bearing adjusting
shim.

1:0b

liT

10. Remove front oil seal and pinion front bearing inner cone.
11 . Remove pinion bearing outer races with a brass drift.

SPD563
•
12. Remove pinion rear bearing inner cone and drive pinion [JS,
adjusting washer.
Tool number: ST30031000 (J22912-01)

SPD018

Differential Case
1. Remove side bearing inner cones.
To prevent damage to bearing, engage puller jaws in groove.
Tool numbers:
Groove
@ ST33051001 (J22888-20)
@ ST33061000 (J8107-2)

-
i(j
'

SPD207A

PD-83 747
 DISASSEMBLY I H2338 I
Differential Case (Cont'd)
Be careful not to confuse the left and right hand parts.

SPD022

2. Spread out lock straps and loosen ring gear bolts in a

criss-cross fashion.

3. Tap ring gear off differential case with a soft hammer.

Tap evenly all around to keep ring gear from binding.

SPD024

4. Separate differential case LH and RH.

Put match marks on both differential case LH and RH sides
prior to separating them.

748 PD-84
 INSPECTION I H233B I

Ring Gear and Drive Pinion

Check gear teeth for scoring, cracking or chipping.
If any damaged part is evident, replace ring gear and drive pinion ll;iffi\
as a set (hypoid gear set).

4-pinion typo Differential Case Assembly

Check mating surfaces of differential case, side gears, pinion mate
gears, pinion mate shaft, and thrust washers. [p~

II
SPD717

Bearing
1. Thoroughly clean bearing.
2. Check bearings for wear, scratches, pitting or flaking.
Check tapered roller bearing for smooth rotation. If damaged,
replace outer race and inner cone as a set.

SPD715

PD-85 749
 LIMITED SLIP DIFFERENTIAL I H233B I

No. of discs and plates {One side) Differential case

couple bolt
~el H2338
tclJ54 - 64 (5.5 - 6.5, 40 - 4 7 ) \

Friction disc 5 Lock str:p ~'\~

Friction plate 6
Spring disc 1
Spring plate 1
Pinion mate shaft . ·· . .·· : ~·' ~
Friction plate*
~~1)\'Q ,_
~ \d) gl Differential

~Theus! block case "B"

~\ I "- Pinion mate thcust washec

"L Pinion mate gear

tclJ ' N•m (kg-m, ft-lb)
Side gear
* : For number of discs of plates,
refer to table. SPD252A

CAUTION:
Do not run engine when only one wheel (rear) is off the
ground.

Preparation for Disassembly

CHECKING DIFFERENTIAL TORQUE
Measure differential torque with Tools.
If it is not within the specifications, inspect components of limited
Tool@
slip differential.
Differential torque:
201-240 N·m
(20.5- 24.5 kg-m, 148- 177 ft-lb)
Tool numbers:
@ KV38105210 ( )
@ KV381 05220 ( )

Disassembly
1. Remove side bearing inner cone with Tool.
2. Remove ring gear by spreading out lock straps.
3. Loosen ring gear bolts in a criss-cross fashion.
4. Tap ring gear off gear case with a soft hammer.
Tap evenly all around to keep ring gear from binding.

750 PD-86
 LIMITED SLIP DIFFERENTIAL I H233B I
Disassembly (Cont'd)
. . Press 5. Remove differential case by spreading out lock straps. :liJ[
6. Remove couple bolts on differential cases A and B with a
Tool
press.
Tool number: ST33081 000 ( ) i!lfo\
7. Separate differential cases A and B.
Draw out component parts (discs and plates, etc.).
Put marks on gears and pressure rings so that they can be ~l!u
reinstalled in their original positions.

SPD276

CD Inspection
CONTACT SURFACES
1. Clean the disassembled parts in suitable solvent and blow dry I'~
with compressed air.
2. If the following surfaces are found with burrs or scratches, ci'C
smooth with oil stone. "b
CD Differential case B
® Differential case A
® Side gear Cillf
@ Pinion mate gear
® Pinion mate shaft
® Thrust block !~11
(f) Friction plate guide

II
SPD291

DISC AND PLATE

1. Clean the discs and plates in suitable solvent and blow dry with
compressed air.
2. Inspect discs and plates for wear, nicks and burrs.

3. Check friction discs or plates for warpage.

~~ Allowable warpage:
0.08 mm (0.0031 in)
-=-···_ ~ If it exceeds limits, replace with a new plate to eliminate
Mik
possibility of clutch slippage or sticking.

SPD279

PD-87 751
 LIMITED SLIP DIFFERENTIAL I H233B I
Inspection (Cont'd)
4. Measure frictional surfaces and projected portions of friction
discs, plates, spring disc and plate.
If any part has worn beyond the wear limit, replace it with a
new one that is the same thickness as the projected portion.
Wear limit:
0.1 mm (0.004 in) or less

B
A

fl\
-~·
•
•
• : Measuring poinU
A : Projected portion
B : Frictional surface
A- 8 =Wear limit mm (in)

SPD403

Adjustment
FRICTION DISC AND FRICTION PLATE END PLAY
End play of friction disc and friction plate can be calculated by using
the following equation and should be adjusted within the following
range.
Adjustment can be made by selecting friction disc having two
different thicknesses.
End play E:
0.05- 0.15 mm (0.0020- 0.0059 in)
E =A- (B +C)
A: Length of differential case contact surface to differen-
tial case inner bottom.
8: Total thickness of friction discs, friction plates, spring
disc and spring plate in differential case on one side.
C: Length of differential case contact surface to back side
of side gear.

Differential case B 1. Measure values of "A".

Standard length A:
49.50 - 49.55 mm (1.9488 - 1.9508 in)

752 PD-88
 LIMITED SLIP DIFFERENTIAL H233B

Adjustment (Cont'd)
2. Measure thickness of each disc and plate. ~I
Total thickness "B":
19.24- 20.26 mm (0.7575- 0.7976 in)
No. of discs and plates (One side):
Friction disc 5
Friction plate 6
Spring disc 1
Spring plate 1

3. Measure values of "C".

a. Attach a dial indicator to the base plate.
b. Place differential case Bon the base plate, and install a master
Suitable block "''"'.2.
[master gauge 30 mm gauge on case B.
(1.18 in)] Then adjust the dial indicator scale to zero with its tip on the
master gauge.

l!i1i'
SPD418

c. Install pinion mate gears, side gears and pinion mate shaft in ffil1i'
differential case B.
d. Set dial indicator's tip on the side gear, and read the indication.
Suitable block Example: 'ill"
E =A- D =A- (B + C) = 0.05 to 0.15 mm
A= 49.52 mm
B = 19.45 mm
C =29.7 mm
D=B+C E=A-D
B ... 19.45 A ... 49.52
+C ... 29.7 -D ... 49.15
49.15 0.37
From the above equation, end play of 0.37 mm exceeds the
specified range of 0.05 to 0.15 mm.
Select suitable discs and plates to adjust correctly. lll'l

Assembly
Friction disc Prior to assembling discs and plates, properly lubricate them by
dipping them in limited slip differential oil. lllffil
1. Alternately position specified number of friction plates and
Friction plate friction discs on rear of side gear.
Always position a friction plate first on rear of side gear. ~~

SPD421

PD-89 753
 LIMITED SLIP DIFFERENTIAL I H233B I
Assembly (Cont'd)
2. Install spring disc.
Spring disc Align the twelve angular holes in spring disc with the
hexagonal area of the side gear.

SPD422

3. Install spring plate.

Spring plate

SPD423

Friction plate 4. Install friction plate guides.

Correctly align the raised portions of friction plates, and apply
grease to inner surfaces of friction plate guides to prevent
them from falling.

SPD424

5. Install differential case B over side gear, discs, plates and

friction plate guide assembly.
• Install differential case B while supporting friction plate
guides with your middle finger by inserting through oil
hole in differential case.
• Be careful not to detach spring disc from the hexagonal
part of the side gear.

6. Install p1mon mate gears and pinion shaft to differential

case B.

SPD426

754 PD-90
LIMITED SLIP DIFFERENTIAL I H2338 I
Assembly (Cont'd)
7. Install thrust block. I~J

'L©

8. Install side gear to pinion mate gears.

9. Install each disc and plate.
Use same procedures as outlined in steps 1. through 4.

©1

10. Install differential case A.

Position differential cases A and 8 by correctly aligning marks
stamped on cases.

•
11. Tighten differential case bolts.
12. Place ring gear on differential case and install new lock straps
and bolts.
~~:RJ
Tighten bolts in a criss-cross fashion, lightly tapping bolt head
with a hammer.
Then bend up lock straps to lock the bolts in place.
13. Install side bearing inner cone.
14. Check differential torque.

PD-91 755
 ADJUSTMENT H2338

For quiet and reliable final drive operation, the following five
adjustments must be made correctly:
1. Side bearing preload
2. Pinion gear height
3. Pinion bearing preload. Refer to "ASSEMBLY", PD-98.
4. Ring gear-to-pinion backlash. Refer to "ASSEMBLY", PD-99.
5. Ring and pinion gear tooth contact pattern

Pinion Gear Height

1. Make sure all parts are clean and that the bearings are well
lubricated.
2. Assemble the pinion gear bearings into the pinion pre-load
shim selector Tool, J34309.

SPD196A

• Rear Pinion Bearing - the rear pinion bearing pilot,

J34309-8, is used to center the rear pinion bearing only. The
rear pinion bearing locking seat, J34309-4, is used to lock the
bearing to the assembly.
• Front Pinion Bearing - make sure the J34309-3, front pin-
ion bearing seat is secured tightly against the J34309-2 gauge
anvil. Then turn the front pinion bearing pilot, J34309-5, to
secure the bearing in its proper position.

SPD197A

3. Place the p1nron preload shim selector Tool gauge screw

assembly, J34309-1, with the pinion rear bearing inner cone
installed, into the final drive housing.

4. Install the J34309-2 gauge anvil with the front pinion bearing
into the final drive housing and assemble it to the J34309-1
gauge screw. Make sure that the J34309-16 gauge plate will
turn a full 360 degrees, and tighten the two sections by hand
\ to set bearing pre-load.
II
-~

5. Turn the assembly several times to seat the bearings.

I)
I .
;--
\;'- SPD217A

756 PD-92
 ADJUSTMENT I H233B I
Pinion Gear Height (Cont'd)
6. Measure the turning torque at the end of the J34309-2 gauge CllJ
anvil using Tool.
Tool number: ST3127SOOO (J25765-A)
Turning torque specification: !ftc§,
0.4- 0.9 N·m (4- 9 kg-em, 3.5- 7.8 in-lb)

SPD234A

7. Place the J34309-12 "H233B" pinion height adapter onto the !''~
gauge plate and tighten it by hand.
CAUTION:
Make sure all machined surfaces are clean.

SPD208A

PINION HEIGHT ADJUSTING WASHER SELECTION

8. Position the J25269-18 side bearing discs and the arbor into
the side bearing bores.

SPD286A

9. Install the bearing caps and torque the bolts.

Specification:
!:OJ: 93 - 103 N·m (9.5 - 10.5 kg-m, 69 - 76 ft-lb)

SPD237A
~1
10. Select the correct standard pinion height adjusting washer
thickness using a standard gauge of 2.5, 3.0, or 3.5 mm
(0.098, 0.118, or 0.138 in) and J34309-1 01 feeler gauge. Mea- liJ$,
sure the distance between the J34309-12 "H233B" pinion
height adapter and the arbor.

PD-93 757
 ADJUSTMENT H233B
Pinion Gear Height (Cont'd)
11. Write down your exact total measurement.

SPD779

12. Correct the pinion height washer size by referring to the "pinion
head height number".
There are two numbers painted on the pinion gear. The first
one refers to the pinion and ring gear as a matched set and
should be the same as the number on the ring gear. The sec-
ond number is the "pinion head height number," and it refers
to the ideal pinion height from standard for the quietest opera-
tion. Use the following chart to determine the correct pinion
height washer.
L Head number (H)
SPD542 Add or Remove from the Selected
Pinion Head Height Number Standard Pinion Height Washer
Thickness Measurement
-6 Add 0.06 mm (0.0024 in)
-5 Add 0.05 mm (0.0020 in)
-4 Add 0.04 mm (0.0016 in)
-3 Add 0.03 mm (0.0012 in)
-2 Add 0.02 mm (0.0008 in)
-1 Add 0.01 mm (0.0004 in)
0 Use the selected washer thickness
+1 Sub1ract 0.01 mm (0.0004 in)
+2 Subtract 0.02 mm (0.0008 in)
+3 Subtract 0.03 mm (0.0012 in)
+4 Subtract 0.04 mm (0.0016 in)
+5 Subtract 0.05 mm (0.0020 in)
+6 Subtract 0.06 mm (0.0024 in)

13. Select the correct ptmon hetght washer.

Drive pinion height adjusting washer:
Refer to SDS, PD-1 06.

14. Remove the J34309 pinion preload shim selector tool from the
final drive housing and disassemble to retrieve the pinion
bearings.

758 PD-94
 ADJUSTMENT I H233B I

Tooth Contact
Gear tooth contact pattern check is necessary to verify correct
relationship between ring gear and drive pinion. l!iJJ(,
Hypoid gear sets which are not positioned properly may be noisy,
or have short life or both. With a pattern check, the most desirable
contact for low noise level and long life can be assured. "'"'
COU(~

1. Thoroughly clean ring gear and drive pinion teeth.

2. Sparingly apply a mixture of powdered ferric oxide and oil or
equivalent to 3 or 4 teeth of ring gear drive side.

SPD005

3. Hold companion flange steady and rotate the ring gear in both ~1i'
directions.

l?t'c

Usually the pattern will be correct If you have calculated the shims correctly and the backlash is correct.
M
However, in rare cases you may have to use trial-and-error processes until you get a good tooth contact pattern.
The tooth pattern is the best indication of how well a differential has been set up.
~[Fl
Heel contact Face contact Toe contact Flank contact

<!P~
@11

To correct, increase thickness of pinion IPI"'

M
To correct, reduce thickness of pinion
height adjusting washer in order to bring height adjusting washer in order to make
drive pinion close to ring gear. drive pinion go away from ring gear.

___ /~h ~1i'

~b\

~
~~
When adjustment is completed, be sure to wipe
off completely the ferric oxide and oil or their
equivalent.
~~~=
SPD007

PD-95 759
 ASSEMBLY I H233B I

Differential Case
1. Measure clearance between side gear thrust washer and
differential case.
Clearance between side gear thrust washer
8 and differential case (A - B):
Less than 0.15 mm (0.0059 in)
The clearance can be adjusted with side gear thrust washer.
Refer to SDS, PD-106.
2. Apply gear oil to gear tooth surfaces and thrust surfaces and
check to see they turn properly.

3. Install differential case LH and RH.

4. Install differential case on ring gear.

5. Place differential case on ring gear.

6. Apply locking agent [Locktite {stud lock) or equivalent] to ring
gear bolts, and install them.
Tighten bolts in a criss-cross fashion, lightly tapping bolt head
with a hammer.

SPD746

7. Press-fit side bearing inner cones on differential case with Tool.

Tool numbers:
@ ST33190000 (J25523)
Tool@ @ ST33081000 ( )

Tool@
PD353

760 PD-96
 ASSEMBLY I H233B I

Differential Carrier
1. Press-fit front and rear bearing outer races with Tools.
Tool@ Tool numbers:
@ ST30611 000 (J25742-1)
{I\ I "'
@ ST30621 000 (J25742-5)
~PJ~ © ST30613000 (J25742-3)

Pinion rear
bearing outer race

Tool@

bearing outer race

SPD580

2. Select drive p1mon adjusting washer. Refer to ~~l

Adjusting
"ADJUSTMENT", PD-92.
washer
3. Install drive pinion adjusting washer in drive pinion, and press- 'ii'l'
fit pinion rear bearing inner cone in it, with press and Tool.
Tool number: ST30901000 (J26010-01)
Tool

4. Place pinion front bearing inner cone in gear carrier.

SPD581
@J'ii'
5. Apply multi-purpose grease to cavity at sealing lips of oil seal.
Install front oil seal.
Tool numbers:
@ ST30720000 (J25405)
@ KV38102510 (

[[Ql)Z

PD-97 761
 ASSEMBLY H233B

Differential Carrier (Cont'd)

Drive pinion bearing 6. Install drive pinion bearing spacer, pinion bearing adjusting
spacer_.-~- shim and drive pinion in gear carrier.

SPD935-A

7. Insert companion flange into drive pinion by tapping the

companion flange with a soft hammer.

8. Tighten pinion nut to the specified torque.

The threaded portion of drive pinion and pinion nut should be
free from oil or grease.
Tool number: KV38104700 (J34311)

9. Turn drive pinion in both directions several times, and measure

pinion bearing preload.
Tool number: ST3127SOOO (J25765-A)
Pinion bearing preload (Without front oil seal):
1.2- 1.5 N·m (12- 15 kg-em, 10- 13 in-lb}
If preload is out of specification, adjust the thickness of spacer and
shim combination by replacing shim and spacer with thinner one.
• Start from the combination of thickest spacer and shim.
• Combine each spacer and shim thickness one by one until the
correct specification is achieved.

10. Install differential case assembly with side bearing outer races
into gear carrier.
11. Position side bearing adjusters on gear carrier with threads
properly engaged; screw in adjusters lightly at this stage of
assembly.
Tool number: ST32580000 (J34312)

762 PD-98
 ASSEMBLY I H233B I
Differential Carrier (Cont'd)
12. Align mark on bearing cap with that on gear carrier and install Iilli
bearing cap on gear carrier.
• Do not tighten at this point to allow further tightening of side
bearing adjusters. IT~!%

SPD265

13. Tighten both right and left side bearing adjusters alternately [i';[;
and measure ring gear backlash and total preload at the same
time. Adjust right and left side bearing adjusters by tightening
them alternately so that proper ring gear backlash and total IF[i';
preload can be obtained.
Ring gear-to-drive pinion backlash:
0.15 - 0.20 mm (0.0059 - 0.0079 in) ©ib

ffi),'jj'
• When checking preload, turn drive p1mon in both
directions several times to set bearing rollers.
Tool number: ST3127SOOO (J25765-A)
Total preload:
1.7- 2.5 N·m (17- 25 kg-em, 15- 22 in-lb)

•
14. Tighten side bearing cap bolts.
15. Install side lock finger in place to prevent rotation during
operation.

16. Check runout of ring gear with a dial indicator.

Runout limit: 0.08 mm (0.0031 in)
• If backlash varies excessively in different places, the variance Iii!':,
may have resulted from foreign matter caught between the ring
gear and the differential case.
• If the backlash varies greatly when the runout of the ring gear
is within a specified range, the hypoid gear set or differential [i';[b
case should be replaced.
17. Check tooth contact. Refer to "ADJUSTMENT", PD-95.

PD-99 763
 SERVICE DATA AND SPECIFICATIONS (SDS)

Propeller Shaft
GENERAL SPECIFICATIONS
2WD models
Wheelbase Standard Long

Transmission MIT Air MIT Air

Propeller shaft model 3S71A

Number of joints 3
Coupling method with
Sleeve type
transmission

Type of journal bearings Solid type {disassembly type)

Distance between yokes

88.1 (3.47)
mm (in)

Shaft length mm (in)

(Spider to spider)

1st 651.5 (25.65) 549.9 (21.65) 651.5 (25.65) 549.9 (21.65)

2nd 675.2 (26.58) 975.2 (38.39)

Shaft outer diameter

mm (in)

1st 63.5 (2.50)

2nd 63.5 (2.50)

4WD models
Location Front Rear

Wheelbase - Standard Long

Propeller shaft model 2F71H 28808 3S80B

Number of joints 2 3
Coupling method with transmission Flange type Sleeve type

Type of journal bearings Solid type {disassembly type)

Distance between yokes mm (in) 88.1 (3.47)

Shaft length mm (in)

(Spider to spider)

1st 514.1 (20.24) 938.1 (36.93) 398.0 (15.67)

2nd - 840.3 (33.08)

Shaft outer diameter mm (in)

1st 63.5 (2.50) 63.5 (2.50) 63.5 (2.50)

2nd - 63.5 (2.50)

764 PD-100
 SERVICE DATA AND SPECIFICATIONS (SDS)
Propeller Shaft (Cont'd)
SERVICE DATA
Unit: mm (in)

Propeller shaft runout limit 0.6 (0.024)

Journal axial play 0.02 (0.0008) or less

Snap ring
Unit· mm (in)

Thickness Color Part number

1.99 (0.0783) White 37146·C9400
2.02 (0.0795) Yellow 37147-C9400
2.05 (0.0807) Red 37148-C9400
2.08 (0.0819) Green 37149·C940D
2.11 (0.0831) Blue 37150-C9400
2.14 (0.0843) Light brown 37151-C9400
2.17 (0.0854) Black 37152-C9400
2.20 (0.0866) No paint 37153-C9400

PD-101 765
 SERVICE DATA AND SPECIFICATIONS (SDS)

Final Drive
GENERAL SPECIFICATIONS
2WD models
Transmission M!T AfT

Body type Regular/King cab King cab King cab Regular/King cab

Vehicle type Except SE SE XE' SE/XE

Standard I Optional Standard I Optional Standard I Optional Standard I Optional

Final drive model H190A C200 H190A

2-pinion / LSD 2-pinion / LSD 2-pinion

I LSD 2-pinion / LSD

Gear ratio 3.545 3.900 4.111

Number of teeth
39/11 39/10 37/9
(Ring gear/drive pinion)

Oil capacity (Approx.) 1.5 1.3 1.5

r (US p1, Imp pt) (3-1/8, 2-5/8) (2-3/4, 2-1/4) (3-1/8, 2-5/8)

*: Option

4WD models
Front final drive R180A

4-pinion

Gear ratio 4.625

Oil capacity {Approx.)
1.3 (2-3/4, 2-1/4)
e (US pt, Imp pt)
Rear final drive Standard
I Optional

H2338

4-pinion
I LSD

Gear ratio 4.625

Number of teeth
37/8
(Ring gear/drive pinion)

Oil capacity (Approx.)

2.8 (5-7/B, 4-7/8)
f (US pt, Imp pt)

766 PD-102
 SERVICE DATA AND SPECIFICATIONS (SDS)
Final Drive (Cont'd)
INSPECTION AND ADJUSTMENT (R180A) Drive pinion height adjustment i;lil
Available pinion height adjusting washers
Ring gear runout
Thickness mm (in) Part number
Ring gear runout limit mm (in) 0 05 (0.0020)
3.09 (0.1217) 38154-P6017
3.12 {0.1228) 38154-P6018
Axle bearing adjustment 3.15 (0.1240) 38154-P6019
318 (0.1252) 38154-P6020
Axle bearing end play mm (in) 0-0.1 (0- 0.004) 3.21 (0.1264) 38154-P6021
3.24 (0.1276) 38154-P6022
Available axle bearing adjusting shims
3.27 (0.1287) 38154-P6023
Thickness mm (in) Part number 3.30 (0.1299) 38154-P6024
3.33 (0.1311) 38154-P6025
0.10 (0.0039) 38233-01811
3.36 (0.1323) 38154-P6026
0.20 (0.0079) 38233-01812 38154-P6027
3.39 (0.1335)
0.30 (0.0118) 38233-01 G13
3.42 (0.1346) 38154-P6028
0.40 (0.0157) 38233-01 G 14
3.45 (0.1358) 38154-P6029
0.50 (0.0197) 38233-01G10
3.48 (0.1370) 38154-P6030
3.51 (0.1382) 38154-P6031
3.54 (0.1394) 38154-P6032
Side gear adjustment 38154-P6033
3.57 (0.1406)
Side gear backlash 3.60 (0.1417) 38154-P6034
(Clearance between side gear and Less than 0.15 (0.0059) 3.63 (0.1429) 38154-P6035
differential case) mm (in) 3.66 (0.1441) 38154-P6036

Available side gear thrust washers

Thickness mm (in) Part number

Drive pinion preload adjustment
Drive pinion bearing preload Adjusting washer
0.75- 0.78
0.78-0.81
0.81 - 0.84
(0.0295-
(0.0307-
(0.0319 -
0.0307}
0.0319)
0.0331)
38424-W201 0
38424-W2011
38424-W2012
_:a:::d:::J":::'':::'"C'g:::m:::e:::t:::ho:::d:__ _ _ _ _ _ -+___ :an:::d::.:'sp:::a:::c:er_:____ f~11F
Drive pinion preload
0 84 - 0.87 (0.0331 - 0.0343) 38424-W2013 N·rn {kg-em, in-lb)
0.87 - 0.90 (0.0343 - 0.0354) 38424-W2014

Ill
0.90 - 0.93 (0.0354 - 0.0366) 38424-W2015 1.1 - 1.7
With front oil seal
0.93 - 0.96 {0.0366 - 0.0378) 38424-W2016 (11- 17, 9.5- 14.8)
0.96- 0.99 (0.0378- 0.0390) 38424-W2017
_Available drive pinion bearing preload adjusting washers
____:__:::__:_=___::_::::.:..:~::...:==::::=_:::::__ • I
Thickness mm (in) Part number
Side bearing adjustment
6.59 (0.2594) 38127-01800
Differential carrier assembly turning 6.57 (0.2587) 38127-01G01
34.3- 39.2
resistance 6.55 (0.2579) 38127-01G02
(3.5- 4.0, 7.7- 8.8)
N (kg, lb) 6.53 (0.2571) 38127-01803
6.51 (0.2563) 38127-01 G04
Side bearing adjusting method Adjusting shim 6.49 (0.2555) 38127-01G05
Available side retainer shims 6.47 (0.2547) 38127-01806
6.45 (0.2539) 38127-01807
Thickness mm (in) Part number 6.43 (0.2531) 38127-01G08
6.41 (0.2524) 38127-01G09
0.20 (0.0079) 38453-01 GOO
6.39 (0.2516) 38127-01G10
0.25 (0 0098) 38453-01 G01
0.30 (0.0118) 38453-01 G02 6.37 (0.2508) 38127-01G11
6.35 (0.2500) 38127-01G12
0.40 (0.0157) 38453-01 G03
0.50 (0.0197) 38453-01 G04 6.33 (0.2492) 38127-01G13
6.31 (0.2484) 38127-01G14

Total preload adjustment _A_v_a_ila_b_le_dr_iv_e_:p_in_io_n_b_e_a_ri_ng::_:_prTe_lo_a_:d_:a:::dl:::.":::"_'".::9_:'_:P_ac_:e_rs_ _ _ ~~

Length rnm (in) Part number
Total preload 1.2-2.3
N·m (kg-em, in-lb) (12- 23, 10- 20) 52.20 (2.0551) 38130-78500
52.40 (2.0630) 38131-78500
0.13-0.18 52.60 (2.0709) 38132-78500
Ring gear backlash mm (in)
{0.0051 - 0.0071) 52.80 (2.0787) 38133-78500
53.00 (2.0866) 38134-78500
53.20 (2.0945) 38135-78500

PD-103 767
 SERVICE DATA AND SPECIFICATIONS (SDS)
Final Drive (Cont'd)
INSPECTION AND ADJUSTMENT (H190A) Drive pinion height adjustment
Available drive pinion height adjusting washers
Ring gear runout
Thickness mm (in) Part number
Ring gear runout limit mm (in) 0.08 (0.0031)
2.58 (0.1016) 38154-PBOOO
2.61 (0.1028) 38154-P6001
Side gear adjustment 2.64 (0.1039) 38154-P6002
2.67 (0.1051) 38154-P6003
Side gear backlash 2.70 (0.1063) 38154-P6004
(Clearance between side gear to Less than 0.15 (0.0059) 2.73 (0.1075) 38154-PBOOS
differential case) mm (in) 2.76 (0.1087) 38154- P6006
2.79 (0.1098) 38154-P6007
Available side gear thrust washers
2.82 (0.1110) 38154-P6008
Conventional models
2.85 (0.1122) 38154-P6009
Thickness mm (in) Part number 2.88 (0.1134) 38154-P6010
2.91 (0.1146) 38154-PBOii
0.75 (0.0295) 38424-E3000
2.94 (0.1157) 38154-P6012
0.80 (0.0315) 38424-E3001
2.97 (0.1169) 38154-P601 3
0.85 (0.0335) 38424-E3002
3.00 (0.1181) 38154-P6014
0.90 (0.0354) 38424-E3003
3.03 (0.1193) 38154-P6015
LSD models 3.06 (0.1205) 38154-P6016
3.09 (0.1217) 38154-P6017
Thickness mm {in) 10 color Part number 3.12 (0.1228) 38154-P6018
1.50 (0.0591) None 38424-41 woo 3.15 (0.1240) 38154-P6019
1.60 (0.0630) White 38424-41W01 3.18 (0.1252) 38154-P6020
1.70 (0.0669) Yellow 38424-41 W02

Drive pinion preload adjustment

- Additional service for LSD model - Drive pinion bearing preload adjust-
Collapsible spacer
ing method
Differential torque adjustment
Drive pinion preload
Differential torque N-m (kg-em, in-lb)
N·m (kg-m, H-lb)
1.1 - 1.6
69- 118 With front oil seal
New parts (11- 16, 9.5- 13.9)
(7 - 12, 51 - 87)
39-74
Used parts
(4 - 7.5, 29 - 54)
Side bearing adjustment
Number of discs and plates Differential carrier assembly turning 34.3- 39.2
resistance N {kg, lb) (3.5- 4.0, 7.7- 8.8)
Friction disc 4
Friction plate 4 Side bearing adjusting method Adjusting shim
Spring disc 2 Available side bearing adjusting shims
Spring plate 2
Thickness mm (in) Part number
Wear limit of plate and disc
0.1 (0.004)
mm (in) 0.10 (0.0039) 38455-61200
0.12 (0.0047) 38453-61201
Allowable warpage mm (in) 0.15 (0.0059) 38453-61202
Friction disc and plate 0.08 (0.0031) 0.17 (0.0067) 38453-61203
0.20 (0.0079) 38456-61200
Available discs and plates 0.25 (0.0098) 38453-61204
0.30 (0.0118) 38453-61205
Part name Thickness mm (in) Part number
0.40 (0.0157) 38453-61206
1.75 (0.0689) 38433-41 woo 0.50 (0.0197) 38457-61200
Friction disc
1.85 (0.0728) 38433-41W01

Friction plate 1.75 (0.0689) 38432-41WOO Total preload adjustment

Spring disc 1.75 (0.0689) 38436-N321 0
Total preload 1.2-2.2
Spring plate 1.75 (0.0689) 38435-N3210 N·m (kg-em, in-lb) (12- 22, 10- 19)

0.13- 0.18
Ring gear backlash mm (in)
(0.0051 - 0.0071)

768 PD-104
 SERVICE DATA AND SPECIFICATIONS (SDS)
Final Drive (Cont'd)
INSPECTION AND ADJUSTMENT (C200) Drive pinion height adjustment
Available pinion height adjusting washers
Ring gear runout
Thickness mm (in) Part number
Ring gear runout limit mm (in) 0.05 (0.0020)
3.09 (0.1217) 38154-P6017
3.12 (0.1228) 38154-P6018
Side gear adjustment 3.15 (0.1240) 38154-P6019
3.18 (0.1252) 38154-P6020
Side gear backlash 3.21 (0.1264) 38154-P6021
{Clearance between side gear and Less than 0.15 (0.0059) 3.24 (0.1276) 38154-P6022
differential case) mm {in) 3.27 (0.1287) 38154-P6023
Available side gear thrust washers
3.30 (0.1299) 38154-P6024
3.33 (0.1311) 38154-P6025
Thickness mm (in) Part number 3.36 (0.1323) 38154-P6026
3.39 (0.1335) 38154-P6027
0.75 (0.0295) 38424-N3110
3.42 (0.1346) 38154-P6028
0.78 (0.0307) 38424-N3111
3.45 (0.1358) 38154-P6029
0.81 (0.0319) 38424-N3112
3.48 (0.1370) 38154-P6030
0.84 (0.0331) 38424-N3113
3.51 (0.1382) 38154-P6031
0.87 (0.0343) 38424-N3114
3.54 (0.1394) 38154-P6032
0.90 (0.0354) 38424-N3115
3.57 (0.1406) 38154-P6033
0.93 (0.0366) 38424-N3116
3.60 (0.1417) 38154-P6034
3.63 (0.1429) 38154-P6035
Side bearing adjustment 3.66 (0.1441) 38154-P6036

Differential carrier assembly turning 34.3- 39.2

resistance N (kg, lb) (3.5- 4.0, 7.7- 8.8) Total preload adjustment
Available side bearing adjusting washers Total preload 1.2-2.3
N·m (kg-em, in-lb) (12. 23, 10- 20)
Thickness mm (in) Part number
0.13-0.18
2.00 (0.0787) 38453-N31 00 Ring gear backlash mm (in)
(0.0051 - 0.0071)
2.05 (0.0807) 38453-N3101
2.10 (0.0827) 38453-N3102
2.15 (0.0846) 38453-N31 03 - Additional service for LSD model -

•
2.20 (0.0866) 38453-N31 04
2.25 (0.0886) 38453-N31 05
(C200)
2.30 (0.0906) 38453-N31 06 Differential torque adjustment
2.35 (0.0925) 38453-N3107
2.40 (0.0945) 38453-N3108 Differential torque 88- 108
2.45 (0.0965) 38453-N3109 N·m (kg-m, ft-Jb) (9.0- 11.0, 65- 80)
2.50 (0.0984) 38453-N3110
255 (0.1004) 38453-N3111 Number of discs and plates
2 60 (0.1 024) 38453-N3112 Friction disc 12
Friction plate 12
Spring plate 2
Wear limit of plate and disc
0.1 (0.004)
mm (in)

Allowable warpage of friction disc

0.08 (0.0031)
and plate mm (in)

Available discs and plates

Part name Thickness mm (in) Part number

38433-C6002
1.5 (0.059)
(Standard type)
Friction disc
38433-C6003
1.6 (0.063)
(Adjusting type)

Friction plate 1.5 (0.059) 38432-C6001

Spring plate 1.5 (0.059) 38435-C6011

PD-105 769
 SERVICE DATA AND SPECIFICATIONS (SDS)
Final Drive (Cont'd)
INSPECTION AND ADJUSTMENT (H233B) Drive pinion height adjustment
Available pinion height adjusting washers
Ring gear runout
Thickness mm (in) Part number
Ring gear runout limit mm (in) 0.08 (0.0031)
2.58 (0.1016) 38151-01JOO
2.61 (0.1 028) 38151-01J01
Side gear adjustment 2.64 (0.1039) 38151-01J02
2.67 10.1051 I 38151-01J03
Side gear backlash 2.70 (0.1063) 38151-01J04
(Clearance between side gear to Less than 0.15 (0.0059) 2.73 (0.1075) 38151-01J05
differential case) mm (in) 2.76 (0.1087) 38151-01J06
2.79 (0.1098) 38151-01J07
Available side gear thrust washers
2.82 (0.1110) 38151-01J08
Thickness mm (in) Part number 2.85 (0.1122) 38151-01J09
2.88 (0.1134) 38151-01J10
1.75 (0.0689) 38424-T5000 2.91 (0.1146) 38151-01J11
1.80 (0.0709) 38424-TS001 38151-01J12
2.94 (0.1157)
1.85 (0.0728) 38424-T5002 38151-01J13
2.97 (0.1169)
3.00 (0.1181) 38151-01J14
3.03 (0.1193) 38151-01J15
- Additional service for LSD model - 3.06 (0.1205) 38151-01J16
309 (0.1217) 38151-01J17
Differential torque adjustment 38151-01J18
3.12 (0.1228)
Differential torque 201 - 240 3.15 (0.1240) 38151-01J19
N·m {kg-m, ft-lb) (20.5- 24.5, 148- 177) 3.18 (0.1252) 38151-01J60
3.21 (0.1264) 38151-01J61
Number of discs and plates 3.24 (0.1276) 38151-01J62
3.27 (0.1287) 38151-01J63
Friction disc 10
3.30 (0.1299) 38151-01J64
Friction plate 12
3.33 (0.1311) 38151-01J65
Spring disc 2
3.36 (0.1323) 38151-01J66
Spring plate 2
3.39 (0.1335) 38151-01 J67
Wear limit of plate and disc 3.42 (0.1346) 38151-01J68
0.1 (0.004)
mm (in) 3.45 (0.1358) 38151-01J69
3.48 (0.1370) 38151-01J70
Allowable warpage of friction disc
0.08 (0.0031) 3.51 (0.1382) 38151-01J71
and plate mm (in)
3.54 (0.1394) 38151-01J72
Available discs and plates 3.57 (0.1406) 38151-01J73
3.60 (0.1417) 38151-01J74
Part name Thickness mm (in) Part number 3.63 (0.1429) 38151-01J75
1.48- 1.52 38433-C6000 3.66 (0.1441) 38151-01J76
(0.0583 - 0.0598) (Standard type}
Friction disc
1.58-1.62 38433-C6001
(0.0622 - 0.0638) (Adjusting type)

1.48-1.52
Friction plate 38432-C6000
(0.0583 - 0.0598)

1.48-1.52
Spring disc 38436-C6000
(0.0583 - 0.0598)

1.48-1.52
Spring plate 38435-C601 0
(0.0583 - 0.0598)

770 PD-106
 SERVICE DATA AND SPECIFICATIONS (SDS)
Final Drive (Cont'd)
Drive pinion preload adjustment Total preload adjustment ~I

Drive pinion bearing preload adjust- Total preload 1.7-2.5

Adjusting shim and spacer
ing method N·m (kg-em, in-lb) (17- 25, 15- 22)

Drive pinion preload 0.15- 0.20

Ring gear backlash mm (in)
N·m (kg-em, in-lb) (0.0059 - 0.0079)

1.2- 1.5 Side bearing adjusting method Side adjuster

Without front oil seal
(12- 15, 10- 13)

Available drive pinion preload adjusting shims

Thickness mm (in) Part number

2.31 (0.0909) 38125-82100
2.33 (0.0917) 38126-82100
2.35 (0.0925) 38127-82100
2.37 (0.0933) 38128-82100
2.39 (0.0941) 38129-82100
2.41 (0.0949) 38130-82100
2.43 (0.0957) 38131-82100
2.45 (0.0965) 38132-82100
2.47 (0.0972) 38133-82100
2.49 (0.0980) 38134-82100
2.51 (0.0988) 38135-82100
2.53 (0.0996) 38136-82100
2.55 (0.1004) 38137-82100
2.57 (0.1012) 38138-82100
2.59 (0.1020) 38139-82100

Available drive pinion preload adjusting spacers

Length mm (in) Part number

4.50 (0.1772) 38165-76000

4.75 (0.1870) 38166-76000
5.00 (0.1969) 38167-76000
5.25 (0.2067) 38166-01 JOO

•
5.50 (0.2165) 38166-01J10

PD-107 771
 FRONT AXLE & ~~
FRONT SUSPENSION

SECTION FA IL©

CONTENTS
PRECAUTIONS AND PREPARATION ... ........................ 2 FRONT AXLE ................................................................ 15 ©lb
Precautions................................ ........................ 2 FRONT AXLE (4WD) ..................................................... 17
Special Service Tools ................................................. 2 Manual-lock Free-running Hub .................................. 17
Commercial Service Tools ........................................... 2 Auto-lock Free-running Hub ...................................... 18 u1il1i'
FRONT AXLE AND FRONT SUSPENSION ................... 3 FRONT AXLE ................................................................24
ON-VEHICLE SERVICE ....... .......................................... 5 Wheel Hub and Rotor Disc ........................................ 24
Front Axle and Front Suspension Parts ...................... 5 Knuckle Spindle .........................................................25 5\1
Front Wheel Bearing .................................................... 6 FRONT AXLE (4WD) ....................... ............................ 28
Preload Adjustment (2WD) .................................... 6 Drive Shaft .................................................................28
Preload Adjustment (4WD) .................................... 7 FRONT SUSPENSION .................................................. 34 1i'IP
Front Wheel Alignment ................................................ 8 Shock Absorber .........................................................36
Preliminary Inspection ............................................. 8 Torsion Bar Spring ..................................................... 36
Camber, Caster And Kingpin Inclination ................. 9 Stabilizer Bar ............................................................. 39 i1l!!
Adjustment .............................................................. 9 Upper Link ................................................................ .40
Toe-In ....................... .. .............................. 12 Tension Rod or Compression Rod .......................... .42
Front Wheel Turning Angle........... .. ............... 13 Lower Link ................................................................ .43
Drive Shaft....................................... .. ............... 14 Upper Ball Joint and Lower Ball Joint. ...................... 44
SERVICE DATA AND SPECIFICATIONS (SDS) ......... .45 :Rib\
General Specifications .............................................. .45
Inspection and Adjustment ....................................... .46

773
 PRECAUTIONS AND PREPARATION

Precautions
• When installing rubber parts, final tightening must be car-
ried out under unladen condition* with tires on ground.
* Fuel, radiator coolant and engine oil full. Spare tire,
jack, hand tools and mats in designated positions.
• Use flare nut wrench when removing or installing brake
tubes.
• After installing removed suspension parts, check wheel
alignment and adjust if necessary.
Commercial service tool
• Always torque brake lines when installing.
SBR686C

Special Service Tools

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here

Tool number Unit application

(Kent-Moore No.) Description
Tool name 2WD 4WD

ST29020001 Removing ball joint for

&
(J24319-01) knuckle spindle
Gear arm puller
X X

NT143

HT72520000 Removing tie-rod outer end

~
(J25730-B)
Ball joint remover X X

NT146

KV401021SO Installing wheel bearing

( - )
Bearing race drift

KV40105400
NT153
$ outer race

Removing or installing wheel

X X

(J36001)
Wheel bearing
lock nut wrench

NT154
7r bearing lock nut
- X

Commercial Service Tools

Tool name Description
CD Flare nut crowfoot Removing and installing each brake piping
® Torque wrench

NT360 a: 10 mm (0.39 in)

774 FA-2
 FRONT AXLE AND FRONT SUSPENSION

2WD

SEC. 400·401·406
When installing rubber parts, final tightening
must be carried out under unladen condition•
with tires on ground.
• Fuel, radiator coolant and engine oil lull.
Spare tire, jack, hand tools and mats in
designated positions.

~~16- 22
(1.6 - 2.2, 12 - 16)

Shock ab••o,t>e,,

toJ 16 - 23 (1.6 - 2.3. 12 - 17)

~ 71 - 103 (7.2 - 10.5, 52 - 76)

Stabilizer
Anchor

FRONT~

/AI!

T!IF

30 - 40 ~!))
(3.1 - 4.1, 22 - 30)

link assembly
Cotter i
~ 109- 147
(11.1 - 15.0, 80 - 108) Rotor i
Tension rod ~ 118 - 191
(12.0 - 19.5, 87 - 141)
Wheel
16 - 22
(1.6- 2.2, 12 - 16) ~ 118 - 147 (12 - 15, 87 - 108)-

~~ 114-147
(11.6- 15.0, 84 - 108)

~' N-m (kg-m. ft-lb)

AFA101

FA-3 775
 FRONT AXLE AND FRONT SUSPENSION

4WD

SEC. 390·400·401·406
When installing rubber parts, final tightening
must be carried out under unladen condition•
with tires on ground.
Fuel, radiator coolant and engine oil full.
Spare tire, jack, hand tools and mats In
designated positions.

ttJ:l16 - 22 (1.6 - 2.2, 12 -

Anchor arm..,

Shock absorber,
ttJ:l30 - 40 (3.1 - 4.1, 22-
to:l109 - 147
(11.1 - 15.0, 80 - 108)
Torsion bar spring
Upper link assrerrrbly• "\

to:l 71 - 103 (7.2 - 10.5, 52 -

FRONT

78 - 147 (8.0 . 15.0, 58 - 108)

rc,on•er p;n ~

toJ 51 - 61 (5.2 - 6.2, 38 - 45)

~ toJ 109 - 147 (11.1 - 15.0, 80-

~ to:l16 - 22 (1.6 - 2.2, 12-

Upper ball plate

Drive shaft assembly

118 - 191
Lower ball joint
(12.0 - 19.5, 87 - 141)

Cotter pin

ttJ:l : N•m (kg-m, ft-lb)

AFA097

776 FA-4
 ON-VEHICLE SERVICE

Front Axle and Front Suspension Parts

• Check front axle and front suspension parts for excessive play,
cracks, wear or other damage. u!ul''
a. Shake each front wheel to check for excessive play.
• If looseness is noted, adjust wheel bearing end play, then
check ball joint end play. ~ITiu
b. Make sure that the cotter pin is inserted.
c. Retighten all nuts and bolts to the specified torque.
(.C!l: Refer to FRONT SUSPENSION, FA-34. L©
d. Check front axle and front suspension parts for wear, cracks
SMA525A or other damage.

• Check shock absorber for oil leakage and other damage .

• Check suspension ball joint for grease leakage and ball joint
dust cover for cracks and other damage.

SFA451B

• Check ball joint for vertical end play.

Upper ball joint:
0.1 - 1.4 mm (0.004 - 0.055 in) at side frame.
a. Jack up front of vehicle and set the stands.
b. Remove road wheel.
c. Clamp dial indicator onto upper link and place indicator tip on
~ro\
knuckle near upper ball joint. rl0
d. Jack up lower link [Approx. 20 mm (0.79 in).]
e. Place a pry bar between upper link and upper link spindle.
f. While pushing and releasing pry bar, observe maximum dial
indicator value.
g. If upper ball joint movement is beyond specifications, remove
and recheck it. Refer to "Upper Ball Joint and Lower Ball liil£
Joint", "FRONT SUSPENSION", FA-44.

Lower ball joint:

2WD
0.1 - 1.3 mm (0.004 - 0.051 in) 111@
4WD
sFA3o3A 0. 7 mm (0.028 in) or less
~=============~ a. Jack up front of vehicle and set the stands at side frame. 18l'if
b. Clamp dial indicator onto transverse link and place indicator tip
on lower edge of brake caliper.
c. Make sure front wheels are straight and brake pedal is l~ffii
depressed.
d. Place a pry bar between transverse link and inner rim of road
wheel. ~6
e. While pushing and releasing pry bar, observe maximum dial
indicator value.
f. If lower ball joint movement is beyond specifications, remove ICD?r
and recheck it. Refer to "Upper Ball Joint and Lower Ball
AFA119 Joint", "FRONT SUSPENSION", FA-44.
------------------------~

FA-5 777
 ON-VEHICLE SERVICE

Front Wheel Bearing

• Check that wheel bearings operate smoothly.
• Check axial end play.
Axial end play: 0 mm (0 in)
• Adjust wheel bearing preload if there is any axial end play or
wheel bearing does not turn smoothly.

SMA571A

2WD PRELOAD ADJUSTMENT (2WD)

Adjust wheel bearing preload after wheel bearing has been
replaced or front axle has been reassembled.
1. Before adjustment, thoroughly clean all parts to prevent dirt
entry.
2. Apply multi-purpose grease sparingly to the following parts:
• Rubbing surface of spindle
• Contact surface between lock washer and outer wheel bearing
: Multi-purpose • Hub cap (as shown at left)
grease point • Grease seal lip
SFA3558

3. Tighten wheel bearing lock nut to the specified torque.

to.J: 34- 39 N·m (3.5 - 4.0 kg-m, 25- 29 ft-lb)
4. Turn wheel hub several times in both directions to seat wheel
bearing correctly.
5. Again tighten wheel bearing lock nut to the specified torque.
to.J: 34- 39 N·m (3.5 - 4.0 kg-m, 25- 29 ft-lb)

SFA890

6. Turn wheel bearing lock nut back 45 degrees.

With castle nut
7. Fit adjusting cap and new cotter pin. Align cotter pin slot by
loosening nut 15 degrees or less.

SFA452B

8. Measure wheel bearing preload and axial end play.

Axial end play: 0 mm (0 in)
Wheel bearing preload
(As measured at wheel hub bolt):
[New grease seal]
9.8 - 28.4 N (1.0 - 2.9 kg, 2.2 - 6.4 lb)
[Used grease seal]
9.8 - 23.5 N (1.0 - 2.4 kg, 2.2 - 5.3 Ib)
Repeat above procedures until correct bearing preload is obtained.

778 FA-6
 ON-VEHICLE SERVICE
Front Wheel Bearing (Cont'd)
9. Spread cotter pin.
10. Install hub cap.

PRELOAD ADJUSTMENT (4WD)

Adjust wheel bearing preload after wheel bearing has been
replaced or front axle has been reassembled.
Adjust wheel bearing preload as follows:
1. Before adjustment, thoroughly clean all parts to prevent dirt
entry.

SRA417

4WD 2. Apply multi-purpose grease sparingly to the following parts:

• Threaded portion of spindle
• Contact surface between wheel bearing washer and outer
wheel bearing !'IE
• Grease seal lip
• Wheel hub (as shown at left)

: Multi-purpose
grease point

SFA891

3. Tighten wheel bearing lock nut with Tool.

tD.J: 78 - 98 N·m (8 - 10 kg-m, 58 - 72 ft-lb)
4. Turn wheel hub several times in both directions.
5. Loosen wheel bearing lock nut so that torque becomes 0 N·m 11'
(0 kg-m, 0 ft-lb).
6. Retighten wheel bearing lock nut with Tool.
~: 0.5-1.5 N·m (0.05- 0.15 kg-m, 4.3- 13.0 in-lb)

7. Turn wheel hub several times in both directions.

8. Retighten wheel bearing lock nut with Tool.
~: 0.5- 1.5 N·m (0.05- 0.15 kg-m, 4.3- 13.0 in-lb)
9. Measure wheel bearing axial end play.
Axial end play: 0 mm (0 in)

10. Measure starting force "A" at wheel hub bolt.

SMA580A

FA-7 779
 ON-VEHICLE SERVICE
Front Wheel Bearing (Cont'd)
11. Install lock washer by tightening the lock nut within 15 to 30
degrees.
12. Turn wheel hub several times in both directions to seat wheel
bearing correctly.
13. Measure starting force "B" at wheel hub bolt. Refer to step 10.
14. Wheel bearing preload "C" can be calculated as shown below.

I C=B-A I
Wheel bearing preload "C":
7.06-20.99 N (0.72- 2.14 kg, 1.59-4.72 lb)
15. Repeat steps 3 through 14 until correct axial end play and
wheel bearing preload are obtained.
16. Install free-running hub.
Front Wheel Alignment
Before checking front wheel alignment, make a preliminary inspec-
tion (Unladen*).
*· Fuel, radiator coolant and engine oil full. Spare tire, jack, hand
tools and mats in designated positions.

PRELIMINARY INSPECTION
1. Check tires for wear and proper inflation.
2. Check outside and inside wheel runout.
Wheel runout average
[(Outside runout value + Inside runout value) x 0.5]:
Refer to SDS, FA-48.
3. Check front wheel bearings for looseness.
4. Check front suspension for looseness.
5. Check steering linkage for looseness.
6. Check that front shock absorbers work properly by using the
standard bounce test.

7. Measure vehicle height (Unladen): H =A- B mm (in)

Refer to SDS, FA-46.
a. Exercise the front suspension by bouncing the front of the
vehicle 4 or 5 times to ensure that the vehicle is in a neutral
height attitude.
b. Measure wheel alignment.
Refer to ALLOWABLE LIMIT in SDS, FA-46.
c. If wheel alignment is not as specified, adjust vehicle posture.
Refer to ADJUSTING RANGE in SDS, FA-46.
d. Adjust wheel alignment.
Refer to ADJUSTING RANGE in SDS, FA-46.

780 FA-8
 ON-VEHICLE SERVICE
Front Wheel Alignment (Cont'd)
CAMBER, CASTER AND KINGPIN INCLINATION
Before checking camber, caster or kingpin inclination, move
vehicle up and down on turning radius gauge to minimize li:ltl:,
friction. Ensure that the vehicle is in correct posture.
• Measure camber, caster and kingpin inclination of both
right and left wheels with a suitable alignment gauge and !;~I
adjust in accordance with the following procedures.

Kingpin Camber (Unladen):

inc! ination Camber Refer to SDS, FA-46.
Kingpin inclination (Unladen):
Refer to SDS, FA-46.
0

0
90°

lfif
SFA895

Caster Caster (Unladen):

Refer to SDS, FA-46.

Front . . . .

SFA896-A

ADJUSTMENT
Both camber and caster angles are adjusted by increasing or
decreasing the number of adjusting shims inserted between upper rnlllil
link spindle and frame.

FA-9 781
 ON-VEHICLE SERVICE
Front Wheel Alignment (Cont'd)
r Adjusting shim 8 Before removing or installing adjusting shim(s), be sure to
Frame bracket place a jack under lower link.
Adjusting shim A
Adjusting shim standard thickness:
2WD
2.9 mm (0.114 in)
4WD
4.0 mm (0.157 in)
• Do not use four or more shims at one place.
• When installing shim 8, always face the pawl towards
Upper link spindle and insert it from bracket side. Use only one
spindle
shim B in a place.
Adjusting shim 8
• Total thickness of shims must be within 8.0 mm (0.315 in).
(For fine adjustment) • Difference of total thickness of the front and rear must be
Adjusting shim A
within 3.0 mm (0.118 in).

lN
• Determine thickness and number of shims necessary for
adjusting camber and caster, in accordance with the fol-
lowing graph.
[Example]
Shim thickness
Shim thickness
a. When service data value minus measured value is equal to:
1.0 (0.039) 1.0 (0.039) Caster angle: . -30'
2.0 (0.079)
2.6 (0.102)
2.0 (0.079) Camber angle: +30'
2.9 (0.114) [2WD only] Unit: mm (in) b. Obtain the intersecting point of lines in accordance with the
4.0 (0.157) [4WD only] graph.
SFA970-A
c. Choose shims which are nearest to the intersecting point.
d. For the above example:
2WD:
Add 2.0 mm (0.079 in) shim on front side.
Add 3.0 mm (0.118 in) shim on rear side.
4WD:
Add 1.0 mm (0.039 in) shim on front side.
Add 3.0 mm (0.118 in) shim on rear side.

782 FA-10
 ON-VEHICLE SERVICE
Front Wheel Alignment (Cont'd)
1\ll~
2WD

!/lifo\

~ilj]

IL©

. _ ~©
Required rear shim
~----~~---+~--~~----~~--~~_,~'~._--~~~--~ mm (in)
-3 (-0.12) 3 (0.12)
!'ill

©IL

1/lilF
~- /
~- / -3 (-0.12)
ff\'j'

/
/
1:1'
SFA477BA

4WD !PI9J
mm (in)

E
~ 3 (0.12)

-3 (-0.12)/
/
/

FA-11 783
 ON-VEHICLE SERVICE
Front Wheel Alignment (Cont'd)
TOE-IN
Measure toe-in using the following procedure.
WARNING:
Hub center • Always perform the following procedure on a flat surface.
height
• Make sure that no one is in front of the vehicle before
pushing it.
1. Bounce front of vehicle up and down to stabilize the posture.
2. Push the vehicle straight ahead about 5 m (16 ft).
3. Put a mark on base line of the tread (rear side) of both tires at
the same height of hub center. This mark is a measuring point.
SFA614B 4. Measure distance "A" (rear side).
5. Push the vehicle slowly ahead to rotate the wheels 180
Lines parallel to degrees (1/2 turn).
center line of body
• If the wheels have rotated more than 180 degrees (1/2
turn), try the above procedure again from the beginning.
Never push vehicle backward.
6. Measure distance "8" (front side).
Total toe-in:
Refer to SDS, FA-46.

t:?
Front

7. Adjust toe-in by varying the length of both steering tie-rods.

a. Loosen clamp bolts or lock nuts.
b. Adjust toe-in by turning both the left and right tie-rod tubes
equal amounts.

Make sure that the tie-rod bars are screwed into the tie-rod
Front tube more than 35 mm (1.38 in).

u Make sure that the tie-rods are the same length.

Standard length (A = B):
2WD

r==JA=B~
344 mm (13.54 in)
4WD
281 mm (11.06 in)
c. Tighten clamp bolts or lock nuts, then torque them.

SFA897

784 FA-12
 ON-VEHICLE SERVICE
Front Wheel Alignment (Cont'd)
FRONT WHEEL TURNING ANGLE
1. Set wheels in straight-ahead position. Then move vehicle for-
ward until front wheels rest properly on turning radius gauge.
2. Rotate steering wheel all the way right and left; measure turn-
ing angle.
~- A • On power steering models, turn steering wheel to full lock and ~liiu
\rr.1. ~Inside
apply force (at circumference of steering wheel) of 98 to 147 N
iJ Angle A:
tke on turn (10 to 15 kg, 22 to 33 lb) with engine at idle.
- r---·---
Front )\
I--
Angle 8:
Outside tire on turn • Do not hold the steering wheel at full lock for more than lb©
15 seconds.
SFA439BA Wheel turning angle (Full turn):
Refer to SDS, FA-46.

©l

3. Adjust stopper bolt if necessary.

[2WD]
Standard length "L1 ": 20 mm (0.79 in)

[4WD]
Standard length "L2 ": 26.5 mm (1.043 in)

Rear Side
' /
·~ 1'0
·~

\- I I \ \ k
!
'r
'

:;• ~"--=,u-'~::_c_-c-'-~~-
}
\ --/ ,)

SFA480BA

FA-13 785
 ON-VEHICLE SERVICE

Drive Shaft
• Check for grease leakage and damage.

SFA901

786 FA-14
 FRONT AXLE

2WD
SEC. 400

/Knuc kl e spindle

~
I

~ IL©

©l

FRONT
'D'I'

CUJ. N•m (kg -m, ft-lb) Wheel hub cap~E:i!l_/

~; N·m (kg-m, in-lb)
SFA559BA

FA-15 787
 FRONT AXLE

4WD

SEC. 391·400

Rotor disc

FRONT

Wheel hubE;!

Manual-lock fre e-running hub sub-assembly

~""""~
\\ Spacer l!i3!
Grease seal "C"
Drive sh aft assembly

I!I'l!l ~

Needle bearing

~
Knuckle spindle l!£a!l I!Ei!l
\_

\ Baffle plate
Grease seal "B" 1!8!1

\~3.4-5.9
t:J.l' N•m (kg-m. ft-lb)

~: N·m (kg-m. in-lb)

(0.35 - 0.6' 30 .4- 52.2)

AFA104

788 FA-16
 FRONT AXLE (4WD)

Manual-lock Free-running Hub

SEC. 400 Drive shaW\
Lubricating parts ~1.2 -1.8 (0.12. 0.18, 10.4, 15.~ ..... \ .._
When installing manual-lock free-running hub,
use multi-purpose grease. i -~Th\ (~"\:.·:"}, '
. ~,....,~· '-'!~_.,..'
Manual-lock free*runn1ng .~\. '-~\·: "' .
hub sub-assembly' _/__.....----\ ,h. ~.: "" Wheel beanng
~25-34 Y'\/ ~ ~ \ '-lock nut
(25-3518- 2s) / ~ ~ \ \. -Lockwasher
· ~-' / ___ ___.---- ('"\ ~ - \ 'Drive clutch'
~ .~ \J \_Snap nng• ~ ~: N·m (kg-m, 1n-lb)
-~ 1:0l N·m (kg-m, ft-lb)
AFA105

REMOVAL AND INSTALLATION

• Set knob of manual-lock free-running hub in the FREE posi-
fun. W
• Remove manual-lock free-running hub with brake pedal
depressed.

• Remove snap ring and then draw out drive clutch.

•
• When installing manual-lock free-running hub, make sure the
hub is in the FREE position. 11lf
Apply multi-purpose grease to the parts shown in the above
illustration.
• Check operation of manual-lock free-running hub after instal-
lation.
INSPECTION
• Check that the knob moves smoothly and freely,
• Check that the clutch moves smoothly in the body.

FA-17 789
 FRONT AXLE (4WD)

Auto-lock Free-running Hub

SEC. 400
Lubricating parts
When installing auto-lock free-running hub, use NISSAN
GENUINE GREASE (KRC19-00025) or equivalent
grease

Auto-lock free-running hub

assembly

'B"

A
B

~: N·m (kg-m, in-lb)

rcJ.J· N-m (kg-m, tt-lb)
AFA106

REMOVAL AND INSTALLATION

• Set auto-lock free-running hub in the FREE position.
• Remove auto-lock free-running hub with brake pedal
depressed.

• Remove snap ring.

Brake B
• Remove washer B, washer A and brake B.
• After installing auto-lock free-running hub, check operation.
When installing it, apply recommended grease to the parts
shown in the above illustration.

SFA829

INSPECTION
Brake A Thoroughly clean parts with cleaning solvent and dry with com-
pressed air.

Brake "A" and "B"

Measure the thickness "L" of brake "A" and "B".
If thickness is less than the specified limit, replace brake "A" and
Brake B "B" as a set.
Wear limit l:
15.5 mm (0.610 in)
SFA458BA

790 FA-18
 FRONT AXLE (4WD)
Auto-lock Free-running Hub (Cont'd)
TROUBLE-SHOOTING
Noise occurring in the auto-lock free-running hub under any of the
conditions described below is not indicative of a problem. Noise
can be eliminated by properly operating the transfer lever.

Noise

l L©
Was the transfer lever shifted from the 1Yes..._ Shifting the transfer lever
"2H" to the "4H" position while the vehicle r------- from the "2H" to the "4H"
was operated at a speed greater than 40 position in high-speed

(1
Housing hub rotates km/h (25 MPH)? operation (Fig. 11 --> Fig.
m ),
i~i:~~~~~at
is sometimes diffi-
as the same speed
wheels. No
cult. At this point, a clatter-
Dnve shaft JS .. fr2il
held statiOna~l ~ ~ ing occurs in the auto hub.

f ~ - If shifting is stopped
halfway, the drive shaft no

~IL
longer rotates and the cam
is held in the "LOCK" posi-

o~lth
tion (Fig. !;) ). In this
case, the noise will con-
Vehicle In the transfer
lever In the "2H" position tinue until the vehicle is
SFA516A
stopped. When this occurs,
decrease vehicle speed to
less than 40 km/h (25
MPH), return the transfer
lever to the "2H" position
once and then reshift to
the "4H" position.
Gears will then be
engaged and the noise will
cease (Fig. [!) ).

®
(Go to next page.)

(1

~
~ ~
:
~
,/Gears engage.

~~__;;;"""""":==~ Noise ceases.

Transfer lever in the "4H" position

SFA518A

FA-19 791
 FRONT AXLE (4WD)
Auto-lock Free-running Hub (Cont'd)
®
l
Was the transfer lever shifted from the Yes
c______. When noise occurs in the
"2H" to the "4H" position while the vehicle auto hub while shifting
was operated at a speed less than 40 from the "2H" to the "4H"
km/h (25 MPH)? position (Fig.liJ --> Fig.
No
m), do not stop shifting
halfway. When shifted to
the "4H" position, the
"4WD" pilot lamp will come
on to indicate that the
gears are engaged prop-
erly and that the vehicle is
set in the 4WO mode.
Noise will then cease (Fig.
[!I ). If shifting is stopped
halfway, noise will con-
tinue. In such a case,
return the transfer lever to
the "2H" position once and
re-shift it to the "4H" posi-
tion. Gears will then be
engaged and the noise will
cease (Fig. [!I ). (If the
lever is left in the "2H"
position, the noise will con-
tinue until the vehicle is
stopped.)

®
(Go to next page.)

792 FA-20
 FRONT AXLE (4WD)
Auto-lock Free-running Hub (Cont'd)

Was the vehicle started after the transfer Yes A clicking noise can some-
1- lever was shifted from the "2H" to the f-----o times occur in the auto hub
"4H" or "4L" position? when the gears are
engaged. This is not a
No
problem.
Noise can be encountered
during rapid acceleration
Vehicle stoppage
SFA519A
while rear wheels are slip-
ping on snowy roads,
muddy roads, slopes, etc.
(Fig. I!] ~ Fig. 1§1 ).

-··(
Gears are not In such a case, release the
engaged due to accelerator pedal to reduce
faster drive shaft engine speed. Gears will
rotates fast. - -
/rotation.
. D- then be engaged and the
noise will cease (Fig.
r-"F:='="~ Gear squeaks.
[!) ).
~sing g~ is held stationary.
Abrupt standing start/acceleration
Was the vehicle backed up when the Yes When backing up the
while rear wheels are slipping SFA520A
transfer lever was in the "4H" or the "4L" ~ vehicle with the transfer in
position, or was the vehicle backed up the ••4H" or the "4L•'
while on a downgrade when the transfer position, auto-hub gears
lever was in the "4H" or the "4L" posi- sometimes disengage but
tion? ~oon reengage (Fig.
I) ~ Fig. (!1 --> Fig.
No
1:1 ) with a clicking noise.
This is not a problem.
Noise will also occur if the
vehicle is accelerated rap-
idly while the gears are
Vehicle starting to back up disengaged. In such a
SFA521A
case, release the accelera-
tor pedal once to decrease
(l Return spring

g;~~~d~~~r
engine speed. Gears will

~
Gears sometimes
disengage.
then be engaged and the
noise will cease (Fig.
[!) ).
t--H\"'l3+H
'=rUJ Was the vehicle turned on a dry
pavement, when the transfer lever was in
Yes
~
Under these conditions,
noise occurs in tires
the "4H" or the "4L" position? (creaking) or in the power
train (rattling) - not in the
Gears in "unlocked" condition No
SFA522A auto hub.
Avoid driving in the condi-
(l tions described above as it
may lead to tire wear.

Reverse
"LOCK"
q
HU~'
~-
_L4Y
=
O'""""""l
©
(Go to next page.)

v---u-:::jF~~!!J
position -?

Gears engaged in reverse

SFA523A

FA-21 793
 FRONT AXLE (4WD)
Auto-lock Free-running Hub (Cont'd)
D Front

t Locked

!
D1fferent1al
Was the vehicle moved in one direction
after the vehicle was driven in another
direction when the transfer lever was in
the "4H" or the "4L" position and then
returned to the "2H" position?
-
Yes Auto-hub gears will disen-
gage with a resultant noise
(clicking). If the distance
the vehicle is moved in the
opposite direction is short
[less than 1 m (3 ft)] or if
2H
No
the rotation angle of the
One side In "unlocked" condition SFA524A
left and right wheels is not
the same (as in rounding a
corner), gears on one side
will disengage (Fig. D ).
Under this condition, a
noise (crushing, etc.) might
occur while driving in the
"2H" position. If only gears
on one side are unlocked,
the locked drive shaft
rotates at the same speed
as wheels; however, the
unlocked drive shaft is
made to rotate in the
reverse direction by the
differential. This forces the
auto hub's slide gear to
lock in the reverse direc-
tion. As a result, noise
occurs.
If this happens, slowly move
the vehicle straight back
approximately 2 to 3 m (7 to
10 ft) with the transfer lever
in the "2H" position to dis-
engage the gears on the
other side.

@
(Go to next page.)

794 FA-22
 FRONT AXLE (4WD)
Auto-lock Free-running Hub (Cont'd)
@II

I!J~(l~i~i.\- 1
-
Rotat;ng

"'"'~(
Was the vehicle driven with the transfer Yes In extremely cold weather
lever in the "2H" position in extremely (areas), the viscosity of
cold weather? differential oil is greater
than in moderate weather.
rotates
d_ue t~ oil ( ~
;0 ~/
No
When the auto hubs are
VISCOSity. \j unlocked with the transfer
Vehicle operating in extremely cold weather with lever set to the "2H"
IL©
transfer lever In the "2H" position SFA A position, one auto hub can
525
sometimes remain locked.
This causes noise during
operation. Noise can also
occur in the auto hub when
the front propeller shaft is
rotated due to the viscosity
resistance of the transfer
1!1 ).
fluid (Fig.
In such a case, drive in the
"4H" position for approxi-
mately 10 minutes until the
vehicle warms up, and
return the transfer lever to
the "2H" position to elimi-
nate the noise.

Disassemble and check the auto hub.

Refer to FA-18.

FA-23 795
 FRONT AXLE

Wheel Hub and Rotor Disc

REMOVAL AND INSTALLATION
• Remove free-running hub assembly. - 4WD -
Refer to FRONT AXLE (4WD) -Auto-lock Free-running Hub
or Manual-lock Free-running Hub, FA-17.
• Remove brake caliper assembly without disconnecting
hydraulic line.
Be careful not to depress brake pedal, or piston will pop out.
Make sure brake hose is not twisted.

4WD • Remove lock washer. - 4WD -

I

SFA364B

• Remove wheel bearing lock nut.

2WD: With suitable tool
4WD: With Tool

SFA365B

• Remove wheel hub and wheel bearing.

Be careful not to drop outer bearing.
• After installing wheel hub and wheel bearing, adjust wheel
bearing preload.
Refer to PRELOAD ADJUSTMENT of Front Wheel Bearing in
ON-VEHICLE SERVICE, FA-6.

SFA832

DISASSEMBLY
• Remove bearing outer races with suitable brass bar.

FA858

796 FA-24
 FRONT AXLE
Wheel Hub and Rotor Disc (Cont'd)
INSPECTION @I

Thoroughly clean wheel bearings and wheel hub.

Wheel bearings
• Make sure wheel bearings roll freely and are free from noise,
cracks, pitting and wear. ~1\lu

Wheel hub
• Check wheel hub for cracks by using a magnetic exploration l©
or dyeing test.

ASSEMBLY
• Install bearing outer race with Tool until it seats in hub.

"- KV401021SO
I l
©6

SFA943

2WD 4WD • Pack multi-purpose grease in wheel hub and hub cap.

OJ : Multi-purpose
grease point AFA 122

• Apply multi-purpose grease to each bearing cone .

• Pack grease seal lip with multi-purpose grease, then install it
into wheel hub with suitable drift.

Inner side
SFA459B

Knuckle Spindle
REMOVAL
• Remove free-running hub assembly. - 4WD -
Refer to FRONT AXLE (4WD)- Auto-lock Free-running Hub
or Manual-lock Free-running Hub, FA-17.

FA-25 797
 FRONT AXLE
Knuckle Spindle (Cont'd)
• Separate drive shaft from knuckle spindle by slightly tapping
drive shaft end. - 4WD -

• Separate tie-rod from knuckle spindle with Tool.

Install stud nut conversely on stud bolt so as not to damage
stud bolt.

\ _ HT72520000
(J25730~B)

SFA840-A

• Separate knuckle spindle from ball joints.

(1) Loosen (do not remove) upper and lower ball joint tightening
I~ nuts.

O: Loosen
(not remove)
SFA927

(2) Separate knuckle spindle from upper and lower ball joint studs
with Tool.
During above operation, never remove ball joint nuts which
are loosened in step (1) above.
Tool:
2WD
ST29020001 (J24319-01)
4WD
HT72520000 (J25730-B)

(3) Remove ball joint tightening nuts.

Support lower link with jack.
(4) Remove knuckle spindle from upper and lower links.

INSPECTION
Knuckle spindle
• Check knuckle spindle for deformation, cracks and other dam-
age by using a magnetic exploration or dyeing test.

798 FA-26
 FRONT AXLE
Knuckle Spindle (Cont'd)
Bearing spacer - 2WD -
• Check bearing spacer for damage.

Needle bearing - 4WD -

• Check needle bearing for wear, scratches, pitting, flaking and
burn marks. ~u:l

2WD INSTALLATION
• Install bearing spacer onto knuckle spindle. - 2WD -
Make sure that bearing spacer is facing in proper direction.
Apply multi-purpose grease.

SFA945-A

4WD • Install needle bearing into knuckle spindle. - 4WD -

Knuckle spindle Make sure that needle bearing is facing in the proper direction.
Apply multi-purpose grease.

Seal lip

Needle bearing
SFA962
~~l
• Install knuckle spindle to upper and lower ball joints with lower
link jacked up.
CAUTION: Ill~!
Make sure that oil and grease do not come into contact with
tapered areas of ball joint, knuckle spindle and threads of ball
~i~ ~
• Connect tie-rod to knuckle spindle.

SFA929

• After installing knuckle spindle, adjust wheel bearing preload.

Gil'
4WD
Refer to PRELOAD ADJUSTMENT of Front Wheel Bearing in
ON-VEHICLE SERVICE, FA-6.
• After installing drive shaft, check drive shaft axial end play.
Do not reuse snap ring once it has been removed.
Refer to FRONT AXLE (4WD) - Drive shaft, FA-28.

SFA369B

FA-27 799
 FRONT AXLE (4WD)

Drive Shaft
SEC. 391 Wheel side (ZF1 00)
KA24E
~~--------

.:o;._j
~ L~o
~~
n (Rzeppa Jmnt}

IU ~ !711 J
/C"CIIp~
r-Dcive shaft
Snap nng '4:1 ---...____1 ~~
----
~~"'ii\ iJJ ,~/ ,r-~ 34 - 44 N•m
1
I1 I
.________ , ____\, (3.5 - 4.5 kg-m, 25 - 33 ft-lb)

Joint assembly ~i \ r--.---.._ _J 1

...,._j' \ [~- J
(Wheel side)
Boot band~
(Large) Boot
,1 L
I
---..____
~
-~
--------
"""' @-,1
(Wheel:~::':d~_j ~~-~0~.
~~----r:(S'~t)
(Small) l._\./ ~ ~ -:::t
Boot band~_V~~.----- .• I ~ Q n:
Boot-~ . l~i \ rr I I
Slide joint hous1ng_j 1--._,_ ~.\
1

\
'L\
Spider assembly-' \:-------~\J
Snap ring~-----' \
Final drive side Plug seal~---
(TS82F)
SFA874-A

REMOVAL
1.
Remove bolts fixing drive shaft to final drive.
2.
Remove free-running hub assembly with brake pedal
depressed. Refer to FRONT AXLE (4WD) -Auto-lock Free-
running Hub or Manual-lock Free-running Hub, FA-17.
3. Remove brake caliper assembly without disconnecting brake
hydraulic line.
Be careful not to depress brake pedal, or piston will pop out.
Make sure that the brake hose is not twisted.
4. Remove tie-rod ball joint. Refer to FRONT AXLE - Knuckle
sFA236 Spindle, FA-25.
~==============~ 5. Remove nuts fixing lower ball joint on lower link.
Support lower link with jack.
6. Remove upper ball joint fixing bolt.
7. Remove shock absorber lower bolt.

SFA843

8. Remove drive shaft with knuckle.

Cover drive shaft boot with a suitable protector.

800 FA-28
 FRONT AXLE (4WD)
Drive Shaft (Cont'd)
@I
9. Separate drive shaft from knuckle by slightly tapping it.

DISASSEMBLY
Final drive side (TS82F)
1. Remove plug seal from slide joint housing by lightly tapping i"l'i
around slide joint housing.
2. Remove boot bands.

3. Move boot and slide joint housing toward wheel side, and put 5\11
Matching marks matching marks.

SFA963

4. Remove snap ring. M

®1'1

~v

\ SFA964
l'lili

llii1i'
5. Detach spider assembly with press.

iiilffil

"~
uiQJ:?:

SFA392

FA-29 801
 FRONT AXLE (4WD)
Drive Shaft (Cont'd)
6. Draw out boot.
Cover drive shaft serration with tape to prevent damaging the
boot.

SFA799

Wheel side (ZF1 00)

CAUTION:
The joint on the wheel side cannot be disassembled.
• Before separating joint assembly, put matching marks on drive
shaft and joint assembly.
• Separate joint assembly with suitable tool.
Be careful not to damage threads on drive shaft.
• Remove boot bands.

INSPECTION
Thoroughly clean all parts in cleaning solvent, and dry with com-
pressed air. Check parts for evidence of deformation or other dam-
age.

Drive shaft
Replace drive shaft if it is twisted or cracked.

Boot
Check boot for fatigue, cracks and wear. Replace boot with new
boot bands.

Joint assembly (Final drive side)

• Replace any parts of double offset joint which show signs of
scorching, rust, wear or excessive play.
• Check serration for deformation. Replace if necessary.
• Check slide joint housing for any damage. Replace if neces-
sary.

Joint assembly (Wheel side)

Replace joint assembly if it is deformed or damaged.

ASSEMBLY
• After drive shaft has been assembled, ensure that it
moves smoothly over its entire range without binding.
• Use NISSAN GENUINE GREASE or equivalent after every
overhaul.

802 FA-30
 FRONT AXLE (4WD)
Drive Shaft (Cont'd)
Final drive side (TS82F)
1. Install new small boot band, boot and side joint housing to
drive shaft.
Cover drive shaft serration with tape to prevent damaging
\ boot during installation.

1©
SFA800

2. Install spider assembly securely, making sure marks are prop- §i(::
erly aligned.
• Press-fit with spider assembly serration chamfer facing
shaft.
I"~

3. Install new snap ring.

Suitable tool 10\L

Chamfer
SFA397

4. Pack with grease.

Specified amount of grease:
95 - 105 g (3-35 - 3-70 oz) 1i'J'
5. Make sure that the boot is properly installed on the drive shaft
groove. Set the boot so that it does not swell or deform when
its length is "L 1 ".
Length "L 1 ": 95- 97 mm (3_74- 3_82 in)

SFA460BA

f11~
6. Lock new large boot band securely with a suitable tool, then
lock new small boot band.
7. Install new plug seal to slide joint housing by lightly tapping it.
~~

--~
Apply sealant to mating surface of plug seal.

.. ,(
Boot band

SFA443B

Wheel side (ZF1 00)

1. Install new small boot band and boot on drive shaft.
Cover drive shaft serration with tape to prevent damaging
boot during installation.

SFASOO

FA-31 803
 FRONT AXLE (4WD)
Drive Shaft (Cont'd)
2. Set joint assembly onto drive shaft by lightly tapping it.
Install joint assembly securely, ensuring that marks which were
made during disassembly are properly aligned.

Wood
SFA884

3. Pack drive shaft with specified amount of grease.

Specified amount of grease:
135- 145 g (4.76 • 5.11 oz)
4. Make sure that the boot is properly installed on the drive shaft
groove. Set the boot so that it does not swell or deform when
its length is "L2'.
Length "L2 ": 96 · 98 mm (3.78 · 3.86 in)
5. Lock new large boot band securely with a suitable tool.
6. Lock new small boot band.

INSTALLATION
• Apply multi-purpose grease.

grease point

SFA887

• Install bearing spacer onto drive shaft.

Make sure that the bearing spacer is facing in the proper direc-
tion.
• After installing wheel hub and wheel bearing, adjust wheel
bearing preload. Refer to PRELOAD ADJUSTMENT of Front
Wheel Bearing in ON-VEHICLE SERVICE, FA-6.

\___ Drive shaft

SFA846

• When installing drive shaft, adjust drive shaft axial end play by
selecting a suitable snap ring.
(1) Temporarily install new snap ring on drive shaft in the same
thickness as it was installed before removal.

SFA940

804 FA-32
 FRONT AXLE (4WD)
Drive Shaft (Cont'd)
(2) Set dial gauge on drive shaft end.
(3) Measure axial end play of drive shaft.
Axial end play:
0.45 mm (0.0177 in) or less
(4) If axial end play is not within the specified limit, select another
snap ring.
1.1 mm (0.043 in) 1.3 mm (0.051 in)
1.5 mm (0.059 in) 1.7 mm (0.067 in)
!L©
1.9 mm (0.075 in) 2.1 mm (0.083 in)
SFAB47
2.3 mm (0.091 in)

FA-33 805
806

1\)
SEC. 401·406
Dust cover
Anchor arm bolt =E
0
Upper link spindle
Adjust shims · /Anchor arm l!'2i!
Select when adjusting

~~Snapnng
wheel alignment.

~~Anchor bolt pivot

(Qf

~
~ ®
®-----tp;l30 - 40 (3.1 - 4.1, 22 - 30) ~
~-Nut
~ tp;l16 - 22 (1.6 . 2.2, 12 . 16) ~

~Washer
Upp" link _) Tensoon bar spnng
........---~ .,
~. A
___.-Washer
~ ~~-
~8. 1 69-95)....
11 (0.8 -1.. ~ ~ Lower hnk sp ~
/ indle ~ lJ
0
l!'2i! Shock absorber
~--------Cotter ~ z
~
pin
~
u
Bound bumper __/ Nut16 . 2 2
22 12 . 16) Nut
-1
~ (1.6- ., tp;l68 - 88 ~• ~ 118. 191 en
/l))
c
w'
""' - - ! l J - Front spring
~
r
1
(6.9. 9.0,
50·65)
~
o_ (12.0 - 19.5, 87 . 141)

Dust cover
en
"I::J
m
z
torque arm ~49-64
(5.0 - 6.5,
en

CiampA/~
6
(j
-~ 36 - 47) 0
,~-~7. z
~~,4~---
_t::J-r ~

·~
tp;l16 - 22
~Lower link
(1.6 . 2.2, 12 . 16) @

FRONT

0
tp;l1o9 . 147
Bushing-®'

(11.1 - 15.0, 80 . 108) ~-

L_
®
I

- /
'! I
~j
I
•
•
•
When removing each suspension part, check
wheel alignment and adjust If necessary.
When Installing a bushing, do not allow it to
project beyond the surface area of the washer.
Do not allow the bushings and washers to come
In contact with grease, oil soapy water, etc.
When Installing rubber parts, final tightening
must be carried out under unladen condition•
Nut """16 - 22 (1.6 - 2212·~
. • • with tires on the ground.
tp;l114 - 147 .-.. I I • Fuel, radiator coolant and engine oil full.
(11.6 - 15.0, 84 . 108) ·~ - -
Spare tire, jack, hand tools and mats in

~ -~- ~
~

"'
00
designated positions

~ tp;l. N·m lkg-m 11-lb)

[iJ: N·m (kg-m. ln-lb)
~ ~1\c=J~
U \litJ\J
-- Z.nsion rod ! • When removing or Installing brake tubes, use
flare nut torque wrench.
'l'
 SEC. 401·406
~
·~....go 7~~> ~ 30)~
Spring washer Upper link bu shing outer washer c

~ ~]
Adjusting. s h'ms
I wheel alignmen t "@i) ,., 30.40 (3.1. 4.1, 22.
- .,.,,. 0 • • .-.

.c~~ ~ <:_..------ ~'-Upper ~.,. '~®

select them. v. . k bushing l!il!\ Anchor arm ®

-·· _)<., >:~.. .... llP

" _... '
.~~
..... ,. .., ... ,
--.~~l'l .<~·~
lon

~ ·• ....... " '~ _ ,~·

..., .

':' / Bu:hong<~.~-. ......., ~ :

,
' ·, ""' ,.,. \\
.... ,...., ' fiJ
!
,., To
109frame
• 14=:/708) . ® u (4 6 • 6.1,
l!il!J?
~ ~
,-,. (11.1 • 15.0, 80 • o ®" D st .cover

T~ ~~58
Upper hnk . . t Nut Washer
,-,. (72. 10.5, . die ____./'= (8.0. 15.0,

-~ ~ .
,., 71 •upper
103 link
52 spm
• 76) D Upper ballclamp
st cover lOin ff"'>l tDJ 78 .- 14.7
108)
0
Anchor bolt pilot

. t

~~ --"~ ~, ~=>~ ~
"T1

~'
~ ~ ::0

~
Bushong cover ___....-----Cotter
Boun pm .•. , ' ..,. .,.,89. 118 (9.1. 12.0, 66.
0

~o ~ =~- ~ ~ ~ ~~Shock A:,~ ~ ' , ~ · -

Ous
______- '-,. Anchor arm bolt
.
\
d bumpef c
,<1> z
- •-""Y: . -1
en
~ c
"\~ .~l
'E/

.
(,) .. ... absorber 147
en
(II
r%' ~ "tl
Stabohzer «'»
:i\.Y \ ·: : \ •
R '
'> . ,,..,., m
\ ~
,.. " S I \C'Y .-.. (11.6.
.
15.0,
" . z
··..
" ' 84 - 108)
en
0
z
., ~'>~l- ~0 - l ~
~ .-.Nut~"' .~~~
.....,
. . .
(5.2 • 6.2,
•.-
,., 1~. 147
.-.. (11 1 • 15.0,
80 . 108)- Y ~ .. ··
.

.
" " ~u
12 • 16)
'
,., 16 . 22 - , ~-

... %!" .-
• •
.•
o Compressoon r o dI ))(
e

.....
.~~- •
When removing each suspension part, check
wheel alignment and adjust If necessary.

... ~ -..... '" ~

When installing a bushing, do not allow it to

t:? . G Nut ,.,

"~ 118 • 1
" . project beyond the surface area of the washer.
Do not allow the bushings and washers to come
In contact with grease, oil, soapy water, etc.
FRONT
'"
@ .-.. "."
(4.8 - 6.2,
35-45)
Lower ball joint __..-------
~
. ___-----
· ;~. ;
-1 -
fl "".
Nut
"'·
87 • 108)-

191
When installing stabilizer bar, compression rod,
lower and upper links, final tightening must be
carried out under unladen condition* with tires
on the ground.
Fuel, radiator coolant and engine oil full
ust cover ~ ~o-.1 1 1
D
> il .,,.,118. 19 5 Spare tire, jack, hand tools and mats in
designated positions

i tDJ N·m (kg-m, ft-lb)

Cotter pm •.~-- • -----=-
(12. 0 •
87 - 141)
. '
• When removing or Installing brake lubes, use
flare nut torque wrench.
807

·~
~
~ (9.21 :2Q) @i'J ~_l
ICiiJ 5:1'
""' ~
@2] ell [ljjiJ [I
Q ITiJ §;
?:-!, F )~· <cc:J (!li;D ~ ~ ]1o=> lf5J
""' ~ [~'-"-'
"""
[jjj]

"" CQ ~ 20--:o
 FRONT SUSPENSION

Shock Absorber
REMOVAL AND INSTALLATION
When removing and installing shock absorber, do not allow oil or
grease to contact rubber parts.

INSPECTION
Except for nonmetallic parts, clean all parts with suitable solvent
and dry with compressed air.
Use compressed air to blow dirt and dust off of nonmetallic parts.
SFA931
• Check for oil leakage and cracks. Replace if necessary.
• Check piston rod for cracks, deformation and other damage.
Replace if necessary.
• Check rubber parts for wear, cracks, damage and deformation.
Replace if necessary.
Torsion Bar Spring
REMOVAL
• Remove adjusting nut.

SFA851-A

• Move dust cover, then detach snap ring from anchor arm.
• Pull out anchor arm rearward, then withdraw torsion bar spring
rearward. - 2WD -
• Remove torque arm. - 2WD -

• Remove torque arm fixing nuts, then withdraw torsion bar

spring forward with torque arm. - 4WD -
INSPECTION
• Check torsion bar spring for wear, twist, bend and other dam-
age.
• Check serrations of each part for cracks, wear, twist and other
damage.
• Check dust cover for cracks.

808 FA-36
 FRONT SUSPENSION
Torsion Bar Spring (Cont'd)
INSTALLATION AND ADJUSTMENT
Adjustment of anchor arm adjusting nut is in tightening direc-
tion only.
Do not adjust by loosening anchor arm adjusting nut.
1. Install torque arm to lower link. - 2WD -
2. Coat multi-purpose grease on the serration of torsion bar ~~\il
spring.

3. Place lower link in the position where bound bumper clearance li':lti
"C" is 0.
Clearance "C": 0 mm (0 in)

Lower
link

SFA549

4. Install torsion bar spring. - 2WD -

• Install torsion bar spring with torque arm. - 4WD -
Rear Be sure to install right and left torsion bar springs correctly.

SFA854

5. Set anchor arm. W''

2WD
Standard length "G":
2WD
G!~
6- 18 mm (0.24- 0.71 in)
4WD
50 - 60 mm (1.97 - 2.36 in)
~11

~§

SFA912-A

11111
4WD

Iii~

I'll

~[D?I

SFA853-A

FA-37 809
 FRONT SUSPENSION
Torsion Bar Spring (Cont'd)
6. Install snap ring to anchor arm and dust cover.
-2WD-
Make sure that the snap ring is properly installed on the
anchor arm groove.

-4WD-
Make sure that the snap ring and anchor arm are properly
installed.

------ ----------
-- --~--

Snap ring

member

SFA739B

2WD 7. Tighten anchor arm adjusting nut to get L dimension.

Standard length "L":
I 2WD
49 mm (1.93 in)
4WD
77 mm (3.03 in)

SFA855-A

810 FA-38
 FRONT SUSPENSION
Torsion Bar Spring (Cont'd)
8. Bounce vehicle with tires on ground (Unladen) to eliminate @I
friction of suspension.
9. Measure vehicle posture "H".
(1) Exercise the front suspension by bouncing the front of the lJlL~
vehicle 4 or 5 times to ensure that the vehicle is in a neutral
height attitude.
(2) Measure vehicle posture ... Dimension "H". G;l:i
H = A - 8 mm (in) "Unladen"
Refer to WHEEL ALIGNMENT (Unladen) in SDS, FA-46.
l©

10. If height of the vehicle is not within allowable limit, adjust ~'"'
~e0
vehicle posture.
Refer to WHEEL ALIGNMENT (Unladen) in SDS, FA-46.
11. Check wheel alignment if necessary. 1'1:'
Refer to WHEEL ALIGNMENT (Unladen) in SDS,FA-46.

Stabilizer Bar
REMOVAL
• Remove stabilizer bar connecting bolts and clamp bolts.

INSPECTION
• Check stabilizer bar for twist and deformation.
Replace if necessary.
• Check rubber bushing for cracks, wear and deterioration.
Replace if necessary.

SFA738B

INSTALLATION
• Install bushing outside of white mark painted on stabilizer.
White mark !}Dffi~

SFA858

FA-39 811
 FRONT SUSPENSION

Upper Link
REMOVAL
• Remove shock absorber upper fixing nut.

• Remove bolts fixing upper ball joint on upper link.

Support lower link with jack.
• Remove upper link spindle fixing bolts.

SFA918

INSTALLATION
• Tighten upper link spindle with camber adjusting shims.
• After fitting, check dimensions "A" and "8".
A: 110 mm (4.33 in)
B: 32 mm (1.26 in)

SFA919

•
'-.......__~ .
•
Install upper ball joint on upper link .
Install shock absorber upper fixing nut.
Tighten upper link spindle lock nuts under unladen condition
with tires on ground.
• After installing, check wheel alignment. Adjust if necessary.
Refer to FA·8.

~~~~
t='J SFA920

DISASSEMBLY
• Press out upper link spindle with bushings.
INSPECTION
• Check upper link spindle and rubber bushings for damage.
Replace if necessary.
• Check upper link for deformation and cracks. Replace if nee·
essary.

FA688

812 FA-40
 FRONT SUSPENSION
Upper Link (Cont'd)
• Press
ASSEMBLY
• Apply soapsuds to rubber bushing.
• Press upper link bushing.
Press bushing so that the flange of bushing securely contacts
Upper link the end surface of the upper link collar.
bushing

Upper link

lb©
SFA102

~II,;
• Insert upper link spindle and inner washers. ~
Install inner washers with rounded edges facing inward.
• Press another bushing. IP~
Press bushing so that the flange of bushing securely contacts
the end surface of the upper link collar.
©lb

• Temporarily tighten nuts.

Temporarily tighten SFA105

FA-41 813
 FRONT SUSPENSION

Tension Rod or Compression Rod

REMOVAL AND INSTALLATION
• Remove fixing nuts on lower link and frame.
Support lower link with jack.

2WD Bushing • Install tension rod. - 2WD -

Make sure that the bushings and washers are installed prop-
erly.

• Install compression rod. - 4WD -

Make sure that the bushings and washers are installed prop-
erly.

SFA873-A

814 FA-42
 FRONT SUSPENSION

@[
Lower Link
REMOVAL AND INSTALLATION
• Remove torsion bar spring. Refer to REMOVAL in Torsion Bar
Spring, FA-36.
Make matching mark on anchor arm and crossmember when
loosening adjusting nut until there is no tension on torsion bar
spring.

4WD
Matching mark

Anchor arm
SFA938-A

• Separate lower link ball joint from knuckle spindle.

-2WD-
Refer to FRONT AXLE - Knuckle Spindle, FA-25.
• Separate lower ball joint from lower link. - 4WD -

• Remove front lower link fixing nut.

• Remove bushing of lower link spindle from frame with suitable ~11'
tool.
• When installing, apply soapy water to bushing.
• After installing lower link, adjust wheel alignment and vehicle
height. Refer to FA-8.
INSPECTION
Lower link and lower link spindle
• Check for deformation and cracks. Replace if necessary.
Lower link bushing
L __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _SFAB72
__ ~
• Check for distortion and damage. Replace if necessary.

FA-43 815
 FRONT SUSPENSION

Upper Ball Joint and Lower Ball Joint

REMOVAL AND INSTALLATION
• Separate knuckle spindle from upper and lower links.
Refer to FRONT AXLE - Knuckle Spindle, FA-25.

INSPECTION
• Check ball joint for vertical end play "A".
Upper ball joint:
0.1 - 1.4 mm (0.004 - 0.055 in)
AFA120
Lower ball joint:
2WD
0.1 - 1.3 mm (0.004 - 0.051 in)
4WD
0.7 mm (0.028 in) or less
Replace ball joint if movement is beyond specifications.

• Check dust cover for damage.

Replace dust cover and dust cover clamp if necessary.

816 FA-44
 SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications
TORSION BAR SPRING
Applied model 2WD 4WD

Spring diameter x length mm {in) 22.6 X 885 (0.890 X 34.84) 26.0 X 1,205 (1.024 X 47.44)
Spring constant
16.5 (1.68, 94.1) 25.7 (2.62, 146.7)
N/mm (kg/mm, lb/in)

SHOCK ABSORBER l©
2WD 4WD
Applied model
Except Heavy duty Heavy duty U.S.A. Canada

Shock absorber type Non-adjustable

Damping force
[at 0.3 m (1.0 ft)/sec.] N (kg, lb)

579- 794 1,089. 1,461 1,599-2,128 1,687 - 2,236

Expansion
(59- 81, 130- 179) (111 - 149, 245- 329} (163- 217, 359- 478) (172 - 228, 379 - 503)

216- 333 314-471 559- 814 432- 647

Compression
(22 - 34, 49 - 75) (32- 48, 71 - 106) (57- 83, 126- 183) (44- 66, 97- 146)

STABILIZER BAR DRIVE SHAFT (4WD)

Applied model 2WD 4WD Drive shaft joint type

Stabilizer bar diameter Final drive side TS82F

23.0 (0.906) 26.0 (1.024)
mm (in)
Wheel side ZF100

Fixed joint axial end play

1 (0.04)
limit mm (in)
TENSION ROD OR COMPRESSION ROD
Diameter mm (in)
Applied model 2WD 4WD
Wheel side {0 1 ) 29.0 (1.142)
Rod diameter mm {in) 22.0 (0.866) 23.5 (0.925)
Grease

Nissan genuine grease or

Quality
equivalent

Capacity g (oz)
95. 105
Final drive side
(3.35- 3.70)

Wheel side 135- 145 (4.76- 5.11)

Boot length mm {in)

Final drive side (L 1 ) 95- 97 (3.74- 3.82)

Wheel side {L2 ) 96- 98 (3.78- 3.86)

Final drive side /

~~
L

Wheel side

SFA877A

FA-45 817
 SERVICE DATA AND SPECIFICATIONS (SDS)

Inspection and Adjustment

WHEEL ALIGNMENT (Unladen*1)
2WD
ALLOWABLE LIMIT ADJUSTING RANGE

Camber Minimum -0"20' (-0.33') -0'05' (-0.08')

Nominal 0'25' (0.42') 0'25' (0.42')

Maximum 1 °10' (1.17') 0'55' (0.92')

Degree minute
(Decimal degree) Left and right difference 45' (0.75°) or less

Caster Minimum -0'23' (-0.38') -0'08' (-0.13')

Nominal 0'22' (0.37') 0'22' (0.37')

Maximum 1'07' (1.12') 0'52' (0.87')

Degree minute
(Decimal degree) Left and right difference 45' (0.75°) or less

Kingpin inclination Minimum 8°20' (8.33') 8'35' (8.5SC)

Nominal 9'05' (9.08') 9'05' (9.0SC)

Degree minute
(Decimal degree) Maximum 9'50' (9.83') 9'35' (9.58')

Total toe-in Minimum 1 (0.04) 2 (0.08)

Nominal 3 (0.12) 3 (0.12)

Distance (A- B)
mm(in) Maximum 5 (0.20) 4 (0 16)

Minimum 5' (0.08') 10' (0.17')

Angle (left plus right)
Nominal 15' (0.25') 15' (0.25')
Degree minute
(Decimal degree) Maximum 25' (0.42') 20' (0.33')

Wheel turning angle Minimum 34'00' (34.00') 36'00' (36.00')

Inside Nominal 38'00' (38.00') 38'00' (38.00')

Degree minute
(Decimal degree) Maximum 38'00' (38.00') 38'00' (38.00')
Full turn*2
Outside Minimum 31'00' (31.00') 33'00' (33.00')

Nominal 35"00' (35.00') 35'00' (35.00")

Degree minute
(Decimal degree) Maximum 35'00' (35.00") 35'00' (35.00')

Vehicle posture

Lower arm pivot height (H) mm (in) 108- 118 (4.25- 4.65) 111- 115 (4.37- 4.53)

~owec link spindle cen17

~ fr~ ~~
>7 4~1\\'" ~\;
~··~t"
v:;~t=~-
-1
. •. '<~
A -~
i IH A -
I . I

Tensi~d'~ttac~inj b:lt l 8

~"\,\\\\\\;\\"\\\\\\\\\\\'C:\\\
SFA709-A

1. Fuel, rad1ator coolant and engme 011 full. Spare t1re, Jack, hand tools and mats 1n designated pos1t1ons.
*2: On power steering models, wheel turning force (at circumference of steering wheel) of 98 to 147 N (10 to 15 kg, 22 to 331b) with engine idle.

818 FA-46
 SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont'd)
4WD @I

ALLOWABLE LIMIT ADJUSTING RANGE

Camber Minimum -0"05' (-0.08") 0"10' (0.17')

Degree minute Nominal ou40' (0.67') 0'40' (0.67")

{Decimal degree)
Maximum 1"25' (1.42') 1'10' (1.17")

Left and right difference 45' (0.75°) or less

Caster Minimum 0'33' (0.55') 0'48' (0.80')

Degree minute Nominal 1'18' (1.30') 1'18' (1.30')
(Decimal degree}
Max1mum 2°03' (2.05') 1°48' (1.80')

Left and right difference 45' (0.75°) or less

Kingpin inclination Minimum T21' (7.35') T36' (7.60')

Degree minute Nominal 8°06' (8.10') 8'06' (8.10')

(Decimal degree)
Maximum 8°51' (8.85') 8'36' (8.60')

Total toe-in Minimum 2 (0.08) 3 (0.12)

Distance (A - B) Nominal 4 (0.16) 4 (0.16)

mm (in)
Maximum 6 (0.24) 5 (0.20)
Angle {left plus right) Minimum 9' (0.15') 14' (0.23')
Degree minute
Nominal 19' (0.32') 19' (0.32')
(Decimal degree)
Maximum 29' (0.48') 24' (0.40')

Wheel turning angle Minimum 31°00' (31.00') 33°00' (33.00")

Inside Nominal 35°00' (35.00') 35'00' (35.00')

Degree minute
(Decimal degree) Maximum 35°00' (35.00') 35'00' (35.00')
Full turn*2
Outside Minimum 29"00' (29.00') 31°00' (31.00')

Nominal 31°00' (31.00") 33°00' (33.00')

Degree minute
(Decimal degree) Maximum 33~00' (33.00') 33°00' (33.00')

Vehicle posture

Lower arm pivot height (H) mm (in) 41 -51 (1.61 - 2.01) 44.48 (1.73- 1.89)

,_,,
Center of
0
\~ --
lower link spindle ~ ~ F !-
./ 41]L"-i(fl
H I r::s;.,_f
-. ...__, '~Jij
A l _.
8
,_____
Bottom of ~@
.

steering stopper bracket

~

~
SFA710-B

.
1: Fuel, rad1ator coolant and eng1ne oil full. Spare t1re, JaCk, hand tools and mats 1n des1gnated pos1t1ons.
~~I
~
*2: On power steering models, wheel turning force (at circumference of steering wheel) of 98 to 147 N (10 to 15 kg, 22 to 331b) with engine idle.

FA-47 819
 SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont'd)
WHEEL BEARING DRIVE SHAFT (4WD)
--------~--~-------------
2WD Drive shaft axial end play
0.45 (0.0177) or less
mm {in)
Wheel bearing axial end play
0 (0)
mm (in)

Wheel bearing lock nut

Drive shaft end snap ring
Tightening torque 34-39 Thickness mm {in) Part No.
N·m {kg-m, ft-lb) (3.5 - 4.0. 25 - 29)
1.1 (0.043) 39253-88G1 0
Return angle degree 1.3 (0.051) 39253-BBG 11
1.5 (0.059) 39253-88G12
Wheel bearing starting torque 1.7 (0.067) 39253-BBG 13
At wheel hub bolt 1.9 (0.075) 39253-BBG 14
9.8- 28.4 2.1 (0.083) 39253-BBG 15
With new grease seal
(1.0 - 2.9, 2.2 - 6.4) 2.3 (0.091) 39253-88G16
N (kg, lb)

With used grease seal 9.8- 23.5

N (kg, lb) (1.0 - 2.4, 2.2 - 5.3) UPPER BALL JOINT
Vertical end play limit "A"
0.1 - 1.4 (0.004 - 0.055)
4WD mm (in)

Wheel bearing lock nut

Tightening torque 78-98 LOWER BALL JOINT

N·m (kg-m, ft-lb) (8 - 10, 58 - 72)
Applied model 2WD 4WD
Retightening torque after loosen-
0.5- 1.5 Vertical end play limit "A" 0.1 - 1.3 0.7 (0.028)
ing wheel bearing lock nut
(0.05- 0.15, 0.4 -1.1) mm (in) {0.004- 0.051) or less
N·m (kg-m, ft-lb)

Axial end play mm (in) 0 (D)

Starting force at wheel hub bolt
A
N (kg, lb)

Turning angle degree 15°·30°

Starting force at wheel hub bolt
B
N (kg, lb)

Wheel bearing preload at wheel hub

bolt N (kg, lb)

7.06- 20.99
B-A (0.72- 2.14, 1.59- 4.72)

WHEEL RUNOUT AVERAGE*

Steel

Wheel type Aluminum 14 inches

15 inches
Painted Plated

Radial runout limit 0.3 0.8 0.5 0.6

mm (in) (0.012) (0.031) (0.020) (0.024)
Lateral runout limit 0.3 0.8 0.8 0.8
mm{in) (0.012) (0.031) (0.031) (0.031)
. Wheel runout average - (Outside runout value + lns1de runout value)
X 0.5

820 FA-48
 REAR AXLE & @~

REAR SUSPENSION

SECTION RA
l©

CONTENTS
PRECAUTIONS AND PREPARATION ............................ 2 REAR AXLE .................................... ................................ 5 ,©l
Precautions ..................................................................2 Components ................................................................. 5
Special Service Tools .................................................. 2 Removal ....................................................................... 5
Commercial Service Tools ...........................................2 Inspection................ .............................................. ?
REAR AXLE AND REAR SUSPENSION ........................ 3 Installation ....................................................................7
ON-VEHICLE SERVICE ................................................ .4 REAR SUSPENSION ....................................................... 9
Rear Axle and Rear Suspension Parts ...................... .4 Shock Absorber ......................................................... 10 ffi\11
Rear Wheel Bearing ................................................... .4 Leaf Spring ................................................................ 10
SERVICE DATA AND SPECIFICATIONS (SDS) .......... 12
General Specifications ............................................... 12 1i'IP
Inspection and Adjustment ........................................ 12

821
 PRECAUTIONS AND PREPARATION

Precautions
• When installing rubber parts, final tightening must be car-
ried out under unladen condition* with tires on ground.
*: Fuel, radiator coolant and engine oil full. Spare tire,
jack, hand tools and mats in designated positions.
• Use flare nut wrench when removing or installing brake
tubes.
• After installing removed suspension parts, check wheel
alignment and adjust if necessary.
Commercial service tool
• Always torque brake lines when installing.
SBR686C

Special Service Tools

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here

Tool number
(Kent-Moore No.) Description
Tool name

KV40101000 Removing rear axle shaft

b
(J25604-01)
Axle stand

(jj
NT159

ST36230000 Removing rear axle shaft

~'
(J25840-A)
Sliding hammer

NT126

ST38020000 Removing wheel bearing lock nut

( - )
Bearing lock nut wrench
~

NT160

HT72480000 ,--- Removing wheel bearing

I"'
(J25852-B)
= I~
~ ~
Rear axle shaft bearing ((
puller l\
CCC
1'---
NT161
L, ~

ST37840000 Installing rear axle shaft

( - )
Rear axle shaft guide

NT162
@
Commercial Service Tools
Tool name Description
G) Flare nut crowfoot Removing and installing each brake piping
® Torque wrench

NT360 a: 10 mm (0.39 in)

Rear axle oil seal drift Installing oil seal

a: 74 mm (2.91 in) dia.

b: 68 mm (2.68 in) dia.
NT163 c: 10 mm (0.39 in)

822 RA-2
 REAR AXLE AND REAR SUSPENSION

2WD
SEC. 380•430-431
When installing rubber parts, final tightening
must be carried out under unladen condition~
~ 78-98 (8.0-10.0,58-72),
with tires on ground.
* Fuel, radiator coolant and engine oil full.
Spare tire, jack, hand tools and mats in
designated positions.

Front

~ : N·m (kg-m, ft-lb)

ARA068

4WD

SEC. 380-430-431 When installing each rubber part, final

tightening must be carried out under
unladen condition* with tires on ground.
Fuel, radiator coolant and engine oil
full. Spare tire, jack, hand tools and
mats in designated positions.

r tc.J 16 • 22 (1.6. 2.2. 12 • 16)

~ ~~~
0 tc.J 78(8.0• .9810.0, 58 • 72)

Q
Front

tc.J • N•m (kg·m, ft-lb) SAA751A

RA-3 823
 ON-VEHICLE SERVICE

Rear Axle and Rear Suspension Parts

Check rear axle and rear suspension parts for excessive play, wear
or damage.
• Shake each rear wheel to check for excessive play.

SMA525A

• Retighten all nuts and bolts to the specified torque.

~: Refer to REAR SUSPENSION, RA-9.

SRA839

• Check shock absorber for oil leakage or other damage.

• Check shock absorber bushing for excessive wear or other
damage.

Rear Wheel Bearing

• Check that wheel bearings operate smoothly.
• Check axial end play.
Axial end play:
Refer to SDS, RA-12.

SRA006

824 RA-4
 REAR AXLE

Components
SEC. 430
Wheel bearing lock nut
Rear axle case
[!lJ 147 - 196 (15 - 20, 108 - 145)

L!
(Rear !mal drive
-Model: H190A, H233B) Wheel bearing lock washer ~

Plain washer

~ @ /
r Wheel bearing IEEi!l

t:jjl,
Filler plug
~59 _ 98 @tlj /-Wheel bearing outer race
(6- 10,
43 _ 72) 'W,
~
~
..,.
(Bearing grease seal .., !!'211
~f"' .Air breather Bearing spacer- lbf} 0
....____ _"' Bearing cage.../ \.lY' -Baffle plate
0
1
(!l.l 54- 74 "-.._ /Axle shaft
£,., (s.s - 7.5, "-
•o - 54) 1
;

D ! Case seal
0
/'~a@j
( \_Oil seal
Rear axle case
(Rear final drive
-Model: C200)
[!lJ 54 • ;;o-.-."
(5.5 . 7.5,
40 • 54)
'7 ~ m to seal lip

Axle case end shim

Adjust axial end play by
selecting suitable shims 1i'f'

J
I Front

~ : N•m (kg-m, ft-lb)

ARA076

Removal
• Disconnect parking brake cable and brake tube.
• Remove nuts securing wheel bearing cage with baffle plate. ~il'l

• Draw out axle shaft with Tool.

When drawing out axle shaft, be careful not to damage oil seal.
• Remove oil seal.
Do not reuse oil seal once it is removed.
Always install new one.

KV40101000
(J25604-01)
SRAD03

RA-5 825
 REAR AXLE
Removal (Cont'd)
• Unbend lock washer with a screwdriver.

SRA104

• Remove bearing lock nut with Tool.

SRA728

• Remove wheel bearing together with bearing cage and baffle

plate from axle shaft.
HT72480000
IJ25852-B)

~0~0

0
0
0

n SRA729

• Remove grease seal in bearing cage with suitable bar.

• Remove wheel bearing outer race with a brass drift.

SRA595C

826 RA-6
 REAR AXLE

@I
Inspection
AXLE SHAFT
• Check axle shaft for straightness, cracks, damage, wear or u!ll!i\
distortion. Replace if necessary.

WHEEL BEARING
• Make sure wheel bearing rolls freely and is free from noise,
cracks, pitting or wear.

SRA010 AXLE CASE

c__ _ _ _ _ _ _ _ _ _ _ _ __ j • Check axle case for yield, deformation or cracks. Replace if rs©
necessary.

Installation
• Install wheel bearing outer race with a brass drift.
• Install a new grease seal in bearing cage.
After installing new grease seal, coat sealing lip with multi- ©IL
purpose grease.

~]'

Axle shaft
• Install bearing spacer with chamfer side facing axle shaft ''
flange.
Bearing spacer

SAA510

• Install wheel bearing inner race with a brass drift.

• Coat each bearing cone with multi-purpose grease.
Specified amount of grease:
8- 12 g (0.28- 0.42 oz)

SRA011

• Install plain washer and a new wheel bearing lock washer.

• Tighten wheel bearing lock nut.
Fit wheel bearing lock washer lip in wheel bearing lock nut
groove correctly by tightening lock nut. Be sure to bend it up.

RA-7 827
 REAR AXLE
Installation (Cont'd)
• Install a new oil seal with suitable tool.
After installing new oil seal, coat sealing lip with multi-pur-
pose grease.

• Apply recess of axle case end with multi-purpose grease.

• Apply gear oil to the spline of axle shaft. Coat seal surface
of axle shaft with multi-purpose grease (as shown left).

e1 : Lubricating portion

SRA652A

• Adjust axial end play.

a. Select end shims.
Standard thickness: 1.5 mm (0.059 in)
Axle case end shim: Refer to SDS, RA-12.
Do not insert end shims between case seal and bearing cage.

b. Insert axle shaft with Tool as a guide.

When inserting axle shaft, be careful not to damage oil seal.
c. Measure end play of axle shaft.
Axial end play:
Servicing one side axle
0.02 - 0.15 mm (0.0008 - 0.0059 in)
Servicing both side axles
On first axle (right or left)
0.30- 0.90 mm (0.0118- 0.0354 in)
On second axle
0.02- 0.15 mm (0.0008- 0.0059 in)
d. If axial end play is not within the specified limit, reselect axle
Drum case end shims.
While adjusting axial end play, be careful not to damage oil
seal.

SRA006

828 RA-8
 REAR SUSPENSION

2WD

.//

Rear spnng sh:a~~kle-- 1 1e

Rear spnng pa
Damper\ _ /
~ ,/
__.
~ \Rear sprmg bushrng

tc!J16-22 X~ b
(1.6- 2.2,
/ / / 16)
-~1-~
(]:/'
r/Cj,
:
Ci@
;(@ ·, € ~
L ___________ _J/ / Re:, spnng . tc!J78 _·: \

' / chp bolt (U-bolt) (8.0 - 10.0,

/
./ 58 -72)

/ \..Rear spring (Leaf spring)

~tc!l 30- 40 (3.1- 4.1, 22- 3 0 ) / '

o~· ........ Ji l_____ ·-._

·---..:~
Shock absorber

When Installing rubber parts, final

tightening must be carried out under
unladen condition* with tires on ground.
* Fuel, radiator coolant and engine oil
Rear sprmg bush1ng l]r-€-o_~~7 ih-~
tc!J3o- 40 (3.1- 4.1, 22-301.,
full. Spare tire, jack, hand tools and
mats In designated positions. Rear spnng front pm
J """
~-,.j
16- 21 11.6- 2.1, 12- 151 e
\

tc!J' N-m (kg-m. ft-lb) tc!J 88 - 98 (9.0 - 10.0, 65 - 72)J SAA593CA

4WD

RA-9 829
 REAR SUSPENSION

2WD models Shock Absorber

REMOVAL AND INSTALLATION
• Remove shock absorber by disconnecting upper and lower
end.

4WD models
I

SRA701

INSPECTION
• If oil leakage, cracks or deformation occurs, replace shock
absorber assembly.
• If rubber bushings are cracked or deformed, replace rubber
bushings.

Leaf Spring
REMOVAL AND INSTALLATION
• Disconnect shock absorber lower end, and remove U-bolts.

• Disconnect spring shackle.

830 RA-10
 REAR SUSPENSION
Leaf Spring (Cont'd)
• Disconnect front pin. ~~J

SRA705

4WD INSPECTION
• Check leaf spring for cracks. Replace if necessary.
• Check front bracket and pin, shackle, U-bolts and spring pad
for wear, cracks, straightness or damaged threads. Replace if
~11:

necessary.
• Check all bushings for deformation or cracks. Replace if nee-
essary.
~(;!,

[4WD: Rear spring front bushing]

Make sure that front bushing is properly installed.
uHii'
SRA535A

INSTALLATION
• Apply soapsuds to rubber bushing.
• Install spring shackle and front pin, and finger tighten the nuts. ~~~
• Install spring pad and nuts under leaf spring or axle case.
• Tighten U-bolt mounting nuts diagonally.
Tighten U-bolts so that the lengths of all U-bolts under spring ~D)
pad are the same.
• Install shock absorber, and finger tighten the nuts.

All same length

• Remove stands and bounce the vehicle to stabilize suspen-

sion. (Unladen)

l
SRA703

~11
• Tighten spring shackle nuts, front pin nuts and shock absorber
nuts.
When installing rubber parts, final tightening must be carried llffil
out under unladen condition* with tires on the ground.
• Fuel, radiator coolant and engine oil full. Spare tire, jack, hand
tools and mats in designated positions. ~l

RA-11 831
 SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications
LEAF SPRING AND SHOCK ABSORBER

2WD
Applied model Canada 4WD
U.S.A.
Regular Cab
I King Cab Option

Leaf spring

Spring length x width mm (in) 1 ,200 X 60 (47.24 X 2.36)

7 (0.28)- 1
7 (0.28)- 2 7 (0.28)- 2 7 (0.28)- 2 8 (0.31)- 1
Spring thickness - number of leaves mm (in)
13 (0.51)- 1 12 (0.47)- 2 13 (0.51)- 1 12 (0.47) -1
13 (0.51)- 1
Free camber "S" mm (in) 171.0 (6.73) 183.0 (7.20) I 164.5 (6.48) 171.0 (6. 73) 106.0 (4.17)
Shock absorber

Shock absorber type Non-adjustable

Maximum length mm (in) 508 (20.00) 528 (20.79)

265- 422
Compression N (kg, lb) 157-275 (16- 28, 35- 62)
(27 - 43, 60 - 95)

\
Helper spring

SRA657A SRA658A

Inspection and Adjustment

WHEEL BEARING
Total end play mm(in) 0.02- 0.15 (0.0008- 0.0059)
Thickness
Part number
mm (in)

0.05 (0.0020) 43086-?011 0

Available rear axle case end 0.07 (0.0028) 43087-?0110
shims 0.1 0 (0.0039) 43088-?0110
0.15 (0.0059) 43086-89500
0.20 (0.0079) 43089-?011 0
0.50 (0.0197) 43090-P0110
1.00 (0.0394) 43036-01 GOO

832 RA-12
 BRAKE SYSTEM ~~

SECTION BR
CONTENTS
PRECAUTIONS AND PREPARATION ........................... 2 REAR WHEEL ANTI-LOCK BRAKE SYSTEM ........... 30
Supplemental Restraint System (SRS) "AIR Purpose ..................................................................... 30
BAG".... ........... .......................... ...... 2 Operation. .. ................................................. 30 C:iL
Commercial Service Tools ......................................... 3 System Description .................................................. 30
CHECK AND ADJUSTMENT ........................................ .4 System Components...................... .. ................ 31
Checking Brake Fluid Level. ....................................... .4 Hydraulic Circuit............................. .. ................ 31 ITtll
Checking Brake Line .................................................. .4 Removal and Installation ........................................... 32
Changing Brake Fluid ................................................. .4 TROUBLE DIAGNOSES ............................................... 33
AIR BLEEDING ...............................................................5 How to Perform Trouble Diagnoses for Quick
Bleeding Procedure ................................................... 5 and Accurate Repair.......... .. ....................... 33
BRAKE HYDRAULIC LINE........................... .. ..... 6 Symptom Chart ......................................................... 34 'TIP
CONTROL VALVE .......................................................... 8 Preliminary Check 1 .................................................. 35
Proportioning Valve (4WD) ........ .. ......................... 8 Self-diagnosis ............................................................36
Load Sensing Valve (2WD) ........................................ 9 Component Parts and Harness Connector
BRAKE PEDAL AND BRACKET.. .............................. 11 Location .......... .. ................. 37
Adjustment......... .. .. 12 Circuit Diagram..... .. .................................... 38
MASTER CYLINDER ................................................... 13 Wiring Diagram -ABS-.......... .. ................. 39 Pi~\
BRAKE BOOSTER....................................... .. ... 16 Diagnostic Procedures ................................ .41
On-vehicle Service .................................................. 16 Electrical Components Inspection ............................ 49
VACUUM HOSE ............................................................ 18 SERVICE DATA AND SPECIFICATIONS (SDS) ......... 50 Jilffi'
FRONT DISC BRAKE .. .......... 19 General Specifications.......... .............. ..50
Pad Replacement........... ................ 19 Inspection and Adjustment ..................................... 51
REAR DRUM BRAKE ................................................... 24
PARKING BRAKE CONTROL ..................................... 28
~~-~---· ...................... ~

When you read wiring diagrams:

• Read Gl section, "HOW TO READ WIRING DIAGRAMS".
• See EL section, "POWER SUPPLY ROUTING" for power distribution circuit.
When you perform trouble diagnoses, read Gl section, "HOW TO FOLLOW FLOW CHART
IN TROUBLE DIAGNOSES" and "HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN
ELECTRICAL INCIDENT".

833
 PRECAUTIONS AND PREPARATION

Supplemental Restraint System (SRS) "AIR

BAG"
The Supplemental Restraint System "Air Bag", used along with a seat belt, helps to reduce the risk or sever-
ity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of an air bag mod-
ule (located in the center of the steering wheel), a diagnosis sensor unit, warning lamp, wiring harness, a crash
zone sensor (4WD models) and spiral cable. Information necessary to service the system safely is included
in the RS section of this Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed
by an authorized NISSAN dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses are covered with yellow insulation either just before the
harness connectors or for the complete harness, for easy identification.

Brake System
• Use brake fluid DOT 3.
• Never reuse drained brake fluid.
• Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
• To clean master cylinder parts, disc brake caliper parts or
wheel cylinder parts, use clean brake fluid.
• Never use mineral oils such as gasoline or kerosene. They
Commercial service tool
will ruin rubber parts of the hydraulic system.
SBR686C • Use flare nut wrench when removing and installing brake
tubes.
• Always torque brake lines when installing.
WARNING:
• Clean brakes with a vacuum dust collector to minimize the
hazard of airborne materials.

834 BR-2
 PRECAUTIONS AND PREPARATION

Commercial Service Tools

Tool name Description

G) Flare nut crowfoot Removing and installing each brake piping

® Torque wrench

NT360 a: 1 o mm (0.39 in)

Brake fluid pressure gauge Measuring brake fluid pressure

NT151

BR-3 835
 CHECK AND ADJUSTMENT

Checking Brake Fluid Level

• Check fluid level in reservoir tank. It should be between Max
and Min lines on reservoir tank.
• If fluid level is extremely low, check brake system for leaks.
• If the brake warning lamp comes on, check brake fluid level
OK switch and parking brake switch.

MIN

SBR418CB

Checking Brake Line

CAUTION:
If leakage occurs around joints, retighten or, if necessary,
replace damaged parts.
1. Check brake lines (tubes and hoses) for cracks, deterioration
and other damage. Replace any damaged parts.
2. Check for oil leakage by fully depressing brake pedal while
engine is running.

SBR389C

Changing Brake Fluid

CAUTION:
• Refill with new brake fluid DOT 3.
• Always keep fluid level higher than minimum line on res-
ervoir tank.
• Never reuse drained brake fluid.
• Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
1. Clean inside of reservoir tank, and refill with new brake fluid.
ssR992 2. Connect a vinyl tube to each air bleeder valve.
L __ _ _ _ _ _ _ _ _ _ _ _ _---" 3. Drain brake fluid from each air bleeder valve by depressing
brake pedal.
4. Refill until brake fluid comes out of each air bleeder valve.
Use same procedure as in bleeding hydraulic system to refill
brake fluid. Refer to "Bleeding Procedure", BR-5.

836 BR-4
 AIR BLEEDING

~~~
Bleeding Procedure
CAUTION:
• Carefully monitor brake fluid level at master cylinder dur-
ing bleeding operation.
u:ii!P~

• If master cylinder is suspected to have air inside, bleed air

from master cylinder first. Refer to "Installation", "MAS- ~~~~
TER CYLINDER", BR-15.
• Fill reservoir with new brake fluid DOT 3. Make sure it is
full at all times while bleeding air out of system.
LC:
SBR995
• Place a container under master cylinder to avoid spillage
of brake fluid.
• Rear Wheel Anti-Lock Brake system:
Before bleeding air, be sure to turn ignition switch OFF
~~:0

and disconnect battery ground cable and actuator con-

nector.
?lg
• Bleed air in the following order.
a. LSV air bleeder (Models equipped with LSV)
b. Left rear brake
:G:l
c. Right rear brake
d. Left front brake
e. Right front brake
l!iu1i'
f. ABS actuator

1. Connect a transparent vinyl tube to air bleeder valve. fo\11

2. Fully depress brake pedal several times.
3. With brake pedal depressed, open air bleeder valve to release
air. w
4. Close air bleeder valve.
5. Release brake pedal slowly.
6. Repeat steps 2 through 5 until clear brake fluid comes out of ~[Q;·
air bleeder valve.
7. Tighten air bleeder to the specified torque.
Ill 7- 9 N·m (0.7- 0.9 kg-m, 61 - 78 in-lb) ?!k
SBR4i9C

BR-5 837
 BRAKE HYDRAULIC LINE

2WD Front brake Rear brake

Three-way connector
~ Mounting bolt
8- 11 (0.8- 1.1, 69- 95)
Five-way connector

Front

¢
• Mounting bolt
5 - 7 (0.5 - 0.7, 43 - 61)

7
L Brake booster
to.J Mounting
bolt
L Three-way connector 17- 21 (1.7- 2.1, 12- 15}

0 Flare nut Primary line

15-18 (1.5 -1.8,11 -13) Secondary line

• Connecting bolt
17- 19 (1.7 - 2.0, 12 - 14)
~ N•m (kg-m, in-lb)

~ N·m (kg-m, ft-lb) ABR387

4WD Front brake

ABS actuator

Front Flarenut ~
~15 - 18
¢ (1.5- 1.8, 11 - 13)
Proportioning valve ---!':::;;=:~ Three-way connector
(Do not disassemble.) ~ Mounting bolt
Master cylinder
8- 11 (0.8- 1.1, 69- 95)

= Primary line
0 Flare nut - Secondary line
15-18 (1.5 -1.8,11- 13)
~ : N·m (kg-m, in-lb)
• Connecting bolt
17- 19 (1.7- 2.0, 12- 14) ~ N·m (kg-m, ft-lb) ABR388

838 BR-6
 BRAKE HYDRAULIC LINE

REMOVAL ~~u

CAUTION:
• Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
• All hoses must be free from excessive bending, twisting ~i\i
and pulling.
1. Connect vinyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve by depressing l~
brake pedal.
SBR992 3. Remove flare nut connecting brake tube and hose, then with-
draw lock spring. ~~
4. Cover openings to prevent entrance of dirt whenever discon-
necting brake line.

INSPECTION
Check brake lines (tubes and hoses) for cracks, deterioration and
other damage. Replace any damaged parts.

INSTALLATION
CAUTION:
• Refill with new brake fluid DOT 3.
• Never reuse drained brake fluid.
1. Tighten all flare nuts and connecting bolts.
Flare nut: ?[I)
t:C!J: 15- 18 N·m (1.5- 1.8 kg-m, 11- 13 ft-lb)
Connecting bolt:
t:C!J: 17-19 N·m (1.7- 2.0 kg-m, 12-14 ft-lb) lf'L~
Commercial service tool
2. Refill until new brake fluid comes out of each air bleeder valve.
SBR686C 3. Bleed air. Refer to "Bleeding Procedure", BR-5.

BR-7 839
 CONTROL VALVE

Proportioning Valve (4WD)

INSPECTION
CAUTION:
• Carefully monitor brake fluid level at master cylinder.
• Use new brake fluid DOT 3.
• Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
paint areas, wash it away with water immediately.
• Depress pedal slowly when raising front brake pressure.
• Check rear brake pressure 2 seconds after front brake
SBRB22BA
pressure reaches specified value.
Brake fluid pressure gauge
• Disconnect ABS harness connectors from ABS actuator
relay box before checking.
1. Connect Tool to air bleeders of front and rear brakes on either
LH or RH side.
2. Bleed air from the Tool.
3. Check fluid pressure by depressing brake pedal.
Unit: kPa (kg/cm2 , psi)

Wheelbase Standard Long

Applied pressure (Front brake) D, 5,884 (60. 853) 6,375 (65. 924)
2,942 - 3,334 3.432 . 3,825
ABR184 Output pressure {Rear brake) 0 2
(30 • 34. 427 • 483) (35 . 39, 498 . 555)

If output pressure is out of specifications, replace master cylinder

assembly (buill-in type).
4. Bleed air after disconnecting the Tool. Refer to "Bleeding
Procedure", BR-5.

p, kPa (kg/em', psi)

Front brake fluid pressure
SBR705AA

REMOVAL AND INSTALLATION (Built-in type)

• Always replace proportioning valve and master cylinder
as an assembly.
• Refer to "Removal", "MASTER CYLINDER", BR-13.

840 BR-8
 CONTROL VALVE

Load Sensing Valve (2WD)

Load Sensing Valve
SEC. 462

Sensor spring Ea!

~: N•m (kg-m, in-lb)

~ : N•m (kg-m, ft-lb) [P~
ABR383

REMOVAL AND INSTALLATION

CAUTION:
• Refill with new brake fluid DOT 3.
• Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
1. Replace damaged load sensing valve linkage as an assembly. ~1
2. When disassembling, apply multi-purpose grease to linkage.
3. Tighten all flare nuts and bolts.
to.J: 15- 18 N·m (1.5- 1.8 kg-m, 11- 13 ft-lb)
4. Bleed air. Refer to "Bleeding Procedure", BR-5.

BR-9 841
 CONTROL VALVE
Load Sensing Valve (2WD) (Cont'd)
INSPECTION
1. Ensure vehicle is unladen condition•.
• Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated positions.
2. Have a driver sit in the driver's seat and one person sit on the
rear of the vehicle. Then have the person on the rear of the
vehicle slowly get off. This is necessary to stabilize suspension
deflection.
3. Adjust length "L" as follows:
a. Loosen stopper bolt locknut.
b. Pull lever against stopper bolt and adjust by turning stopper
bolt.
c. Tighten stopper bolt locknut.
Length "L":
Approx. 189 mm (7.44 in)

4. Install pressure gauge to front and rear brake.

5. Bleed air from the Tool.
6. Raise front brake pressure to 5,884 kPa (60 kg/cm 2 , 853 psi)
and 9,807 kPa (1 00 kg/cm 2 , 1,422 psi) and check rear brake
pressure.
Rear brake pressure:
Refer to table below.

SBR013B

7. Set down weight slowly over axle center so that sensor spring
length becomes the same as when in loaded condition (refer
to table below). Check rear brake pressure in the same way
described in step 6.
Unit· kPa (kg/cm 2 psi)

U.S.A. Canada

2,942 • 3,727 2,942 . 3,727

Without weight
(30 . 38, 427 • 540) (30 . 38, 427 . 540)
3,432 . 4,805 3,334. 4,707
With weight
SBR014B (35 • 49, 498 . 697) (34 . 48, 483 . 683)

842 BR-10
 BRAKE PEDAL AND BRACKET

Removal and Installation !ill

SEC. 465

Stop lamp switch

/ ~12. 15 (1.2 ·1.5. 9. 11)

~
0

Clevis pin"

~13. 16 (1.3. 1.6, 9. 12) /

~8. 11 (0.8- 1.1, 69- 95) Brake pedal

Replace plastic stopper located at

the end of clevis pin if deformed
or damaged.

~ ' N•m (kg·m, fHb)

~ : N•m (kg-m, in-lb)

ABR454

Inspection
Check brake pedal for following items:
Stopper
• Brake pedal bend
• Clevis pin deformation
• Crack of any welded portion
• Crack or deformation of clevis pin stopper
0

SBA997

BR-11 843
 BRAKE PEDAL AND BRACKET

Input rod Adjustment

Lock nut ~ 16-22 Check brake pedal free height from melt sheet.
_J _ _ _ _ (1.6- 2.2, 12 -16)
H: Free height
Refer to SDS BR-51.
Stop lamp
switch and D: Depressed height
'-'>..,--, ASCD brake Refer to SDS BR-51.
~~~f"'--' switch Under force of 490 N (50 kg, 110 lb)
tt=!J12 -15 with engine running
(1.2-1.5,
9- 11)
C 1 : Clearance between pedal stopper and
threaded end of stop lamp switch
0.3 - 1.0 mm (0.012 - 0.039 in)
C2 : Clearance between pedal stopper and
threaded end of ASCD switch
0.3- 1.0 mm (0.012- 0.039 in)
A A: Pedal free play at clevis
1 -3 mm (0.04- 0.12 io)

Melt sheet

Dash insulator
tt=!J 'N -m (kg-m, ft-lb}
ABR486

If necessary, adjust brake pedal free height.

1. Loosen lock nut and adjust pedal free height by turning brake
booster input rod. Then tighten lock nut.
• Make sure that the tip of input rod stays inside.

SBR930

2. Loosen lock nut and adjust clearance "C 1 " and "C 2 " with stop
lamp switch and ASCD brake switch respectively. Then tighten
lock nuts.
3. Check pedal free play.
• Make sure that stop lamps are off when pedal is released.
4. Check depressed height of brake pedal while engine is run-
ning. If lower than specification, check for leaks, air in system
and damage to components (master cylinder, wheel cylinder,
etc.).

844 BR-12
 MASTER CYLINDER

SEC. 460

Primary piston assembly~

Reservoir tank

'~\-.:--·
Piston cup*

Secondary return spring Primary piston assembly~

\~on~a~~:~nas:~~~\
4WD

fJ
> \- _ _ .-=\LVY
\
Stoppeo-cap

Cylinder body (/\~':: P;stoncup•

\~
kg·m,~
/ / \_ P;ston cup •
tc!J12 -15 N·m (1.2 ·1.5
8.7-10.8 ft-lb) Spring seat

Secondary retum spring

2WD
, * Lubricate piston cup with brake fluid or rubbe
grease when assembling master cylinder.
~12 -15 N-m (1.2 -1.5 kg-m,
Cylinder body 8.7-10.8 H-lb)

Removal
CAUTION: i\Jl
• Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately. [iii:)
• In the case of brake fluid leakage from the master cylinder,
disassemble the cylinder. Then check piston cups for
deformation and scratches and replace necessary parts. ~~
1. Connect a vinyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve, depressing brake
pedal to empty fluid from master cylinder. 1~ 1'\
3. Remove brake pipe flare nuts.
4. Remove master cylinder mounting nuts.

BR-13 845
 MASTER CYLINDER

Disassembly
1. Bend claws of stopper cap outward.

2. Remove piston assemblies.

• If it is difficult to remove secondary piston assembly,
gradually apply compressed air through fluid outlet.
3. Draw out reservoir tank.

SBR939A

Inspection
Check master cylinder inner wall for pin holes and scratches.
Replace if damaged.

Assembly
Secondary piston
1. Insert secondary piston assembly. Then insert primary piston
assembly.
• Pay attention to direction of piston cups in figure at left.
Also, insert pistons squarely to avoid scratches on cylin-
Primary piston der bore.

SBR012A

2. Install stopper cap.

• Before installing stopper cap, ensure that claws are bent
inward.
3. Push reservoir tank seals into cylinder body.
4. Push reservoir tank into cylinder body.

846 BR-14
 MASTER CYLINDER

()]I
·~.
Installation
CAUTION:
• Refill with new brake fluid DOT 3.
• Never reuse drained brake fluid.
1. Place master cylinder onto brake booster and secure mount-
ing nuts lightly. [gill
2. Tighten mounting nuts.
~: 12- 15 N·m (1.2- 1.5 kg-m, 8.7- 10.8 ft-lb)
3. Fill up reservoir tank with new brake fluid.
4. Plug all ports on master cylinder with fingers to prevent air
ABR190 suction while releasing brake pedal.
5. Have driver depress brake pedal slowly several times until no rge::
air comes out of master cylinder.
6. Fit brake lines to master cylinder.
7. Tighten flare nuts.
~: 15- 18 N·m (1.5 -1.8 kg-m, 11- 13 ft-lb)
8. Bleed air from brake system. Refer to "Bleeding Procedure",
BR-5.

BR-15 847
 BRAKE BOOSTER

On-vehicle Service
OPERATING CHECK
• Depress brake pedal several times with engine off. After
exhausting vacuum, make sure there is no change in pedal
stroke.
• Depress brake pedal, then start engine. If pedal goes down
slightly, operation is normal.

SBR002A

AIRTIGHT CHECK
OK NG • Start engine, and stop it after one or two minutes. Depress
brake pedal several times slowly. Booster is airtight if pedal
stroke is less each time.
• Depress brake pedal while engine is running, and stop engine
with pedal depressed. The pedal position should not change
after holding pedal down for 30 seconds.

SBR365AA

SEC. 460-465•470 Removal

Master cylinder
~ 13-16 CAUTION:
{1.3·1.6,
9 -12} • Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
0
painted areas, wash it away with water immediately.
~12-15
(1.2 -1.5,
9- 11)
u \\1\Bmke
.. 1.

\
pedal • Be careful not to deform or bend brake pipes during
removal of booster.
Brake booster
~16-22 ~-"\}
\ ·.""
(1.6- 2.2,
A: N-m (kg-m, tt-lb) 12 -16) ABR373

Inspection
OUTPUT ROD LENGTH CHECK
1. Apply vacuum of -66.7 kPa (-500 mmHg, -19.69 inHg) to
brake booster with a hand vacuum pump.
2. Check output rod length.
Specified length:
10.275- 10.525 mm (0.4045- 0.4144 in)

SBR281A

848 BR-16
 BRAKE BOOSTER

Installation
CAUTION:
• Be careful not to deform or bend brake pipes during instal-
lation of booster.
• Replace clevis pin if damaged.
• Refill with new brake fluid DOT 3.
• Never reuse drained brake fluid.
• Take care not to damage brake booster mounting bolt
thread when installing. Due to the narrow angle of IL©
installation, the threads can be damaged by the dash
panel.

~ 1. Before fitting booster, temporarily adjust clevis to dimension ~©

'{wo, Approx. 160 mm (6.30 In)
4WD: Approx. 165 mm (6.50 in)
shown.

/ lr--
2.

3.
Fit booster, then secure mounting nuts (brake pedal bracket to
brake booster) lightly.
Connect brake pedal and booster input rod with clevis pin.
i'~

4. Secure mounting nuts.

rcr ~: 13- 16 N·m (1.3- 1.6 kg-m, 9- 12 ft-lb) ©IL
5. Install master cylinder. Refer to "Installation", "MASTER
CYLINDER", BR-15.
~

lclevlo 6.
7.
Adjust brake pedal height and free play. Refer to BR-12.
Secure lock nut for clevis.
IT~lr
SBR116BB
~: 16-22 N·m (1.6- 2.2 kg-m, 12- 16 ft-lb)
8. Bleed air. Refer to "Bleeding Procedure", BR-5. 0\11

BR-17 849
 VACUUM HOSE

Removal and Installation

fit More than 24 mm

(0.94 In)
CAUTION:
When installing vacuum hoses, pay attention to the following
points.
• Do not apply any oil or lubricants to vacuum hose and
check valve.

- _llJlS(
Connect hose until it contacts
• Insert vacuum tube into vacuum hose as shown.

protrusion on vacuum tube.

SBR225B

• Install check valve, paying attention to its direction.

[]~I ) '~~
¢ ' 11)

Intake manifold Brake booster

side side

¢l E··.·
uuu

....
·= :]¢
SBR498A

Inspection
HOSES AND CONNECTORS
Check vacuum lines, connections and check valve for airtightness,
improper attachment chafing and deterioration.

CHECK VALVE

~
Check vacuum with a vacuum pump.

Booster side Engine side Connect to booster

Vacuum should exist.
side
Connect to engine
Vacuum should not exist.
side

SBR943A

850 BR-18
 FRONT DISC BRAKE

@II
Pad Replacement
WARNING:
Clean brake pads with a vacuum dust collector to minimize the i&lffil
hazard of airborne materials.
CAUTION:
• When cylinder body is open, do not depress brake pedal IEl'i
or caliper piston will pop out.
• Be careful not to damage piston boot or get oil on rotor.
Always replace shims when replacing pads. l©
• If shims are rusted or show peeling of the rubber coat,
replace them with new shims.
• It is only necessary to remove connecting bolt if disas- IE©
sembling or replacing caliper assembly. Otherwise, sus-
pend cylinder body with wire so as not to stretch brake
hose. !'IE

1. Remove master cylinder reservoir cap.

2. Remove lower pin bolt.

3. Open cylinder body upward. Then remove pad retainers and

rtt3l
inner and outer shims.
Standard pad thickness:
CL28VA model
11 mm (0.44 in)
CL28VD model
10 mm (0.39 in)
Pad wear limit:
2.0 mm (0.079 in)
• Carefully monitor brake fluid level because brake fluid will ~@
return to reservoir when pushing back piston.

SBR010B

BR-19 851
 FRONT DISC BRAKE

CL28VA

v
~72-97
(7.3- 9.9,
53 - 72)
JA@
/jl]o N•m (kg-m, in-lb)

~' N•m (kg-m, ft-lb)

m®o PBC (Poly Butyl Cuprysil) grease
or silicone-based grease point \___Torque member
m®o Rubber grease point
[]@: Brake fluid point SBR691CA

CL28VD

~Air bleeder cap ~

~ Air bleeder ~ 7 - 9 (0.7 - 0.9, 61 - 78)

Cylinder body

"\Inner shim

\ Pad

w
Pad-
~~
Outer shim
I
J
~: N-m (kg-m, in-lb)
~ : N•m (kg-m. ft-lb)
f!C! ® : PBC (Poly Butyl Cuprysll) grease or
I Pad retainer
silicone-based grease point
I!C!@ : Rubber grease point
Torque member j
m® [ ] ·~· : Brake fluid point
SBA176CB

852 BR-20
 FRONT DISC BRAKE

Removal
WARNING:
Clean brake pads with a vacuum dust collector to minimize the 8oTIJil
hazard of airborne materials.
CAUTION:
Suspend caliper assembly with wire so as not to stretch brake fli!i
hose.
Remove torque member fixing bolts and connecting bolt.
• It is only necessary to remove connecting bolt if disas- LC;
sembling or replacing caliper assembly. Otherwise, sus-
pend caliper assembly with wire so as not to stretch brake
hose. ~c~;

itll

Disassembly
WARNING:
Do not place your fingers in front of piston.
CAUTION:
• Do not scratch or score cylinder wall.
• CL28VD type front disc brake uses plastic pistons, handle IP!Qi
them carefully.
1. Push out piston and dust cover with compressed air.
For CL28VD (2-piston type), use a wooden block so that both I'Jil
L Wooden block pistons come out evenly.
SBR085A
2. Remove piston seal with a suitable tool.
Inspection - Caliper
CYLINDER BODY •
• Check inside surface of cylinder for score, rust, wear, damage : •
and presence of foreign objects. If any of the above conditions
are observed, replace cylinder body. '!!"'
• Minor damage from rust or foreign objects may be eliminated ~"
by polishing the surface with a fine emery sandpaper. Replace
cylinder body if necessary.
CAUTION:
Use brake fluid to clean. Never use mineral oil.

PISTON
-for steel piston (CL28VA) -
Check piston for score, rust, wear, damage and presence of foreign ["IJ',
objects. Replace if any of these conditions are observed.
CAUTION:
Piston sliding surface is plated. Do not polish with emery sand- ~L
paper even if rust or foreign objects are stuck to sliding surface.
-for plastic piston (CL28VD) -
Check pistons for uneven surface, chips and cracks. Replace if any
Check surface. of these conditions are observed.
SBR177C

BR-21 853
 FRONT DISC BRAKE
Inspection - Caliper (Cont'd)
SLIDE PIN, PIN BOLT AND PIN BOOT
Check for wear, cracks and other damage. Replace if any of these
conditions are observed.

Inspection - Rotor
RUNOUT
1. Check runout using a dial indicator.
• Make sure that wheel bearing axial end play is within the
specifications before measuring. Refer to FA section
("Front Wheel Bearing", "ON-VEHICLE SERVICE").
Maximum runout:
0.07 mm (0.0028 in)
2. If the runout is out of specification, machine rotor with on-car
brake lathe ("MAD, DL-8700", "AMMCO 700 and 705" or
equivalent).
THICKNESS
Thickness variation (At least 8 positions):
Maximum 0.02 mm (0.0008 in)
If thickness variation exceeds the specification, machine rotor with
on-car brake lathe.
Rotor repair limit:
CL28VA 20.0 mm (0.787 in)
CL28VD 24.0 mm (0.945 in)

SBR090A

Assembly
1. Insert piston seal into groove on cylinder body.
2. With piston boot fitted to piston, insert piston boot into groove
on cylinder body and install piston.
3. Properly secure piston boot.
CAUTION:
• Secure dust seal properly.
• Lubricate with new brake fluid before installing plastic pis-
tons (CL28VD) into cylinder body.

SBR178C

Piston boot

Piston seal
Cylinder
body

Piston
SBR179CA

854 BR-22
 FRONT DISC BRAKE

Installation
CAUTION:
• Refill with new brake fluid DOT 3.
• Never reuse drained brake fluid.
1. Install caliper assembly.
2. Install brake hose to caliper securely.
3. Install all parts and secure all bolts.
4. Bleed air. Refer to "Bleeding Procedure"', BR-5.

SBR084A

BR-23 855
 REAR DRUM BRAKE

LT30A (4WD)

Back plate

~53- 63 (5.4-
•· ·~
4

39-46)

Shoe hold-down j
Lever assembly

~'N·m(k g~m, in-lb)

~'N·m(k g-m,fHb)
:Brake g rease point
•
~@:Brake fluid point
l!!f!@:Rubber grease point etum spring
ABR367

LT26B (2WD)

Plug

li!l• -11 (0.6-1.1.52-(

~53-63(5.4-6 ~J~·
39- 46)
4
· •

Shoe hold-down pin

~ : N. m (kg-m, in-lb) Q
Front
Return spring

•eatJlJ
Shoe
~' N·m (kg-m. ft-lb)
:Brakegrease point
• Spnng
~@:Brake fluid point Shoe hold-down spring
Retainer
Eli@,Rubber grease point ABR368

856 BR-24
 REAR DRUM BRAKE

Removal @l~
WARNING:
Clean brake lining with a vacuum dust collector to minimize li!lffi\
the hazard of airborne materials.
CAUTION:
Make sure parking brake lever is completely released. ~~,!

1. Release parking brake lever fully, then remove drum. [g[::

Wheel
cylinder • If drum is hard to remove, the following procedures
should be carried out.
a. Remove plug. Then shorten adjuster to make clearance !P~
between brake shoe and drum.
Adjuster
Plug

Adjuster lever

. . Push

SBR280B

L~J
b. Install two bolts as shown. Tighten the two bolts gradually.

Bolts (MS x 1.25)

SBR093A

2. After removing retainer, remove spring by rotating shoes.

Adjuster strtJt • Be careful not to damage wheel cylinder piston boots.
• Be careful not to damage parking brake cable when sepa-
rating it.
Retainer
3. Remove adjuster.
4. Disconnect parking brake cable from toggle lever.

Cable

ABR369

llil'u"
5. Remove retainer clip with a suitable tool. Then separate toggle
lever and brake shoe.

ABR408

BR-25 857
 REAR DRUM BRAKE

Inspection - Wheel Cylinder

• Check wheel cylinder for leakage.
• Check for wear, damage and loose conditions.
Replace if any such conditions exists.

ABR370

Wheel Cylinder Overhaul

~~m®~
• Check all internal parts for wear, rust and damage. Replace if
necessary.
• Pay attention not to scratch cylinder when installing pistons.
7
(j (ff(f®
(p) ~
.., "" J
"""'I!'Eilii'·
~@
I!C!!@ · Rubber grease

SBR215B

Inner diameter Inspection - Drum

Maximum inner diameter (Repair limit):
LT26B 261.5 mm (10.30 in)
LT30A 296.5 mm (11.67 in)
• Contact surface should be finished with No. 120 to 150 emery
sandpaper.
• Using a brake lathe, machine brake drum if it shows score
marks, partial wear or stepped wear.
• After brake drum has been completely reconditioned or
replaced, check drum and shoes for proper contact pattern.
SBR095A

Inspection - Lining
Check lining thickness.
A Standard lining thickness:
LT26B 5.5 mm (0.217 in)
0 LT30A 6.1 mm (0.240 in)
Lining wear limit (A):
LT26B 1.5 mm (0.059 in)
LT30A 1.5 mm (0.059 in)

SBR021A

Installation
• Always perform shoe clearance adjustment. Refer to
BR-29.
1. Fit toggle lever to brake shoe with retainer clip.
2. Apply brake grease to the contact areas shown at left.

ABR371

858 BR-26
 REAR DRUM BRAKE
Installation {Cont'd)
3. Shorten adjuster by rotating it.
• Pay attention to direction of adjuster.

Wheel Screw

Left Left-hand thread

Right Right-hand thread

4. Connect parking brake cable to toggle lever.

5. Install all parts.

1!!5:1!1 : Should be lubricated with grease ABR396

• Be careful not to damage wheel cylinder piston boots .

6. Check that all parts are installed properly.

• After installation is completed, adjust shoe-to-drum clear-
ance.
7. Install brake drum.
8. When installing new wheel cylinder or overhauling wheel
cylinder, bleed air. Refer to "Bleeding Procedure", BR-5.
9. Adjust parking brake. Refer to BR-29.
• Install all the parts by referring to the figure below.

Cable
ABR372

LT30A model
• After installing crank lever on back plate, make sure that there
is no play between crank lever and back plate. If play exists, fli'
adjust bolt ® and lock nut @.

LT30A LT26B

LH wheel
SBR100CA

BR-27 859
 PARKING BRAKE CONTROL

2WD

AdjusterE!
ll!ls-11 (o.s-1.1,69-95)

[jj 8·11 (0.8·1.1,69-95)

4WD
~-!lls-11 (O.B-1.1,69-95)

,-)':!
'---'dil'\-5"-ii !
~I

Front cable
-k~~ - ~~ rII!J 8-11 (0.8 ·1.1. 69- 95)
11!18·11 (0.8·1.1.69·95) ~/ ~
~---- ~ ~\
~--l===~~:c~-=-~ -~"
"--~-- ~ ~1

Adjuste• "'

~ 3.1 - 4.3 {0.32 - 0.44, 27.8 - 38.2)

IIJ :N · m {kg-m, in-lb) ABR411

860 BR-28
 PARKING BRAKE CONTROL

Removal and Installation @JI

• Be careful not to damage cable.

• Make sure there is no free play after installation.
Inspection
1. Check control lever for wear and damage. Replace if neces- l'iik!
sary.
2. Check wires for discontinuity and deterioration. Replace if nee-

3. -~ warning lamp and switch. Correct if necessary.

Check w
4. Check part at each connecting portion and, if found deformed
or damaged, replace. !'l<:(;

Adjustment
Adjust parking brake as follows:
-LT26B-
1. Pull parking brake lever several times until clicking sound does
not occur from rear brakes. 10iL
2. Release parking brake lever.
3. Loosen lock nut @, rotate adjusting nut @.
4. Tighten lock nut @. l!:i'il
5. Pull control lever with specified amount of force. Check lever
Locknut@ stroke and ensure smooth operation.
Adjusting nut@
Number of notches: Refer to SDS, BR-51 J\1

ABR395

LT30A(4WD) - LT30A-
1. Release parking brake lever.
2. Depress brake pedal fully at least 10 times. ~~
3. Loosen lock nut @, rotate adjuster @.
4. Tighten lock nut @.
5. Pull control lever with specified amount of force. Check lever IFJ\
stroke and ensure smooth operation.
Number of notches: Refer to SDS, BR-51.

ABR409

BR-29 861
 REAR WHEEL ANTI-LOCK BRAKE SYSTEM

Purpose
The Rear Wheel Anti-Lock Brake System (ABS) consists of electronic and hydraulic components. It controls
rear braking force so locking of the rear wheels can be avoided.
TheABS:
1) Improves proper tracking performance during severe braking.
2) Eases obstacle avoidance during severe braking.
3) Improves vehicle stability.
Operation
• When the vehicle speed is less than 10 km/h (6 MPH) this system does not work.
• The Rear Wheel Anti-Lock Brake System (ABS) has self-test capabilities. The system turns on the ABS
warning lamp for a few seconds each time the ignition switch is turned ON. After the engine is started, the
ABS warning lamp turns off. The system performs a circuit check when the ignition switch is first turned
ON. If a malfunction is found during this check, the ABS warning lamp will stay on.
• While driving, a mechanical noise may be heard and slight pedal pulsation may be felt during ABS opera-
tion. This is a normal condition.
CAUTION:
When driving in 4WD, the rear wheel anti-lock brake system is not effective in most cases. The rear
wheels will lock if the front wheels lock because the transfer mechanically couples the front and rear
axles together. If this happens, the rear wheel anti-lock brake system may not function but the ordi-
nary brakes will operate normally. The ABS warning lamp will then turn on. The above condition is not
a malfunction and the rear wheel anti-lock brake system can be re-activated by starting the engine
again. The ABS warning lamp will then go off.

Control unit System Description

Magnee:t;/j{,~~~!,'U
Sensor 1 Low carbon steel
REAR SENSOR
Magnetic flux J -_}-Coil The rear sensor unit consists of a gear-shaped sensor rotor and a
Tooth '
; '
: / Sensor rotor sensor unit. The sensor unit consists of a bar magnet around which

~of
a coil is wound. The sensor rotor is installed on the companion
one tooth flange and the sensor unit is installed on the rear axle housing. A
sine-wave current is generated by the rear sensor unit as the rear
v~ axle pinion rotates. The frequency and voltage increase as the
rotating speed increases.
V: Induced electromotive force
SBR124B

120 8 ABS CONTROL UNIT

• The ABS control unit computes the rear axle pinion rotating speed
by reading the signal from the rear sensor unit. Then it supplies a
DC current to the ABS actuator. If any electrical malfunction is
detected in the system, the ABS control unit causes the ABS warn-
ing lamp to turn on. In this condition, the ABS system will be deac-
tivated by the ABS control unit, and the vehicle's brake system
reverts to normal operation.

ABR400

Control unit is located under driver's seat.

862 BR-30
 REAR WHEEL ANTI-LOCK BRAKE SYSTEM

System Components
Stoplamp switch Waminglamp

ABS control unit

ABS actuator

ABR374

Hydraulic Circuit

ABS control unit

Front brake

Reservoir

~:~:_ ____________ j I c===~l

L------~~~- ::-:---
Actuator
J
Master cylinder

Front.
ABR406 ~J'f

BR-31 863
 REAR WHEEL ANTI-LOCK BRAKE SYSTEM

Removal and Installation

CAUTION:
Be careful not to damage sensor edge and sensor rotor teeth.
In case the final drive assembly needs to be removed, discon-
nect the ABS sensor from the assembly and move it away.
Failure to do so may result in damage to the sensor wires
making the sensor inoperative.
REAR SENSOR AND CONTROL UNIT
Control unit is located under driver's seat.
11!]4-6
(04-06 //'[~2.5-3.4
3~. 52) ' --!I
'/
j (0.25 • 0.35,
21.7-30.4)

\\~
'\\:~-·\.
t' \,-~ -~
~0~~
Companion flange

i drive
11!1 N · m (kg-m, in-lb)

Sensor rotor ~ N-m (kg-m, ft-lb)

~ 196 --284 (20- 29, 145- 210) ABR401

ACTUATOR
Removal
1. Disconnect battery cable.
2. Drain brake fluid.
Refer to "Changing Brake Fluid", "CHECK AND ADJUSTMENT",
BR-4.
3. Disconnect connectors, brake pipes and remove fixing nuts.

~18- 23 (1.8- 2.3, 13- 17)

Installation
CAUTION:
~36- 50 After installation, refill brake fluid. Then bleed air. Refer to
(3.7- 5.1, "Bleeding Procedure", BR-5.
27 - 37)
1. Connect brake pipes temporarily.
2. Secure fixing bolts.
3. Torque brake pipe flare nuts.
4. Connect connectors and battery cable.

864 BR-32
 TROUBLE DIAGNOSES

How to Perform Trouble Diagnoses for Quick

and Accurate Repair
WORK FLOW

L__ _ _ _ _ _ _c_H_E_C,K_IN_ _ _ _ _ _ _ _ H Reference item

l
LISTEN TO CUSTOMER COMPLAINTS

~
INVESTIGATE ITEMS YOU SHOULD CARRY OUT Go to Symptom Chart,
RELATED TO EACH SYMPTOM AND NOTE I- BR-34.

~
CHECK FOR ANY SERVICE BULLETINS.

Go to Preliminary
.I ELIMINATE GOOD SYSTEMS ON GOOD PARTS
f.- Check, BR-35.

I .
Not se If-dragnostrc rtem
I
Self-diagnostic item

~
DETERMINE MALFUNC-
Go to Self-diagnosis,
TIONING CIRCUIT(S) OR
PART(S).
1- BR-36.

Self-diagnosis

• Go to Diagnostic
Procedure(s) 1-6,
BR-41 - 44.
ELIMINATE GOOD PART(S), HARNESS(ES) OR CON-
NECTOR(S) THROUGH ELECTRICALLY TESTING
-- • Go to Component
Parts and Harness
Connector
Location, BR-37.

Malfunctioning
harness{es) and Malfunctioning parts
connector(s)

1
INSPECTION ON THE Go to Diagnostic Pro-
BASE OF EACH COMPO-
NENT
I- cedure(s) 7-13, BR-45-
48.

REPAIR
l
I I I REPAIR OR REPLACE

NG I
I FINAL CHECK
I
~OK
CHECK OUT

BR-33 865
 TROUBLE DIAGNOSES

Symptom Chart

8.. §
En
8~ U) BR-49 Rear sensor unit and ABS actuator 0
~-=
·;:: .$
~ ai
w c

BR-48 Warning flashing 5 00000

;;~----+---------------------------~~--~~--~-~
z BR-47 Warning flashing 13,14 or 15 0000
C>
c
E ~---f----------------------~f--r-f~--i
~ ~
=> "' BR-47 Warning flashing 6 0000
~fD
e~ ~----~-----------------------1--+--t--~-r-i
o..,s
u -~
BR-47 0000
Warning flashing 9 or 10
~t:~----+---------------------------~-r---c~~-1~-l
c Q
e>u
~ " BR-46 Warning flashing 3 or 8 0000
0 ~
.~ ~----~-----------------------1--t--t--~1--1
~
o; BR-45 Warning flashing 4 0000
~~---r--------------------t-~-r-t~--1
BR-45 Warning flashing 2 or 7 0000

BR-44 Diagnostic Procedure 6 0

BR-43 Diagnostic Procedure 5 0

i!'
=>

e"
"0

BR-42 Diagnostic Procedure 4 0

0..
u
tlg BR-41 Diagnostic Procedure 3 0
~
i5
BR-41 Diagnostic Procedure 2 0

BR-41 Diagnostic Procedure 1 0

~ ~ BR-35 Preliminary Check 2 0

-~ ~ ~----+--------------------------1---r-1---r-1--4
mB
0::: BR-35 Preliminary Check 1 0

w
(!)

1f:
w w
a: ()
::> z :;;
0 w 0
w
() a:
w a_l-
0 "- :;;
a:
0..
w
a: >-
en

866 BR-34
 TROUBLE DIAGNOSES

m .40 laaaaaal 120 8 Preliminary Check 1

....

\-
20. 0
·20£
0 n =
140·
•

.9
m
1. Turn ignition switch ON. No
~ dure 6,
Go to Diagnostic Proce-
2. Check warning lamp activation. BR-44.
~Ia"N~•m<>LY
160
a a al 108
• When ignition switch is turned on, warn- If OK, replace ABS control
ing lamp should turn on. unit.

Warning lamp~ Yes

:?}l:os::- m
Check warning lamp deactivates within a No Go to Preliminary Check
ABR400 few seconds. f----> 2 below.

m laaaaaal 120
•8
Yes
~
20.
•
40
0 n 0 140·
[!1
\- o20~ .9 Check warning lamp reactivation.
~ Go to Preliminary Check

~Ia a a al 1 o• o
160 2 below.
No
UNL.Eili:El FUEl DNLY

ABS
0

ABA399
1. Drive vehicle with 2WD for 1 minute or
more at 40 km/h (25 MPH) or more.
2. Check warning lamp reactivation.
No
-Yes Go to Preliminary Check
2 below.

[!1
"- 20
•
.40 raaaaaal
0
n 0
120

140.
• 8 I!]
1. Stop engine.
2. Turn ignition switch ON.
-OK Self-operating function is
OK.
\- o20 # .9 Check actuator clicking noise, when

~ Ia a a al
160 warning lamp turns off.
•
UNLEADED FUEL ONLY 1 00 ~ NG
-0
Warning lamp~ Check actuator.
Refer to BR-49.
:?Ass::-
ABA400

I!] Located behind second cross C

~membe:t~1~\ c
,~fii'~ ~ \<
~~~~~~
~1 ~ --'~
Usten for actuator clicking
noise in a quiet area. SBA524B

I\QJUJ rb"\11 9
Preliminary Check 2

'QJ 1. Start engine. No Check brake fluid level.

f---->
L:1
2. Ground the check terminal of check con- Go to Diagnostic Proce-

;;)y 4 nectar.
3. Check the warning lamp flashing.
Yes
dure 6, BR-44.
~OK

dt~~~ , 2 3 r o
j Replace ABS control unit
I

~8m
1
Count the number of flashes.
Go to Self-diagnosis, BR-36.

ABR398

BR-35 867
 TROUBLE DIAGNOSES

Self-diagnosis
CHECKING THE NUMBER OF WARNING LAMP FLASHES
When a problem occurs in the ABS, the ABS warning lamp on the instrument panel turns on. As shown in the
table, the control unit performs sell-diagnosis.
To obtain satisfactory sell-diagnosing results, the vehicle must be driven in 2WD above 40 km/h (25 MPH) for
at least one minute before the self-diagnosis is performed. After the vehicle has been stopped, the number of
ABS warning lamp flashes is counted by grounding the check terminal, with the engine running, thereby iden-
tifying a malfunctioning part or unit by the number of flashes.
If more than two parts or units malfunction at the same time, the ABS warning lamp will flash to indicate one
of the malfunctioning parts or units. After the part or unit has been repaired, the ABS warning lamp will then
flash to indicate that the other part or unit is malfunctioning.
No. of warning lamp
Detected items Malfunctioning cause or part Diagnostic Procedure
flashes
2 Open Diagnostic Procedure 7
7 ISO solenoid Short circuit Diagnostic Procedure 7
4 ASS actuator Blocked Diagnostic Procedure 8
3 Open Diagnostic Procedure 9
DUMP solenoid
B Short circuit Diagnostic Procedure 9
9 Open Diagnostic Procedure 10
10 Rear sensor Short circuit Diagnostic Procedure 10
6 Erratic Diagnostic Procedure 11
13, 14 or 15 ASS control unit - Diagnostic Procedure 12
5 Other Diagnostic Procedure 13

CAUTION:
When driving in 4WD, the rear wheel anti-lock brake system is not effective in most cases. The rear
wheels will lock if the front wheels lock because the transfer mechanically couples the front and rear
axles together. If this happens, the rear wheel anti-lock brake system may not function but the ordi-
nary brakes will operate normally. The ABS warning lamp will then turn on. The above condition is not
a malfunction and the rear wheel anti-lock brake system can be re-activated by starting the engine
again. The ABS warning lamp will then go off.

868 BR-36
 TROUBLE DIAGNOSES

Component Parts and Harness Connector

Location

Stoplamp switch Warning lamp

ABS control untt

Rear sensor

ABS actuator

Under driver's seat

~ ABS control unit connector
·d/ Rear sensor unit
Rear sensor unit connector @)

ABSactuato~ liD%(
~~Second crossmember ABR402

BR-37 869
870

@ With power windows

I
I BAT"' I IGNITION SWITCH
ON or START j

~FUSE 0FUSE FUSE

-----<'V-
r::S\ BRAKE WARNING
To power qv
window
system r!Til STOP
LAMP
r.:S.\ABS

\:?)WARNING
LAMP
To bulb check relay
-1
SWITCH LAMP
::rJ
To
(") 0
stop
lamps
...0 c:
D:J
D:J I c: r-
,' ' ;::;: m
::rJ
I
8 2 ' 0
w 0
00
I I
ABS CONTROL UNIT iii'
...
(,Q >
G')
17 4 1 11 6 5 9 10 I I i I I : I»
3
z
0
en
m
en

,-i---------r---------r--------,ABS BRAKE
,,--------
~I ~I
PARKING
ACTUATOR FLUID BRAKE
n r ,~~~~~~~~~~~~~

ill
LEVEL SWITCH
DUMP DUMP ISOLATION
UACTUATOR
SOLENOID
! SWITCH
? SOLENOID SWITCH
'\ ~J'
REAR
SENSOR

IT_

ID
"'w
8
 TROUBLE DIAGNOSES

Wiring Diagram -ABS-

BATIERY I· BR-ABS-01
(M143)(i,ij§) I
WIL ~:With power windows

Qlll---•----::1,
:t~,,~··-1-,
10A
Refer to "EL-POWER".

~@]
RIB
rn
r-----~~~----,STOP
LAMP
SWITCH
Ci1W

BIG
ll4Jl
GN
To +w;G~
EL-WINDOW Iil
_ ToEL·TAIUL
._ I
.G/Ui-----•·G/Y~Nexlpage

B/G 8/G G/Y

~~~~~~--~~-~3~1----------~~~~=~1~---------. ~~~TAOL
IGN IGN STOP LAMP
SW UNIT
BRAKE DUMP ISOLATION ~
FLUID DUMP ACTUATOR SOLENOID \!!ill§~
sw SOLENOID(+) SW (+)

.
._
~ lbj'dJ lbjdJ lkjdJ
WIG

·----
r---2L~~-,BRAKE
._

FLUID
B
~

o
B

,1,:.~1
DUMP
GY/R
~

GY/R
Y
~
lo;IJ~------ -l[ijll------- -IClJf---- -1~1@

--~~~~~~--~~~~~~--~~4~11___, ABS
Y
LGIR
~(Mi09)

LG/R

ISOLATION
ACTUATOR
LEVEL
SOLENOID SOLENOID
@
SWITCH
(M59)

·-·
LOW

~
IB
(M~9)
~
•B
@Qj)
~
•B
Clilli9>
tr· B •
B
.......
(M1nl . . _....
._
__
DIODE(Mj§)
W/G~BRIY....:.BR/Y~Next page

1 =2
3 4 5 6 7 sl
910 11 2 1314
eM.®
BR

1 2 3 4 si(Mj§) 123405676@7§) £@
6 7 8 9 101 w 17 1211109 B \:ill/ w

IIQi:t\

ABR485

BR-39 871
 TROUBLE DIAGNOSES
Wiring Diagram -ABS- (Cont'd)

BR-ABS-02
Refer to "EL-POWER".

JOINT
CONNECTOR-2
Preceding -<:& ...,. W/B <Mill) @]§)@)
page G!Y""'l L..:S~W/B~W/,
r1l
r------'--=--'----------,ABS W/B
CHECK ~
CONNECTOR r11Li1J77l::l::::::::~-:::~~
'-;-:--,..-----,--,-,.--::---,c--;---,-l@ I BRAKE ~~~~~NATION
L-i-J 4-J 4-J 4-J r,..~PNING @),@
8 W OR RIG

I r.:- 1 ~ ~ ~
m 'B

~~~~ECTOR-1 ~
~~

·-
·--..
•I .,_

-:-::-~-=-~r:/::ll~:::::--1 • l!r----------1!1~~:5~
UR

- UR
BRIY

- BR!V
BN

L B/Y .To
EL-WARN

l.bi=!J
:
:
e
.-----~'
I It ~
•
B 1 __ I mOR
~
W

--~~~~~~~~~~~~ABS
m R/G
11211

-- SENSOR SENSOR LAMP CONTROL

W OR (-) (+) PARKING UNIT
(~)

( ,...
•' - -
-- •
,
page
Preceding _.....-sL
"'--'::j BRIY ~ r•:::~;:=-==;
I
~ . . -- ~ .... I
~ / BAN

WOR
~~ G!Y
~ ~ DIODE
11111 11211
REAR
11111
,------"--j--"-----, PARKING
"'156'
~

ri
SENSOR BRAKE IL2JI

B
~~
(~)(Ml§l
B
@ SWITCH
(M127)

- =r"
G!Y

Refer to last page (Foldout page).

1 =2 D @jQ)
13 4 516 7 8 12345(~) (ijill)
lg 0 11"2 1314 678910 w <filll) @

12 3 405 6 7 B<&iTI§') ~@
17 1211109 B Uill GY

ABR361-B

872 BR-40
 TROUBLE DIAGNOSES

Diagnostic Procedure 1
Brake pedal
SYMPTOM: Pedal vibration or noise

Check whether the symptom appears only Yes When brake is suddenly
when brake is applied suddenly. applied, ABS works and
produces pedal vibration or
No
noise.

Yes Self-operation of ASS func-

tions properly.

Diagnostic Procedure 2
SYMPTOM: Long stopping distance
Refer to worksheet results.
Check if road condition is slippery with Yes Stopping distance may be ©lb
snow or gravel. longer than vehicles which
are not equipped with ABS.
No iYll
SBR530A Disconnect ABS actuator connector and Connect ABS actuator con-
'--------------------' check whether stopping distance is still nector.
long. Go to Preliminary Check
1 and 2, BR-35.
Yes Go to Self-diagnosis,
BR·36.

Perform usual brake inspection and air

bleeding.

Diagnostic Procedure 3
SYMPTOM: Brake pedal stroke is large.
Check whether the symptom usually No Vehicles equipped with
Brake pedal appears. ABS may have a tendency
to increase pedal stroke
Yes
during operation.

Check for accumulation of air by trying to No Periorm brake inspection.

bleed air. Refer to BR-19.

SAT797A

BR-41 873
 TROUBLE DIAGNOSES

Diagnostic Procedure 4
SYMPTOM: ABS does not work.
Check whether warning lamp activates. Yes Go to Preliminary Check
Go to Preliminary Check 1, BR-35. 2, BR-35.
Go to Self-diagnosis,
No
BR-36.

Check whether vehicle is in 4WD condi- Yes Go to Self-diagnosis,

tion. ~ BR-36.

l No
Check whether vehicle speed is under 1 0 Yes ABS does not work in this
km/h (6 MPH). ~ condition.

l No
Check ABS actuator and rear sensor. ~ Replace damaged parts.
Refer to BR-49.

l OK
Check main power supply and ground cir- ~ Repair faulty part.
cuit.
Refer to BR-44.

l OK
Check operation of ABS. ~ Replace ABS control unit.
Refer to BR-49.

874 BR-42
 TROUBLE DIAGNOSES

Diagnostic Procedure 5
SYMPTOM: ABS works frequently.

CHECK BRAKE FLUID PRESSURE. NG Replace master cylinder.

Check whether brake fluid pressure distri-
bution is normal.
Refer to BR·B or BR·10.

OK

SBR013B Perform usual brake inspection. Repair.

~----------------------~
OK

When wheel lock occurs frequently due to

hard braking operation, the ABS operates
at each occurrence of wheel lock.
Accordingly, frequent ABS operation is
normal under severe braking conditions
where wheel lock would occur frequently
due to braking.
~!Iii'

BR-43 875
 TROUBLE DIAGNOSES

m Diagnostic Procedure 6
~
OIHONNIO~T
ABS control

II
unit connector ~

11 II
IV MAIN POWER SUPPLY AND GROUND CIRCUIT (Not
self-diagnostic item)
~
2 D

u;/ '\B m
CHECK WARNING LAMP POWER SUP-
No
[!]
CHECK GROUND CIA-
PLY. f-----+ CUlT.
1. Connect battery cable and confirm bat- Check harness continuity,
tery voltage is 12V. between ASS control unit
CYJI
+
2. Disconnect ABS control unit connector. terminal @ and suitable
3. Turn ignition switch ON. body ground.
ABR362 4. Do approx. 12 volts exist between ABS Continuity should exist.
®
control unit connector terminals and
OK
!;] @? .j.NG

~
DISCDNI~ECT
ABS control
unit connector@
IV Yes Repair har-
ness or
WJJ 1"''ffil @)
connectors.

B/G r B Check and replace fuse,

warning lamp or relays if
necessary.
Repair ignition harness,
relay and warning lamp
[Y] connectors.
+
!;]
ABR363 No
CHECK ABS RELAY POWER SUPPLY. Check and replace fuse,
[!] ABS control CISto~NE:T
1. Turn ignition switch ON. f-----+ ASS relay, or repair har-
unit connector@ [;d IV 2. Do approx. 12 volts exist between ASS
control unit connector terminals @, @
ness and connectors.

nu~~, 111
3 and@?
~Yes

[ill
•
'] l!l
CHECK STOP LAMP SWITCH POWER
SUPPLY.
1. Depress brake pedal.
2. Do approx. 12 volts exist between ASS
No
Adjust stop lamp switch if
----> necessary. Replace stop
lamp switch. if necessary or
repair harness or connec-
®
control unit connector terminals tors.
~ and@?
ABR364
Yes
l§t
l!l
~ 10 ~
DISCONNECT
CHECK PARKING BRAKE POWER SUP- Adjust parking brake switch,
PLY. if necessary. Replace park-
1. Confirm that brake fluid level is ing brake switch, if neces-
ABS control ~ adequate. sary or repair harness or
unit connector ~ GN
lf necessary, refill it. connector.
2. Turn ignition switch ON.
!Ill I loll'\. •ll 3. Do approx. 12 volts exist between ASS
®
control unit connector terminals and

[Y]
+
'1 ABR365
@ without parking brake applied?
Do approx. 0 volts exist with parking
brake applied?

l§t
~
ASS control Dlfir.O~NCCI

II
unit connector @

L 11 II
IV
B";/
Ds

~B 00
[Y]
+
ABA366

876 BR-44
 TROUBLE DIAGNOSES

m Diagnostic Procedure 7
~
DISCONNECT

ABS control
unit connector@
IV ABS ACTUATOR ISO SOLENOID SHORT CIRCUIT OR
OPEN (Warning lamp flashing number 2 or 7)

LGIA
l!,lllld l'lU ~ Remove battery negative terminal connec-
tor.
B

[ID
m 1
CHECK ISO SOLENOID.
Check resistance between ABS control ~I Replace ABS control unit.
I
ABR375 unit connector terminals CD
and @.
Resistance: Approximately 4fl

m ~NG

ABS actuator
~iv CHECK ABS CONTROL UNIT GROUND
NG
Repair harness or connec-
---+ tor.
CIRCUIT.
connector@ Go to Diagnostic Procedure 6, BR-44.

@ m 1 OK

--
OK
©L

n
B CHECK ABS ACTUATOR GROUND Repair harness or connec-

~
CIRCUIT. tors.
[ID - Check harness continuity between ABS
actuator terminal @ and suitable body
~ ground.
ABR377

I!) I!) 1 NG

ABS actuator
~iv CHECK ISO SOLENOID.
Check resistance between ABS actuator ~ Repair harness and con-
nectars between ISO sole-
connector@ connector terminals G) and @. noid and ABS control unit.
Resistance: Approximately 4!1
6fj -roK

Replace ABS actuator.

~
..
rem
-=...:::
T

ABA376

m Diagnostic Procedure 8
~
OISCIJNNECT
ABS control
unit connector@
IV ABS ACTUATOR ISO SOLENOID BLOCKED (Warning
lt:±±:J.blllll
~
lamp flashing number 4)

( [ID
=-..::::
Remove battery negative terminal connector.

m t
CHECK ABS ACTUATOR SWITCH. ~
Does continuity exist between ABS control
Replace ABS control unit.
I
unit terminal @ and suitable body ground?
"""" ABR378
Continuity should not exist.
IS]
~
DISCONNECT

IV m
tNG

ABS actuator Does continuity exist between ABS actua- ~ Replace ABS actuator.
connector@ tor terminal® and suitable body ground?

~
Continuity should not exist.

~OK

(l_8_ ~
Repair harness and connectors between
ABS actuator and ABS control unit
~

ABR379

BR-45 877
 TROUBLE DIAGNOSES

m Diagnostic Procedure 9
ABS control
unit connector@
~ ABS ACTUATOR DUMP SOLENOID SHORT CIRCUIT OR
DISCDNN(CT
OPEN (Warning lamp flashing number 3 or 8)
GYIR
17
I I I I lol I" IV Remove battery negative terminal

~· 00 connector.

[ill
==-..::::
m
CHECK DUMP SOLENOID.
1 ~ Replace ABS control unit.
ABR380 Check resistance between ABS control
unit connector terminals @ and @.
m
~iv
Resistance:
Approximately 1.5!!
ABSactuator
connector@) ~ NG

~
CHECK ABS CONTROL UNIT GROUND
CIRCUIT. ~ Repair harness or
connector.

n
Go to Diagnostic Procedure 6, BR-44.

~ l
.
Q
OK
-,j,.
T

ABR377
m
CHECK ABS ACTUATOR GROUND
CIRCUIT.
10\ Repair harness or
connectors
[!] OiSCONNECT

~ IV Check harness continuity between ABS

actuator terminal @ and suitable body
ABS actuator
ground.
connector@l

EM [!]
l NG

CHECK DUMP SOLENOID. 10\ Repair harness or

~
Check resistance between ABS actuator connectors between dump
[ill '
connector terminals ®and @. solenoid and ABS control
Resistance: unit..
ABR381 Approximately 1.5!1

l"NG

Replace ABS actuator.

878 BR-46
 TROUBLE DIAGNOSES

r.i.1 ABS control

Diagnostic Procedure 10
unit connector@
Low REAR SENSOR OPEN OR SHORT CIRCUIT (Warning
Ill I I bl 'mi OR
lamp flashing number 9 or 10)
/High Remove battery negative terminal connec-

~
DISCONNECT

IV w
tor.

@1 [Q]
• r.i.1
ABR382 CHECK REAR SENSOR. ~ Replace ABS control unit.
Check resistance between ABS control
m DISCONNOGT
unit connector terminals @ and @.
~ IV Resistance:
1.22 - 1.48 kfl
Rear sensor
connector® NG

dE m
Check resistance between rear sensor OK Repair harness or connec-
------>
[Q] unit connector terminals ® and G). tors between ABS control
Resistance: unit and rear sensor.
- 1.22 - 1.48 k!l
ABR384
NG

Replace rear sensor unit.

Diagnostic Procedure 11
SENSOR SIGNAL ERRATIC (Warning lamp flashing 10~
number 6)
CHECK REAR SENSOR ROTOR TOOTH NG Replace rear sensor rotor
CONDITION. with companion flange.
1. Remove propeller shaft.
2. Remove companion flange, refer to
''DISASSEMBLY'' in PO section.
3. Check rotor on companion flange.

l OK

Replace ASS control unit.

Diagnostic Procedure 12
ABS CONTROL UNIT (Warning lamp flashing 13, 14 or
15)
ASS control unit malfunction.

Replace ASS control unit.

BR-47 879
 TROUBLE DIAGNOSES

Diagnostic Procedure 13
Other (Warning lamp flashing 5)
Overhaul both rear brakes.

1
Go to Preliminary Check 1, BR·35. ~ Inspection END
Check whether system is OK.
I
1NG
Check whether warning lamp flashing is ~ Replace ABS actuator.
still 5. I
1No
Inspect system again referring to number
of warning lamp flashes.

880 BR-48
 TROUBLE DIAGNOSES

Electrical Components Inspection

REAR SENSOR UNIT AND ACTUATOR

NG
CHECK REAR SENSOR SIGNAL. CHECK REAR SENSOR
1. Raise vehicle. Confirm it is safe to ROTOR for following
rotate rear wheels. points:
2. Start engine and rotate rear wheels • Tooth condition
with transmission in 0 position or first • Installation on compan-
gear position. ion flange
3. Check rear sensor signal voltage • Deformation
SBR373D between control unit terminals @ and • Wear
® with AC voltmeter. • Looseness
Voltage: 0.4V or more
MIT at 700 rpm NG OK
AfT at 850 rpm
Replace Replace
OK rear sensor rear sensor
rotor with unit
companion
flange.

CHECK PULSING VOLT-

AGE FROM ABS CON-
TROL UNIT.
Check pulsing voltage for
ISO and DUMP solenoid
between ASS control unit
OK terminals @ and @, and
terminals CD
and @.
Voltage: 0.3 - 3.5V for
approx. 13 msec.
Use suitable digital voltme-
ter. Pulsing voltage
appears when ASS warn-
ing lamp goes off after igni-
tion is turned on.

NG

CHECK ABS OPERATION as follows: Replace Replace

1. Periorm ABS check in a safe place ABS con- ABS actua-
without obstacles in the vicinity. trol unit. tor.
2. Drive the vehicle for more than one
minute at speeds over 40 km/h (25

•
MPH) in the 2WD mode, then check
that the warning lamp does not light on
the instrument panel. After this, check
for operation.
3. Check if ordinary braking effect occurs,
and also check that the rear wheels do
not lock when abrupt braking causes
the front wheels lock.

OK NG

SBR545B ABS is good con- Replace ABS

~;================~
actuator.
00 Ldition.
__ _ _ _ _ _ _ _ ~

ABS control
[;j
unit connector~
GY/R

1!~'1 I I ld I", j] i5
LG/R
8
00
ABR386

BR-49 881
 SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications

4WD
Applied model 2WD
Standard wheelbase
I Long wheelbase

Front brake

Brake model CL28VA CL28VD

Cylinder bore diameter x number of pistons

60.6 (2.386) X 1 42.8 (1.685) X 2
mm (in)

IN:
126.5 X 43 X 11
(4.98 X 1.69 X 0.43)
Pad length x width x thickness mm (in) 146.6 X 48.5 X 10 {5.77 X 1.909 X 0.39)
DUT:
129x43x11
(5.08 X 1.69 X 0.43)

250 X 22
Rotor outer diameter x thickness mm (in) 277 X 26 (10.9 X 1.02)
(9.84 X 0.87)

Rear brake

Brake model LT26B LT30A

Cylinder bore diameter

22.22 (718) 20.64 (13116)
mm(in)

Lining length x width x thickness 249.6 X 50 X 5.5 296x50x6.1

mm (in) (9.83 X 1.97 X 0.217) (11.65 X 1.97 X 0.240)

Drum inner diameter mm (in) 260.0 (10.24) 295.0 (11.61 I

Master cylinder

Bore diameter mm (in) 25.40 (1)

Control valve

Linkage type load

Valve model Proportioning valve within master cylinder
sensing valve

Split point {kPa (kg/cm 2 , psi)] x reducing ratio (Variable) x 0.23 2,452 (25, 356) X 0.2
I 2,942 (30, 427) X 0.2

Brake booster

Booster model M195T M215T

Diaphragm diameter Pri.: 205 {8.07) Pri.: 230 {9.06)

mm (in) Sec.: 180 {7.09) Sec.: 205 (8.07)

Recommended brake fluid DOT3

882 BR-50
 SERVICE DATA AND SPECIFICATIONS (SDS)

@I
Inspection and Adjustment
DISC BRAKE BRAKE PEDAL
Unit· mm (in) Unit· mm (in) ~til
Brake model CL2BVA CL28VD Free height "H"*

Pad wear limit M!T 209 - 219 (8.23- 8.62)

Minimum thickness 2.0 (0.079) AfT 212- 222 (8.35- 8.74)

Rotor repair limit Depressed height "D"

[under force of 490 N (50
Minimum thickness 20.0 (0.787) 24.0 (0.945) 120.0 (4.72)
kg, 110 lb) with engine run-
ning]
DRUM BRAKE Clearance "C" between
Unit· mm (in) pedal stopper and threaded
0.3- 1.0 (0.012- 0.039)
end of stop lamp switch or
Brake model LT26B LT30A
ASCD switch
Lining wear limit
Pedal free play
Minimum thickness 1.5 (0.059)
At clevis 1.0-3.0 (0.039- 0.118)
Drum repair limit
At pedal pad 4- 12 (0.16- 0.47)
Maximum inner
261.5 (10.30) 296.5 (1 1 .67) *: Measured from surface of melt sheet to pedal pad.
diameter

Out-of-round limit o. t5 (o.oos9) PARKING BRAKE CONTROL

Control type Stick lever

Lever stroke
10- 12
[under force of 196 N (20 kg, 44 lb)]

Lever stroke when warning switch comes on

BR-51 883
 STEERING SYSTEM ,~u

SECTION ST
CONTENTS
PRECAUTIONS AND PREPARATION ............... ............ 2 POWER STEERING SYSTEM (Model: PB59K) .......... 20
Supplemental Restraint System (SRS) "AIR Description .................................................................20
MG" ........................................................................ 2 POWER STEERING GEAR (Model: PB59K) ............... 21 l(;l
Steering System ........................................................2 Removal and Installing ............................................. 21
Special Service Tools....... .. .................................... 3 Power Steering Gear Component ............................ 21
Commercial Service Tool ............................................. 4 Pre-disassembly Inspection and Adjustment.. .......... 22 !K,·:1ll~
ON-VEHICLE SERVICE .................................................. 5 Disassembly ..............................................................23
Steering System ......................................................... 5 Assembly .................................................................24
Checking and Adjusting Drive Belts (For power POWER STEERING SYSTEM (Model: PB48S) ........... 27 il!l
steering)....................... ............................. 5 Description ........................................ ..................... .. 27
Checking Fluid Level ................................................ 5 POWER STEERING GEAR (Model: PB48S) ...... 28 fp
Checking Fluid Leakage ........................................... 6 Removal and Installing .............................................. 28
Bleeding Hydraulic System.. .............. .. .. 6 Power Steering Gear Component ............................ 28
Checking Steering Wheel Turning Force (For Pre-disassembly Inspection and Adjustment.. ........... 29 [1'Ul;
power steering) ............................................................7 Disassembly ...............................................................30
Checking Steering Wheel Play............... .. ............ 7 Assembly .................................................................32
Checking Neutral Position on Steering Wheel ............ 8 POWER STEERING OIL PUMP ........................... ........ 35 [';!,
Checking Front Wheel Turning Angle .......................... 8 Disassembly and Assembly......... .. ................ 35
Checking Hydraulic System ......................................... 8 Pre-disassembly lnspection ....................................... 35
STEERING WHEEL AND STEERING COLUMN .... .... 10 lnspection ...................................................................36 Th'iii
Steering Wheel .......... .. .... 10 Disassembly ............................................................. 36
Steering Column......................................... .. .. 11 Assembly ................................................................... 37
Disassembly and Assembly.. .. ............................ 12 STEERING LINKAGE.. .. ................... 38 ~Jm;
Inspection ................................................................... 13 Removal and Installation.. .. ....................... 38
MANUAL STEERING GEAR (Model: VB66K) ....... ..... 14 Disassembly ............................................................. 39
Removal and Installation ............ . .. .................... 14 Inspection ................................................................ .40
Disassembly ............................................................. 15 SERVICE DATA AND SPECIFICATIONS (SDS) ........ .41
Assembly and Adjustment.. .................................... 15 General Specifications ............. ............................ ... .41 Wl~
Inspection ................................................................ 18 Inspection and Adjustment ...................................... .41

885
 PRECAUTIONS AND PREPARATION

Supplemental Restraint System (SRS) "AIR

BAG"
The Supplemental Restraint System "Air Bag" used along with a
seat belt, helps to reduce the risk or severity of injury to the driver
in a frontal collision. The Supplemental Restraint System consists
of an air bag module (located in the center of the steering wheel),
a diagnosis sensor unit, warning lamp, wiring harness, a crash
zone sensor (4WD models) and spiral cable. Information necessary
to service the system safely is included in the RS section of this
Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could
increase the risk of personal injury or death in the event
of a collision which would result in air bag inflation, all
maintenance must be performed by an authorized NISSAN
dealer.
• Improper maintenance, including incorrect removal and
installation of the SRS, can lead to personal injury caused
by unintentional activation of the system.
• Do not use electrical test equipment on any circuit related
to the SRS unless instructed to in this Service Manual.
SRS wiring harnesses are covered with yellow insulation
either just before the harness connectors or for the com-
plete harness, for easy identification.

Steering System
• Before disassembly, thoroughly clean the outside of the unit.
• Disassembly should be done in a clean work area. It is important to prevent the internal parts from
becoming contaminated by dirt or other foreign matter.
• For easier and proper assembly, place disassembled parts in order on a parts rack.
• Use nylon cloths or paper towels to clean the parts; common shop rags can leave lint that might
interfere with their operation.
• Before inspection or reassembly, carefully clean all parts with a general purpose, non-flammable
solvent.
• Before assembly, apply a coat of recommended ATF* to hydraulic parts. Petroleum jelly may be
applied to 0-rings and seals. Do not use any grease.
• Replace all gaskets, seals and 0-rings. Avoid damaging 0-rings, seals and gaskets during instal-
lation. Perform functional tests whenever designated.
*: Automatic Transmission Fluid type DEXRON™ II E, DEXRON™ Ill, or equivalent.

886 ST-2
 PRECAUTIONS AND PREPARATION

Special Service Tools

The actual shapes of Kent~Moore tools may differ from those of special service tools illustrated here.

Unit application
Tool number
(Kent-Moore No.) Description Power
Manual
Tool name steering
steering

ST27180001 Removing steering wheel

·~r··~'"·
rr
(J25726-A)
Steering wheel puffer

X X

29 mm @ @ MB x 1.25 pitch
(1.14 in)

NT544

HT72520000 Removing ball joint and

(J25730-B)
l/~ swivel joint

r~
Ball joint remover
X X
i~il
PAT.P a: 33 mm (1.30 in)
b: 50 mm (1.97 in)
NT546 r: R11.5 mm (0.453 in)

ST29020001 Removing pitman arm

(J24319-01 I
Steering gear arm puller

NT551
l!J: ~ a: 34 mm (1.34 in)
b: 6.5 mm (0.256 in)
c: 61.5 mm (2.421 in)
X X

KV48101500 Removing and installing

(J28802)
Lock nut wrench /------ -'~· lock nut

~b
X -
a: 73.1 mm (2.878 in)
b: 100 mm (3.94 in)
c: 12 mm (0.47 in)
NT534 d: 60 mm (2.36 in) dia.

KV48101400 Adjusting and tightening

(J28803)
Adjusting plug wrench Cb: "~
--jj-- e
lock nut

X -
a: 46.7 mm (1.839 in)
b: 8.5 mm (0.335 in) dia.
NT539 c: 7 mm (0.28 in)

ST3127SOOO Measuring turning torque

(See J25765-A)
CD GG91 030000
(J25765-A)
Torque wrench
@ HT62940000
~
~
1/4 Torque wrench
with range of X X
11
1/4 to 318" 2 _9 N•m
( - )
Socket adapter ~ , , (30 kg-em,
3/8 to 1/2 26 in-lb)
@ HT62900000
( - )
Socket adapter NT541

ST-3 887
 PRECAUTIONS AND PREPARATION
Special Service Tools (Cont'd)
Unit application
Tool number
(Kent-Moore No.) Description
Manual Power
Tool name
steering steering

KV48100301 Steering gear is installed.

~~
( - )
b
•
Strut & steering gearbox b
attachment
X X
" 0

d "":Y d a: 162 mm (6.38 in)

b: 110 mm (4.33 in)
c: 190 mm (7.48 in)
NT543 d: 9 mm (0.35 in)

ST27091000
(J26357 and J26357-10)
Pressure gauge
To oil pump
outlet PF3/8"
(female)
0 /
To control valve
I
PF3/8"
Measuring oil pressure

~ (male)
- X
Shut-off valv~~
NT547

KV481009SO Installing oil seal

( - )

~~
Oil seal drift set
(f) KV481 00910
( - )
Drift
@ KV48100920
(J26367)
~~ - X

Adapter
@ KV48100930
(J26367)
Adapter NT174

KV48100700 Adjusting worm bearing pre-

(J26364)
Torque adapter
6) load

X X

NT169

Commercial Service Tool

Unit application
Tool name Description
Manual Power
steering steering

Boot band attachment Installing boot band

~ 'r,\_--fr,'r)\ s ..._,~

;....
Unit: mm (in)

\\
-:l
~ '~'""'
':>.
~
-:a, -:*'
:' ",';\
fr- ; 1rl 1\ I 1 \tt'
\\1+\--1,,
--\:..- ....
0.
ii
~w
a. g, !!;I
l\~T
-
A-~II\ . X X
;~P
. =- j-..
81o.31l ~ ~
25 (Q.98l \"-" OSl
\"-" 52 (2·
NT175

888 ST-4
 ON-VEHICLE SERVICE

Steering System !li~

~:~;fo\

Steering wheel
llfu!l

IL©

Steering colc1mn~
~©
tank

I'~

-Oil pump if][L

l:Jl'il

}\11

Steering linkage
L __ Ste•erir1g gear assembly 'ill'
~:stee:dng linkage

Manual steering Power steering

~~

~~
AST166

Checking and Adjusting Drive Belts (For power M

steering)
Refer to MA section ("Checking Drive Belts", "ENGINE MAINTE-
NANCE"). ~i't

Checking Fluid Level

Check fluid level referring to the scale on the dipstick.
Use "HOT" range for fluid temperatures of 50 to sooc (122 to lilt'\
176°F). Use "COLD" range for fluid temperatures of 0 to 30°C (32
to 86°F).
CAUTION: ~IL
• Do not overfill.
• Recommended fluid is Automatic Transmission Fluid type
"DEXRON™ II E, DEXRON™ Ill", or equivalent. u~J.{

SST280B

ST-5 889
 ON-VEHICLE SERVICE

Checking Fluid Leakage

Check lines for proper attachment, leaks, cracks, damage, chafing
or deterioration.
1. Run engine between idle speed and 1,000 rpm.
• Make sure temperature of fluid in reservoir tank rises to 60
to BO"C (140 to 176"F).
2. Turn steering wheel right-to-left several times.
3. Hold steering wheel at each "lock" position for five seconds
and carefully check for fluid leakage.
CAUTION:
SST621A
Do not hold steering wheel at lock position for more than 15
seconds.
4. If fluid leakage from any line is noticed, loosen flare nut and
then retighten.
Do not overtighten connector as this can damage 0-ring,
washer and connector.
5. If fluid leakage from power steering pump is noticed, check
power steering pump. Refer to ST-35.
6. If fluid leakage from power steering gear is noticed, check
power steering gear. Refer to ST-20 (4WD models), or ST-27
(2WD models).

Bleeding Hydraulic System

1. Raise front end of vehicle until wheels are clear of the ground.
2. Add fluid to reservoir tank to specified level. Then quickly turn
steering wheel fully to right and left and lightly touch steering
stoppers.
Repeat steering wheel operation until fluid level no longer
decreases.
3. Start engine.
Repeat step 2 above.
• Incomplete air bleeding will cause the following to occur:
a. Air bubbles in reservoir tank
b. Clicking noise in power steering pump
c. Excessive buzzing in power steering pump
When this happens, bleed air again.
Fluid noise may occur in the valve or power steering pump. This is
common when the vehicle is stationary or while turning the steering
wheel slowly. This does not affect the performance or durability of
the system.

890 ST-6
 ON-VEHICLE SERVICE

Checking Steering Wheel Turning Force (For

power steering)
1. Park vehicle on a level, dry surface and set parking brake.
2. Start engine and run at idle speed or 1,000 rpm.
3. Bring power steering fluid up to adequate operating tempera-
ture. [Make sure temperature of fluid is approximately 60 to ~~:~
aooc (140 to 176°F).]
Tires need to be inflated to normal pressure.
4. Check steering wheel turning force when steering wheel has l:Q:
SST491B
been turned 360° from neutral position.
Steering wheel turning force:
PB48S-type
24.5 - 29.4 N (2.5 - 3.0 kg, 5.5 • 6.6 lb)
PB59K-type
39 N (4 kg, 9 lb) or less
5. If steering wheel turning force is out of specification, check the
following:
a. Hydraulic system. Refer to "Checking Hydraulic System", ©l
ST-8.
b. Steering Column. Refer to ST-11.
c. Front suspension and axle. Refer to FA section ("Front Axle
and Front Suspension Parts", "ON-VEHICLE SERVICE").
d. Steering gear turning torque. Refer to "TURNING TORQUE
MEASUREMENT", ST-22 (4WD models), or ST-29 (2WD !1:,1(
models).

Checking Steering Wheel Play

• Place wheels in a straight ahead position and check steering
~~P~ m
Steering wheel play:
35 mm (1.38 in) or less
• If it is not within specification, check the following for loose or
worn components.
a. Steering column. Refer to ST-11.
b. Front suspension and axle. Refer to FA section ("Front Axle [iil!!J
and Front Suspension Parts", "ON-VEHICLE SERVICE".)
L _ _ _ _ _ _ _ _ _ __::s~sT:.:••=e• c. Steering gear. [Refer to ST-14 (manual steering), ST-20
(power steering 4WD), or ST-27 (power steering 2WD).] ~l

ST-7 891
 ON-VEHICLE SERVICE

NG
Checking Neutral Position on Steering Wheel
OK
• Make sure that wheel alignment is correct.
Wheel alignment:
Refer to FA section ("Inspection and Adjustment",
"SERVICE DATA AND SPECIFICATIONS").
• Verify that the steering gear is centered before removing the
steering wheel.
Checking
1. Check that the steering wheel is in the neutral position when
SST490BA driving straight ahead.
2. If it is not in the neutral position, remove the steering wheel and
reinstall it correctly.
3. If the neutral position is still not correct:
a. Loosen tie-rod lock nuts.
b. Move tie-rods, in opposite direction, the same amount on both
left and right sides.
This will compensate for error in the neutral position.

Checking Front Wheel Turning Angle

1. Rotate steering wheel fully right, then left; measure turning
angle.
Turning angle of full turns:
Refer to FA section ("Inspection and Adjustment",
"SERVICE DATA AND SPECIFICATIONS".)
2. If it is not within specification, check stopper bolt adjustment.
Refer to FA section ("FRONT WHEEL TURNING ANGLE",
"Front Wheel Alignment".)

SMA127

ST27091000 Checking Hydraulic System

{J26357 and Before starting, check belt tension, driving pulley and tire pressure.
J26357-1 0)
1. Set Tool. Open shut-off valve. Then bleed air. Refer to "Bleed-
High- ing Hydraulic System", ST-6.
2. Run engine at idle speed or 1,000 rpm.
• Make sure temperature of fluid in reservoir tank rises to 60
to 80°C (140 to 176°F).
WARNING:
Warm up engine with shut-off valve fully opened. If engine is
started with shut-off valve closed, fluid pressure in power
steering pump increases to maximum. This will raise fluid tem-
perature abnormally.
3. Check pressure with steering wheel fully turned to left and right
positions while idling at 1 ,000 rpm.
CAUTION:
Do not hold the steering wheel at full lock position for more
than 15 seconds.
Oil pump maximum pressure:
7,649 - 8,238 kPa
(78- 84 kg/cm 2 , 1,109- 1,194 psi) at idling
4. If power steering pressure is below standard pressure, slowly
close shut-off valve and check pressure.

892 ST-8
ON-VEHICLE SERVICE
Checking Hydraulic System (Cont'd)
CAUTION: @JI
Do not close shut-off valve for more than 15 seconds.
• When pressure reaches maximum pressure, gear is damaged .
Check power steering gear. Refer to ST-20 (4WD models), or
ST-27 (2WD models).
• When pressure remains below standard pressure, pump is
damaged. Check power steering pump. Refer to ST-35.
~~~~

5. If power steering pressure is higher than standard pressure,

power steering pump flow control valve is damaged. Check
~©
power steering pump. Refer to ST-35.
6. After checking hydraulic system, remove Tool and add fluid as
necessary. Then completely bleed air out of system. Refer to
ST-6. 11;C;:

©l

/j{J

ST-9 893
 STEERING WHEEL AND STEERING COLUMN

~ 29 - 39 (3.0 - 4.0, 22 - 29}

Steering wheel ~ 3.9- 4.4 (0.4- 0.5, 34.7- 44.2)

,....,,;, b''gmodule

Spiral cable

Steering tube assembly

Dynamic
mass damper
~29-39
(2WD models)
(3.0-4.0,
22-29)

~24-29 ~ 'lteering wheel

(2.4- 3.0,

I cable

Lower joint

Dash insulator Dash insulator

II] : N · m (kg-m, in-Jb)

Non-till type Till type
~ : N · m (kg-m, ft -I b) AST164

Steering Wheel
REMOVAL AND INSTALLATION
1. Remove air bag module and spiral cable. Refer to RS section
["Air Bag Module and Spiral Cable", "SUPPLEMENTAL
RESTRAINT SYSTEM (SRS)"].
2. Disconnect horn connector and remove steering wheel nut.
3. Remove steering wheel mass damper.

SBF812E

4. Remove steering wheel using Tool.

• For installation, refer to RS section ["Air Bag Module and Spi-
ral Cable", "SUPPLEMENTAL RESTRAINT SYSTEM (SRS)"].

SST515B

894 ST-10
 STEERING WHEEL AND STEERING COLUMN

(~1
Steering Column
REMOVAL
CAUTION:
• The rotation of the spiral cable (SRS "Air bag" component
part) is limited. If the steering gear must be removed, set
the front wheels in the straight-ahead direction. i;;i!U
Do not rotate the steering column while the steering gear
is removed.
• Remove the steering wheel before removing the steering LC:'
lower joint to avoid damaging the SRS spiral cable. Refer
to ST-10.
1. Remove steering wheel, refer to ST-10. ~·0
2. Remove driver lower finisher and reinforcement.
3. Disconnect combination switch electrical connectors and air
bag harness connector. 1.~1:'"
4. Remove key interlock cable (AfT models).
5. Pull back carpet and remove dash insulator.
6. Remove bolt from lower joint. C;l
7. Remove two steering column bolts and remove steering col-
umn.

INSTALLATION
• When installing steering column, finger-tighten all lower
bracket and clamp retaining bolts; then tighten them securely. l'f'
Make sure that undue stress is not applied to steering column.
• When fitting steering lower joint, be sure tightening bolt faces
cutout portion. m
• Align spiral cable correctly when installing steering wheel.
Refer to RS section ["Air Bag Module and Spiral Cable",
"SUPPLEMENTAL RESTRAINT SYSTEM (SRS)"].
Lower joint CAUTION:
ssr666A After installation, turn steering wheel to make sure it moves
L __ _ _ _ _ _ _ _ _ _ _ _ __ j smoothly. Ensure the number of turns from the straight for-
ward position to left and right locks are the same. Be sure that
the steering wheel is in a neutral position when driving
straight ahead. IBIRJ

ST-11 895
 STEERING WHEEL AND STEERING COLUMN

Disassembly and Assembly

~25-34
~25-34(2.5-3.5, 18-25)~ ~ £9 (2.5 - 3.5,
~~-"' 18-25)~
I
~24-29
Steering column
shaft IE!

I
~_y;"'{.-~
I \
_ Steering column
uppershatti!EJ'y.z?
I'
~
1 ' n-,;wn'7l! I
'-nlC n.--z

(H-3.0, 17-22)~- I " ''

~ 24-29" l II /f Tilt mechanism

\~~ ;;io, ;t t5 / ~ J~ ;/ /}
e Do not disassemble it.
• After installing steering

.:h.~·
column, check tilt

1
mechanism operation.

il• .... ,.,.

Non-tilt type .
22
1~
). ·_ /
@
""' 1
j]
--~ ""---Lower tube assembly

~~:~~~:;Jumn--# ~®.,
,_IT"~~ (~%\11 •\
~ : N · m (kg-m, in-lb) ~ 24- 29_/ - ~ ~d ~ ~ 9-14 (0.9 -1.4, 78 -122}
~' N-m (kg-m, ft-lb) (2.4- 3,0, 11- 22) Tilt type
ASTi93

• When disassembling and assembling, unlock steering lock

with key,
Lock nut • Remove combination switch.
• Install lock nut on steering column shaft and tighten the nut to
specified torque.
II I Lock nut:
tD.J: 25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)

SST490C

Self-shear type screw • Steering lock

a. Break self-shear type screws using a drill or other appropriate
tool.

SST741A

b. Install self-shear type screws, then tighten until heads break

off.

Self-shear screw

896 ST-12
 STEERING WHEEL AND STEERING COLUMN
Disassembly and Assembly (Cont'd)
Tilt mechanism
20 (0.79) After installing steering column, check tilt mechanism operation.

10 (0.39)

Unit. mm (m)

SST582BB

L, Inspection
• When steering wheel does not turn smoothly, check the steer-
ing column as follows and replace damaged parts. IF~

'ZND
a. Check column bearings for damage or unevenness. Lubricate
with recommended multi-purpose grease or replace steering
column as an assembly, if necessary. ©l
b. Check jacket tube for deformation or breakage. Replace if
necessary.
• When the vehicle is involved in a light collision, check dimen- IT~~
sion "L". If it is not within specifications, replace steering col-
SST709A umn as an assembly.
Column length "L, & L2 ": /},[
L1 = 895.0 - 898.6 mm
(35.24 - 35.38 in)
L2 = 863.1 - 866.7 mm ll'
(33.98 - 34.12 in)

ST-13 897
 MANUAL STEERING GEAR (Model: VB66K)

Removal and Installation

SEC. 480
Worm shaft to rubber coupling - - - - - - - - - - . , ~ : N·m (kg-m. ft-lbl
~ 24 - 29 (2.4 - 3.0, 17 - 22)
Align the groove in worm shaft with
the bolt hole in rubber coupling flange
yoke, and press coupling bolt through
the undercut section of worm shaft

J~-------ST29020001 (J24319-01}
Sector shaft to pitman arm
~ 235 - 265 (24 - 27, 174 - 195) I
!
• Install pitman arm.
Align four grooves of gear arm serrations with
four projections of sector shaft serrations,
Gear housing to frame
~ 84 - 96 (8.6 - 9.8, 62 - 71)
J I
and install and tighten lock washer and nut.
SST630AB

SEC. 480
Lock nut-------~
tt=il34 - 54 (3.5 - 5.5, 25 - 40) ~
~44-54 ~
11:1!lvo-Sector
(4.5- 5.5, 33- 40) shaft cover

Q-Gasket~
-Lock nut
Adjusting shim~
/ tt=!l226 - 255 (23 - 26, 166 - 188)
Refer to SDS. \_
Foller plug ~
Sector shaft adjusting screw~
~15- 25 (1.5- 2.5, 11- 18) ~-011 seal•!•
\
\
r- Beanngs
~
~ -
~AdjUSting plug
Sector shaft
I I ~
~ I
\ I
Steering gear housing-- ~~ ®>
·,,

Oil seal~-....._~

.
~
~ /tt=il235 - 265
Spnng washer- ~ (24 - 27, 174 - 195)
tt=!l: N-m (kg-m, ff-lb)
SST312CA

898 ST-14
MANUAL STEERING GEAR (Model: VB66K)

Disassembly
1. Place steering gear in a vise using Tool.

2. Set worm gear in a straight-ahead position.

3. Remove sector shaft together with sector shaft cover.
CAUTION:
• When pulling sector shaft out, be careful not to damage oil lf~
seal or associated parts.
• Do not remove sector shaft needle bearings from steering
gear housing. If necessary, replace gear housing as an ©[L
assembly.

ST725

4. Loosen adjusting plug lock nut using Tool.

5. Remove worm gear together with worm bearing.

CAUTION:
• Be careful not to rotate ball nut fully to either end of worm ~l'l
gear.
Ends of ball guides will be damaged if nut is rotated until
it stops at end of worm gear.
• Do not separate ball nut from worm gear assembly.
If necessary, replace entire unit as an assembly.
• Do not remove sector shaft needle bearings from steering ,x~
gear housing. "'"'
If necessary, replace entire gear housing as an assembly.

Assembly and Adjustment

Apply multi-purpose grease to sealing area of new oil seals for
sector shaft and worm gear. " .•••
1n!/,".\

WORM GEAR BEARING PRELOAD

1. Drive oil seal into place. !1'l
Before installing oil seal, coat oil seal contacting face with
gear fluid.

ST-15 899
 MANUAL STEERING GEAR (Model: VB66K)
Assembly and Adjustment (Cont'd)
2. Place worm gear assembly together with worm gear bearing
into gear housing.

3. Adjust worm gear bearing preload using Tools.

CAUTION:
• Always adjust worm gear bearing preload by turning
adjusting plug in clockwise direction.
• Before measuring preload, rotate worm gear a few turns in
both directions to seat worm gear bearing.
Worm gear bearing preload:
0.69 - 0.88 N·m
(7.0 - 9.0 kg-em, 6.1 - 7.8 in-lb)

SST824C

4. Apply suitable sealant to inner surface of lock nut.

Apply sealant

Lock nut SST090

900 ST-16
 MANUAL STEERING GEAR (Model: VB66K)
Assembly and Adjustment (Cont'd)
5. Tighten lock nut using Tools.
Lock nut:
~: 226-255 N·m (23- 26 kg-m, 166- 188 ft-lb)

SST825C

• When tightening lock nut, use the chart shown at left to deter- I~&;
mine the proper reading of torque.
Torque wrench (Length of torque wrench vs. setting or reading of torque)
6. After tightening lock nut, check worm gear bearing preload to [5[!';
make sure it is within specification.

0.1 m
(0.3 H)
(ft-lb) N-m li<g-n) l~fl
12101

12001

{1901

1<801

11701

IT SOl

11501

11401

""'l
(12011

SST308A

Adjusting shim SECTOR SHAFT END PLAY

Upper
(sector cover ~
~ Select and install proper adjusting shim to achieve proper end play
side)
between sector shaft and adjusting screw.
Sector shaft end play:
0.1 mm (0.004 in) or less
Sector shaft adjusting screw shims:
Refer to SDS, ST-42.

SST092

Gasket
STEERING GEAR PRELOAD AND BACKLASH
1. Set worm gear in a straight-ahead position.
Carefully insert sector shaft in gear housing, being careful not ll!~
to scratch oil seal.
2. Turn adjusting screw until sector shaft just contacts ball nut.
Temporarily tighten lock nut. l';l
3. Lubricate contacting portion of sector shaft and ball nut with
gear oil or bearing grease.

ST-17 901
 MANUAL STEERING GEAR (Model: VB66K)
Assembly and Adjustment (Cont'd)
4. Adjust steering gear turning torque in a straight-ahead position
using Tool, then lock with lock nut.
CAUTION:
• Always adjust steering gear preload by turning adjusting
screw in clockwise direction.
• Rotate worm gear a few turns in both directions to seat
steering gear assembly.
a. Measure turning torque at 360" position from straight-ahead
position using Tools.
Turning torque at 360":
SST174C 0.69- 0.88 N·m (7.0- 9.0 kg-em, 6.1 - 7.8 in-lb)
b. Measure turning torque at straight-ahead position.
Straight-ahead position is a position where stub shaft is
turned 2.14 turns (two full turns and 50") from lock position.
Turning torque at straight-ahead position:
0.20 - 0.39 N·m (2.0 - 4.0 kg-em, 1.7 - 3.5 in-lb)
higher than turning torque at 360"
Maximum turning torque:
1.08 N·m (11.0 kg-em, 9.5 in-lb)
If turning torque is not within specifications, adjust by turning
sector shaft adjusting screw.

5. Turn worm gear several times by hand to properly break in

worm bearing.
6. Check steering gear preload. Readjust as necessary.

~It
~I /
SST310A

7. Measure total preload.

8. Check backlash.
Measure backlash at top end of pitman arm in straight-ahead
position.
Backlash (in straight-ahead position):
0.1 mm (0.004 in) or less

SST030

Inspection
Clean all the disassembled parts in solvent, then check con-
dition.
SECTOR SHAFT
1. Check gear teeth surface for pitting, burrs, cracks or any other
damage, and replace as necessary.
2. Check sector shaft serration for distortion and replace as nec-
essary. Also check gear housing for deformation.

902 ST-18
 MANUAL STEERING GEAR (Model: VB66K)
Inspection (Cont'd)
STEERING WORM ASSEMBLY @I
1. Inspect ball nut gear teeth surface. Replace if pitting, burrs,
wear or any other damage is found.
2. Ball nut must rotate smoothly on worm gear. If found to be too
tight, assembly should be replaced. Check rotation of ball nut
as follows:
CAUTION:
Be careful not to allow ball nut to rotate fully to either end of
Moves downward
worm gear. IL©
under own weight a. Move ball nut to either end of worm gear. Gradually stand
SST098 worm shaft and ball nut assembly on end until ball nut moves
downward on worm gear under its own weight. ~©
b. If ball nut does not move freely over entire stroke, replace
assembly.
Be careful not to damage ball nut guide tube while check is :peg
being made.
BEARING
©l
1. Inspect worm gear bearing for wear, pitting or any other dam·
age. Replace as necessary.
When replacing worm gear bearing, replace bearing and outer
race as a set.
2. If sector shaft needle bearings are worn or damaged, replace
gear housing as an assembly.

OIL SEALS
• Discard any oil seal which has been removed.
• Replace oil seal if sealing surface is deformed or cracked.
• Discard oil seal if spring is fatigued or dislocated.

ST-19 903
 POWER STEERING SYSTEM (Model: PB59K)

Description
SEC. 492•497 SEC. 493
• 3 ~ 4 (0.3 - 0.4, 26 - 35)

Oil tank
).V''Cf-..._.. [iii] 2.5 . 3.4
(0.25 • 0.35. 21.7 • 3Q.4)
High-pressure hose
Oil pump
Low-pressure hose

tc.J39 • s1 (4.0 • s.2, 29 • 38)

~Steering gear
0
(liJ~ ~-tc.)84 - 96 (8.6 - 9.8. 62 - 71)
~- ..._,.

~ : N·m (kg-m, in-lb) tc.)235 - 265 (24 - 27. 174 - 195) ~

tc.J ' N•m (kg·m. fHb) AST168

CAUTION:
• Parts which can be disassembled are strictly limited.
Never disassemble parts other than those specified.
• Disassemble in as clean a place as possible.
• Clean your hands before disassembly.
• Do not use rags; use nylon cloths or paper towels.
• Follow the procedures and cautions indicated in the Ser-
vice Manual.

904 ST-20
 POWER STEERING GEAR (Model: PB59K)

Removal and Installing

Before removal, clean gear housing and oil pump exteriors
using a steam cleaner. Then dry with compressed air.
STEERING GEAR

SEC. 492
r~ 39 . s1 t•.o - s.2. 29 _ 38)

:.___._,J; $;>.,;/ / ' \

• Plug openings of gear housing, and
securely locate hose connectors at a ---
r- \I I,;:. 1
~))
-
position higher than oil pump and cover

•
with rag.
Be extremely careful to prevent entry of I \', r~~\I~
foreign matter into hoses through \ I
~-'
\ 1...-----f ____.--
- Lower joint to stub shaft
connectors. =;- 1\-~ :oJ
24 - 29 (2.4 - 3.0, 17 - 22)

d \~~
• When installing gear arm, align four
cl
---- ~
grooves of gear arm serrations with
four projections of sector shaft
serrations, and install and tighten lock
~) 84 - 96 (8.6 - 9.8, 62 - 71)

p~--=
washer and nut
I f""

Sector shaft to pitman arm

~235- 265 (24- 27, 174- 195)
~ -· I
Pitman arm to tie-rod
~
L__
N·m (kg-m, ft-lb)
~ 54 - 98 (5.5 - 10.0, 40 - 72)

SST123CB

Power Steering Gear Component

•
Gear housing
/_/""" U-packing
_/
'--------------Oil sea' ~ ~: N·m (kg-m, ft-lb)

AST169

ST-21 905
 POWER STEERING GEAR (Model: PB59K)

Pre-disassembly Inspection and Adjustment

Before disassembling power steering gear component parts,
make sure there is no oil leakage around sealing portion and
check steering turning torque as follows:
Check sealing portion.
• Sector shaft cover 0-ring
• Sector shaft U-packing
• Sector shaft oil seal
• Rear housing 0-ring
• Gear housing 0-ring
Discard any oil seal and 0-ring which have been removed.
Replace oil seal and 0-ring if sealing surface is deformed or
cracked.

TURNING TORQUE MEASUREMENT

1. Measure turning torque at 360' position.
a. Install steering gear on Tool.

ST3127SOOO b. Turn stub shaft all the way to right and left several times.
(See J25765-A) c. Measure turning torque at 360' position from straight-ahead
position with Tools.
Turning torque at 360':
0.15-0.78 N·m (1.5- 8.0 kg-em, 1.3-6.9 in-lb)

(J26364)

d. Measure turning torque at straight-ahead position.

Straight-ahead position is a position where stub shaft is
turned 2.14 turns (two full turns and 50') from lock position.
Turning torque at straight-ahead position:
0.25- 1.32 N·m (2.5- 13.5 kg-em, 2.2- 11.7 in-lb)
higher than turning torque at 360'
Maximum turning torque:
1.03- 1.47 N·m (10.5- 15 kg-em, 9.1- 13.0 in-lb)
If turning torque is not within specifications, adjust by turning
sector shaft adjusting screw.
SST653A

906 ST-22
 POWER STEERING GEAR (Model: PB59K)
Pre-disassembly Inspection and Adjustment
(Cont'd) IB'I
2. Tighten adjusting screw lock nut with tools.

I i'f'
I l,·-8'

SST654A

~ KV48100301 Disassembly
r~~/~ I - I Before disassembly, measure turning torque.

~r
If not within specifications, replace steering gear assembly.
CAUTION:
Oil sealing parts, dust cover, copper washer and snap ring
must not be used again after removal. :C:t
1. Place steering gear in a vise with Tool.
~~/
, I I --" 2. Set worm gear in a straight-ahead position.

' l y-SST040
3. Loosen (do not remove) sector shaft cover bolt.
4. Knock out end of sector shaft with a plastic hammer.
5. Remove sector shaft by hand.

SST319C

6. Remove oil seal.

7. Remove U-packing.
CAUTION: ~[gj
When removing oil seal and U-packing, be careful not to
scratch gear housing.

•
U-packing
--(
--~ - / I rOilseal

SST320C

ST-23 907
 POWER STEERING GEAR (Model: PB59K)
Disassembly (Cont'd)
8. Remove lock nut, then loosen adjusting screw using a screw-
driver. Separate sector cover and sector shaft.

Adjusting screw

SST321C

g_ Remove 0-ring.
10. Remove U-packing_
CAUTION:
• When removing U-packing, be careful not to scratch sec-
tor cover, needle bearing, etc.
• Needle bearing cannot be disassembled. If it is damaged,
remove sector cover assembly.

11. Remove dust seal.

12. Remove rear housing bolts.
13. Remove rear housing together with worm gear assembly.
CAUTION:
Worm gear assembly cannot be disassembled. When it is
removed, be careful not to disengage worm gear from shaft or
allow it to drop.
14. Remove teflon ring and 0-ring of worm gear assembly.

Assembly
1. Install new 0-ring on worm gear assembly.
• Apply a thin coat of ATF to new 0-ring.
2. Install new teflon ring on worm gear assembly.
• Make sure that teflon ring is seated in correct position.
3. Install new 0-ring into rear housing.

0-ring~

~ /Teflon ring~
---.---!y----

0-ring~

SST340C

908 ST-24
 POWER STEERING GEAR (Model: PB59K)
Assembly (Cont'd)
4. Install worm gear assembly with rear housing into the gear Clll
housing.
CAUTION:
• Apply a thin coat of ATF inside gear housing and piston
before insertion.
• Be careful not to damage teflon ring at piston end when
inserting worm gear assembly into gear housing.

SST341C

5. Gradually tighten rear housing bolts in a criss-cross fashion.

SST326C

6. Install new 0-ring into sector shaft cover.

• Before installing, apply a thin coat of ATF to 0-ring.
7. Install new U-packing into sector shaft cover.
• Before installing, apply a thin coat of ATF to U-packing.
• Direct grooved side of U-packing to needle bearing.

8. Install sector shaft into sector shaft cover.

Set adjusting screw to its outermost position.
• Before installing sector shaft, apply multi-purpose grease
to adjusting screw and adjusting screw shim.
~~

Adjusting screw

SST321C

9. Install new oil seal into gear housing with suitable tool.
• Before installing oil seal, apply multi-purpose grease to oil
seal lips.

44 mm (1.73 in) dla.

SST327C

ST-25 909
 POWER STEERING GEAR (Model: PB59K)
Assembly (Cont'd)
10. Set piston rack at straight-ahead position.
Turn piston rack about 1oo to 15° toward yourself with your
finger.
This enables smooth insertion of sector gear.

ST696

11. Gradually insert sector shaft into gear housing.

12. Tighten sector shaft cover bolts.
13. Set worm gear turning torque by turning sector shaft adjusting
screw and locking with lock nut.
Refer to "TURNING TORQUE MEASUREMENT", "Pre-disas-
sembly and Adjustment", ST-22.
• If set and adjusting turning torque is considerably differ-
ent from the value before disassembly, replace the entire
assembly.
14. Check sector shaft end play in neutral position.
SST328C End play:
Less than 0.1 mm (0.004 in)
If not within specification, adjust it with adjusting screw.
15. Check worm gear preload. If not within specification, readjust
it.

910 ST-26
 POWER STEERING SYSTEM (Model: PB48S)

Description Cill

SEC. 493
SEC. 492•497
• 3 . 4 (0.3 . 0.4. 26 . 35)

~.....__"-....._ Oil tank

U'>~ll~~----......_~ 2.s- 3.4 IL©
(0.25 . 0.35. 21.7 . 30.4)
__..- High-pressure hose
High-pressure switch
Low-pressure hose Oil pump

~ 39 . 49 (4 • 5. 29 . 36)

~ 29 . 39 (3 • 4. 22 . 29)

~ Steering gear

~ : N·m (kg-m, in-lb)

~ ' N·m (kg·m. fHb) AST170

This power steering adopts spool valve

control which was developed in a techni-
cal tie·up with the ZF Company.
Only the sealing parts can be replaced. The remaining parts must I'I',\
be replaced as an assembly.
CAUTION:
• Parts which can be disassembled are strictly limited .
Never disassemble parts other than those specified.
• Disassemble in as clean a place as possible .
• Clean your hands before disassembly.
• Do not use rags; use nylon cloths or paper towels .
• Follow the procedures and cautions indicated in the Ser-
vice Manual.

ST-27 911
 POWER STEERING GEAR (Model: PB48S)

Removal and Installing

Before removal, clean gear housing and oil pump exteriors
using a steam cleaner. Then dry with compressed air.
STEERING GEAR
SEC. 492

rRl 39 • 49 (4 • 5, 29 • 36)

1Rl29- 39 (3- 4, 22- 29)-

'\ ''------ Lower joint to stub shaft
e Plug openings of gear housing, and
securely locate hose connectors at a 1RJ24 - 29 (2.4 - 3.0, 17 . 22)
position higher than oil pump and cover
with rag. --.. \
~ 1RJ84 . 96 (8.6 . 9.8, 62 . 71)
,\~ -
e Be extremely careful to prevent entry of
foreign matter into hoses through
connectors.
\ \~~ I

~(~~+Cc••••~}
• When installing gear arm, align four
grooves of gear arm serrations with
four projections of sector shaft
serrations, and install and tighten lock
washer and nut.

~: N·m {kg-m. ft-lb)

~ 137 - 177 (14 - 18, 101 - 130} ___/

/ -
f__ Pitman arm to tie-rod
~54 - 98 (5.5 - 10.0, 40 - 72) SST127CB

Power Steering Gear Component

-~--------·----·---------~--~~~~~~~~~~~~~~~~~~-

SEC. 492 .~o-ring~

///---Lock nut tcJ 34- 40 (3-.5- 4.1, 25- 30)
d~/ /-Copper washer~
~.t ~/

~u[9J;:/.
,~Sector cover
o " -0-ring ~
~ / _____ Adjusting shim (Refer to SDS.)

Bolt
)
~Sector shaft adjusting screw
1RJ26- 32 ~"
(2.7 - 3.3, 20 - 24)
Sector shaft

Torx screw-~
1RJ26 - 32
(2.7 - 3.3,
20 - 24)
\ "'-O~ring ~
L Worm gear and rear

\\~ housing assembly

~~ ~o11seal (Do not disassemble.)

~~ '-o-nng~
\_ Rear cover rRJ• N•m (kg-m, ft-lb)
, \_Snap nng
SST128CB
· - - Dust cover

912 ST-28
 POWER STEERING GEAR (Model: PB48S)

Pre-disassembly Inspection and Adjustment !ill

Before disassembling power steering gear component parts,
make sure there is no oil leakage around sealing portion and f!uJl
check steering turning torque as follows:
Check sealing portion.
• Adjusting screw nut 0-ring [l';lfl
• Sector shaft cover 0-ring
• Sector shaft oil seal
• Rear cover oil seal and 0-ring L©
• Rear housing 0-ring
• Gear housing 0-ring
Discard any oil seal and 0-ring which have been removed. Replace I~©
oil seal and 0-ring if sealing surface is deformed or cracked.

TURNING TORQUE MEASUREMENT

1. Measure turning torque at 360" position.
a. Install steering gear on Tool.

b. Turn stub shaft all the way to right and left several times.
c. Measure turning torque at 360" position from straight-ahead
position with Tools.
Turning torque at 360":
0-1 - 1.2 N·m (7 - 12 kg-em, 6.1 - 10.4 in-lb)

y"
KV48100700
(J26364)

d. Measure turning torque at straight-ahead position.

Straight-ahead position is a position where stub shaft is
turned 2.14 turns (two full turns and 50") from lock position.
Turning torque at straight-ahead position:
0.1 - 0.4 N·m (1 - 4 kg-em, 0.9 - 3.5 in-lb)
higher than turning torque at 360" ~~
If turning torque is not within specifications, adjust by turning
sector shaft adjusting screw.

SST653A

ST-29 913
 POWER STEERING GEAR (Model: PB48S)
Pre-disassembly Inspection and Adjustment
(Cont'd)
2. Tighten adjusting screw lock nut with tools.

SST654A

Disassembly
Before disassembly, measure turning torque.
If not within specifications, replace steering gear assembly.
CAUTION:
Oil sealing parts, dust cover, copper washer and snap ring
must not be used again after removal.

ADJUSTING SCREW LOCK NUT 0-RING

Remove adjusting screw lock nut, and replace 0-ring.

SECTOR SHAFT OIL SEAL

1. Set stub shaft in a straight-ahead position.
Straight-ahead position is a position where stub shaft is
turned 2.14 turns (two full turns and 50°) from lock position.
0-,ing '
Lock nut
Copper washer
SST044

2. Disconnect sector shaft cover bolt.

Do not turn lock nut unless necessary; otherwise it will dam-
age 0-ring, resulting in an oil leak.

SST655A

3_ Draw out sector shaft.

20 mm (0.79 in)
Knock out end of sector shaft approximately 20 mm (0.79 in).

SST656A

914 ST-30
POWER STEERING GEAR (Model: PB48S)
Disassembly (Cont'd)
4. Connect a roll of plastic film to sector shaft.
Plastic film:
Thickness 0.1 mm (0.004 in)
Length x width
200 x 200 mm (7.87 x 7.87 in)
5. Pull out sector shaft by hand.
Attach plastic film to needle bearings located at two places ~uAl
inside gear housing while simultaneously pulling out sector
shaft so that bearings will not drop into housing.

SST657A

REAR HOUSING 0-RING

1. Remove torx screw.

Iff
SST149A

2. Remove rear housing together with worm gear assembly.

CAUTION:
• When worm gear assembly is removed, piston may turn if'
and come off under its own weight. Hold piston to prevent
it from turning.
• If piston-to-rear housing clearance exceeds 35 mm (1.38 ~©
in) recirculating ball will be out of groove of worm gear; do
not reinstall piston but replace the entire assembly.
• Be careful not to damage teflon ring at piston end when
removing. I'!~

SST807

3. Remove 0-rings.

SST808

REAR COVER 0-RING AND OIL SEAL

1. Remove snap ring, then rear cover.
2. Remove 0-ring and oil seal.

SST150A

ST-31 915
 POWER STEERING GEAR (Model: PB48S)

r 0 -nng Assembly
ADJUSTING SCREW LOCK NUT 0-RING
Insert new 0-ring into adjusting screw lock nut
• Before inserting, apply a thin coat of petroleum jelly to
- t-- -- I-- 0-ring.
• Insert 0-ring to make sure it fits into groove.

LAd-ustin g screw lock 11ut

SST052

SECTOR SHAFT OIL SEAL

dOBseal • When installing, be sure to use new oil seal, dust seal,
(j{(/)~Back-up dng
•
back-up ring and snap ring.
Before installing, apply a thin coat of petroleum jelly to
new oil seal and dust seal.

.....JJpDust seal

ST832

1. Press new oil seal and then install back-up ring with Tool.
KV481009SO
I -- I

SST826C

2. Install a new snap ring into gear housing_

CAUTION:
• Turn snap ring to make sure it fits into groove.
Snap ring
• Always install snap ring with R face facing inward.

Outside

Inside '1
A face

SST725A

3. Press a new dust seal.

4. Fit new 0-ring into sector shaft cover.
• Before installing, apply a thin coat of petroleum jelly to
O-rin g.
• Make sure that 0-ring is installed properly and is not dam-
aged by sector shaft.

SST316A

916 ST-32
 POWER STEERING GEAR (Model: PB48S)
Assembly (Cont'd)
Adjusting shim SECTOR SHAFT END PLAY
Upper
(sector cover
side)
+~ Select suitable adjusting shim and adjust end play between sector
shaft and adjusting screw.
Sector shaft end play:
0.01 - 0.03 mm (0.0004 - 0.0012 in)
Sector shaft adjusting screw shims:
Refer to SDS, ST-42.

SST092

REAR COVER 0-RING AND OIL SEAL

1. Install new 0-ring and oil seal.
2. Install rear cover, then install snap ring. !"~
CAUTION:
a. Turn snap ring to make sure it fits into grooves.
b. Always install snap ring with its rounded edge facing rear iD'L
cover.

SST155A

REAR HOUSING 0-RING

1. Install new 0-rings.
a. Before installing, apply a thin coat of petroleum jelly to Tf'
O-rin g.
b. Make sure 0-ring is installed correctly and is not damaged
by worm gear. ~[15)

SST808
~~
2. Gradually insert worm gear and rear housing assembly into
gear housing, being careful not to damage oil seal and 0-rings.
3. Install torx screws.

ll
Criss-cross fashion
SST153A

ST-33 917
 POWER STEERING GEAR (Model: PB48S)
Assembly (Cont'd)
SECTOR SHAFT
1. Set piston rack at straight-ahead position.
Turn piston rack about 10° to 15° toward yourself with your
finger. This permits smooth insertion of sector gear.
2. Wrap vinyl tape around serration area of sector shaft.
Vinyl tape prevents oil seal lip from being damaged during
insertion.
3. Gradually insert sector shaft into gear housing, being careful
not to damage oil seal.
ST696
When inserting sector shaft into gear housing, remove plastic
film. Be careful not to drop bearings into gear housing.
4. Tighten sector shaft cover bolts.
5. Check turning torque and steering gear preload.
Refer to "TURNING TORQUE MEASUREMENT", "Pre-disas-
sembly Inspection and Adjustment", ST- 29.
• If turning torque is considerably different from the value
before disassembly, replace the entire assembly.

SST059

918 ST-34
 POWER STEERING OIL PUMP

Disassembly and Assembly @]]

SEC. 490

Gasket ~f'l

L Suction pipe

Cam ring

Rear housing

. - 4.3, 23 - 31)
toJ31- 42 (32
~-N
. ·m (kg-m, ft-!b)
ip,~

AST167 ~Jj

Pre-disassembl
Disassemble th y Inspection
le~k
~ny
are found e power steering .1
• Oil fro Ol pump only if the I .
• Deformed :;' pomt shown . ollow1ng items
• Poor performr amaged pulley In the figure.
ance. ·

SST984A

ST-35 919
 POWER STEERING OIL PUMP

Inspection
PULLEY AND PULLEY SHAFT
• If pulley is cracked or deformed, replace it.
• If fluid leak is found around the pulley shalt, replace the oil
seal.
Disassembly
CAUTION:
• Parts which can be disassembled are strictly limited.
Never disassemble parts other than those specified.
• Disassemble in as clean a place as possible.
• Clean your hands before disassembly.
• Do not use rags; use nylon cloths or paper towels.
• When disassembling and reassembling, do not let foreign
matter enter or contact the parts.

• Remove snap ring, then draw drive shalt out.

• Be careful not to drop drive shaft.

SST010B

• Remove oil seal.

• Be careful not to damage front housing.

• Remove connector.
Front housing
• Be careful not to drop control valve.

SST036A

920 ST-36
 POWER STEERING OIL PUMP

Assembly
Assemble oil pump, noting the following instructions.
• Make sure 0-rings and oil seal are properly installed.
• Always install new 0-rings and oil seal.
• Be careful of oil seal direction.
• Cam ring, rotor and vanes must be replaced as a set if neces- i'!liiu
sary.
• When assembling, coat each part with ATF.

Rear housing side Front housing side • Pay attention to the direction of rotor.
Punchmark

SST289A

;~\11
• When assembling vanes to rotor, rounded surfaces of vanes
must face cam ring side.
Faces inside

Flat portion

Round portion

SST843A

Insert pin Q~ into pin groove CD of front housing and front side ~
• plate. Then install cam ring ® as shown at left.
Cam ring:
D, is less than D2

SST497A

ST-37 921
 STEERING LINKAGE

Removal and Installation

SEC. 485 ~54-98
2WD (5.5 - 10.0. 40 - 72)
Tie-rod clamp nut
.-;;; / Tie-rod assembly7 Pitman arml
~ 14 - 20 (1.4 - 2.0. 10 . 14)
IffY
-
(LH) I
@) )_----"£II(> Tie-rod assembly
(RH) 1;>~:-::::::::1~~~ @ ,
Boot bandA ~- 0~ ~
~ ~ __:..___::;,~ ~'' ,,/rp

\
~ 78 ,~
--1~~--"'~,1-, 'IT~~~~/~
98 . Relay md7

I
~ ~ .. -
72)
. 98 (5.5 - 1o.o. 4o - 121 1
1 ~ Manual steering~'
1 ~235- 265 (24- 27, 174- 195)

Y _ \ \ Power steering
~ 137 . 1n (14 - 18, 101 - 130)

~ ~t~54- 98 (5.5. 10.0, 40- 72)

Idler arm~
@ L. ~ : N•m (kg-m, ft-lb)
~~54. 69 (5.5. 7.0, 40- 51)
SST317CA

SEC. 485
4WD

~ : N·m (kg-m, ft-lb) SST318CA

Remove pitman arm with Tool.

Pitman arm

ST29020001
(J24319-01)

J SST100

922 ST-38
 STEERING LINKAGE
Removal and Installation (Cont'd)
Remove tie-rod from knuckle arm with Tool.

SST313A

2WD Disassembly
IDLER ARM ASSEMBLY
L • Apply coat of multi-purpose grease to bushing.
• Press bushing into idler body, and insert shaft of idler bracket
carefully until bushing protrudes.

CROSS ROD AND TIE-ROD

1. When tie-rod ball joints and tie-rod bar are separated, adjust
tie-rod length correctly.

-·~o"
Adjustment should be done between ball stud centers.
-• o"'" boll ""d 2. Lock tie-rod clamp nut so that ball joint on outer ball stud is as ffi\1i'
follows with respect to that on inner ball stud.
Ball point L: Standard
Inner ball center 344 mm (13.54 in) ... 2WD
stud
281 mm (11.06 in) ... 4WD
View V CAUTION:
Make sure that tie-rod bars are screwed into tie-rod tube more IDIQJ
Front side than 35 mm (1.38 in).

SST639A

4WD

--=-------,
L

•
Front side

View X

SST637A

ST-39 923
 STEERING LINKAGE

Ball joint Inspection

.......... A
BALL JOINT AND SWIVEL JOINT
~8 1.
Check joints for play. If ball or swivel stud is worn and play in
axial direction is excessive or joint is hard to swing, replace as
t c a complete unit.
Swinging force (Measure point: Cotter pin hole) "A":

~
Ball joint
10.8- 107.9 N (1.1- 11.0 kg, 2.4-24.3 lb)
Rotating torque "B":
Ball joint
SST827C
0.5 - 4.9 N·m (5 - 50 kg-em, 4.3 - 43.4 in-lb)
Swivel joint
Swivel joint
0.5 - 4.9 N·m (5 - 50 kg-em, 4.3 - 43.4 in-lb)
~8
Axial end play "C":
Ball joint

t c
0.1 - 0.8 mm (0.004 - 0.031 in)
Swivel joint

e SFAB17A
•
•
0.1 - 1.0 mm (0.004 - 0.039 in)
2. Check condition of dust cover. If it is cracked excessively,

•
replace dust cover.
When replacing dust cover, be careful not to damage it.
Lubricate joint with multi-purpose grease, if necessary.
When installing boot band with commercial service tool, be
careful not to overexpand it. Refer to ST-4.
CAUTION:
Be careful not to apply grease or oil to taper of joint.
Boot band IDLER ARM ASSEMBLY
Tie-rod
Commercial tool • Check rubber bushing of idler arm for breakage, wear or play,
and if necessary replace.
• Lubricate idler arm assembly with multi-purpose grease, if nec-
essary.
Oust cover
When lubricating, refer to "BALL JOINT AND SWIVEL JOINT".
CROSS ROD AND TIE-ROD
Check tie-rod and cross rod for breakage, bends or cracks, and
replace with a new one if necessary.
STEERING DAMPER
Check for oil leaking from damper, and replace if necessary.
FIXING LOCATION
• Check fixing location (nuts and cotter pins) for looseness, play
or breakage.
• When looseness or play is found, check for wear on tapered
portion of joints, gear arm of idler arm.
• When reassembling each joint, use new cotter pins.

924 ST-40
 SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications
Manual Steering wheel axial play
Steering column type steering
Power steering
mm (in)
0 (0) r~~1LA1
{Collapsible)
2WD 2WD 4WD Steering wheel play
35 (1.38) or less
mm (in)
Steering gear type VB66K PB48S PB59K ~UjJ
Turns of steering wheel on the
vehicle 5.8 3.7 3.4
(Lock-to-lock)
LC
24.4-
Steering gear ratio 16.5 15
26.84
l2f•'
:5'0

II'~
Inspection and Adjustment
STEERING COLUMN
[;[L
Unit· mm (in)

Dimension "L"

2WD model 895.0 - 898.6 (35.24- 35.38) liour

4WD model 863.1-866.7 (33.98- 34.12)

L~"f
Non-tilt type Tilt type

*'Ei=JI'I~'L~=~J ~I ~~
L
111¥'
" 8
2WD

~·[QI

4WD
~I " * ~-
AST194
[f~

~1;/,1
ilH

ST-41 925
 SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont'd)
MANUAL STEERING GEAR POWER STEERING SYSTEM
(Model: VB66K) (Model: PB48S)

Worm bearing preload 0.69- 0.88 Steering wheel turning force

N·m (kg-em, in-lb) (7.0 - 9.0, 6.1 - 7.8) (at 360° from neutral posi-
24.5 - 29.4 (2.5 - 3.0, 5.5 - 6.6)
tion and circumference of
Steering gear turning torque
steering wheel) N (kg, lb)
N·m (kg-em, in-lb)
Oil pump pressure 7,649 - 8,238
360° position from straight-ahead 0.69 - 0.88
kPa (kg/cm 2 , psi) (78- 84,1,109- 1,194) at idling
position (7.0 - 9.0, 6.1 - 7.8)
Fluid capacity Approximately 900 - 1 ,000 (30.4-
Straight-ahead position 33.8, 31.7- 35.2)
0.20- 0.39 mf (US fl oz, Imp fl oz)
(As compared with steering
(2.0 - 4.0, 1.7 - 3.5)
wheel turned 360°) Normal operating tempera-
60-80 (140- 176)
ture "C ("F)
Maximum turning torque 1.08 (11.0, 9.5)
Steering gear turning torque
Backlash at pitman arm top end (in a
N·m (kg-em, in-lb)
straight-ahead position) 0-0.1 (0- 0.004)
mm (in) 360° position from
0.7- 1.2 {7- 12, 6.1 - 10.4)
straight-ahead position
End play
(Between sector shaft and adjusting 0.1 (0.004) or less Straight-ahead position
screw) mm (in) (As compared with steer- 0.1 - 0.4 (1 - 4, 0.9 - 3.5) higher
ing wheel turned 360°)
Thickness
Part number
mm (in) Backlash at pitman ann top
end (in a straight- 0-0.1 (0- 0.004)
Adjusting shim thickness 1.95 (0.0768) 48129-84500
ahead position) mm (in)
2.00 (0.0787) 48130-84500 End play (Between sector
2.05 (0.0807) 48131-84500 shaft and adjusting screw) 0.01 - 0.03 (0.0004- 0.0012)
mm (in)
Oil capacity r (US pt, Imp pt) Approx. 0.62 (1-3/8, 1-1/8)
Adjusting shim thickness Thickness
Part number
mm(in)

1.575 - 1.600
48213-80100
STEERING LINKAGE (0.0620 - 0.0630)

1.550 - 1.575
48214-80100
Applied model 2WD 4WD (0.0610- 0.0620)

Relay-rod swivel joint 1.525 - 1 .550

48215-80100
(0.0600 - 0.061 0)
0.5-4.9
Rotating torque
- (5- 50, 1.500 - 1.525
N·m (kg-em, in-lb) 48216-80100
4.3- 43.4) (0.0591 - 0.0600)

0.1 - 1.0 1.475 - 1.500

Axial end play mm(in) - 48217-80100
(0.004 - 0.039) (0.0581 - o.o591 I

Tie-rod & relay-rod ball joint 1.450 - 1.475

48218-801 00
{0.0571 - 0.0581)
Swinging force at cotter pin 10.8- 107.9
hole N (kg, lb) (1.1- 11.0, 2.4- 24.3)

Rotating torque 0.5-4.9

N·m (kg-em. in-lb) (5 - 50, 4.3 - 43.4)

Axial end play mm (in) 0.1 - 0.8 (0.004 - 0.0311

Tie-rod standard engine (L)

344 (13.54) 281 (11.06)
mm (in)

926 ST-42
 SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont'd)
POWER STEERING SYSTEM ·~:]

(Model: PB59K)
Steering wheel turning force
(at 360° from neutral posi-
39 (4, 9) or less
tion and circumference of
steering wheel) N (kg, lb)

7,649 - 8,238
Oil pump pressure
(78- 84, 1,109- 1,194)
kPa (kg/cm 2 , psi)
at idling

Fluid capacity Approximately 1,000 - 1,100

m1: (US II oz. Imp fl oz) (33.8- 37.2, 35.2- 38.7)

Normal operating tempera-

60- 80 (140- 176)
ture 'C ('F)
Steering gear turning torque
N·m (kg-em, in-lb)

360" position from

0.15-0.78 (1.5- 8.0, 1.3- 6.9)
straight-ahead position

Straight-ahead position
0.25- 1.32 (2.5- 13.5, 2.2- 11.7)
(As compared with steer-
higher
ing wheel turned 360°)

Maximum turning torque 1.03-1.47 (10.5 -15,9.1 - 13.0)

Backlash at pitman arm top

end {in a straight- 0- 0.1 (0- 0.004)
ahead position) mm (in)

End play (at sector shaft

end in neutral position) 0.1 (0.004) or less
mm (in)

ST-43 927
 RESTRAINT SYSTEM (i~

SECTION RS
CONTENTS
PRECAUTIONS ....................................... ....................... 2 Checking Deployment Tool ................................. 13
Supplemental Restraint System (SRS) "AIR Deployment Procedures For Air Bag Module
BAG".............................. .................. 2 (Outside of Vehicle) ..................................... 14 gUo
SEAT BELTS .................................................................. 3 Deployment of Air Bag Module While Mounted
Front Seat Belt... ........................................................ .4 In Vehicle .............................................................. 15
Rear Seat Belt ............................................................. 5 Disposing of Air Bag Module ............................... 15 IToll
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) .. ......... 6 TROUBLE DIAGNOSES- Supplemental
Precautions for SRS "Air Bag" Service ........... 6 Restraint System (SRS) ...... ......................................... 17
Special Service Tools..... .................. 6 How to Perform Trouble Diagnoses for Quick 5Ji'
Description ................................................................. 7 and Accurate Repair....................... .............. ...... 17
SRS Component Parts Location ............................... 8 Schematic .............. ................... .. ...... .. ...... . . ..19 lf
Maintenance Items .. . ............ 8 Wiring Diagram -SRS- ............................................. 20
Diagnosis Sensor Unit and Crash Zone Sensor ......... 9 Self-diagnosis............... ....................................... 22
Removal And Installation ........................................ 9 Diagnostic Procedures ......................................... 22 ~)~~~
Air Bag Module and Spiral Cable ............................. 10 Trouble Diagnoses for Air Bag Warning Lamp .......... 35
Removal .............................................................. 10 Diagnostic Procedures ........................................ 35
Installation .......................................................... 11 COLLISION DIAGNOSIS ......... ..................................... 37 i'Jc
Disposal of Air Bag Module... .............. ........... 13 SRS inspection ................................................ 37

When you read wiring diagrams: 18ilcl

• Read Gl section, "HOW TO READ WIRING DIAGRAMS".
• See EL section, "POWER SUPPLY ROUTING" for power distribution circuit.
When you perform trouble diagnoses, read Gl section, "HOW TO FOLLOW FLOW ©T
CHART IN TROUBLE DIAGNOSES" and "HOW TO PERFORM EFFICIENT DIAGNOSIS
FOR AN ELECTRICAL INCIDENT".

929
 PRECAUTIONS

Supplemental Restraint System (SRS) "AIR

BAG"
The Supplemental Restraint System "Air Bag", used along with a
seat belt, helps to reduce the risk or severity of injury to the driver
in a frontal collision. The Supplemental Restraint System consists
of an air bag module (located in the center of the steering wheel),
a diagnosis sensor unit, a crash zone sensor (4WD models),
warning lamp, wiring harness and spiral cable.
WARNING:
• To avoid rendering the SRS inoperative, which could
increase the risk of personal injury or death in the event
of a collision which would result in air bag inflation, all
maintenance must be performed by an authorized
NISSAN dealer.
• Improper maintenance, including incorrect removal and
installation of the SRS, can lead to personal injury caused
by unintentional activation of the system.
• Do not use electrical test equipment on any circuit related
to the SRS unless instructed to in this Service Manual.
SRS wiring harnesses are covered with yellow insulation
either just before the harness connectors or for the com-
plete harness, for easy identification.

930 RS-2
 SEAT BELTS

CAUTION: !&I
• Do not disassemble buckle or seat belt assembly.
• Replace anchor bolts if they are deformed or worn out.
• Never oil tongue and buckle. uYl&\
• If any component of seat belt assembly is questionable, do not repair. Replace the seat belt
assembly.
• If webbing is cut, frayed, or damaged, replace seat belt assembly. ~iil
• When replacing seat belt assembly, use a genuine NISSAN seat belt assembly.
• After any collision, inspect all seat belt assemblies, including retractors and other attached
hardware. l©

RS-3 931
 SEAT BELTS

Front Seat Belt

SEC. 868

With bucket seat

~ 24-31 (2.4- 3.1, 17- 23)

With bench seat

~24- 31 (2.4- 3.1, 17- 23)

tc!J24 . 31 (2.4 • 3.1. 17 • 23)

ARS126
~ : N. m {kg-m, fl-lb)

Removal
Remove front seat. Refer to BT section ("Front
Seat"', "SEAT"). @ Remove pillar anchor cover and anchor bolt.
G) Remove buckle. ® Remove guide plate.
® Remove floor anchor bolt. ® Remove retractor bolts and
@ Remove lower side finisher. remove retractor.

932 RS-4
 SEAT BELTS

Rear Seat Belt

SEC. 869

tql24 . 31 (2.4. 3 .•
2 17-23)

~: N·m (kg-m, ft-lb)

ARS125

Removal e
CD Remove un derseat storag .
@Remove
® Remove sea
buc~l~~lt anchor bolt.

RS-5 933
 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

Precautions for SRS "Air Bag" Service

• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service
Manual. SRS wiring harnesses are covered with yellow insulation either just before the harness connec-
tors or for the complete harness, for easy identification.
• Before servicing the SRS, turn ignition switch OFF, disconnect both battery cables and wait at least 3
minutes.
For approximately 3 minutes after the cables are removed it is still possible for the air bag to deploy.
Therefore, do not work on any air bag system connectors or wires until at least 3 minutes have passed.
• Diagnosis sensor unit and crash zone sensor (4WD models) must always be installed with arrow mark"¢"
pointing toward the front of the vehicle for proper operation. Also check diagnosis sensor unit for cracks,
deformities and rust before installation and replace if necessary.
• The spiral cable must be aligned with the neutral position since its rotations are limited. Do not attempt to
turn steering wheel or column after removal of steering gear.
• Handle air bag module carefully. Always place it with the pad side facing upward.
• Do not use old special bolts after removing any SRS parts; replace with new special bolts. Conduct self-
diagnosis to check entire SRS for proper function.
• If front of vehicle is damaged in a collision, always check the crash zone sensor and the wiring harness
(4WD models).

Special Service Tools

The actual shapes of Kent~Moore tools may differ from those of special serivce tools illustrated here.

Tool number
(Kent-Moore No.) Description
Tool name

KV991072SO Disposing of air bag module

(J38381·KIT)
Air bag deployment kit

KV991 06400
(J38381)
Deployment tool
NT357

KV99105300 Anchor the air bag module

(J41246)
Air bag module bracket

NT354

HT61961000 and Use for special bolts

HT62152000 combined c [TAMPER RESISTANT TORX (Size T50)]
(J38219)
*Special torx bit
a: 3.5 (0.138) dia.
a b: 8.5 - 8.6 (0.335 - 0.339) dia.
c: approx. 10 (0.39) sq.
NT361 Unit: mm (in)

Special tool or commercial equivalent

934 RS-6
 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

~[
Description
2WD models
The diagnosis sensor unit will deploy the air bag if the G-sensor activates simultaneously with the sating sen- UJlftl
sor while the ignition switch is ON.
4WD models ~utl
The diagnosis sensor unit will deploy the air bag if the G-sensor and/or the crash zone sensor activates
simultaneously with the sating sensor while the ignition switch is ON.

Crash zone sensor Diagnosis sensor unit

Ignition Air bag signal
(4WD models only) G-sensor Safing sensor
ON ON ON ON
ON ON ON ON
ON ON ON ON ON

~
!g)
Spiral Driv-;--
cable air bag module
Ignition Diagnosis sensor unit
switch
(ON or STARn
• Auxiliary power source (condenser)
o--
• Drive circuit

• CPU

I • G sensor

«~ • Sating sensor
xFI~
"'L-----;atte<y I Crash zone sensor

0 : With 4-wheer drive ARS111

RS-7 935
 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

SRS Component Parts Location

SEC. 240•253•484•680

Wiring harness

Crash zone
sensor (4WD)

Air bag module

Spiral cable
sensor unit ARS124

Maintenance Items
1. Check "AIR BAG" warning lamp operation
After turning ignition key to the ON position. "AIR BAG" warning lamp illuminates. The "AIR BAG" warn-
ing lamp will turn off after about 7 seconds if no malfunction is detected.
If any of the following "AIR BAG'' warning lamp conditions occur, immediately check the air bag system.
Refer to RS"22 for details.
• The warning lamp does not illuminate when the ignition switch is turned ON.
• The warning lamp does not turn off about 7 seconds after the ignition switch is turned ON.
• The warning lamp turns off about 7 seconds after the ignition switch is turned ON, but it turns on again
or blinks.
2. Visually check SRS components
a. Crash zone sensor (4WD models).
• Check crash zone sensor to ensure the arrow marks face the front of the vehicle.
• Check body and sensor bracket for deformities and rust.
• Check sensor case for dents, cracks, deformities and rust.
• Check sensor harness for binding, connector for damage and terminals for deformities.
b. Diagnosis sensor unit
• Check diagnosis sensor unit and bracket for dents, cracks and deformities.
• Check connectors for damage and terminals for deformities.
c. Air bag module and steering wheel
• Remove air bag module from steering wheel. Check harness cover and connectors for damage, terminals
for deformities and harness for binding.
• Install air bag module to steering wheel to check fit and alignment with the wheel.
• Check steering wheel for excessive free play.
d. Spiral cable
• Check spiral cable and combination switch for damage.
• Check connectors and protective tape for damage.
• Check steering wheel for noise, binding and heavy operation.
e. Main harness and air bag harness
• Check connectors for poor connections and damage and terminals for deformities.
• Check harnesses for binding, chafing and cuts.
CAUTION:
Replace previously used special bolts with new ones.

936 RS-8
 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

Diagnosis Sensor Unit and Crash Zone Sensor

CAUTION:
• Before servicing SRS, turn the ignition switch OFF, disconnect both battery cables and wait for at
least 3 minutes.
• The special bolts are coated with a bonding agent while the other bolt is for ground. Do not use
old bolts after removal; replace with new coated bolts.
• Check diagnosis sensor unit for proper installation.
• Check diagnosis sensor unit to ensure that there are no deformities, dents, cracks or rust. If there
are any visible signs of damage, replace with a new one.
• Check diagnosis sensor unit brackets to ensure they are free of deformities and rust.
• Replace diagnosis sensor unit if it has been dropped or sustained an impact.
• Check crash zone sensor for proper installation.
• Check crash zone sensor to ensure that there are no deformities, dents, cracks or rust. If there are ii';(;
any visible signs of damage, replace the crash zone sensor.
• Check crash zone sensor bracket to ensure that it is free of deformities and rust.

SEC. 253 REMOVAL AND INSTALLATION

Ground
bolt~ CAUTION:
~~~,~~~,~117
1 -m~ I Before servicing SRS, turn the ignition switch OFF, disconnect 1FT'
both battery cables and wait at least 3 minutes.
Front

Q Diagnosis sensor unit

1. Disconnect driver air bag module connector.
2. Remove console box. Refer to BT section ("INSTRUMENT
Special bolt~
sensor
PANEL").
tc!J15·25
3. Disconnect diagnosis sensor unit connector.
(1.5- 2.5, unit~ N-m (kg-m, tt-lb)
4. Using the TAMPER RESISTANTTORX (Size T50), remove the
11 -18) ARS115
three special bolts, then remove ground bolt. The diagnosis
sensor unit can then be removed.
NOTE:
To install, reverse the removal procedure.

SEC. 253 Crash zone sensor (4WD models)

1. Disconnect driver air bag module connector.
2. Disconnect crash zone sensor connector.
3. Using the TAMPER RESISTANTTORX (Size T50), remove the
three special bolts. The crash zone sensor can then be
removed.
NOTE:
To install, reverse the removal procedure.

--------
~: N-m (kg-m, ft-lb) sensor ARS112

RS-9 937
 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

Air Bag Module and Spiral Cable

SEC. 253·484

ARS161

REMOVAL
CAUTION:
• Before servicing SRS, turn the ignition switch OFF, dis-
connect both battery cables and wait for at least 3 min-
utes.
• Always work from the side of air bag module.
1. Remove lower lid from steering wheel, and disconnect air bag
module connector.

SBF811E

2. Remove LH and RH side lids and ASCD steering switch (if so

equipped). Using the TAMPER RESISTANT TORX (Size T50),
remove left and right special bolts. The air bag module can
then be removed.

SBF812E

CAUTION:
• Always place air bag module with pad side facing upward.
• Do not attempt to disassemble air bag module.
• The special bolts are coated with a bonding agent. Do not
use old bolts after removal; replace with new coated bolts.

ARS113

938 RS-10
 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Air Bag Module and Spiral Cable (Cont'd)
• Do not drop or impact air bag module. Replace air bag
module if it has been dropped or sustained an impact.
• Do not expose the air bag module to temperatures exceed-
Air bag ing 90"C (194"F).
module
• Do not allow oil, grease or water to contact the air bag
module.

SBF814E

3. Set steering wheel in the neutral position.

4. Disconnect horn connector and remove steering wheel nut.
5. Remove steering wheel mass damper.
r,~
6. Using steering wheel puller, remove steering wheel. Be careful
not to overtighten puller bolt on steering wheel.
CAUTION:
Do not tap or bump the steering wheel.
7. Remove steering column cover.
8. Disconnect air bag harness and main harness connectors. IU
SBF239F

!1;"]'
9. Remove the four spiral cable retaining screws. The spiral cable
can then be removed.
CAUTION:
• Do not attempt to disassemble spiral cable.
TF
• Do not apply lubricant to the spiral cable.

ARS119

INSTALLATION
Combination
switch
1. Set the front wheels in the straight-ahead position.
2. Align the turn signal cancel tab with the notch of the combina- 19li~l
0 tion switch as shown.

Back side of
steering wheel
Steering wheel
guide pin

•
I

RS-11 939
 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Air Bag Module and Spiral Cable (Cont'd)
3. Rotate the spiral cable fully clockwise until tight.
4. Rotate spiral cable counterclockwise as specified below. Align
the white pin with the alignment mark.
Specified turns for spiral cable:

Applied model Specified turns from neutral position

With power steering Approx. 2.5

Without power steering Approx. 4

CAUTION:
The spiral cable may snap during steering operation if the
cable is installed improperly. Also, with the steering linkage
disconnected, the cable may snap by turning the steering
With power steering:
wheel beyond the specified number of turns. Always perform
Approx. 2.5 turns SRS self-diagnosis after installing the air bag module.
Without power steering: 5. Connect spiral cable air bag harness and main harness con·
Approx. 4 turns
nectors and tighten screws. Install steering column cover.

Alignment mark
ARS128

6. Install mass damper on steering wheel.

7. Install steering wheel, setting spiral cable pin guide, and pull·
ing spiral cable harness through.
8. Connect horn connector.
9. Tighten steering wheel nut.
tc!J: 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb)

SBF818E

10. Position air bag module and tighten with new special bolts.
11. Connect air bag module connector.
12. Install ASCD switch and tighten screws.
13. Install all lids.
14. Connect both battery cables.
15. Conduct Self-diagnosis to ensure entire SRS operates prop·
erly (Use CONSULT or warning lamp check). Turn steering
wheel to the left end and then to the right end fully to make
sure that the spiral cable is set in the neutral position.
16. If "AIR BAG" warning lamp blinks (in User mode), it shows that
the spiral cable may be snapped due to its improper position.
SBF812E
Perform Self-diagnosis again (Use CONSULT or warning lamp
check). If a malfunction is detected, replace the spiral cable
with a new one.

940 RS-12
 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

Disposal of Air Bag Module

• Make sure to deactivate air bag modules before disposing of
them. Also, before disposing of a vehicle equipped with an air
bag system, deactivate air bag modules. If such a system has
already been deployed due to an accident, dispose of as indi-
cated in "DISPOSING OF AIR BAG MODULE", RS-15.
• Do not dispose of the air bag module undeployed .
• When deploying the air bag module, always use the Special
Service Tool; Deployment tool (Kent-Moore No. J38381 ). ~
• When deploying the air bag module, stand to the side of the
1

-~
module at least 5 m (16 It) away.
• Due to heat, do not touch air bag module for at least 30 min-
utes after deployment.
l'l©

• Be sure to wear gloves when handling a deployed air bag

module.
• Never apply water to a deployed air bag module .
• Wash your hands after finishing work .

CHECKING DEPLOYMENT TOOL

Connecting to battery
• Place vehicle outdoors with at least 6 m (20 It) of open space uU:
Deployment tool
(KV991 06400 on all sides.
(J38381)) • Use a voltmeter to make sure the vehicle battery is fully
charged. r~
CAUTION:
The battery must show voltage of 9.6V or more.
~i1J
Remove the battery from the vehicle and place it on dry wood
SRS019
blocks approximately 5 m (16 It) away from the vehicle.
• Wait 3 minutes after the vehicle battery is disconnected before [ii1:1,
proceeding.
• Connect red clip of deployment tool to battery positive termi-
nal and black clip to negative terminal.
CAUTION:
Make sure the polarity is correct. The right side lamp in the
tool, m_arhked "hdep~oyhme_ndt tool power", sdhould glowhwith a :21'
green 11g t. 11 I e ng I s1 e 1amp g1ows re , reverse I e con-
nections to the battery.
Deployment tool check
Press the deployment tool switch to the ON position. The left side
lamp in the tool, marked "air bag connector voltage" should illumi-
nate. If it does not illuminate, replace the tool. ~'TI'
Air bag deployment tool lamp illumination chart
(Battery connected)
Lett side lamp, green* Right side lamp, green*
Switch operation "AIR BAG CONNECTOR "DEPLOYMENT TOOL
VOLTAGE" POWER"
OFF OFF ON
ON ON ON
*· If th1s lamp glows red, the tool 1s connected to the battery Incorrectly.
SBF266H Reverse the connections and make sure the lamp glows green.
------------------------~

RS-13 941
 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Disposal of Air Bag Module (Cont'd)
DEPLOYMENT PROCEDURES FOR AIR BAG MODULE
15 (0.59) 15 (0.59) (OUTSIDE OF VEHICLE)
Deploying air bag module while it is mounted in vehicle may dam-
170 (6.69) ?tp< age vehicle. Deploy air bag module as a unit except when dispos-
ing of vehicle.
Anchor air bag module in a vise secured to a firm foundation dur-
ing deployment.
= =
Air bag module bracket
Deployment of air bag module (outside of vehicle)
[KV991 05300 (J41246)] 1. Make an 8.5 mm (0.335 in) diameter hole in air bag module
c:."":::;':::'m:::m~On:::)==========AR=S=1~62 bracket (SST: J41246) at the position shown in figure at left.
r 2. Using wire, secure air bag module to air bag module bracket
(SST: J41246) in two places as shown.
CAUTION:
Use wire of at least 1 mm (0.04 in) diameter.
3. Firmly secure air bag module bracket (SST: J41246) (with air
bag module attached) in the vise.
Make sure vise is firmly secured and will not pivot.

4. Connect deployment tool (SST: J38381) to air bag module

connector.

bracket
[KV991 05300
{J41246)]

Air bag module 5. Connect red clip of deployment tool to battery positive termi-
nal and black clip to negative terminal.
6. The lamp on the right side of the tool, marked "deployment tool
power", should glow green, not red.
7. Press the button on the deployment tool. The left side lamp on
the tool, marked "air bag connector voltage", will illuminate and
Deployment tool
the air bag module will deploy.
[KV991 06400 CAUTION:
(J38381)] When deploying the air bag module, stand to the side of the
module at least 5 m (16 It) away.
ARS117

942 RS-14
 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Disposal of Air Bag Module (Cont'd)
DEPLOYMENT OF AIR BAG MODULE WHILE MOUNTED ·:Jil
IN VEHICLE
When disposing of a vehicle, deploy air bag module while it is
mounted in vehicle.
CAUTION:
When deploying air bag module, ensure vehicle is empty. ~Ji!
1. Turn ignition switch OFF, disconnect both battery cables and
wait at least 3 minutes.
2. Disconnect air bag module connector. l•i;;
3. Connect deployment tool (SST: J38381) connector to air bag
SBF811E module.
4. Connect red clip of deployment tool to battery positive termi- !\~
nal and black clip to negative terminal.
5. The lamp on the right side of the tool, marked "deployment tool
power", should glow green, not red. ]'~
6. Press the button on the deployment tool. The left side lamp on
the tool, marked "air bag connector voltage", will illuminate and
the air bag module will deploy. ©l

[0]iJ

ARS036

DISPOSING OF AIR BAG MODULE

Deployed air bag module is very hot. Before disposing of air bag
modules, wait at least 30 minutes. Seal them in a plastic bag before 11'
disposal.
CAUTION:
• Never apply water to a deployed air bag module. Fll
• Be sure to wear gloves when handling a deployed air bag
module.
• No poisonous gas is produced upon air bag module :Sclc
deployment. However, be careful not to inhale gas since it
ARso12 irritates throat and can cause choking.
L . __ _ _ _ _ _ _ _ _ _ _ _ _ ~ • Do not attempt to disassemble air bag module. I'll~
• Air bag module cannot be reused.
• Wash your hands after finishing work.

RS-15 943
 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

NOTES

944 RS-16
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)

How to Perform Trouble Diagnoses for Quick

and Accurate Repair
A good understanding of the malfunction conditions can make troubleshooting faster and more accurate.
In general, each customer feels differently about a problem. It is important to fully understand the symptoms
or conditions for a customer complaint.

INFORMATION FROM CUSTOMER

WHAT ............ Vehicle model
WHEN ........... Date, Frequencies
WHERE. Road conditions
HOW. Operating conditions, Symptoms

PRELIMINARY CHECK
Check that the following parts are in good order.
• Battery [Refer to EL section ("BATTERY").]
• Fuse [Refer to EL section ("Fuse", "POWER SUPPLY ROUTING").]
• System component-to-harness connections

DIAGNOSIS FUNCTION
The SRS self-diagnosis results can be read by using "AIR BAG" warning lamp and/or CONSULT. The read-
ing of these results is accomplished using one of two modes- "User mode" and "Diagnosis mode".
The User mode is exclusively prepared for the customer (driver). This mode warns the driver of a system
malfunction through the operation of the "AIR BAG" warning lamp.
The Diagnosis mode allows the technician to locate and inspect the malfunctioning part.
The mode applications for the "AIR BAG" warning lamp and CONSULT are as follows:

User mode Diagnosis mode Display type

"AIR BAG" warning lamp X X ON·OFF operation
CONSULT - X Monitoring

DIAGNOSIS MODE FOR CONSULT

• SELF-DIAG [CURRENT]
A current Self-diagnosis result (also indicated by the number of warning lamp flashes in the Diagnosis
mode) is displayed on the CONSULT screen in real time. This refers to a malfunctioning part requiring
repairs.
• SELF-DIAG [PAST]
Diagnosis results previously stored in the memory (also indicated by the warning lamp flashes in the @I~
Diagnosis mode) are displayed on the CONSULT screen. The stored results are not erased until memory
erasing is executed.
• TROUBLE DIAG RECORD ®IF
With TROUBLE DIAG RECORD, diagnosis results previously erased by a reset operation can be displayed
on the CONSULT screen.

• ECU DISCRIMINATED NO.

• ECU DISCRIMINATED NO. • The diagnosis sensor unit for each vehicle model is assigned
with its own individual classification number. This number will ~~lffio
ECU No. be displayed on the CONSULT screen, as shown at left. When
40 replacing the diagnosis sensor unit, refer to the part number for
(45) the compatibility. After installation, replacement with a correct
unit can be checked by confirming this classification number ~~~
on the CONSULT screen.
For NISSAN MODEL 021, the diagnosis sensor unit IIQll~
classification numbers assigned are as follows:
SRS154
2WD models: 40
4WD models: 45
RS-17 945
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)
How to Perform Trouble Diagnoses for Quick
and Accurate Repair (Cont'd)
CAUTION:
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses are covered with yellow insulation either just before the
harness connectors or for the complete harness, for easy identification.
• Do not attempt to repair, splice or modify the SRS wiring harness. If the harness is damaged,
replace it with a new one.
• Keep ground portion clean.

WORK FLOW
ACTION ITEM REFERENCE ITEM

Check in

Listen to customer complaints and requests.

Perform preliminary check. Preliminary check (RS-17)

Check for any Service Bulletins.

Perform self-diagnosis using "AIR BAG" warning lamp.~ User mode DIAGNOSTIC PROCEDURE 1
(RS-22)

Inspect malfunctioning part. - Diagnosis mode e DIAGNOSTIC PROCEDURE 2:

Using CONSULT (RS-23)
Perform self-diagnosis using CONSULT. • DIAGNOSTIC PROCEDURE 3:
OR Using "AIR BAG" warning lamp
Pertorm self-diagnosis using "AIR BAG" warning lamp. (RS-25)

Repair/Replace

NG Final check - Diagnosis mode and User mode e DIAGNOSTIC PROCEDURE 4:

Using CONSULT (RS-26)
OK
• DIAGNOSTIC PROCEDURE 5:
Using "AIR BAG" warning lamp
(RS-29)

Check out

DIAGNOSTIC PROCEDURE 1
-
(RS-22)

946 RS-18
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)

@]
Schematic
® : With 4-wheel drjve

IGNITION SWITCH
ON or START

j COM SINATION

DOOR
~FUSE ¢FUSE ~BAG LED METE R
(AI R BAG
WAR NING LAMP)
SWITCH
LH ~
..J
~·
-WU ..,"j" l
I7 1 15

AIR BAG DIAGNOSIS SENSOR UNIT

3 4 13 14 20 21 2
1---T-o i~IJ'
s PIRAL
cABLE ***
0~ G~ < XF > ll'
DR IVER
AI R BAG
CRASH
ZONE jo 18 2 7 DATA LINK
CONNECTOR
MD DULE
9 fAAA- SENSOR 9 13 FOR CONSULT
[?l[Q;
'---
~&\

AR$105
~

~~

i§;f

RS-19 947
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)

Wiring Diagram -SRS-

RS-SRS-01
IGNITION SWITCH
ON or STAAT

Refer to "EL-POWER".

rt-J10A 10A
LIJ@] [!!]
RIL

COMBINATION
METER
(AIR BAG
WARNING LAMP)
@,@

~ ~~ ~ ~
v
I"

f-' AIR BAG LED

~ ~
G/Y 8

1$1"""""1$1®
(~) 8
RIL G/Y {§§) 8 ffi
1~1-------------------------lcjfJI~l _,_ JOINT
CONNECTOR-2
(lillY
rrnIGN
AIL GN

L-----------------~
r@
WARN/L (~:~&~gSIS
SENSOR
UNIT
(iillj)
...,
ll4dJ

~
8
•
• ...._• ...._
8 8

(®J (Ml05) (M160)

8

Refer to last page (Foldout page).

(lillY
(M155),@
12034{§§)
5 6 7 8 9 10 w

r---------------------------~
I I
I I
I 8 W I
1----------------------------J

ARS106-A

948 RS-20
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)
Wiring Diagram -SRS- (Cont'd)

RS-SRS-02
~~~~~!!~
CRASH
ZONE
SENSOR

~@) lhjdl~
GD <8E) : With 4·wheel drive

I* *~~~~L~L I I
w y BR PU

w y BR PU
~~~----------~~~(Z101)
(~) 1~1---l[~illi
(~)
W L BR PU

I+
W
I
L
~BR PU

ffi ffi ffi~

"-"'!-'.'o;!;-;----;:-;:!--0:;!7-;-------f.~":--~:2':-----,AIR BAG
SQ. DR(+) SQ. DR( ) CZS(+) CZS(-) DIAGNOSIS
SENSOR
UNIT
GND DOOR SW SSS RX SSS TX (~)
~,r-:~1--~,~~~,~--------~,~:~,~~,~~~,~~
8 BR Y R

IE!J~------- -1~~------------------ -li!JI---- ~r!JI <~>

I I
8 BR Y R <Mill)

, _ BR +roEL-CHIME

BR Y R
ffi ~ ~ OATALINK
CONNECTOR
FOR CONSULT

c___ _ _ ____J I(M153)

lhjdl
8

i-i1
8
..... _._
_._ 8
I B
~
B

(~) (~) (~~) <f!!JJ>

(M29)
® , o 34 <w>
GY 5 6 7 8 9 10 w

cffu®
GY

ARS106-B

RS-21 949
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)

Self-diagnosis
DIAGNOSTIC PROCEDURE 1
Checking SRS operation by using "AIR BAG" warning lamp-
User mode
1. After turning ignition switch from OFF to ON, "AIR BAG" warn-
ing lamp operates.
2. Compare "AIR BAG" warning lamp operation to the chart
below.

SRS045

"AIR BAG" warning lamp operation- User mode- SRS condition Reference item

No malfunction is
detected.
IGN ON
No further action is neces-
ON I sary.

OFF

MRS095A

The system has a problem Go to DIAGNOSTIC PRO-

IGN ON and needs to be repaired CEDURE 2 or 3. RS-23 or
as indicated. 25.
ON
I
OFF
0.5 sec
I! ) 0.5 sec.
'

MRS096A

Air bag is deployed. Go to COLLISION

DIAGNOSIS, RS-38.
IGN ON

ON
I
Air bag fuse, diagnosis Go to DIAGNOSTIC PRO-
OFF sensor unit or harness is CEDURE 8, RS-36.
malfunctioning and needs
to be repaired.
MRS097A

One of the following has Go to DIAGNOSTIC PRO-

occurred and needs to be CEDURE 9, RS-36.
IGN ON
repaired:
• Meter fuse is open
ON • "AIR BAG" warning
lamp circuit is shorted
OFF -------------------------------------- or open
• Diagnosis sensor unit is
malfunctioning
MRS098A

NOTE:
If "AIR BAG" warning lamp operates differently from the
operations shown above, refer to "AIR BAG" warning lamp
operation- Diagnosis mode-, DIAGNOSTIC PROCEDURE 3
(step 4), RS-25.

950 RS-22
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)
Self-diagnosis (Cont'd)
DIAGNOSTIC PROCEDURE 2 ( 00 with CONSULT)
Inspecting SRS malfunctioning parts by using CONSULT -
Diagnosis mode
1. Turn ignition switch OFF.
2. Connect CONSULT to data link connector.

3. Turn ignition switch ON.

NISSAN 4. Touch START.

CONSULT

START

SUB MODE I
SRS046

5. Touch AIRBAG.
I~ SELECT SYSTEM Dl
I ENGINE I
I AIR BAG I

SBF884F

6. Touch SELF-DIAG [CURRENT].

1~ sELECT DIAG MODE ol
SELF·DIAG [CURRENT I

SELF-DIAG [ PAST I

TROUBLE DIAG RECORD

ECU DISCRIMINATED NO.

SRS047

7. Diagnostic codes are displayed on SELF-DIAG [CURRENT] .

• SELF-DIAG [CURRENT I • D
FAILURE DETECTED
CONTROL UNIT

ERASE I PRINT I
SRS048

RS-23 951
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)
Self-diagnosis (Cont'd)
• If no self-diagnostic failure is detected on SELF-DIAG
• SELF-DIAG [CURRENT l • D [CURRENT] even though a malfunction is detected in
FAILURE DETECTED DIAGNOSTIC PROCEDURE 1, go to DIAGNOSTIC PROCE-
* NO SELF DIAGNOSTIC DURE 6, RS-31.
FAILURE INDICATED.

FURTHER TESTING
MAY BE REQUIRED. **

I ERASE II PRINT
JAS049

8. Touch PRINT.
9. Compare diagnostic codes to the CONSULT DIAGNOSTIC
CODE CHART.
10. Touch BACK key of CONSULT until SELECT SYSTEM MODE
appears, then turn off CONSULT.
11. Turn ignition switch OFF, then disconnect CONSULT and both
battery cables.
12. Repair the system as outlined by the Repair order that corre-
sponds to the problem code in CONSULT DIAGNOSTIC
CODE CHART. For replacement procedure of component
parts, refer to RS-9.
13. After repairing the system, go to DIAGNOSTIC PROCEDURE
4, RS-26.
CONSULT DIAGNOSTIC CODE CHART

Repair order
Diagnostic item Explanation/Possible causes •Recheck SRS using CONSULT
at each replacement

NO SELF DIAGNOSTIC • No malfunction is detected. Go to DIAGNOSTIC PROCEDURE 6, RS-31.

FAILURE INDICATED
AIRBAG MODULE • Air bag module circuit is open (including the 1. Visually check wiring harness connections.
[OPEN] spiral cable). 2. Replace the harness if it has visible damage.
3. Replace air bag module.
AIRBAG MODULE • Air bag module circuit is shorted to some
(Before disposing of it, it must be deployed.)
[VB-SHORT] power supply circuit (including the spiral
4. Replace spiral cable.
cable).
5. Replace diagnosis sensor unit.
AIRBAG MODULE • Air bag module circuit is shorted to ground
IGND·SHORn (including the spiral cable).
AIRBAG MODULE • Air bag module circuits are shorted to each
[SHORT] other.
CRASH ZONE SEN-CTR • Crash zone sensor circuit is open, or 1. Visually check wiring harness connections.
[OPEN/UPR-VB-SHORT] • Crash zone sensor circuit is shorted to some 2. Replace the harness if it has visible damage.
(4WD models) power supply circuit. 3. Replace crash zone sensor.
4. Replace diagnosis sensor unit.
CRASH ZONE SEN-CTR • Both crash zone sensor circuits are shorted,
5. Replace airbag harness for crash zone
[SHORT/UPR-GND-SHORT] or
sensor.
(4WD models) • Crash zone sensor circuit is shorted to
ground.
CONTROL UNIT • Diagnosis sensor unit is out of order. 1. Visually check wiring harness connections.
2. Replace diagnosis sensor unit.
3. Replace the harness if it has visible damage.

INDEFINITE FAILURES • Low battery voltage. Go to DIAGNOSTIC PROCEDURE 4, RS-26,

[AIR BAG] after charging battery.

. ..
Follow the procedures 1n numencal order when repamng malfunct1omng parts. Confirm whether malfunction IS ellmmated
using the "AIR BAG" warning lamp (in User mode) or CONSULT each time repair is finished. If malfunction is still observed,
proceed to the next step. When malfunction is eliminated, further repair work is not required.

952 RS-24
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)
Self-diagnosis (Cont'd)
DIAGNOSTIC PROCEDURE 3 (@
without CONSULT)
Inspecting SRS malfunctioning parts by using "AIR BAG"
warning lamp - Diagnosis mode
NOTE:
SRS will not enter Diagnosis mode if no malfunction is
detected in User mode.
1. Open driver's door.
2. Turn ignition switch from OFF to ON.
3. Press driver's door switch at least 5 times within 7 seconds li[j
after turning ignition switch ON.
SRS is now in Diagnosis mode.
4. "AIR BAG" warning lamp operates in Diagnosis mode as fol- ~~
lows:
NOTE:
If SRS does not enter Diagnosis mode even though malfunc- p~
lion is detected in User mode, go to DIAGNOSTIC PROCE-
DURE 10, RS-37.

No. "AIR BAG" warning lamp operation- Diagnosis mode- SRS condition

@ through @ are repeated. Intermittent

problem has
IGN ON
been detected
ON
I in the past. Go
to DIAGNOS·
OFF
TIC PROCE·
DURE 7,
RS-32.

MRS100A

@ through @ are repeated. The system

NOTE: has a problem
IGN ON
@- Interval I and needs to
ON
I (_d)
®- Start signal (Start signal be repaired.
identifies display modes)
2
OFF 7 sec. @- Interval II

2 sec. 2 sec. Varies with malfunctioning part

@- Indicates malfunctioning
part (0.5 sec. ON and 0.5
sec. OFF is counted as
MRS099A one flash.)

5. Malfunctioning part is indicated by the number of flashes (part

@). Compare the number of flashes to WARNING LAMP ~f
FLASH CODE CHART and locate malfunctioning part.
6. Turn ignition switch OFF, and disconnect both battery cables.
7. Repair the system as outlined by the Repair order in WARN- 1{3:,
lNG LAMP FLASH CODE CHART that corresponds to the
flash code. For replacement procedure of component parts,
refer to RS-9.
~l
8. After repairing the system, go to DIAGNOSTIC PROCEDURE
5, RS-29.

RS-25 953
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)
Self-diagnosis (Cont'd)
WARNING LAMP FLASH CODE CHART

Warning Flash code@ Repair order

Explanation
lamp (# of flashes) *Recheck SRS at each replacement

0 • No malfunction is detected. Go to DIAGNOSTIC PROCEDURE 7, RS-32.

2 • Air bag module circuit is out of order. 1. Visually check wiring harness connections.
2. Replace spiral cable.
3. Replace air bag module.
(Before disposing of it, it must be deployed.)
0. 4. Replace diagnosis sensor unit.
E
.!!' 5. Replace main harness.
.,:;;
C>
c 6 • Crash zone sensor is out of order. 1. Visually check wiring harness connections.
2. Replace crash zone sensor.
3
3. Replace diagnosis sensor unit.
b<( 4. Replace air bag harness for crash zone sensor.
"'a: 5. Replace main harness.
~ 7 • Diagnosis sensor unit is out of order. 1. Visually check wiring harness connections.
2. Replace diagnosis sensor unit.
3. Replace main harness.
9 • Low battery or SRS system voltage. 1. Check and, if necessary, charge battery, then go to
("Flash code 9" may not show up even DIAGNOSTIC PROCEDURE 5, RS-29.
if the battery voltage is low.) 2. Replace diagnosis sensor unit.
. ..
Follow the procedures m numencal order when repa1nng malfunct1onmg parts. Conf1rm whether malfunction 1s el1mmated
using the "AIR BAG" warning lamp (in User mode) or CONSULT each time repair is finished. If malfunction is still observed,
proceed to the next step. When malfunction is eliminated, further repair work is not required.

DIAGNOSTIC PROCEDURE 4 ( ®
with CONSULT)
Final checking after repairing SRS by using CONSULT- Diag-
nosis mode
1. After repairing SRS, connect both battery cables.
2. Connect CONSULT to data link connector.
3. Turn ignition switch from OFF to ON.

4. Touch START.
NISSAN

CONSULT

START

SUB MODE
SRS046

954 RS-26
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)
Self-diagnosis (Cont'd)
5. Touch AIRBAG. ilil
I~ SELECT SYSTEM Dl
ENGINE
AIR BAG

'-------------,!SBF884F

6. Touch SELF-DIAG [CURRENT].

I~ SELECT DIAG MODE DI
SELF-DIAG [CURRENT]

SELF-DIAG [ PAST ]

TROUBLE DIAG RECORD

ECU DISCRIMINATED NO.

'------------lSRS047

7. If no malfunction is detected on SELF-DIAG [CURRENT], b'l'U'

• SELF-DIAG I CURRENT I • D repair of SRS is completed. Touch ERASE.
FAILURE DETECTED NO~: W
* NO SELF DIAGNOSTIC Touch ERASE to erase problem (Trouble code) retained in
FAILURE INDICATED.
memory. Otherwise, the diagnosis sensor unit will still sense
a problem in memory when step 13 (Air bag warning lamp [~[Q)
FURTHER TESTING operation check) is performed. As a result, the "AIR BAG"
MAY BE REQUIRED. ** warning lamp will still indicate a malfunction in the system.

ERASE II PRINT J RS049

~ffi1
• If any problem code was displayed on SELF-DIAG
• SELF-DIAG [CURRENT I • D [CURRENT], the malfunctioning part is not repaired com-
FAILURE DETECTED pletely or another malfunctioning part is detected. Go to ::lll"l
CONTROL UNIT DIAGNOSTIC PROCEDURE 2, RS-23, and repair malfunc-
tioning part completely.
8. Touch BACK key of CONSULT. §j

ERASE I PRINT I
SRS048

9. Touch SELF-DIAG [PAST].

I~ SELECT DIAG MODE Dl
I SELF-DIAG I CURRENT I I
SELF-DIAG I PAST I
TROUBLE DIAG RECORD

ECU DISCRIMINATED NO.

'---------___l'SRS050

RS-27 955
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)
Self-diagnosis (Cont'd)
10. Check that no sell-diagnostic failure is detected on SELF-
• SELF-DIAG [ PAST I • D DIAG [PAST].
FAILURE DETECTED
* NO SELF DIAGNOSTIC
FAILURE INDICATED.

FURTHER TESTING
MAY BE REQUIRED. **

I PRINT I SRS062

11. Touch BACK key of CONSULT until SELECT SYSTEM MODE

appears, turn off CONSULT, then disconnect CONSULT.
12. Turn ignition switch OFF.
13. Go to DIAGNOSTIC PROCEDURE 1, RS-22 to check SRS
operation by using "AIR BAG" warning lamp with User mode.

956 RS-28
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)
Self-diagnosis (Cont'd)
DIAGNOSTIC PROCEDURE 5 ( ®
without CONSULT) @'l
Final checking after repairing SRS by using "AIR BAG" warn-
ing lamp - Diagnosis mode and User mode
1. After repairing SRS connect both battery cables.
2. Open driver's door.
3. Turn ignition switch from OFF to ON. . . ~icTI
4. "AIR BAG" warning lamp operates in D1agnos1s mode as
follows:

No. "AIR BAG" warning lamp operation- Diagnosis mode- SRS condition

@ through @ are repeated. No malfunc-

IGN ON tion is
ONI @@® detected or
repair :s com- nB~
OFF pleted.
No further
action is nee-
2 sec.
essary.
MRS100A

@ through @ are repeated. The system

NOTE: has a problem
IGN ON
@ - Interval I and needs to
ON
I :~~ (~) -:~) (g) (~) @ (~) @- Start signal (Start signal be repaired.
identifies display modes)
2
OFF
17 sec.j 13 sec.j I 0.5 sec. 0.5 sec.
@- Interval II
@-Indicates malfunctioning
2 sec. 2 sec. Varies with malfunctioning part
part (0.5 sec. ON and 0.5
sec. OFF is counted as
MRS099A one flash.)

5. If "AIR BAG" warning lamp operates as shown in No. 1 in the

chart above, turn ignition switch OFF to reset from Diagnosis ~]§,
mode to User mode, then go to step 6.

If "AIR BAG" warning lamp operates as in No.2 in chart above, ~J1

the malfunctioning part is not repaired completely, or another
malfunctioning part is detected. Go to DIAGNOSTIC PROCE-
DURE 3, RS-25, and repair malfunctioning part completely. ®f

RS-29 957
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)
Self-diagnosis (Cont'd)
6. Turn ignition switch ON. "AIR BAG" warning lamp operates in
User mode. Compare "AIR BAG" warning lamp operation to
the chart below.
NOTE:
If switching Diagnosis mode to User mode is required while
malfunction is being detected, turn ignition switch from OFF
to ON. Then press driver's door switch at least 5 times within
7 seconds after turning ignition switch ON.
SRS is now in User mode.

"AIR BAG" warning lamp operation - User mode - SRS condition Reference item

No malfunction is
IGN ON detected.

ON I No further action is neces-

sary.

OFF

MRS095A

The system has a problem Go to DIAGNOSTIC PRO-

and needs to be repaired CEDURE 2 or 3, RS-23 or
as indicated. 25.
ON

OFF

MRS096A

Air bag is deployed. Go to COLLISION

IGN ON
DIAGNOSIS, RS-37.

ON
I
Air bag fuse, diagnosis Go to DIAGNOSTIC PRO·
OFF sensor unit or harness is CEDURE 8, RS-35.
malfunctioning and needs
to be repaired.
MAS097A

One of the following has Go to DIAGNOSTIC PRO·

occurred and needs to be CEDURE 9, RS-35.
IGN ON repaired:
• Meter fuse is open
ON • "AIR BAG" warning
lamp circuit is shorted
OFF
or open
• Diagnosis sensor unit is
MRS098A malfunctioning

958 RS-30
TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)
Self-diagnosis (Cont'd)
DIAGNOSTIC PROCEDURE 6 (Continued from
DIAGNOSTIC PROCEDURE 2)
Inspecting SRS malfunctioning record
Is it the first time for maintenance of
SRS? ~ SELF-DIAG [CURRENT]
(which was previously
entered) is still retained in
Yes memory.
Go to DIAGNOSTIC PRO-
CEDURE 4, RS-26.

Go to DIAGNOSTIC PROCEDURE 7,
RS-32.

RS-31 959
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)
Self-diagnosis (Cont'd)
DIAGNOSTIC PROCEDURE 7 (@ with CONSULT)
Inspecting SRS intermittent problem by using CONSULT -
Diagnosis mode
1. Turn ignition switch OFF.
2. Connect CONSULT to data link connector.

3. Turn ignition switch ON.

NISSAN 4. Touch START.

CONSULT

START

SUB MODE ISRS046

5. Touch AIRBAG.
I~ SELECT SYSTEM Dl
I ENGINE I
I AIR BAG I

SBF884F

6. Touch SELF-DIAG [PAST].

1~ sELECT DIAG MODE ol
I SELF-DIAG I CURRENT I I
SELF-DIAG [ PAST I

TROUBLE DIAG RECORD

ECU DISCRIMINATED NO.

SRS050

7. If diagnostic codes are displayed on SELF-DIAG [PAST], go to

• SELF-DIAG [ PAST I • D step 10.
FAILURE DETECTED
CONTROL UNIT

PRINT I
.___ ____.:__:_::.;:..:...;__ _ _....J SRS054

960 RS-32
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)
Self-diagnosis (Cont'd)
If no self-diagnostic failure is detected on SELF-DIAG [PAST], •!ll~
• SELF-DIAG I PAST I • 0 touch BACK and go back to SELECT DIAG MODE.
FAILURE DETECTED
* NO SELF DIAGNOSTIC
FAILURE INDICATED.

FURTHER TESTING
MAY BE REQUIRED. **
PRINT
'------'--'-'.:.;_;_.:_____ ____, SRS062

8. Touch TROUBLE DIAG RECORD.

I~ SELECT DIAG MODE 0 I
I SELF-DIAG! CURRENT I I
I SELF-DIAG I PAST I I
TROUBLE DIAG RECORD

ECU DISCRIMINATED NO.

'------------',SRSOSS

9. Diagnostic code is displayed on TROUBLE DIAG RECORD .

• TROUBLE DIAG RECORD .o
FAILURE DETECTED
ASSIST NB MODULE
[OPEN]

PRINT
ISRS056

10. Touch PRINT.

11. Compare diagnostic codes to the INTERMITTENT PROBLEM
DIAGNOSTIC CODE CHART.
12. Touch BACK key of CONSULT until SELECT SYSTEM MODE ~~!
appears, then turn off CONSULT.
13. Turn ignition switch OFF, then disconnect CONSULT and both
battery cables. ©r
14. Repair the system as outlined by the Repair order that corre-
sponds to the problem code in INTERMITTENT PROBLEM
DIAGNOSTIC CODE CHART. For replacement procedure of
component parts, refer to RS-9.
15. Go to DIAGNOSTIC PROCEDURE 4, RS-26 for final check-
in g. ~y

RS-33 961
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)
Self-diagnosis (Cont'd)
INTERMITTENT PROBLEM DIAGNOSTIC CODE CHART

Repair order
Diagnostic item Explanation
Recheck SRS at each replacement.
NO SELF DIAGNOSTIC • No malfunction is detected. -
FAILURE INDICATED.

AIRBAG MODULE • Air bag module circuit is shorted to some 1. Visually check wiring harness connection.
[VB-SHORT] power supply circuit (including the spiral 2. Replace harness if it has visible damage.
cable). 3. Replace spiral cable.

AIRBAG MODULE • Air bag module circuit is open (including the 1. Visually check wiring harness connection.
[OPEN] spiral cable). 2. Replace harness if it has visible damage.
3. Replace spiral cable.
AIRBAG MODULE • Air bag module circuit is shorted to ground
4. Replace air bag module.
[GND-SHORT] (including the spiral cable).
(Before disposing of it, it must be deployed.)
AIRBAG MODULE • Air bag module circuits are shorted to each
[SHORT] other.
CRASH ZONE SEN-CTR • Crash zone sensor circuit is open, or 1. Visually check wiring harness connections.
[OPEN/UPR-VB-SHORT] • Crash zone sensor circuit is shorted to a 2. Replace harness if it has visible damage.
(4WD models) power supply circuit.
CRASH ZONE SEN-CTR • Both crash zone sensor circuits are shorted, 1. Visually check wiring harness connections.
[SHORT/UPR-GND-SHORT] or 2. Replace harness if it has visible damage.
(4WD models) • Crash zone sensor circuit is shorted to 3. Replace crash zone sensor.
ground.
CONTROL UNIT • Diagnosis sensor unit is out of order. • Replace diagnosis sensor unit.

962 RS-34
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)

Trouble Diagnoses for Air Bag Warning Lamp

DIAGNOSTIC PROCEDURE 8

I I I I I I I I I I I I· lis
SYMPTOM: "AIR BAG" warning lamp does not turn off.
w a1r bag module deployed? Yes._ Replace air bag module
0
U5 and diagnosis sensor unit

rTll
a: No
Refer to COLLISION

I I I I I I~
DIAGNOSIS. RS-38.

I I
jj1s SRS "Air Bag" fuse OK? No _J Replace fuse.
ARS122
~Yes
No
I~ SELECT SYSTEM Dl ® Connect CONSULT and touch
START. f----.
Replace diagnosis sensor
unit.
I ENGINE I • Is AIRBAG displayed on
CONSULT?
I AIR BAG I ~Yes
Is harness connection between warning
lamp and diagnosis sensor unit OK?
~ Connect warning lamp and
diagnosis sensor unit prop-
erly. If warning lamp still
Yes
does not go off, replace
SBF884F harness.

j Replace diagnosis sensor unit.

1il"

DIAGNOSTIC PROCEDURE 9
SYMPTOM: "AIR BAG" warning lamp does not turn on.

I I III LJJJ I 1~1. w

0
U5
Is warning lamp fuse OK?

~Yes
No
.... Replace fuse .

a: 1. Disconnect diagnosis sensor unit con- I Yes• Replace diagnosis sensor

LLI I I I I I I I I I~
nectar. unit.
2. Turn ignition key to ON position.
• Does warning lamp turn on?
ARS123 ~No
Is warning tamp LED ok? No
.... Replace warning tamp LED.

lYes

~
Is harness connection between warning Connect warning tamp and
lamp and diagnosis sensor unit ok? diagnosis sensor unit con-
nectar property.
pes

I Replace harness.

RS-35 963
 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)
Trouble Diagnoses for Air Bag Warning Lamp
B (Cont'd)
io~ DIAGNOSTIC PROCEDURE 10
SYMPTOM: SRS does not enter Diagnosis mode.
[Y] B
~r:=J Disconnect both battery cables and check
battery voltage using circuit tester.
No_. Charge battery.

• Is battery voltage more than 9V?

l
~
Yes
!;]
Remove driver's door switch and check
~ Replace driver's door
SRS058
continuity between driver's door switch switch.
!;] connector terminals G) and @ under the
~ ~ following conditions.
1:8 ('OF•:i
niSCONNtCT

Condition Continuity

u:J
Door switch is depressed
NO
(Door is closed).

Door switch is released (Door

Q YES
is open).

ARS083 res
[!1
[!1 Check harness continuity between driver's No___.j Replace or repair harness.
door switch connector terminal CD
and

~ 1rroo body ground.

• Does continuity exist?

~ +Yes
Replace diagnosis sensor unit.

LaJ~ ARS129
+
Go to DIAGNOSTIC PROCEDURE 3,
R5-25

964 RS-36
 COLLISION DIAGNOSIS

To repair the SRS, perform the following steps.

When SRS is activated in a collision:
CD Replace the diagnosis sensor unit.
® Remove the air bag module.
<IJ Check the SRS components using the table shown below:
• Replace any SRS components showing visible signs of damage (dents, cracks, deformation).
@ Install a new air bag module.
® Conduct self-diagnosis using CONSULT and "AIR BAG" warning lamp. Refer to "Self diagnosis", RS-22,
for details. Ensure that the entire SRS operates properly.
When SRS is not activated in a collision:
CD Check the SRS components using the table shown below:
• Replace any SRS components showing visible signs of damage (dents, cracks, deformation).
® Conduct self-diagnosis using CONSULT and "AIR BAG" warning lamp. Refer to "Self-diagnosis", RS-22
for details. Ensure that the entire SRS operates properly.

SRS inspection
Part SRS is activated SRS is NOT activated
Air bag module REPLACE. 1. Remove air bag module. Check harness cover and connectors for damage, ter-
Install with new minals for deformities, and harness for binding.
bolts. 2. Install air bag module into the steering wheel to check fit and alignment with the
wheel.
3. If no damage is found, reinstall with new bolts.
4. If damaged-REPLACE. Air bag module must be deployed before discarding.
Crash zone sensor 1. Check body and sensor bracket for deformities and rust.
(4WD models) 2. Check sensor case for derlts, cracks, scratches, deformities and rust.
3. Check sensor harness, connector, and terminals for binding, damage, and deformities.
4. If no damage is found, reinstall with new bolts.
5. If damaged-REPLACE.
Diagnosis sensor REPLACE. 1. Check case and bracket for dents, cracks and deformities.
unit Install with new 2. Check connectors for damage and terminals for deformities.
bolts. 3. If no damage is found, reinstall with new bolts.
4. If damaged-REPLACE.
Steering wheel 1. Visually check steering wheel for deformities.
2. Check harness (built into steering wheel) and connectors for damage and terminals for deformities.
3. Install air bag module to check fit and alignment with steering wheel.
4. Check steering wheel for excessive free play.
5. 1f no damage is found, reinstall with new bolts.
6. If damaged-REPLACE.
Spiral cable 1. Visually check spiral cable and combination switch for damage.
2. Check connectors, flat cable and protective tape for damage.
3. Check steering wheel for noise, binding and heavy operation.
4. If no damage is found, reinstall with new bolts.
5. If damaged-REPLACE.
Harness and Con- 1. Check connectors for poor connection and damage and terminals for deformities.
nectars 2. Check harness for binding, chafing, cuts and deformities.
3. If no damage is found, reinstall.
4. Damaged-REPLACE damaged section of harness. Do not attempt to repair, splice or modify any SRS
harness.

RS-37 965
 BODY & TRIM ~ 1

SECTION BT
CONTENTS
PRECAUTIONS ............................................................... 2 SUNROOF .... .................................................................25
Supplemental Restraint System (SRS) "AIR Service Procedure ..................................................... 25
BAG" ............................................................................2 WINDSHIELD AND WINDOWS ..................... .... 26 101
GENERAL SERVICING ......................... . ................. .... 3 Windshield ........................... . .............................. 27
Clip and Fastener ......................................................3 Back Window ....... .. .. ...................... .......... .... ..28
BODY END ............................................................... .... 6 Rear Side Window ..................................................... 29
Front End ................................................................... 6 MIRROR .........................................................................30
Rear End .................................................................... 7 Door Mirror. ................................................................30
Step Bumper... .. . .. ........... ............ .. ..... ..... 8 Rearview Mirror ....................................................... 31 JW
DOOR ........... .................................................................9 CAB AND REAR BODY ......... ...................................... 32
Front Door........... .............. ............................... 9 Removal ............................ . . ................... 32 Yf
INSTRUMENT PANEL ..................................... 10 Cab Body... ............... . ....... 32
INTERIOR TRIM ...................... ..................................... 13 Rear Body ........................................... . ......... 32
Side and Floor Trim ~ Passenger room ....... . ... 13 Body Mounting ........................................... . ..... 33 PC!
Roof Trim.................... ............................ 15 BODY ALIGNMENT ....................................... . ...... 34
EXTERIOR ................................................................... 17 Engine Compartment... ............................... . ..... 35
SEAT............................... . ....................... 23 Underbody.................... .............. ....................... 36 ]'["\
Front Seat .................................................................23
Jump Seat ~ King Cab Model. ................................. 24

** For seat belt, refer to MA and RS section.

For wiring diagrams of body electrical systems, refer to EL section.

967
 PRECAUTIONS

• When removing or installing various parts, place a cloth or padding on the vehicle body to prevent
scratches.
• Handle trim, molding, instruments, grille, etc., carefully during removal or installation. Be careful not to soil
or damage them.
• Apply sealing compound where necessary when installing parts.
• When applying sealing compound, be careful that the sealing compound does not protrude from parts.
• When replacing any metal parts (lor example, body outer panel, members, etc.), be sure to take rust
prevention measures.

Supplemental Restraint System (SRS) "AIR

BAG"
The Supplemental Restraint System "Air Bag", used along with a
seat belt, helps to reduce the risk or severity of injury to the driver
in a frontal collision. The Supplemental Restraint System consists
of an air bag module (located in the center of the steering wheel),
a diagnosis sensor unit, warning lamp, wiring harness, a crash
zone sensor (4WD models) and spiral cable. Information necessary
to service the system safely is included in the RS section of this
Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could
increase the risk of personal injury or death in the event
of a collision which would result in air bag inflation, all
maintenance must be performed by an authorized
NISSAN dealer.
• Improper maintenance, including incorrect removal and
installation of the SRS, can lead to personal injury caused
by unintentional activation of the system.
• Do not use electrical test equipment on any circuit related
to the SRS unless instructed to in this Service Manual.
SRS wiring harnesses are covered with yellow insulation
either just before the harness connectors or for the com-
plete harness, for easy identification.

968 BT-2
 GENERAL SERVICING

Clip and Fastener

• Clips and fasteners in BT section correspond to the following numbers and symbols.
• Replace any clips and/or fasteners which are damaged during removal or installation.

Symbol
Shapes Removal & Installation
No.

Removal:
Remove by bending up with
flat-bladed screwdrivers or

T if ~
clip remover.
@D

'~~1
f)

SBF302H SBF367BA

<§:>

cf~T~l ~~>
~~~)
9 Removal:
Remove with a clip remover.
~

:----
SBF303H SBF423H

Push cente' pin t o /

catching position.

s
(Do not remove

i
Push

• center pin by hitting it.)

T T•
<§> Push

~ ~
$ {),

Installation:

SBF258G SBF708E

Removal:

<@)
- 'b&k
!-- ~ (J -
~
~
SBF1048 SBF147B

BT-3 969
 GENERAL SERVICING
Clip and Fastener (Cont'd)
Symbol
Shapes Removal & Installation
No.

Removal:
Remove by bending up with
flat-bladed screwdrivers.

l J'L Radiator
t V~ ~
grille

~
SBF351C SBF352C

SBF353C

Removal:
Clip-A

TA§
I Finisher
c~-J \
(~Seal
F~
~;;;;;\~ I >~.~~J-
lJ Ftat-btadedJ ~J 1 1
~
' \ Clip-8
screwdriver 1• l G
Clip-B J /11 (rommet
I

~(Grommet) Body panel }_Clip-A

SBF651B SBF6528

Removal:

SBF648B SBF649B

SBF317C SBF5718

970 BT-4
 GENERAL SERVICING
Clip and Fastener (Cont'd)
Symbol
Shapes Removal & Installation
No.

Removal:
Holder portion of clip must be

~
spread out to remove rod.

~
SBF768B
~3¢~ SBF770B

Removal: Installation:

/m'
~ ~ l&~
Rotate 45°
@l> to remove.

SBF145B
Removal:
; ~

SBF085B

Removal:
1. Screw out with a Phillips
screwdriver.

T
2. Remove female
Tr.:
I

~ T I I portion with
flat~bladed
~ screwdriver. ~

~~ ~ ¥
'i
~
@

SBF078B
{i SBF992G

II

BT-5 971
 BODY END

Front End
• Hood adjustment: Adjust at hinge portion.
• Hood lock adjustment: After adjusting, check hood lock control operation. Apply a coat of grease to hood
lock engaging mechanism.
• Hood opener: Do not attempt to bend cable forcibly. Doing so could increase effort required to unlock hood.
• Bumper finisher: It is made of plastic. Do not use excessive force and keep oil away from it.

SEC. 260•261•262•620•623•650•656

Hood hinge
Hood lock adjustment
• Adjust hood so that hood primary lock \
meshes at a position where hood is 1 to 1.5 \
mm (0.039 to 0.059 in) lower than fender.
• After hood lock adjustment, adjust \
bumper rubber. \
• When securing hood lock, ensure it does \
not tilt. Striker must be positioned
at the center of hood primary lock. \
• After adjustment, ensure that hood \
primary and secondary lock operate properly. \ When removing,
remove cowl top grille.
Hood lock secondary latch hooking length

~0.-1:75- mm;:tj- I Hood

0.374 in) ~~ =
1
~Secondary latch ~ Hood adjustment

1111 5.1- 6.5

(0.52 ~ 0.66,
45.1 ~ 57.3)

* : Bumper assembly mounting bolt

:ell : N•m (kg-m. ft-lb)
~ : N•m (kg-m, in-lb)
m: Should be lubricated with grease

ABT157

972 BT-6
 BODY END

Rear End
SEC . 9J OA •940A

n,0
lS\0

t,ql ' N. m (kg·m, ft·lb) !;L

EJ: Shouldbe lubricated with
. grease

ABT152

BT-7 973
 BODY END

Step Bumper
SEC. 850

~ 59 - 78 (6.0 - 8.0, 43 - 58)

tt=!l•• .78 (6.9 . 8.0. 50 . 58)

~: N·m (kg-m, ft-lb) ABT163

974 BT-8
 DOOR

Front Door
• For removal of door trim, refer to "INTERIOR TRIM", BT-13.
• After adjusting door lock, check door lock operation.

SEC. 800•803•805

kr.=-. -~ Inside handle installation and adjustment II Door adjusbnent IJ

Front sash
adjustment

~lil!ls-1 -6.5 (O.S:!- 0.<66,-,

45.1 -

• ~ ~ao0 j~il

j~
33.0- 44.3)

adjustment

Rear sash

Door inner panel

'""'
"· ~' '\.. Inside handle

0.5-1.5
Unit: mm Qn) (0.020 • 0.059)

•
Striker adjustment ljl: N ·m (kg-m, in-lb)
~13-16(1.3-1.6, ~' N ·m (kg-m, ft-lb)
9 -12)
II!EI : Should be lubricated
with grease

ABT153

BT-9 975
 INSTRUMENT PANEL

CAUTION:
• Disconnect both terminals from battery in advance.
• Disconnect air bag module connector in advance.
• Be careful not to scratch finishers and other parts.
• Never tamper with or force air bag lid open, as this may adversely affect air bag performance.
REMOVAL - Instrument panel assembly
I Instrument panel assembly I Combination meter I I Audio control J I Heater and A/C control II Console box I
Iremove air bag module and steering wheel.
Refer to RS and ST sections. I
Steering column cover
lCD • Remove four screws. I
I I
I® Instrument lower panel driver side
e Remove two screws. J[!]
I I
I@ e Cluster lid A
Remove four screws. I
I I
I@) Combination meter
e Remove four screws, then disconnect harness connectors.
I
Glove box assembly
I® • Remove six screws and two pins. I
I I I
I® Instrument lower panel passenger side
e Remove one screw.
J
1Remove ashtray I
1(7) Cluster lid C
• Remove two screws, then disconnect harness connectors. 1131
I I
Audio and deck pocket
I® e Remove four screws, then disconnect harness connectors.
I

I® Heater and NC control

e Remove mask and two screws.
• Disconnect temperature control cable and harness connectors.
I
I
I@ e Instrument stay cover lower center
Remove two screws.
I I!]
I® Instrument lower panel center
• Remove six screws. I
Ventilator grille driver side
I@ e Remove one screw. llil
I
I@ e Defroster grille
Remove three grilles. lr.i.1
~~emove left and right front pillar gar-
nishes. I
I
I® Instrument panel assembly
• Remove nine screws and bolls
marked*.

Center console
I@ e Remove five screws. _I
I
AfT finisher
I@ e Remove four screws, then disconnect harness connector. I
INSTALLATION
Reverse the procedures described above.
Pay attention so as not to scratch the parts (plastic). During installation, fit the dueling parts exactly.

976 BT-10
 INSTRUMENT PANEL

~]

SEC. 272•280•680-685•969

Pawii!J

12

* jf['

Pawl II

Pawl

*: Instrument assembly mounting screws ~[L

ABT154

BT-11 977
 INSTRUMENT PANEL

Pawl

~===4CII

ABT155

978 BT-12
 INTERIOR TRIM

If]]
Side and Floor Trim - Passenger room
• Wrap the tip of flat-bladed screwdriver with a cloth when removing metal clips from garnish.
• When handling interior or exterior parts, do not use excessive force and take care not to damage them. li!l~,

Regular Cab

SEC. 678•749•769•803•805•809

I
Front pillar garnish
Metal clip

XE model
Pawl model
door trim
door trim

Metal clip

Door pocket
(driver side only)

II Manual window regulator handle

Removal

CD
~
(~·Push
~~ Wrap miniature
flat~bladed
screwdriver
with tape

Push the regulator handle clip with a screwdriver

being careful not to scratch handle or door trim.
Then remove the regulator handle from the regulator shaft.

Installation

Before installing, position the regulator handle clip as shown

in figure (1).

45° c=) Front

Pawl Push the regulator handle onto the regulator shaft.

Pawl
Install the regulator handle in place as shown· in
L.__ _ _ _ _ _ _ _ _ _ _- - l L.__ _ _ _ _ _ _ _ _ _ __ , L__'h_•_'_'9_"'_e_w_''-h-th_e_w_l_nct_o_w_c_o_m_o_le_t_•'_Y_"'_o_se_ct_.- - - - - - - - - ' ~rg,y:

ABT217

BT-13 979
 INTERIOR TRIM
Side and Floor Trim - Passenger room
King Cab (Cont'd)
SEC. 678•749•769•799•803•805•809

m m 1!1 I!J

I ·~
~
~'
~
~

~ ~~ ~~~j :::::'~~
if~
~ Pay attentoon to,;;;e
~ ',
'~
d1rect1on of pawl
when installing Gamishy~·--.._ '"'
screw cover.
• Gam;,\
Gac::>

Metal clip OJ
Metal clip IJ

Metal clip 11

Pawl II

SE model
door trim*

Metal clip II

*For XE model door trim,

see "REGULAR CAB".

Front
pillar

After removing screw @,

move arm rest in
direction of arrow @ and
remove it.
ABT160

980 BT-14
 INTERIOR TRIM

Roof Trim
Regular Cab
SEC. 738•769•797•964

Metal clip IJ
Metal clip 111

IJ \ R~of panel II ~Roofpanel

\;~ndsh1eld .-~ Welt retainer Reanoo~~:X // ~
\~·;;~'-f.._F("nt roof'"''
__ .... /;-::
i,...__. .... / /
<;
'i'
t"- ~::" I
:;t./Back window
,, lj weatherstrip

Welt
" ~
~~"-Z.
!'::::::-1
Li,.
Rooftnm

ABT162

•
BT-15 981
 INTERIOR TRIM
Roof Trim (Cont'd)
King Cab
SEC. 738•769•797•964

ABT158

982 BT-16
 EXTERIOR

• Apply sealing compound where necessary while installing parts. ·~I

• When applying sealing compound, be careful that the sealing compound does not protrude from parts.

19

ABTi64

BT-17 983
 EXTERIOR

CD ® Cowl top sealing rubber & grille ® Windshield upper molding

SEC. 660 SEC. 720

Method 1 Cut off top portion of molding
and clean glass and panel
surfaces.

51!•~4
Cowl top grille
•
Apply sealant to top portion of
molding.

q{)
~~"'
~~
Cut off lower portion 4-
of new molding

Pawl Ss.""
Finish well to give it a
good appearance.

adhesive tape Method 2

1. Cut off sealant at glass end.
2. Clean the side on which panel was mounted.
3. Set molding fastener and apply sealant & primer to body
panel, and apply primer to molding.

Apply "'"me1c.~

ABT167

adhesive tape
~--A,ppl•y sealant.
Sealant
~AP'P'Y primer.

4. Install molding by aligning the molding mark located on center

with vehicle center.
Be sure to install tightly so that there is no gap around the
corner.

ABT168

984 BT-18
 EXTERIOR

@)@ Windshield side & lower molding

SEC. 720

ABT169

® Drip weatherstrip ® Door weatherstrip

SEC. 800
~ ______________ Dou bl e-faced adhesive tape
SEC. 767 Double-faced adhes•ve Door weatherstnp

~---
='?~\
"'---,, \\\\
'1\ \1 \:\
\\ I - -
\\\_I

'·,,·,,,':---
;__ _ _
I Roof
_I
I r Dclp chaonel
f8{.. \~r'''''""''
i
1\', ', ;, . ~j; r- Roof ,;de
1 I

J) v/ Q)
~
!

'-~
1

I IS- 1 """' '"'

/
R r~&
1
Drip weatherstnp
L..-.-

Llnner door \\J

ABT170 ABT172

0 Body side welt ® Door corner cover

SEC.769 SEC. 963
(" Door corner outer cover

Seal
~ o, 0

~~~~"-~~n
~ • ·~_-_·.·_1_''
\'ljlt')ll. Seal

•
~~!~::··. . · · ~-.:"\c
Y <.: \ 0
Body side welt
~-~DC~
Body panel__/ =---~\'
Door corner
inner cover

ABT171 ABT173

BT-19 985
 EXTERIOR

@ Door waist inner seal @ Back window

SEC. SEC. 797
800 I Fixed glass type
Fixed glass /~
7
Weatherstrip If{/~___-/---

~-'-~- .· ---::;::;:;
(i:ny~
Bodypa~

ABT174

@ Door waist outer seal

SEC. 800 II Slide glass type
I \ ·, -ti)\)/\ • : Pawl portion • Fixed glass part

\ '\ rz,~'/io:\ , . . - - - - - - - - o uTotcemove. dmw

~
~ ~V molding by
I
\ I
1
.@'f,,O Q
@/ ·'-
1\.1
Side window
glass
l
Outside rotating upper
~
__
side of molding.
~
.@'' /\I ~~ Outs~· ~----
\ \ /

'\ 0',i;_.'l
·V...,. ~ · seal
de d. ooc .· • :.
r' _. - Weatherstri~·;
..,.,.;..."""'' ~~~-~",~ ----~-~- Glass run rubber ·
Bonding portion_) /
Body panel_/ Seal~
Door panel (Inner) • Slide glass part
Inside
\-Door panel (Outer)

ABT175

@ Drafter duct
SEC. 767
_[~J~ Gcommet
·-c=. "--=~ __ \. __ .-- ~-
~t-fl00
~ g;/ L -~
I;
J.~-~-==~ n
-1
I I I/' ~--c.
I
I '
I .____:/
- 1I ] / II
'0.../
ABT177

/
~~Dmftec duct

Body panel_/"
~~
=::::::::
------..
............
Drafter duct
protector
1 Sealer

ABT176

986 BT-20
 EXTERIOR

@ @ Rear side window weatherstrip and @ @ Sunroof weatherstrip and lid

rear side window protector protector
SEC. 830 SEC. 736

~
, S'Omoof lid /
Sunroof lid protector

Rear side window

protector

Rear side window

Sealant
portion
weatherstrip
ABT178 ABT156

@ High-mounted stop lamp

SEC. 268

ABT179 ~,j

BT-21 987
 EXTERIOR

@ @ Fender protector and mudguard

SEC. 767

ABT165

@ Step bumper cover

SEC. 850

ABT166

988 BT-22
 SEAT

. the seat tnm,

. carefully handle ·tI to keep d·crt out and avOI·d damage. !(jl
. or installing t
• When removcng Front Sea

BUCKET SEAT

SEC. 870 Type·l ~~~~

t holder
Head res h0 lder after
• Removeup sea t back trim.
rolling

tDJ 43.55
(4.4- 5.6,
32- 41)

"" 43.55
.-. (4.4. 5.6. 32. 41)

-m ft-lb)

e.
::::.J, N·m (kg • .
Grease-up POint 0 much grease as It w
· {Do not apply to
. ill dcip.)

ABT180

BT-23 989
 SEAT
Fran t Seat (Cont'd)
BENCH SEAT

~ 21-26{2.1-2.7,15-201~--

:g '' ·,rs [Do oot apply too much as ·twill

N-m [kg-m, ft-lb) I drip.)
• Cab Mod e J
m Gce.,e-op po, - t - Kmg ABT181

Jump Sea
SEC. 880

.:~·7
:g 21.26

(kg-m, ft-lb)
: N-m oints
~: Grease-up P
~ t apply too
(Do noas I"twill drip.)
much

ABT182

990 BT-24
 SUNROOF

Service Procedure

SEC. 736 Handle

Female hinge

SBF914A

Hinge bracket

SBF913A

Air deflector Handle base

Drain hose
After installation of drain
hoses, make sure water
drains smoothly·

SBF821A

~ : N·m (kg·m, ft-lb): Wl'~

ABT183

BT-25 991
 WINDSHIELD AND WINDOWS

Cutting sealant REMOVAL

After removing moldings, remove glass using piano wire or power
cutting tool and an inflatable pump bag.
CAUTION:
Be careful not to scratch glass when removing.
INSTALLATION
• Use genuine Nissan Sealant kit or equivalent. Follow
instructions furnished with it.
• Alter installation, the vehicle should remain stationary
until the sealant hardens.
WARNING:
Keep heat and open flames away as primers are flammable.
CAUTION:
Advise the user not to drive the vehicle on rough roads or
surfaces for 24 hours alter installation.
• Do not use sealant which is past its usable term.
• Do not leave cartridge unattended with its cap open.
• Keep primers and sealant in a cool, dry place. Ideally, they
should be stored in a refrigerator.
• Molding must be installed securely so that it is in position
and leaves no gap.

ABT087

992 BT-26
 WINDSHIELD AND WINDOWS

Windshield
Body side
SEC. 720 Install molding fastener. Install dam rubber & spacers with double"
When installing it, heat body panel and faced adhesive tape.
fastener to approx. 30 to 40 C ~86 to 104 F), 1
/- Dam rubber
~-~ r---o~,m-,-,~b-b-,-,- - ,
7
i \I Spacer---.., /
I
~~ =C>\ /
®c-.~
Vehicle L Double-faced
center adhesive tape
'L' : Spacer mounting portion
(Spacer should be installed
at slit portion of dam rubber.) SBF389D

Install spacers to panel. L.H. side only \

/Side molding
I - - Glass f Glass S~ealing wa\sher 7
1
1 I
/~soecec
s,d,
/ ! molding\ \/ ~
~Double-faced j~~ • ".~
~Specec ~
~~ adhesive tape
l,'ili'T
~ ~Body panel

,\
'----- Body panel \\

~Glass \

<~"
-;i ~

'T v~\"

/
L_
,' L_ Double-faced
adhesive tape
Spacer
I., 2~5 1

275
{10.83) {10.83)
I~
Unit: mm lin)
SBF785D
ABT184

Sealant application areas

Apply sealant to windshield Glass Apply sealant to back door window

--50 mm
7-8 mm (1.97 in)
(0.28 - 0.31 in)

//,_~
1'
7'---t----'----. /
,/ · 7 - 8 mm (0.28 - 0.31 in)
Lower side of glass MBF767A
MBF/86A

Apply sealant evenly. _ (0. _ _ Apply sealant additionally to lower

7 8 28 0 311 portion of glass and make it uniform
as shown below.
~Glass

12 - 15
More than 5 mm
(0.47
(0.20 in)

L.._ Original sealant

' - Additional sealant

MBF788A SBF727C
MBF919A

BT-27 993
 WINDSHIELD AND WINDOWS
Windshield (Cont'd)
REPAIRING WATER LEAKS FOR WINDSHIELD
Leaks can be repaired without removing and reinstalling glass.
If water is leaking between caulking material and body or glass, determine the extent of the leak.
This can be done by applying water while pushing glass outward.
To stop the leak, apply primer (if necessary) and then sealant to the leak point.

Back Window
• Window glass is held in place by weatherstripping. For details regarding weatherstrip, refer to
"EXTERIOR", BT-17.
• Using sealant, fill gaps between vehicle body and weatherstrip as necessary.
SEC. 797

Back window weatherstrip

Sliding glass

'i Back window

I

Back window

Remove fixed glass

after removing sash.

ABT185

994 BT-28
 WINDSHIELD AND WINDOWS

~:~j
Rear Side Window
SEC. 830
~~~~~·

Rear side window-

weatherstrip
i~IK:ii
~Rear side window
handle adjustment

lo©

~©

if'~

©l
\ Rear s1de,
window hinge
ilu1i'

J\11

Tl'
ABT186

l~li!l

I'J\

~~

~ll'

~&!

BT-29 995
 MIRROR

Door Mirror
SEC. 963

ABT187

* For Wiring Diagram, refer to "MIRROR" in EL section.

996 BT-30
 MIRROR

Rearview Mirror
REMOVAL
Remove rearview mirror by deflecting spring with screwdriver as [iiuffi\
shown in the figure.

Windshield

Mounting
bracket

Windshield

Mirror assembly

Deflect spring
using screwdriver
Side view

ABT188

Mounting bracket location

INSTALLATION
1. Install mounting bracket as follows:
144.9mm {5.70 in)
Bracket a. Determine mounting bracket position on windshield by mea- 11!1ll
l suring from top of windshield to top of mounting bracket as
shown in the figure.
b.
T Mark location on outside of windshield with wax pencil or
equivalent.
©11

c. Clean attaching point on inside of windshield with an alcohol-

saturated paper towel. liJ::J
d. Sand bonding surface of mounting bracket with sandpaper
Center of windshield
ABF150 (No. 320 or No. 360).
e. Clean bonding surface of mounting bracket with an alcohol-
saturated paper towel.
f. Apply Loctite Adhesive 11067-2 or equivalent to bonding sur-
face of mounting bracket. ~lffil
g. Install mounting bracket at premarked position and press
mounting bracket against glass for 30 to 60 seconds.
h. After five minutes, wipe off excess adhesive with an alcohol- ~l
moistened paper towel.
2. Install rearview mirror.

BT-31 997
 CAB AND REAR BODY

Removal
CAB BODY
• Remove the following parts in engine compartment at least.
(1) Main harness and other wiring harnesses
• Disconnect brake and clutch lines in engine compartment.
• Remove the following parts from underbody at least.
(1) Transmission and transfer control levers
(2) Parking brake control lever and cables
(3) Main harness and other wiring harnesses

SEC. 930 REAR BODY

• Remove the following parts at least.
(1) Rear combination lamp and license plate lamp harness
(2) Fuel filler tube fixing screws

998 BT-32
 CAB AND REAR BODY

Body Mounting
When installing, be sure to use new bolls and nuts (sealant applied bolts or self-lock nuts are used
for all mounting).

ilil'il
A
Regular Cab model
King Cab model

c:Q) : Except for short whee[base model (This bracket is not used for body mounting.)

L_--~-J 19-25 L...._lu~ 31 -42 L....-l'~J 31 . 42

(1.9- 2.6, (3.2 -4.3, (3.2. 4.3,
14- 19) 23- 31) 23- 31)

Section@ Section@ Section@

4WD

2WD

Shim [t = 6.5 mm (0.256 in)] Shim

[t=6.5mm
Shim
(0.256 in)]
[t=4.5mm
(0.177 in)]

~ 20-24
R 20-24 L__ [•.!J 20 - 24
(2.0- 2.4,
(2.0- 2.4, (2.0 -2.4, 14 -17)
14 -17) 14 -17)
~: N·m (kg-m, ft-lb)
Section (Q) Section@
SBF350C

BT-33 999
 BODY ALIGNMENT

• All dimensions indicated in figures are actual ones.

• When using a tracking gauge, adjust both pointers to equal length. Make sure there is no free play.
• When a measuring tape is used, check to be sure there is no elongation, twisting or bending.
• Measurements should be taken at the center of the mounting holes.
• All measurements and mounting hole diameters are expressed in millimeters (mm).
• An asterisk (*) following the value at the measuring point indicates that the measuring point on the other
side is symmetrically the same value.
• The coordinates of the measurement points are the distances measured from the respective dimension
lines in the directions of "x", "y" and "z".
Dimension lines: "x" line - Center line of vehicle
"y" line- Center line of front axle (Any measurement point in front of the dimension line
refers to a minus "-"value.)
"z" line- Datum line (Any measurement point under the dimension line refers to a minus
"-"value.)

[]Y[J : 2WD 2W.SB : Short wheelbase (2WD)

~ :4WD I 2W.LB I : Long wheelbase (2WD)

@§] : Short wheelbase I 4W.SB I : Short wheelbase (4WD)

o::.!D : Long wheelbase I 4W.LB I : Long wheelbase (4WD)

[KJ : Regular Cab

[K] :King Cab

1000 BT-34
 BODY ALIGNMENT

Engine Compartment Slil

MEASUREMENT
#'
//)'

Unit: mm

DETAILED MEASUREMENT POINTS Unit: mm

Upper radiator core support

Cowl top side ! Side radiator core support

I
~~

~ Hoo~~nge ___ _

~
~'~
=• . '
ra· "· .. ,
/'
:/1'\ 8 dlo. (MB)
Front
fender

•
MBF726A

BT-35 1001
 BODY ALIGNMENT

Underbody
MEASUREMENT POINTS
2WD models

. ·~@
~·
~
•
0 ~

e•
~

-"'

~ .~
0
@ill
"' " ·•6!
··~
[!;]~
6!

@.....
@).,..

SBT184

1002 BT-36
 BODY ALIGNMENT
Underbody (Cont'd)
MEASUREMENT POINTS @I
4WD models
~:~Uffi'l

~~~

··~
!,<::';

~0

If'~

©!o

l!u1i'

Yl1i'

ll~

~[[i)

IPYl

];[Rl

§)'[:

~~'

SBT185

BT-37 1003
 BODY ALIGNMENT
MEASUREMENT Underbody (Cont'd)
2WD models
Regular Cab
60
1,480*

® ® ,,..
@-® ®-© ©-@ @ ®
527' 658' 1,040* ,,.. ®-CD
1,236'
®-®
1,481"
®·©
1,654"

All dimensions in this figure are actual

ones.
There are no projected dimensions.
Unit: mm
MBF824AA

King Cab

60
1,480'

(C·,
CD
(a.;
'-
I (6)

® ~-~-~rH"'
®,,.@ @ ® '-!:)
1,164'
®® ®© ©@ @ 0 ®0
527' 658' 1.390' 409' 1,236'
® ®
1,481"
®-@
2,000'
®@
2,480'
:I
All dimensions in this figure are actual
ones.
There are no projected dimensions.
Unit: mm

MBF826A

1004 BT-38
 BODY ALIGNMENT
Underbody (Cont'd)
4WD models ~I

Regular Cab
®0
761"

© @
Q)

@-@
1,167*
©·@ @0 ®·CD
1,040' 454" 1.236' 251'

®@ ®C0
1,646* 1,401'
®·@
2,131'

All dimensions in this figure are actual

ones.
There are no projected dimensions.
Unit: mm
MBF827AA

King Cab
®0
761'

@@
1,390* 251'
® ©
148 •

1,994'
®·©
2,480'

All dimensions in this figure are actual

ones.
There are no projected dimensions.
Unit: mm
MBF829A ~[Q)}Z

BT-39 1005
 BODY ALIGNMENT
Underbody (Cont'd)
DETAILED MEASUREMENT POINTS
Coordinates mm
Hole dia.
Points Detailed points
mm "x" "y" "z"

~:
21.2
®@ 24 450.0 -488.5
~:
71.2

~:
-28.2
©@ 28 Cab body or
605.0 597.5
~:
rear body 21.8
Center of hole on top of bracket mounting insu-
lator mounting IJD ~:
@@ 85 ~---¢-7 hole
593.5
1,637.0
[i<]
-15.0
~:
L / ~ 1,987.0 35.0

~: ~:
2,050.0 171.8
®CD 18 570.0
[Ql] ~:
2,350.0 221.8

~: ~:
3,286.0 171.8
Q:lCD 18 Cab body or
565.0
IT§_]: ~:
rear body 3,586.0 221.8
mounting insu-
Jatar mounting ~:
hole 3,530.0
©CD 22 505.0
IT§_]:
220.0

SBF274B 3,830.0

2WD @jj' 4WD 1

rt~~ Hole for front

!~
~: shock
12w I= ~: ~:
15 434.7 5.6 203.2
@@ ~:
absorber
~: ~: ~:
mounting at
15.3 439.7 1.4 142.0
the bracket

~
SBF668C

Front Front mounting

~~
bracket
I2W.SB 1:
2,059.0
Hole for rear ~: ~:
l(t D~
I2WLB I=
spring front 469.0 2,359.0 -152.0
@@ 12
mounting at I4W 1: I4W.SB 1: ~:
£::::::?- • CJ the bracket 470.5 2,080.0
I4W.LB 1:
-86.0

Inner side ® 2,380.0

SBF795G

1006 BT-40
 BODY ALIGNMENT
Underbody (Cont'd)
Coordinates mm
Hole dia.
Points Detailed points
mm "x" "y" "z"

Front ~ Rear mounting

~
bracket

~
I 2W.SB I'
3,209.0
Hole for rear I 2W.LB I' I2W I'
-J( spring rear 3,509.0 30.0
®®
@"'~
33 480.0
mounting at I 4W.SB I' ~:
~\ the bracket 3,240.0 43.0
Inner side I4W.LB I'
3,540.0

SBF796G

r.=l~®l®
i Hole for body ~:
mounting at 3,530.0
®® 22
rear of side
505.0
~:
170.0

member outer 3,830.0

Side member outer

SBF797G

~:
Tens1on rod
Front bracket
\!::; {: Hole for ten-
sian rod
@@ 27 254.6 -417.1 -92.3

•
mounting at
the bracket

~@

SBF798G

(~;~
//
' ' cJ I
/ x •
~------
~ ~--....._

I
"
\\\

2.- \:;:;
~~
I J'--
1// Hole for local-
I
.4;:.:;::-n
///1P2C' ing at bound
@@ 9
"
0

.@
)

0':
,-
U ..
/"
/~-
-~
bumper
359.5 -3.2 -23.5
G'i;C)
~
/;i .:/
~ / (L//
- //( // bracket

/b /
L~sumper rubber /

SBF799G

BT-41 1007
 BODY ALIGNMENT
Underbody (Cont'd)
Coordinates mm
Hole dia.
Points Detailed points
mm "x'· "y" "z"

I
iY~~ ([)

r ~~-?-
a,J •®
~-' p ~
1
Hole for
rebound

if(!:i,\~
bumper
®<W 10.5 447.0 ~88.0 ~14.9

~~
mounting at
lower link
bracket
~:J__L

SBF800G

c;
~--Compression
rod bracket

Front Hole for com-

F; r'
@@ 27 ¢J I
~
pression rod
mounting at
361.1 294.5 ~ 158.9

- t~
.@® the bracket

wj ::::o_
SBF801G

s -Side member outer

L.._

Hole for wax-

ing at lower
®0 13
I side of side
510.0 1,040.0 ~135.0

'
~+F
member outer

··®CD
I
SBF802G

1008 BT-42
 HEATER & AIR CONDITIONER ~~

SECTION HA
CONTENTS
PRECAUTIONS AND PREPARATION ............................ 2 Trouble Diagnoses for Abnormal Pressure ............... 25
Precautions for Supplemental Restraint System Harness Layout. ......................................................... 28
(SRS) "AIR BAG". .. ......................................... 2 Circuit Diagram .......................................................... 29 ©i
Introduction ................................................................ 3 Wiring Diagram -HEATER- ...................................... 30
Precautions for Working with R-134a ........................ .4 Wiring Diagram -A/G-............................................. 31
General Refrigerant Precautions .................... ... .4 Main Power Supply and Ground Circuit Check ........ 33 f0u!Y
Precautions for Refrigerant Connection ..................... 5 Diagnostic Procedure 1 ............................................. 34
Precautions for Servicing Compressor ........................ 6 Electrical Components Inspection ............................ .41
Special SeNice Tools .................................................. 6 Control Linkage Adjustment.. .................................... .42 L§~f
R-134a SeN ice Tools and Equipment.. ...................... 7 SERVICE PROCEDURES ..................................... ........ 44
Precautions for SeNice Equipment.. ........................... 9 Checking Refrigerant Leaks... .. .. 44 'ii'!f
DESCRIPTION...... ... ............ .. .................................. 11 Refrigerant Lines ...................................................... .47
Refrigeration Cycle ................................................... 11 R-134a SeNice Procedure ....................................... .48
Component Layout .................................................. 12 Compressor Lubricant Quantity ................................. 50 /'IT!
Discharge Air Flow............ ........................ 13 Compressor Mounting ............................................... 52
Control Operation ...................................................... 14 Belt Tension................................... .. ................ 52
TROUBLE DIAGNOSES ............................................... 15 Fast Idle Control Device (FICD) .............................. 52 [FJ!,
How to Perform Trouble Diagnoses for Quick Condenser ................................... . .................... 52
and Accurate Repair .................................................. 15 Compressor .......... ................. ....... .. .................. 53
Operational Check ..................................................... 16 Compressor Clutch ................................................... ,53
Symptom Chart .......................................................... 18 Thermal Protector ......................................................56
Preliminary Check ..................................................... 19 SERVICE DATA AND SPECIFICATIONS (SDS) .......... 57
Performance Test Diagnoses .................................... 22 General Specifications....... .. ........................ 57 [@ill
Performance Chart ................................................... 24 Inspection and Adjustment ....................................... 57

When you read wiring diagrams:

• Read Gl section, "HOW TO READ WIRING DIAGRAMS".
• See EL section, "POWER SUPPLY ROUTING" for power distribution circuit.
When you perform trouble diagnoses, read Gl section, "HOW TO FOLLOW FLOW
CHART IN TROUBLE DIAGNOSES" and "HOW TO PERFORM EFFICIENT DIAGNOSIS
FOR AN ELECTRICAL INCIDENT".

1009
 PRECAUTIONS AND PREPARATION

Precautions for Supplemental Restraint System

(SRS) "AIR BAG"
The Supplemental Restraint System "Air Bag", used along with a seat belt, helps to reduce the risk or sever-
ity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of an air bag mod-
ule (located in the center of the steering wheel), a diagnosis sensor unit, warning lamp, wiring harness, a crash
zone sensor (4WD models) and spiral cable. Information necessary to service the system safely is included
in the RS section of this Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed
by an authorized NISSAN dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses are covered with yellow insulation either just before the
harness connectors or for the complete harness, for easy identification.

1010 HA-2
 PRECAUTIONS AND PREPARATION

Introduction <1,1~
To prevent the ozone layer from being destroyed, R-134a refrigerant has replaced the previously used CFC-12
(R-12). f>ll$:,
The new and previous service tools, refrigerant, lubricant, etc. are not interchangeable due to differences in
their physical properties and characteristics.
Always service the R·134a air conditioner system using the specified tools, lubricant and refrigerant, observ- l~fAI
ing the following precautions:

Identification w
IDENTIFICATION LABEL FOR VEHICLE

A!..R CONDITIONER NISSAN

REFRIGERANT COMPRESSOR LUBRICANT

""'
[PART NO.] R134A
NISSAN AIC SYSTEM OIL TYPE A
(KLHOO • PAGR 0)

0.08 ± 0.05 Kg
AMOUNT (1.76!0.11 Lbs.) 200 ml (6.8 fl. oz.)

CAUTION
PRECAUTION
o REFRIGERANT UNDER HIGH PRESSURE
o SYSTEM TO BE SERVICED BY QUALIFIED PERSONNEL
• IMPROPER SERVICE METHODS MAY CAUSE PERSONAL INJURY.
• CONSULT SERVICE MANUAL.
• THIS AIR CONDITIONER SYSTEM COMPLIES WITH SAE J-639.
N;,...,..,,.,-co. C\0

AHA818

PARTS IDENTIFICATION
1. Compressor label 2. Other component parts label
R134a label
R134a label Part name Identification
R134affl J
USE FOR R134a _
( R134a.ffl J
USE FOR R134<1 _
1. Compressor
2. Cooling unit
A 134a label or Compressor label
A134a label
3. Expansion valve Stamp
R134al!l ~___ _j
L_ ' 4. Condenser A134a label
USE FOR ,-----,
R134a i_ ___ _j 5. Liquid tank R134a label
6. Hose or pipe R134a label
Base color: Light blue
3. Service valves (suction/discharge)
TYPE DKV-r14::C:.__ _ _ _---,

PART NO.

L _____jll "\
(Seal cap) d,

•
SERL NO.

REFRIG. R-134a
OIL DH-PR
200cm' (200cc)
[NISSAN PART No. KLH -PAGRO)
MIN. TEST PRESSURE The service valves are specially designed for the R-134a system.
LOW SIDE 1.6MPa {15kgf/cm'G)
HIGH SIDE 3.0MPB {30kgf/cm'G) Those for the CFC-12 (R-12) system are different in size and configuration.
MFD. ZEXEL CORPORATION
MADE IN JAPAN Refer to "SERVICE COUPLERS", "'Precautions for Service Equipment", HA-1 0.
AHA860

HA-3 1011
 PRECAUTIONS AND PREPARATION

Precautions for Working with R-134a

WARNING:
• CFC-12 (R-12) refrigerant and R-134a refrigerant are not compatible. These refrigerants must
never be mixed, even in the smallest amounts. If the refrigerants are mixed, compressor malfunc-
tion is likely.
• Use only specified lubricant for the R-134a A/C system and R-134a components. If lubricant other
than that specified is used, compressor malfunction is likely.
• The specified R-134a lubricant rapidly absorbs moisture from the atmosphere. The following
handling precautions must be observed:
a: When removing refrigerant components from a vehicle, immediately cap (seal) the component
to minimize the entry of moisture from the atmosphere.
b: When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just
before connecting the components. Connect all refrigerant loop components as quickly as
possible to minimize the entry of moisture into the system.
c: Only use the specified lubricant from a sealed container. Immediately reseal containers of
lubricant. Without proper sealing, lubricant will become moisture saturated and should not be
used.
d: Avoid breathing AIC refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose
and throat. Remove R-134a from the A/C system, using certified service equipment meeting
requirements of SAE J2210 (R-134a recycling equipment), or J2209 (R-134a recovery equip-
ment). If accidental system discharge occurs, ventilate work area before resuming service.
Additional health and safety information may be obtained from refrigerant and lubricant manu-
facturers.
e: Do not allow lubricant to contact styrofoam parts. Damage may result.

General Refrigerant Precautions

WARNING:
• Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the
refrigerant every time an air conditioner system is discharged.
• Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or
air conditioner system.
• Do not store or heat refrigerant containers above 52°C (125°F).
• Do not heat a refrigerant container with an open flame; if container warming is required, place the
bottom of the container in a warm pail of water.
• Do not intentionally drop, puncture, or incinerate refrigerant containers.
• Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns.
• Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent
suffocation.
• Do not introduce compressed air into any refrigerant container or refrigerant component.

1012 HA-4
 PRECAUTIONS AND PREPARATION

Precautions for Refrigerant Connection

WARNING:
Make sure all refrigerant is discharged into the recycling equipment and the pressure in the system
is less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove
it.
CAUTION:
When replacing or cleaning refrigerant cycle components, observe the following.
• Do not leave compressor on its side or upside down for more than 10 minutes. Compressor lubri-
cant will enter low pressure chamber.
• When connecting tubes, always use a torque wrench and a back-up wrench.
• After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture.
• When installing an air conditioner in the vehicle, connect the pipes as the final stage of the opera- IT"©
lion. Do not remove the seal caps of pipes and other components until just before required for
connection.
• Allow components stored in cool areas to warm to working area temperature before removing seal f'll'
caps. This prevents condensation from forming inside A/C components.
• Thoroughly remove moisture from the refrigeration system before charging the refrigerant.
• Always replace used 0-rings. ©~
• When connecting tube, apply lubricant to portions shown in illustration. Be careful not to apply
lubricant to threaded portion.
Lubricant name: Nissan AIC System Oil Type R
Part number: KLHOO-PAGRO
• 0-ring must be closely attached to inflated portion of tube.
• After inserting tube into union until 0-ring is no longer visible, tighten nut to specified torque.
• After connecting line, conduct leak test and make sure that there is no leakage. When the gas ~~l
leaking point is found, disconnect that line and replace the 0-ring. Then tighten connections of seal
seat to the specified torque.
Torque wrench

D-ring

Apply lubricant.

cOO ~/
Plug

SHA525DB

•
HA-5 1013
 PRECAUTIONS AND PREPARATION

Precautions for Servicing Compressor

• Plug all openings to prevent moisture and foreign matter from entering.
• Do not leave compressor on its side or upside down for more than 10 minutes. Compressor lubri-
cant will enter low pressure chamber.
• When replacing or repairing compressor, be sure to remove lubricant from the compessor and
check the lubricant quantity extracted.
• When replacing or repairing compressor, follow Lubricant - Checking and Adjusting Procedure
exactly. Refer to "Compressor Lubricant Quantity", "SERVICE PROCEDURES", HA-50.
• Keep friction surfaces between clutch and pulley clean. If the surface is contaminated, with oil,
wipe it off by using a clean waste cloth moistened with thinner.
• After compressor service operation, turn the compressor shaft by hand more than five turns in
both directions. This will equally distribute lubricant inside the compressor. After the compressor
is installed, let the engine idle and operate the compressor for one hour.
• After replacing the compressor magnet clutch, apply voltage to the new one and check for normal
operation.

Special Service Tools

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number
(Kent-Moore No.) Description
Tool name

KV99231260 Removing shaft nut and clutch disc

(J-38874)
Clutch disc
wrench

NT204

KV99232340 Removing clutch disc

(J-38874)
Clutch disc puller

NT206

KV99234330 Installing pulley

(J-39024)
Pulley installer

NT207
0)
KV99233130 Removing pulley
(J-39023)

~
Center pulley puller

NT208

1014 HA-6
 PRECAUTIONS AND PREPARATION

R-134a Service Tools and Equipment

Never mix R-134a refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/or its lubricant.
Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/
lubricant.
Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles
refrigerant and/or lubricant) are different between CFC-12 (R-12) and R-134a. This is to avoid mixed use of
the refrigerants/lubricant.
Adapters to convert from one size fitting to the other must never be used: refrigerant/lubricant contamination
will occur and compressor failure will result.
Tool number
(Kent-Moore No.) Description Note
Tool name

R-134a refrigerant Container color: Light blue

§~
Container marking: R-134a
Fitting size: Thread size
• large container 1/2"-16 ACME

NT196

KLHOO·PAGRO Type: Polyalkyline glycol oil (PAG), type R

e
( - ) Application: R-134a vane rotary compressors
Nissan A/C System Oil (Nissan only)
TypeR Lubricity: 40 ml (1.4 US fl oz, 1.4 Imp fl oz)

NT197

(J-39500-NI) Function: Refrigerant Recovery and Recycling

Recovery/Recycling
equipment (ACR4)

NT195

(J-39400) Power supply:

Electrical leak detector • DC 12 V (Cigarette lighter)

NT198

(J-39183) Identification:
Manifold gauge set (with • The gauge face indicates R-134a.
hoses and couplers) Fitting size: Thread size
e 1/2"-16 ACME

NT199

HA-7 1015
 PRECAUTIONS AND PREPARATION
R-134a Service Tools and Equipment (Cont'd)
Tool number
(Kent-Moore No.) Description Note
Tool name

Service hoses Hose color:

• High side hose • Low hose: Blue with black stripe
(J-39501-72) • High hose: Red with black stripe
• Low side hose • Utility hose: Yellow with black stripe or
(J-39502-72) green with black stripe
• Utility hose Hose fitting to gauge:
(J-39476-72) e 1/2"-16 ACME

NT201

Service couplers Hose fitting to service hose:

ii
• High side coupler • M14 x 1.5 fitting (optional) or
(J-39500-20) permanently attached.
• Low side coupler
(J-39500-24)

NT202

(J-39650) For measuring of refrigerant

Refrigerant weight scale Fitting size: Thread size
e 1/2"-16 ACME

NT200

(J-39649) Capacity:
Vacuum pump • Air displacement: 4 CFM
(Including the isolator • Micron rating: 20 microns
valve) • Oil capacity: 482 g (17 oz)
Fitting size: Thread size
e 1/2"-16 ACME

NT203

1016 HA-8
 PRECAUTIONS AND PREPARATION

Precautions for Service Equipment

RECOVERY/RECYCLING EQUIPMENT
Follow the manufacturer's instructions for machine operation and
machine maintenance. Never introduce any refrigerant other than
that specified into the machine.

ELECTRONIC LEAK DETECTOR

Follow the manufacturer's instructions for tester operation and l©
tester maintenance.

VACUUM PUMP
Hose fittings:
11
T---r->1""?'1 1/2 -16ACME The lubricating oil contained inside the vacuum pump is not com-
patible with the specified lubricant for R-134a A/C systems. The ~~
vent side of the vacuum pump is exposed to atmospheric pressure.
Therefore, if the pump is switched off after evacuation, the lubri-
cating oil may migrate into the hose. To prevent this, isolate the ©[~
pump from the hose after evacuation (vacuuming).
This migration is avoided by placing a manual shut-off valve near
the hose-to-pump connection, as follows:
• Usually vacuum pumps have a manual isolator valve as part
of the pump. Close this valve to isolate the service hose from
~e~mp. u
Without isolator valve • For pumps without an isolator valve, use a hose equipped with
a manual shut-off valve near the pump end. Close the valve to
isolate the hose from the pump.
• If the hose has an automatic shut-off valve, disconnect the 1iT'
hose from the pump: as long as the hose is connected, the
valve is open and lubricating oil may migrate.
Some one-way valves open when vacuum is applied and close
under a no vacuum condition. Such valves may restrict the pump's
ability to pull a deep vacuum and are not recommended.

RHA270D

MANIFOLD GAUGE SET

Be certain the gauge set has 1/2"-16 ACME threaded connections
for service hoses. Confirm the set has been used only with refrig-
erant R-134a along with specified lubricant.

1/2"-16ACME
SHA533D

Hose fittings to SERVICE HOSES

manifold gauge or recovery/recycling
equipment; 1/2"-16ACME Be certain that the service hoses display the markings described
(colored hose with black stripe). Be certain that all hoses include a
positive shut-off device (either manual or automatic) near the end
of the hoses opposite the manifold gauge.

RHA272D

HA-9 1017
 PRECAUTIONS AND PREPARATION
Precautions for Service Equipment (Cont'd)
SERVICE COUPLERS
Never attempt to connect R-134a service couplers to an CFC-12
(R-12) A/C system. The R-134a couplers will not properly connect
to the CFC-12 (R-12) system. However, if an improper connection
M14 x 1.5 fitting
optional
is attempted, discharging and contamination may occur
(Hose may be
permanently
Shut-off valve rotation AJC service valve
attached to Clockwise Open
coupler)
Counterclockwise Close

RHA2730

REFRIGERANT WEIGHT SCALE

When using a scale which controls refrigerant flow electronically,
assure the following:
• Hose fitting size is 1/2"-16 ACME
Hose fitting:
1/2"~16ACME
• No refrigerant other than R-134a {along with specified lubri-
cant) has been used with the scale.

To manifold gauge

AHA211

CHARGING CYLINDER
Using a charging cylinder is not recommended. Refrigerant may be
vented into the air through the cylinder's top valve when filling the
cylinder.

1018 HA-10
 DESCRIPTION

~~u
Refrigeration Cycle
REFRIGERANT FLOW
The refrigerant flows in the standard pattern. It flows from compressor through condenser, liquid tank, evapo- ~~~~L
rator and back to compressor.
The refrigerant evaporation through the evaporator coil is controlled by an externally equalized expansion
valve, located inside the evaporator case. ~!i:Ju

FREEZE PROTECTION
The compressor cycles on and off to maintain the evaporator temperature within a specified range. When the
v;;
evaporator coil temperature falls below a specified point, the thermo control amplifier interrupts the compres-
sor operation. When the evaporator coil temperature rises above the specification, the thermo control ampli- ~©
tier allows compressor operation.

REFRIGERANT SYSTEM PROTECTION

Dual-pressure switch
The refrigerant system is protected against excessively high or low pressure. The protection is effected by the
dual-pressure switch located on the liquid tank. If the pressure rises or falls out of specifications, the switch ©lb
opens to interrupt the compressor operation.

Pressure relief valve

The refrigerant system is also protected by a pressure relief valve. The valve is located on the end of high
flexible hose near compressor. When refrigerant pressure in the system increases abnormally [over 3,727 kPa i~V
(38 kg/cm 2 , 540 psi)], the relief valve's release port opens automatically. The valve then releases refrigerant
into the atmosphere.

Pressure relief f/-;:>>A High-pressure ESS§J Low-pressure

valve gas liquid
·t!i"'""'~=""
Compressor f:.:-:.:.:.:.:·:·:·:·:l High~pressure !.:.§.)##:::! Low-pressure
liquid gas

t
Outside air

~~Condensec
Blower motor

Liquid tank

u
' Expans;on valve
Dual-pressure switch RHA258D

HA-11 1019
 DESCRIPTION

Component Layout

Side ventilator duct*

Control assembly 7

~- Control finisher
Side ventilator duct*

* : For removal, it is necessary

to remove instrument
assembly.

AHA821

1020 HA-12
 DESCRIPTION

Discharge Air Flow Clil

Air outlets
Foot,,;

l©

Face
Air
iJ Recirculation
,z;LL
Air conditioner

Foot and defrost \~

-.; ~-.;~ . ,,..
'~·=="'---··"

Temperature

door

Defrost@
Bi-level \iJ
11 tEZ '. ::~::~:._:-= I
I1 KZ!:
1

1 1
1

'
CD :To face
@' To foot
@ : To defrost
* : When in REC position

AHA819

HA-13 1021
 DESCRIPTION

Control Operation
switch
rA••ckculaNoncontrollever

= . = ,";J \lW
#OF ~~3=4:=J___CCO LOr==:lc::JDClDI••-H 0 T

Fan control lever Temperature control lever AHA820

FAN CONTROL LEVER

This lever controls fan speed and turns the fan ON and OFF.

MODE CONTROL LEVER

This lever controls the outlet air flow.

TEMPERATURE CONTROL LEVER

This lever allows adjustment of the temperature of the outlet air.

RECIRCULATION CONTROL LEVER

FRESH ~ position:
Outside air is drawn into the passenger compartment.
Recirculation REC c:S::J position:
Interior air is recirculated inside the vehicle.

AIR CONDITIONER SWITCH

The air conditioner switch controls the A/C system. When the switch is depressed with the fan ON, the com-
pressor will turn ON. The indicator lamp will also light.
The air conditioner cooling function operates only when the engine is running.

1022 HA-14
 TROUBLE DIAGNOSES

How to Perform Trouble Diagnoses for Quick

and Accurate Repair
WORK FLOW
CHECK IN Reference item
I I
1
LISTEN TO CUSTOMER COMPLAINT AND CON- Operational Check
FIRM BY PERFORMING OPERATIONAL CHECK. Refer to HA-16.

1
INVESTIGATE ITEMS YOU SHOULD CARRY OUT Symptom Chart
RELATED TO EACH SYMPTOM. Refer to HA-18.

1
CHECK FOR ANY SERVICE BULLETINS.

1
ELIMINATE GOOD SYSTEM(S)/PART(S). Preliminary Check
ifif
Refer to HA-19.

1
CHECK MAIN POWER SUPPLY AND GROUND CIR- Main Power Supply and
CUlTS. Ground Circuit Check
Refer to HA-33.

• Diagnostic Proce-
1
ELIMINATE GOOD PART(S)/HARNESS(ES)/ Harness Layout
dure(s) CONNECTOR(S) ELECTRICALLY. Refer to HA-28.
Refer to HA-34.
• Circuit Diagram Malfunctioning
Refer to HA-29. part(s)

Malfunctioning INSPECT EACH Electrical Components

harness(es)/ COMPONENT Inspection
connector(s) Refer to HA-41.

REPAIR. REPAIR/REPLACE.
I

FINAL CHECK
NGI
1 OK

CHECK OUT

HA-15 1023
 TROUBLE DIAGNOSES

Operational Check
The purpose of the operational check is to confirm that the system
operates properly.

CONDITIONS:
• Engine running at normal operating temperature.

PROCEDURE:
1. Check blower
a. Slide fan control lever to 1-speed.

-=
[m ~ . ""'0 ...
II ..;;; . . ,~ \';/ ® 1 I
b.
Blower should operate on 1-speed.
Slide fan control lever to 2-speed and continue checking
blower speed until all speeds are checked.
IEJJ .Dff1~~4

p
cuLo==oooo--HJ1
c. Leave blower on 4-speed.
~
/??
AHA883

2. Check discharge air

a. J
Slide mode control lever to .. position.
b. Confirm that all discharge air comes out of face vents.
c. Slide mode control lever to : ; position.
=[g]J . ""'0 d. Confirm that discharge air comes out of face vents and foot
",~ ~;;J vents .
~

El .JFF123~ CG~D= ""-IIOT

e. J
Slide mode control lever to .. position.
(\ ' f. Confirm that discharge air comes out of foot vents, with some
air from defrost vents.
g. Slide mode control lever to fJ position.
AHA884 h. Confirm that discharge air comes out of foot vents with some
air from defrost vents.
i. Slide mode control lever to ~ position.
j. Confirm that all discharge air comes out of defrost vents.

3. Check recirculation
a. Slide recirculation control lever to the REG ~ position.
b. Listen for intake door position change (you should hear blower
sound change slightly).

AHA868

1024 HA-16
 TROUBLE DIAGNOSES
Operational Check (Cont'd)
4. Check temperature decrease
a. Slide temperature control lever to full cold.
b. Check for cold air at discharge air outlets.

I] =
II .OFF
.2
=0
J 4
ell
r; 0 ~ '':-~- ~-~ -I
••

" ·.~~"
~ AHA869
lC:

5. Check temperature increase

a. Slide temperature control lever to full hot.
b. Check for hot air at discharge air outlets.

~Ill .~ ell
~ ~
0 ;I ..;; ... ,~ .."}1 ®~I
•oFr1 3 4 COcD==ccm••-HO;

~///~
}?!
AHA870

6. Check A/C switch

Move fan control lever to the desired position (1 to 4) and press air
conditioner switch to turn air conditioner ON.
Indicator light will come on when air conditioner is ON.
.0
~"""-!!~:~
~ ~~
ell
;J \IJ \..,1 \;/ @
CCI r.==oooo••-HOT
Tl

~
AHA871

[~II

HA-17 1025
 TROUBLE DIAGNOSES

Symptom Chart
DIAGNOSTIC TABLE
Diag- Main Power
Preliminary nostic Supply and
PROCEDURE Electrical Components Inspection
Check Proce- Ground Circuit
dure Check
,._ :;;: :;;: :;;: :;;:
"'<i: 0
N
<i:
;;j
<i:
"~ <i:"' "'"'
<i: <i: <i: <i: <i:
N N

"I<i: lI l "'<i:"' "<i: N

REFERENCE PAGE I I I I I I I I I I I I I I
-
§]
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w
~
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"'c E
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i"
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i" "' - [c'l]- (.)
~

"' "' "'"

N ~ ~ >- "'B
~ ~ ~
rw: "' -~
0
0 0
" "
0
0 0
'" ~ w
"''§ 0
"'" "'" "'" "-2 "-2
0
0 0 ~
SYMPTOM
0
~
0
~
0

~
~
w ~ ~ ~ ~
~
w 0 ~"-
0
"tl
0

" " "w E "'B "'~ >- w

"'£; "'£; "'£; E

"' ""'"'
c c c tl0 w w i" w
0 ~ ~ ~
a; .8 -~ ~ a; ~"' c <ii
E
w
c c IL IL lL
~
w
·o;
w w
~ <ii "
c
"'"' 0"'"' """' "" "'""
~ c :;;
~ ~
~ "'>-" "
0 (.) 0
a:"
~
"-- "-- "-- 0 ~
0
~ ~ (ij ~ "'
lL (ij 0 I

AJC does not blow cold air.

Blower motor does not rotate.
•• 0
8
0
0
0 0 0
0
0
0
0 0
0
0
0
0 0 0 0 0
0
Magnet clutch does not
engage when A/C switch and
fan switch are ON. • 8 0 0 0 0 0 0 0 0 0 0

Noise.
Insufficient heating.
•• 0 0
8, 8: The number means check1ng order.
Q: Checking order depends on malfunction in flow chart.

1026 HA-18
 TROUBLE DIAGNOSES

@I
Preliminary Check
PRELIMINARY CHECK 1
A/C does not blow cold air.
DOES AIR FLOW FROM VENTS?
Condition:
• Engine running at operating tern-
n IS BLOWER MOTOR OPERATING
NORMALLY?

perature. Yes ~No

• Ignition switch, A/C switch, and fan
switch are ON. CHECK BLOWER
• Mode control lever is in FACE MOTOR OPERATION.
position and temperature control Go to Diagnostic Pro-
lever is in full cold position. cedure 1, HA-34.

CHECK COMPRESSOR BELT TEN·

SION.
Refer to MA section (''Checking
4 TION.
pes

CHECK COMPRESSOR OPERA· CHECK FOR EVAPORATOR COIL

FREEZE UP.
Remove intake unit. Check if evapo-
Drive Belts", "ENGINE MAINTE· OK rator freezes.
NANCE").
NG OK
~NG OK (Freezes up.) (Does not
freeze up.)
Adjust or replace com- I CHECK REFRIGERATION CYCLE
pressor belt. PRESSURE WITH MANIFOLD
GAUGE CONNECTED.
Refer to Performance Chart, HA-24.
NG OK

CHECK REFRIGERANT. CHECK VENTILATOR

Connect manifold gauge then check DUCT FOR AIR
system pressure. LEAKS.
Refer to "Performance Chart".
HA-24.
Go to Performance CHECK THERMO CONTROL AMP
OK NG Test Diagnoses, OPERATION.
HA-22. Refer to "Electrical Components
Inspection", HA~42.

I CHECK FOR REFRIG· CHECK WATER COCK OPERA· ~Adjust or replace water cock.
ERANT LEAKS. TION.
Warm up engine before checking.
Refer to "Control Linkage
Adjustment", HA-43.

~OK
~Adjust
Go to Diagnostic Procedure 2,
HA-37.
CHECK TEMPERATURE CONTROL
CABLE.
temperature control cable.
I
Refer to "Control Linkage
Adjustment", HA-43.

~OK
VISUALLY INSPECT AIR MIX DOOR. ~Replace air mix door.
Access by removing instrument
panel.

~OK
CHECK THERMO CONTROL AMP.
OPERATION.
Refer to ''Electrical Components
Inspection", HA-42.

HA-19 1027
 TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
PRELIMINARY CHECK 2
Noise
I CHECK WHERE NOISE COMES FROM.

I
~ l l l
Blower motor Compressor Expansion valve Refrigerant line Belt
I I I I

CHECK FOR Inspect the com- Replace expan-

NOISE IN ALL pressor clutch and sian valve.
MODES AND pulley and idler
TEMPERATURE pulley.
SETTINGS.
OK NG
Noise is
constant

CHECK Replace com- Line is fixed Line is not fixed.

BLOWER pressor clutch directly to body.
MOTOR AND and pulley.
FAN FOR Refer to
WEAR. HA-53.

OK NG

Replace CHECK DISC-TO- Fix line with Fix line tightly.

blower PULLEY CLEAR- rubber or vibra-
motor or ANCE. tion absorbing
fan. Refer to HA-55. material.

OK

CHECK CHECK AND ...

BLOWER ADJUST COM-
MOTOR FOR PRESSOR
FOREIGN PAR- LUBRICANT
TICLES. Refer to HA-50.

~NG OK

Remove foreign Replace compres- Belt vibration is Side of belt is

particles from sor and liquid intense. worn out.
intake unit. tank.

Noise is
intermittent Readjust belt Pulley center
tension. does not match.
CHECK AIR DIS- Refer to MA Readjust pulley
CHARGE DUCTS section center.
FOR OBSTRUC- ("Checking Refer to HA~54.
TIONS, FOREIGN Drive Belts",
MATERIALS OR "ENGINE
AIR LEAKAGE. MAINTE-
NANCE").
l NG

Remove obstruc-
tions or repair air
leakage.

1028 HA-20
 TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
PRELIMINARY CHECK 3
Insufficient heating.
DOES AIR FLOW FROM FOOT AREA?
Condition; CHECK BLOWER MOTOR
• Vehicle at operating temperature.
• Ignition switch and fan switch are ON. ~ OPERATION.
Go to Diagnostic Procedure
• Mode control lever is in FOOT position and tem- 1, HA-34.
perature control lever is in full hot position.

1Yes

Check the following:

• Engine coolant level. Refer to MA section.
• Hoses for leaks or kinks.
• Radiator cap. Refer to LC section ("ENGINE
COOLING SYSTEM").
H Repair/replace as necessary.

• Air in cooling system.

1OK

CHECK WATER COCK OPERATION.

Warm up engine before checking.
Refer to "Control Linkage Adjustment", HA-43. ~ Adjust or replace water cock.

1OK

~
CHECK TEMPERATURE CONTROL CABLE. Adjust temperature control
Refer to "Control Linkage Adjustment", HA-43. cable.

10K

VISUALLY INSPECT AIR MIX DOOR.

Access by removing instrument paneL H Replace air mix door.

1OK

CHECK BY FEEL HEATER INLET AND OUTLET

HOSES.

Both hoses Both hoses

cold warm

CHECK THERMOSTAT CHECK HEATER HOSES FOR

INSTALLATION. PROPER INSTALLATION.

1 OK 1 OK

Replace thermostat. Refer Back flush heater core, drain and refill coolant.
to LC section ("Thermostat", Retest.
"ENGINE COOLING SYS-
Hot inlet Both hoses
TEM").
Warm outlet warm

Replace heater
System OK [~ll
I I core.

HA-21 1029
 TROUBLE DIAGNOSES

Performance Test Diagnoses

INSUFFICIENT COOLING

INSUFFICIENT COOLING
I
i NG
CHECK AIR FLOW. .I CHECK BLOWER MOTOR OPERATION. I
iOK lOK tNG

CHECK COMPRESSOR OPERATION. Clogged blower inleUCiogged ®

(Go to
duct/Loose duct connection/
next
OK ~ NG Air leakage, etc.
page.)

®
(Go to
next page.)
OK
CHECK HIGH AND LOW-SIDE PRESSURE. USE
PERFORMANCE CHART. Refer to HA-24.

iNG

RECOVER REFRIGERANT USING RECOVERY

RECYCLING EQUIPMENT AND CHARGE
SPECIFIED AMOUNT OF REFRIGERANT.

l NG
Note
CHECK HIGH AND LOW-SIDE PRESSURE. USE
PERFORMANCE CHART. Refer to HA-24. BOTH HIGH AND LOW-
-+fl
1 OK
PRESSURE SIDES ARE
TOO HIGH.

CHECK DISCHARGE AIR TEMPERATURE. USE HIGH-PRESSURE SIDE

PERFORMANCE CHART. Refer to HA-24. IS TOO HIGH AND LOW- f---+m
NG
l OK
PRESSURE SIDE IS TOO
LOW.

I END HIGH-PRESSURE SIDE

IS TOO LOW AND LOW-
!----+[!]
PRESSURE SIDE IS TOO
HIGH.

Malfunctioning temperature control operation (air BOTH HIGH AND LOW- ----+I!]
mix door position improperly adjusted)/ PRESSURE SIDES ARE
Malfunctioning water cock operation (incorrect TOO LOW.
valve closure)

LOW-PRESSURE SIDE
SOMETIMES BECOMES
----+li!l
NEGATIVE.

Note: fi-lii correspond to those in TROUBLE DIAGNOSES FOR LOW-PRESSURE SIDE

BECOMES NEGATIVE. ----+Gil
ABNORM AL PRESSURE.
Refer to HA-25.

1030 HA-22
 TROUBLE DIAGNOSES
Performance Test Diagnoses (Cont'd)
®

Malfunctioning blower motor fan. Malfunctioning electrical circuit. Malfunctioning blower motor internal
circuit.

Loose fan/Improper contact of fan Discontinued wiring or component

and case/Deformed fan. circuits or poor connection/
Malfunctioning resistor, amplifier,
etc.! Burned out fuse or low battery
voltage.

Magnet clutch does not engage. I Magnet clutch slipping. Belt slipping.
I
I

CHECK MAGNET CLUTCH. CHECK COMPRESSOR BELT AND

Inspect coil circuit, disc-to-pulley BELT TENSION. Refer to MA sec-
clearance. lion ("Checking Drive Belts",
"ENGINE MAINTENANCE").

CHECK ELECTRICAL CIRCUIT

Inspect wiring, components circuit.
- Malfunctioning internal parts of
clutch, compressor.

CHECK ACTIVATION OF SAFETY/

PROTECTION DEVICES. Inspect
devices such as pressure switch,
etc.
- Foreign particles on clutch frictional
suriace or excessive disc clear-
ance.

- Malfunctioning electrical circuit

(poor connection, low battery
voltage, etc.).

HA-23 1031
 TROUBLE DIAGNOSES

Performance Chart
TEST CONDITION
Testing must be performed as follows:
Vehicle location: Indoors or in the shade (in a well-ventilated place)
Doors: Closed
Door window: Open
Hood: Open
TEMP. setting: Max. COLD
Discharge air: FACE VENT
INTAKE lever position: ~ (Recirculation)
FAN speed: 4-speed
Engine speed: 1,500 rpm
Operate the air conditioner system for 10 minutes before taking measurements.

TEST READING
Recirculating-to-discharge air temperature table

Inside air (Recirculating air)

at blower assembly inlet Discharge air temperature at center ventilator
Relative humidity Air temperature "C ("F)
% oc ("F)
20 (68) 6.6- 8.3 (44 - 47)
25 (77) 10.4- 12.4 (51 -54)
50.60 30 (86) 14.2- 16.7 (58- 62)
35 (95) 18.2 - 21.0 (65 - 70)
40 (104) 22.0 - 25.2 (72 - 77)
20 (68) 8.3- 9.8 (47- 50)
25 (77) 12.4- 14.4 (54- 58)
60- 70 30 (86) 16.7- 18.9 (62- 66)
35 (95) 21.0- 23.6 (70- 74)
40 (104) 25.2 - 28.1 (77 - 83)

Ambient air temperature-to-operating pressure table

Ambient air
High-pressure (Discharge side) Low-pressure (Suction side)
Relative humidity Air temperature kPa (kg/em', psi) kPa (kg/em2 , psi)
% oc CF)
20 (68) 961- 1,187 (9.8- 12.1, 139- 172) 108-157 (1.1 -1.6, 16- 23)
25 (77) 1 ,295 - 1 ,599 (13.2 - 16.3, 188 - 232) 161.8 - 215.8 (1.65 - 2.2, 23.5 - 31.3)
50- 70 30 (86) 1,285- 1,569 (13.1- 16, 186- 228) 167- 216 (1.7- 2.2, 24- 31)
35 (95) 1 ,520 - 1 ,863 (15.5 - 19, 220 - 270) 235- 284 (2.4- 2.9, 34- 41)
40 (104) 1,765-2,158 (18- 22,256- 313) 289.3-353.1 (2.95- 3.6, 41.9- 51.2)

1032 HA-24
 TROUBLE DIAGNOSES

Trouble Diagnoses for Abnormal Pressure :!3U

Whenever system's high or low-pressure side is abnormal, diagnose using a manifold gauge. The marker
above the gauge scale in the following table indicates the standard (normal) pressure range. Since the stan-
dard (normal) pressure differs from vehicle to vehicle, refer to HA-24 ("Ambient air temperature-to-operating
pressure table").
~iil
Gauge indication Refrigerant cycle Probable cause Corrective action
Both high and low-pressure • Pressure is reduced soon Excessive refrigerant charge in Reduce refrigerant until speci-
sides are too high. after water is splashed on refrigeration cycle. fied pressure is obtained.
B condenser.

tF"' Air suction by cooling fan is Insufficient condenser cooling • Clean condenser.

~ I~
insufficient. periormance. • Check and repair cooling fan
t as necessary.
G) Condenser fins are
clogged.
~ ~ ® Improper fan rotation of
cooling fan.
@ @ • Low-pressure pipe is not
cold.
Poor heat exchange in con-
denser.
Evacuate repeatedly and
recharge system.
• When compressor is stopped (After compressor operation
v 'rd Td high-pressure value quickly stops, high pressure decreases
AC359A drops by approximately 196 too slowly.)
kPa (2 kg/cm 2 , 28 psi). It t
then decreases gradually Air in refrigeration cycle.
thereafter.
Engine tends to overheat. Engine cooling systems mal- Check and repair each engine l'l"
function. cooling system.
• An area of the low-pressure • Excessive liquid refrigerant Replace expansion valve.
pipe is colder than areas on low-pressure side.
near the evaporator outlet. • Excessive refrigerant dis-
• Plates are sometimes cov- charge flow.
ered with frost. • Expansion valve is open a
little compared with the
specification.
t
G) Improper thermal valve
installation.
® Improper expansion valve
adjustment.
High-pressure side is too high Upper side of condenser and High-pressure tube or parts • Check and repair or replace
and low-pressure side is too high-pressure side are hot, located between compressor malfunctioning parts.
low. however, liquid tank is not so and condenser are clogged or • Check lubricant for contami-
m hot. crushed. nation.

-~

e@~ ~
@ @
'ig 'rd ~
AC360A

HA-25 1033
 TROUBLE DIAGNOSES
Trouble Diagnoses for Abnormal Pressure
(Cont'd)
Gauge indication Refrigerant cycle Probable cause Corrective action
High-pressure side is too low High and low-pressure sides Compressor pressure operation Replace compressor.
and low-pressure side is too become equal soon after com- is improper.
high. pressor operation stops. t
[!) Damaged inside compressor
tF"' packings.

~~ ~ ~
No temperature difference
between high and low-pressure
sides.
Compressor pressure operation Replace compressor.
is improper.
t
@ @) Damaged inside compressor
packings.
'->-
v g
T;j
AC356A
Both high and low-pressure • There is a big temperature Liquid tank inside is clogged a • Replace liquid tank.
sides are too low. difference between receiver little. • Check lubricant for contami-
I!J drier outlet and inlet. Outlet nation.
temperature is extremely low.
tF"' • Liquid tank inlet and expan-

8 I~
sion valve are frosted.
• Temperature of expansion High-pressure pipe located • Check and repair malfunc-
valve inlet is extremely low between liquid tank and expan- tioning parts.
as compared with areas near sion valve is clogged. • Check lubricant for contami-
~ ~ liquid tank. nation.
• Expansion valve inlet may be
@ @) frosted.
• Temperature difference

'-v v r;r occurs somewhere in high-

pressure side.
AC353A • Expansion valve and liquid Low refrigerant charge. Check refrigerant for leaks.
tank are warm or only cool t Refer to "Checking Refrigerant
when touched. Leaking fittings or components. Leaks", HA-44.
Both high and low-pressure There is a big temperature dif- Expansion valve closes a little • Remove foreign particles by
sides are too low. terence between expansion compared with the specifica- using compressed air.
I!J valve inlet and outlet while the tion. • Check lubricant for contami-
-~?"\ valve itself is frosted. t nation.
G) Improper expansion valve

8 ~
adjustment.
® Malfunctioning thermal
valve.
@) Outlet and inlet may be
~ ~ clogged.

@ @) An area of the low-pressure

pipe is colder than areas near
Low-pressure pipe is clogged
or crushed.
• Check and repair malfunc-
tioning parts.
the evaporator outlet. • Check lubricant for contami-
~ 'r;j
r;:j nation.
Air flow volume is not enough Compressor pressure operation Replace compressor.
AC353A
or is too low. is improper.

1034 HA-26
 TROUBLE DIAGNOSES
Trouble Diagnoses for Abnormal Pressure
(Cont'd)
Gauge indication Refrigerant cycle Probable cause Corrective action
Low-pressure side sometimes • Air conditioner system does Refrigerant does not discharge • Drain water from refrigerant
becomes negative. not function and does not cyclically. or replace refrigerant.
I! cyclically cool the compart- t • Replace liquid tank.
ment air. Moisture is frozen at expansion
• The system constantly func- valve outlet and inlet.
tions for a certain period of t
time after compressor is Water is mixed with refrigerant.
stopped and restarted.

AC354A
Low-pressure side becomes Liquid tank or fronVrear side of High-pressure side is dosed Leave the system at rest. Start
negative. expansion valve's pipe is and refrigerant does not flow. it again to check whether or not
Iii frosted or dewed. t the problem is caused by water
Expansion valve or liquid tank or foreign particles.
is frosted. • If water is the cause, initially
cooling is okay. Then the ,..~~.l'
water freezes, causing a
blockage. Drain water from
refrigerant or replace refriger· U?
ant.
• If due to foreign particles,
remove expansion valve and
remove the particles with dry
and compressed air.
• If either of the above methw
AC362A ods cannot correct the
problem, replace expansion
valve.
• Replace liquid tank.
• Check lubricant for contamiw
nation.

HA-27 1035
 TROUBLE DIAGNOSES

Harness Layout

A/Crelay@
(AIR CON)

switch@

~
relay (AIR CON)

AHA822

1036 HA-28
 IGNITION SWITCH
ON or START
IGNITION SWITCH
ACC or ON
I
I
tJFUSE ~FUSE ~FUSE

M) ~6~~~R

,---
FAN
RESISTOR 0~ \-! .--1
I ~-------\
ON OFF
ON
I~~~OITIONER
SWITCH

-1
::D
0 0
THERMO
...
0
c:
Ill
~R (:~ c r-
A1R
:I: CONDITIONER
;::;:
)> +- RELAY m
'
1\) FAN SWITCH ~T"ERM>STOR c c
(0 FFili2i3i4 iii" )>
...
(Q
Ill
C)
z
J 3
1ACV-

lU THERMAL
PROTECTOR

-::;- = =
FICO
SOLENOID
VALVE
0
(/)
m
(/)
Miil
wt+J A/C
COMPRESSOR
I

~
DUAL-
~:~
BLOWER
MOTOR PRESSURE
RELAY SWITCH

21
r
15

tn
ECM
( ECCS CONTROL
MODULE)

,.lC
m
25
1037

[i:ill]
f2J ~
~
@QJ =1.1
?~ """
[p ~ @?) ~
~l'l
!0:' "'"
2-c-"-'
""'r:g; "" ''"
9 ::a (~~
cr=
u
Cii1J
lruiJ
G;--.v
p
(Q)
~ ~
~0
~
 TROUBLE DIAGNOSES

Wiring Diagram -HEATER-

HA-HEATER-01

~~15A Refer to "EL-POWER".

L_fJ0 LI-Jm

-
8

[j BLOWER
MOTOR
RELAY

._.
(iillQ)

1!4Jlll4Jl <'--';--"-----,FAN
8 8 RESISTOR
(@ill)

OFF /
•

!-!--.
-
8 B B
_._ ~ ~

(M~9) (~) CM~60)

m(t;ijQj) FiT,TI1(Mll4) FiT,TI1(M121)

W W n:tm:1 W n:tm:1 B

AHA691

1038 HA-30
 TROUBLE DIAGNOSES

Wiring Diagram -A/C-

HA-A/C-01

BIW ~~15A Refer to "EL-POWER".

~@
113ll(\iill) L_fJtb LtJm
e•
L L
I I~©
L

ffi MOTORBLOWER

@ill)

B lbjdl

cL.e
~~
BLOWER
MOTOR
RELAY
@
L/W

·-------.
•

1'--T-"-------.,FAN
I'Hil

B B RESISTOR
@1])

!-!.....,
B B B
~ ~ ...._
(M49) (M~os) (M~60)

mcffiQ!> ~(@}) ~(iilij) Fii(iillj)

LIJ W ti1Irr1 W ti1Irr1 B ([IT] W

AHA692-A

HA-31 1039
 TROUBLE DIAGNOSES
Wiring Diagram -A/C- (Cont'd)

HA-A/C-02

·-----
©m ...
~ffi
Refer to "EL-POWER".

GIW GIR

m•
. - - - - - - - - - " - T - " - - - - - - , A I R CONDITIONER
THERMO
CONTROL
AMPLIFIER
....
OFF
-- ....
ON
SWITCH
(@g)

@jJ)

lbjdJ
GIL
I
•
G/OR

~
DUAL-
PRESSURE
SWITCH
(M52)

lbjdJ . - - - -...
GIR + G~R
[@ 1o~J_l':l---, ECM
I :=
ARGON ACRL Y (ECCS
CONTROL
MODULE)
.___ _ _ _ ___,(M112)

Refer to last page (Foldout page)

<Mill>

~
101 102 103 104 105 106
107108 109 110111112 1
0
113114 115 116117118

AHA959

1040 HA-32
 TROUBLE DIAGNOSES

Main Power Supply and Ground Circuit Check

POWER SUPPLY CIRCUIT CHECK FOR AJC SYSTEM
Check power supply circuit for air conditioner system.
Refer to "POWER SUPPLY ROUTING" in EL section and "Wir-
ing Diagram".

THERMO CONTROL AMP. CHECK

Thermo control amp.

connector@
~ 1800 Check power supply circuit for thermo control amp. with ignition
switch ON and air conditioner switch ON.
1 . Disconnect thermo control amp. harness connector.

m G/L
l ~ !:"'__
§ 2. Connect voltmeter from harness side.
3. Measure voltage across terminal No. G) and body ground.
Voltmeter terminal
Voltage
©l

8
.,.. Body ground Approx. 12V
AHA829

Check body ground circuit for thermo control amp. with ignition

~
switch ON and fan switch ON.
1800
Thermo control amp.
connector@
1. Disconnect thermo control amp. harness connector.

G/8
m [ill
~
SOFF1234
2. Connect ohmmeter from harness side.
3. Check for continuity between terminal No. ® and body
ground.
Ohmmeter terminal
~
Continuity
8
Body ground Yes
~
AHA830

HA-33 1041
 TROUBLE DIAGNOSES

Flow chart Diagnostic Procedure 1

INCIDENT
No.
SYMPTOM: Blower motor does not rotate.
Fan fails to rotate. • Perform PRELIMINARY CHECK 1 before referring to the
following flow chart.
2 Fan d oesno t roaea
t I t1 -spee d.
Check if blower motor rotates properly at Ill 13 [4]
3 Fan does not rotate at 2-speed. ~ each fan speed. ®
4 Fan does not rotate at 3-speed. @] Conduct check as per flow chart at left. ~
©
5 Fan does not rotate at 4-speed. ~
m -
' 1- (Go to HA-36.)

m CHECK POWER SUPPLY FOR BLOWER

~
Check circuit between igni-

~
Blower motor MOTOR RELAY. tion switch and blower
relay connector ~ Do approx. 12 volts exist between blower motor relay.
motor relay harness terminal No. G) and
M DIS:;GNNEGI

IV body ground?
(Refer to "POWER SUP-
PLY ROUTING" in EL sec-

Le @) m
Yes

Note
tion and Wiring Diagram.)

Check circuit continuity between blower

~ motor relay harness terminals No. ®.®
AHA824 and body ground.

m OK

~
Blower motor
relay connector@
CHECK BLOWER MOTOR RELAY AFTER NG__J Replace blower motor relay.

8
ffit? DPSCDNNCCT

IV
DISCONNECTING IT
Refer to HA-42.
8
[ill OK

~ Reconnect blower motor relay.

"'='"
AHA823 [!]

~
CHECK POWER SUPPLY FOR BLOWER Check power supply circuit
[!]
MOTOR. and i SA fuses (No.
Blower motor

~IV
connector@ Disconnect blower motor harness connec- [4: and ll1J ,
located in
tor. the fuse block).

~ L

~
Do approx. 12 volts exist between blower
motor harness terminal No. G) and body
=[YJ lfOFF1234
ground?
<0= ~Yes
---~~---
®
(Go to next page.)
~ RHA663F
Note:
If the result is NG after checking circuit continuity, repair harness or connec-
tor.

1042 HA-34
 TROUBLE DIAGNOSES
Diagnostic Procedure 1 (Cont'd)
l!l ®
Blower motor
~18
connector @2))

~~ ~
l!l 1
Check circuit continuity between blower OK CHECK BLOWER MOTOR.
ltOT 1 2 3 4
=O= motor harness terminal No. ®and body f----->- Refer to HA-41.
[ill ground.
NG
NG
Continuity exists: OK

~
Reconnect blower motor harness connec· I Replace blower motor.
RHA664F I
tor.

~ cormEcT

Resistor
connector~
~ f) ~
CHECK BLOWER MOTOR CIRCUIT No Disconnect blower motor
~uw BETWEEN BLOWER MOTOR AND ~ and resistor harness con-
RESISTOR. nectars.
[YJ Do approx. 12 volts exist between resistor

00
.OFF 1 2 8 4
~ harness terminal No. ®and body
ground? Iii Note
~ Yes Check circuit continuity
""AHA832 between blower motor har-
ness terminal No. ® and
Iii ~ISCONNEC> resistor harness terminal

~ IV ~ No.@).
Continuity should exist.

j
Blower motor
connector~ Resistor If OK, check harness for
connector§

~
short.
uw

uw
i!I'I @
(Go to next page.)
[ill Note:
• If the result is NG after checking circuit continuity, repair harness or connec-
AHA831 tor.

•
HA-35 1043
 TROUBLE DIAGNOSES
Diagnostic Procedure 1 (Cont'd)
[!I CONNECT
@ ®
Fan switch
~ I) 00
l~
connector@

L!W UR M:OFF1234

~
T
..
1 QJ 4

~:JEJ
CHECK RESISTOR AFTER DISCON-

~
NECTING IT.
+
Refer to HA-41 .
UY UG
OK
~ NG
~
AHA833 j Replace resistor.
I

Ill Reconnect resistor harness connector.

©
~~{)~
Fan switch
connector@ '1
[!I
12] [;r~ t[§J
8]
~
CHECK FAN SWITCH CIRCUIT.
Do approx. 12 volts exist between each fan
B B
switch harness terminal and body ground?
~Q
LB Blower motor
relay connector@
Flow chart
No.
EB
Terminal No.

8
Voltage

!ll ®
AHA827
~ ® Body Approx.

D Fan switch Resistor ~ ® ground 12V

connector@ connector@ @)
~
UR
~f
L!W Yes No

~:JEJ A l2l
D
Check circuit continuity
Note

UY UG UVr-=rUR ~ between fan switch and resis-

@J tor.

~i5 00 AHA834
em
Terminal No.
Conti-
nuity
Fan
Resistor
switch
5 1
Yes
2 4
6 6
3 2

If OK, check harness for

short.

CHECK FAN SWITCH AFTER DISCON- N~ Replace fan switch.

NECTING IT.
Refer to HA-41 .

OK
Ill Note
Check circuit continuity between fan
. switch harness terminal No. @ and
blower motor relay harness terminal No.
®
Note:
If the result is NG after checking circuit continuity, repair harness or connec-
tor.

1044 HA-36
 TROUBLE DIAGNOSES

~I
m Diagnostic Procedure 2
~~0~
Compressor
connector @19 -2 SYMPTOM: Magnet clutch does not engage when AIC
switch and fan switch are ON.
lffil ~
ZfOFF 1 2 3 4

=O= • Perform PRELIMINARY CHECK 1 before referring to the

8 following flow chart.
[J[]
~
ID m
Yes
CHECK POWER SUPPLY FOR COM- __. Check magnet clutch coil
PRESSOR.
-~
NG
Disconnect compressor harness connector.
RHA670F
Do approx. 12 volts exist between com- Replace magnet clutch.
I;] pressor harness terminal No. CD and body Refer to HA-53
ground?
~i5@)
Thennal protector
connector §
-1
No
(1)
§ =a= 6JOFF 1 2 3 4 I;] [!) Note
CHECK POWER SUPPLY FOR THEA- Yes CHECK THERMAL PRO-
8/W
[YJ
+ -
ID MAL PROTECTOR.
Disconnect thermal protector harness con-
nectar.
TECTO A.
Check circuit continuity
between thermal protector
lf:;b

Do approx. 12 volts exist between thermal harness connector terminal

-~
AHA960
protector harness terminal No. CD
and No. G) and compressor
body ground? harness terminal No. G).
Continuity should exist.
[!) No
~ '"""" ~
0FFi ~
18
'
If OK, check harness for
short
Thermal protector Compressor NG
connector §- 1 connector@- 2

G) [ffi] 00 Note
Check circuit continuity between A/C relay I Replace thermal protector. I
B B harness terminal No. ® and thermal pro-
teeter harness terminal No. No. (D.
[ill
Continuity should exist.
- If OK, check harness for short.
AHA961
OK

ivoo~
00 ~
CHECK POWER SUPPLY FOR A!C No Check power supply circuit
Thermal protector
connector @-1
A/C relay
connector@
RELAY. f----. and 1OA fuse (No. [QJ ,
Do approx. 12 volts exist between NC located in the fuse block).
c;s
8/W ~ relay harness terminal No. @ and body
ground?
(Refer to "POWER SUP-
PLY ROUTING" in EL sec-

[ill
8/W
! Yes
tion and Wiring Diagram.)

®
• (Go to next page.)
AHA962
Note:
If the result is NG after checking circuit continuity, repair harness or connec-
~ A!C relay
tor.

~ivOO II
connector§

~~
~
~

""'='"
AHA864

HA-37 1045
 TROUBLE DIAGNOSES
Diagnostic Procedure 2 (Cont'd)
Iii ®
~~~00
A/C relay
connector@
Iii l
~ GIL
§ CHECK POWER SUPPLY FOR AJC
RELAY.
Yes
----+ (Go to @ below.)

CYJ Do approx. 12 volts exist between A/C

+ relay harness terminal No. G) and body
ground?

~ ro
AHA865 [!I
CHECK POWER SUPPLY FOR AJC No Check power supply circuit
[!I SWITCH. ~ and 15A fuse (No. 131 ,
A/C switch

~ID~
Disconnect NC switch harness connector. located in the fuse block).
connector~
Do approx. 12 volts exist between A/C (Refer to "POWER SUP·
db switch harness terminal No. ®and body
ground?
PLY ROUTING" in EL sec-
tion and Wiring Diagram.
GIR
[J[] ~Yes
~ CHECK AJC SWITCH. NG_J Replace A/C switch.
Refer to HA-41.

RHA677F rK
Ill Note
Ill Check circuit continuity between AJC

~ iv~ switch harness terminal No. G) and A/C

relay harness terminal No. G).
AIC switch A/C relay
connector ~ connector @ Continuity should exist.

,,~I'..'I 1~~
If OK, check harness for short.

®
[ill ~
CHECK AJC RELAY AFTER DISCON-
NECTING IT.
NG
... Replace A/C relay.

AHA866 Refer to HA-42.

0 CONNECT
~OK

~ £)
ECM (ECCS control module)
connector@ Reconnect A/C relay.

II ECM JO[coNNECToRII ~
l
-
1s ON
1
EJ 1 0 II Note

! ~vJ_J 1
For terminal arrangement,
GIR I
CHECK COIL SIDE CIRCUIT OF AJC
RELAY.
Disconnect ECM (ECCS control module)
harness connector.
No Check circuit continuity
between A/C relay harness
terminal No. ® and ECM
(ECCS control module) har-
refer to foldout page. Do approx. 12 volts exist between ECM ness terminal No. @.
AHA836 (ECCS control module) harness terminal Continuity should exist.
No. @ and body ground? If OK, check harness for
IJ~~A/C relay For terminal arrangement, short.
connector@ refer to foldout page. +Yes

F~
Reconnect ECM (ECCS control module)
[ill harness connector.

+
~
ECM (ECCS
control module) G/R ©
connector~ (Go to next page.)

i~@;J II ECM "

JO[coNNECTDRil Note:
If the result is NG after checking circuit continuity, repair harness or con nee-
AHA963 tor.

1046 HA-38
 TROUBLE DIAGNOSES
Diagnostic Procedure 2 (Cont'd)
Ia ©
l
CONNECT

Thermo control
amp. connector @ ~ £) Ia

m 00 § CHECK VOLTAGE FOR THERMO CON-

TROLAMP.
Do approx. 5 volts exist between thermo
Yes
f---+ (Go to @ below.)

~
G/OR control amp. harness terminal No. @and
body ground?
-#" No
AHA839
m
m Check circuit continuity between thermo
control amp. harness terminal No. @ and
~iv ~~ dual-pressure switch terminal No.
Continuity should exist.
®.
Dual-pressure Thermo control
@ If OK, check harness for short
switch connector amp. connector @

db
G/OA

[ill
m G/OR Refer to HA-41.
~OK
CHECK DUAL-PRESSURE SWITCH. NG
f---+
Replace dual-pressure
switch.

OK
AHA964
~ Note
Check circuit continuity between ECM
IIJ Dual-pressure For terminal arrangement,
switch connector@ refer to foldout page. (ECCS control module) harness terminal
No. @ and dual-pressure switch harness
~cill terminal No. G).
GIRl [ill Continuity should exist.
If OK, check harness for short.
DISCONNECT
ECM (ECCS control
~OK
10 module) connector 8 G/R

CHECK ECM (ECCS CONTROL MOD-

[lt@;j II ECM "
FicoNNECTOR II ULE).
Refer to EC section.
AHA965

@
IllThenno control amp.
connector@
~ i8@) ~

G/8
m [ill
•

=n=
OFF1234
CHECK POWER SUPPLY FOR THERMO
CONTROL AMP.
Refer to HA-33.

• Ill
CHECK BODY GROUND CIRCUIT FOR Yes Replace thermo control
THERMO CONTROL AMP. amp.
~
AHA830 Disconnect thermo control amp. harness
connector.
Does continuity exist between thermo con-
trol amp. harness terminal No. ®and
body ground?

~No
®
(Go to next page.)

Note: ]~?{
If the result is NG after checking circuit continuity, repair harness or connec-
tor.

HA-39 1047
 TROUBLE DIAGNOSES
Diagnostic Procedure 2 (Cont'd)
00 ®
Thermo control
amp. connector @
[lt i8l@8 l
G/B 11 I Disconnect fan switch harness connector.

[ill 00 Note
G/B Check circuit continuity between thermo
®
~
Fan switch control amp. harness terminal No. and
connector@ fan switch harness terminal No. G).
AHA837 Continuity should exist.
If OK, check harness for short.

OK

CHECK FAN SWITCH.

Refer to HA-41.

NG

I Replace fan sw1tch.

1048 HA-40
 TROUBLE DIAGNOSES

Electrical Components Inspection

FAN SWITCH
Check continuity between terminals at each lever position.
~EVER
TERMINAL POSITION OFF 1 2 3 4
3
5
2
6
4
1

BLOWER MOTOR
Confirm smooth rotation of the blower motor.
• Check that there are no foreign particles inside the intake unit. ~

BLOWER RESISTOR

I ~,=3",-, l:ttivI Check continuity between terminals.

Continuity check

A/C SWITCH
Check continuity between terminals at each switch position.

1118 )f oa ~~odlcator
A/C switch

AHA850

DUAL-PRESSURE SWITCH
High-pressure side line pressure
Operation Continuity
kPa (kg/em'. psi)
Decreasing to 157-216 (1.6- 2.2. 23- 31) Does not
Turn OFF
Increasing to 2.648- 2.844 (27- 29. 384- 412) exist
Increasing to 157- 235 (1.6- 2.4. 23- 34)
Turn ON Exists
Decreasing to 392- 785 (4- 8. 57- 114)

HA-41 1049
 TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
THERMO CONTROL AMP.
Evaporator outlet air temperature Thermo amp.
Tester
"C ("F) operation
Decreasing to 0.1 - 0.9 (32- 34) Turn OFF Approx. 12V
Increasing to 2.5 - 3.5 (37 - 38) Turn ON Approx. OV

THERMAL PROTECTOR
Temperature of compressor
Operation
oc
CF)

Increasing to approx. 145- 155 (293- 311) Turn OFF

Decreasing to approx. 130- 140 (266- 284) Turn ON

AHA849

FUS[
AJC RELAY AND BLOWER MOTOR RELAY
Check circuit continuity between terminals by supplying 12 volts to
coil side terminals of relay.
• Blower motor relay

~lJ~~,~~~
J
Q
SHA324E

• AIC relay

AHA233

Control Linkage Adjustment

VENTILATOR DOOR CONTROL ROD
1. Move side link in direction of arrow.
2. With upper and lower ventilator door levers held in the direc-
tion of the arrow, connect rods (i) and ® to their correspond-
ing ventilator door levers in that order.

1050 HA-42
 TROUBLE DIAGNOSES
Control Linkage Adjustment (Cont'd)
DEFROST DOOR CONTROL ROD
1. Move side link in direction of arrow.
2. Connect rod to side link while pushing defrost door lever in
direction of arrow.

AHA897

MODE CONTROL CABLE

• Move mode control lever to <;iW position.
Set side link in DEF mode.
Pull on outer cable in direction of arrow and then clamp it.
• After positioning mode control cable, check that it oper-
ates properly.

RHA269

WATER COCK CONTROL ROD

• When adjusting water cock control rod, first disconnect
temperature control cable from air mix door lever and then W
adjust control rod. Reconnect temperature control cable
and readjust it. (Refer to next item.)
1. Push air mix door lever in direction of arrow.
2. Pull control rod of water cock in direction of arrow so as to
make clearance of about 2 mm (0.08 in) between ends of rod
and link lever and connect the rod to door lever.
• After connecting water cock control rod, check that it
operates properly.
TEMPERATURE CONTROL CABLE
• When adjusting ventilator door rod and defrost door rod,
first disconnect mode control cable from side link. g]J:l
Reconnect and readjust mode control cable.
• Move temperature control lever to max. COLD position. Set air
mix door lever in full hot mode. Pull on outer cable in direction 1tf
of arrow and then clamp it.

~ • After positioning temperature control cable, check that it

operates properly. 11©
I~C;---·- 1 1
£ax. COLD position AHA854

RECIRCULATION CONTROL CABLE

• Move recirculation lever to ~ position.
Set recirculation lever in REG mode.
Pull on outer cable in direction of arrow and then clamp it.
• After positioning recirculation control cable, check that it
operates properly.
Push
\- ~ position

~~~:-~-~----:--~ ---;;;;- I

I L;-c':_:- ; 0 -======'====Q_
RHA372

HA-43 1051
 SERVICE PROCEDURES

Checking Refrigerant Leaks

PRELIMINARY CHECK
Perform a visual inspection of all refrigeration parts, fittings, hoses,
and components for signs of NC lubricant leakage, damage and
corrosion.

PRECAUTIONS FOR HANDLING LEAK DETECTOR

When performing a refrigerant leak check, use a J39400 NC leak
detector or equivalent. Ensure that the instrument is calibrated and
set properly per the operating instructions.
The leak detector is a delicate device. In order to use the leak
detector properly, read the operating instructions and perform any
specified maintenance.
Other gases in the work area or substances on the NC
components, for example, anti-freeze, windshield washer fluid, sol-
vents and cleaners, may falsely trigger the leak detector. Make
sure the surfaces to be checked are clean. Do not allow the sen-
sor tip of the detector to come into contact with any substance. This
can also cause false readings and may damage the detector.
{J-39400)
Electronic teak detector AHA594

1. Position probe approximately 5 mm (3/16 in) away from point

to be checked.
~Approx .
.......-~ \5mm(3/16in)

AHA951

2. When testing, circle each fitting completely with probe.

AHA596

3. Move probe along component approximately 25 - 50 mm (1-2

in)/sec.

25-50 mm
(1-2in)

AHA597

1052 HA-44
SERVICE PROCEDURES
Checking Refrigerant Leaks (Cont'd)
CHECKING PROCEDURE
To prevent inaccurate or false readings, make sure there is no
refrigerant vapor or tobacco smoke in the vicinity of the vehicle.
Perform the leak test in calm area (low air/wind movement) so that
the leaking refrigerant is not dispersed.
1. Turn engine off.
2. Connect a suitable A/C manifold gauge set to the A/C service
ports.
3. Check if the A/C refrigerant pressure is at least 345 kPa (50 1'0
psi) above 16'C (60'F). If less than specification, evacuate and
recharge the system with the specified amount of refrigerant.
NOTE: At temperatures below 16'C (60'F), leaks may not :1'©
be detected since the system may not reach 345
kPa (50 psi).
4. Conduct the leak test from the high side to the low side at :!'~
points @ through CD. Refer to HA-47.
Perform a leak check for the following areas carefully. Clean
the component to be checked and move the leak detector
probe completely around the connection/component.
©Jo
• Compressor
Check the fittings of high and low pressure hoses, relief valve,
and shaft seal.
• Liquid tank
Check the pressure switch, tube fitting, weld seams and the
iki~~
fusible plug mounts.
• Service valves
Check all around the service valves. Ensure service valve caps l'l"
are secured on the service valves (to prevent leaks).
NOTE: After removing A/C manifold gauge set from service
valves, wipe any residue from valves to prevent any
false readings by leak detector. riD
• Cooling unit (Evaporator)
Turn blower fan on "High" for atleast15 seconds to dissipate
any refrigerant trace in the cooling unit. Insert the leak detec- ~~~'
tor probe into the drain hose immediately after stopping
engine. (Keep the probe inserted for at least ten seconds.)
5. If a leak detector detects a leak, verify at least once by blow-
ing compressed air into area of suspected leak, then repeat
check.
6. Do not stop when one leak is found. Continue to check for ~~
additional leaks at all system components.

HA-45 1053
 SERVICE PROCEDURES
Checking Refrigerant Leaks (Cont'd)
7. Start engine.
B. Set the heater A/C control as follows:
a. A/C switch ON
b. Face mode
c. Recirculation switch ON
d. Max cold temperature
e. Fan speed high
9. Run engine at 1500 rpm for at least 2 minutes.
10. Turn engine off and perform leak check again following steps
4 through 6 on the previous page.

Pressure in high
Refrigerant leaks should be checked immediately after stopping the
pressure line engine. Begin with the leak detector on the high pressure line. The
,•• pressure in the high pressure line will gradually drop after refriger-
ant circulation stops and pressure in the low pressure line will
•
a:• gradually rise, as shown in the graph. Leaks are more easily
detected when pressure is high.
------------
........... ________ .JI .... (Pressure in low
pressure line

Time
Compressor Compressor
starts. stops.
AHA936

11. Discharge A/C system using approved refrigerant recovery

equipment. Repair the leaking fitting or component as neces-
sary.
12. Evacuate and recharge A/C system and perform the leak test
to confirm no refrigerant leaks.
13. Conduct A/C performance test to ensure system works prop-
erly.

1054 HA-46
 SERVICE PROCEDURES

Refrigerant Lines
SEC. 271•274•276 • Refer to page HA-5 regarding "Precautions for Refrigerant
Connection".

l:j]1o- 20 (1.0- 2.0, 87- 174) 8 mm dia.

Cooling unit
~ 20 • 25 (2.0 -2.5,14 -18) 12 mm dia. jf[j'

Dual-pressure
switch@

Low-pressure (Suction) :fi~\

service valve (])
High-pressure (Discharge)
service valve @

Liquid tank

Pressure relief valve

Compressor
Q :Refrigerant leak checking order
-- : (Tightening torque)
U Shaft seal (D
0n
Condenser
(Wrench size>
=

0 : (0-ring size)
~ : N · m (kg-m, in-lb)
~: N-m {kg-m, tt-lb)
Ill :20- 29 (2.0- 3.0, 14- 22)
11 1s-2s (1.s -2.s, ,, -ls)
=

11 =14-18(1.4-1.8,10-13)
[QJ: 10-20 (1.0- 2.0, 87 -174)
~: 8-11 (0.8-1.1,69-95) AHA856

HA-47 1055
 SERVICE PROCEDURES

R-134a Service Procedure

DISCHARGING REFRIGERANT
WARNING:
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and
throat. Remove R-134a from A/C system, using certified service equipment meeting requirements of
SAE J2210 (R-134a recycling equipment), or J2209 (R-134a recovery equipment). If accidental system
discharge occurs, ventilate work area before resuming service. Additional health and safety informa-
tion may be obtained from refrigerant and lubricant manufacturers.

------

Recovery/Recycling
equipment (ACR4)
(J-39500-NI)

SHA5510

EVACUATING SYSTEM AND CHARGING REFRIGERANT

------------,
Preferred (Best) method Alternate method
Manifold gauge set
(J-39183)

----
Fo;:-charging Refrigerant
I
I
container
(HFC-134a)

~~~ ~~2:==~ £d~

1
1 1

/
scale
Weight I
I' (J-39650)1

L _j
For evacuating
Recovery/Recycling _/ vacuum pump
equipment (ACR4) (J-39649)
(J-39500-NI)

SHA552D

1056 HA-48
 SERVICE PROCEDURES
R-134a Service Procedure (Cont'd)
Set the recovery/recycling equipment.

~
Recovered lubricant. Refer to Discharge refrigerant into recovery/
"CHECKING AND ADJUSTING", recycling equipment.
HA-50.

~
Repair or replace parts.

~
I Evacuate (over 25 minutes).
J
~
Check air tightness. "I Repair.
NG
~OK .1
Partial charging [approx. 200 g
(7.05 oz)].

~ J!~T
Preliminary refrigerant leak check.
Refer to "PRELIMINARY CH~CK", NG
HA-44.

~OK 1.

Complete charging (specified amount

less partial charge amount)
Refer to SDS.

~ .2

Check for refrigerant leaks.

Refer to "CHECKING PROCEDURE", NG
HA-45.

~OK
Check for A/C operation and A/C cool~
Performance Test Diagnoses.
ing periormance Refer to HA-22.

~
Remove service couplers from A/C
service valves

~
1 Recover refrigerant in charging hoses.

~
Remove serv1ce tools.

l
Reinstall service valve caps.

Note: *1 Before charging refrigerant, ensure engine is OFF.

*2 Before checking for leaks, start engine to activate air conditioner system then turn engine OFF.
Service valve caps must be installed to prevent leakage.

HA-49 1057
 SERVICE PROCEDURES

Compressor Lubricant Quantity

The lubricant used to lubricate the compressor circulates through
the system with the refrigerant. Whenever any A/C component is
replaced or gas leakage occurs, lubricant must be added.
If lubricant quantity is not maintained properly, the following mal-
functions may result:
• Lack of lubricant: May lead to a seized compressor
• Excessive lubricant: Inadequate cooling (thermal exchange
interference)
LUBRICANT
Name: Nissan A/C System Lubricant Type R
Part No.: KLHOO-PAGRO
CHECKING AND ADJUSTING
Adjust the lubricant quantity according to the flowchart shown
below.
,------------------------,
START

~ Yes
Can lubricant return operation be performed? Perform lubricant return operation, proceeding as follows:
• NC system works properly. 1. Start engine, and set the following conditions:
• There is no evidence of a large amount of • Test condition
lubricant leakage. Engine speed: Idling to 1,200 rpm

l No
NC switch: ON
RECIRCULATION switch: OFF
Fan speed: Max. position

~
Should the compressor be replaced? Temp. control: (Optional) Set so that intake air temperature is
25 to 3D"C (77 to 86°F).
No Yes 2. Perform lubricant return operation for 10 minutes.
3. Stop engine
CAUTION:
If excessive lubricant leakage is noted, do not perform the lubri-
cant return operation.

®
(Go to next page.)

Yes
Is there any part to be replaced? (Evaporator, After replacing any of the following major components, add the correct
condenser, liquid tank or in case there is evi- f----+ amount of lubricant to the system.
dence of a large amount of lubricant leakage?) Amount of lubricant to be added
Lubricant to be added to sys·
No
tem
Part replaced Amount of lubricant Remarks
Ratio
mi: (US fl oz,
(%)
Imp fl oz)
Evaporator 75 (2.5, 2.6) 30 ~

Condenser 75 (2.5, 2.6) 20 ~

Add if compressor is

~
Carry out the NC performance test. L1qu1d tank 5 (0.2, 0.2) to not replaced.*1
30 (1.0, 1.1) ~

Large leak
In case of refrigerant leak
~ ~

Smallleak*2
*1: If compressor is replaced, addition of lubricant is included in the
flow chart.
*2: If refrigerant leak is small, no addition of lubricant is needed.

1058 HA-50
 SERVICE PROCEDURES
Compressor Lubricant Quantity (Cont'd)
@

1. Discharge refrigerant into refrigerant recovery/recycling equipment. Measure lubricant discharged into the recovery/recycling
equipment.
2. Drain the lubricant from the old (removed) compressor into a graduated container and record the amount of lubricant drained.
3. Drain the lubricant from the new compressor into a separate, clean container.
4. Measure an amount of new lubricant equal to amount drained from old compressor. Add this lubricant to new compressor Lg
through the suction port opening.
5. Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant to new compressor
through the suction port opening.
6. If the liquid tank also needs to be replaced, add an additional 5 ml' (0.2 US fl oz, 0.2 Imp fl oz) of lubricant at this time.
Do not add this 5 ml' {0.2 US fl oz, 0.2 Imp fl oz) of lubricant if only replacing the compressor.

Lubricant adjusting procedure for compressor replacement

oO oO
Recovery/
Old New
Recycling
compressor compressor
equipment

! Recocd amount J Record amount

Drain lubricant
from new
,-----------------, compressor
into clean
I I
container
I I
I
I
+ I
I
I I
L ________________ j
Reinstall
"X"m£+"Y"m£ New
of new lubricant lubricant

New
compressor - - - - - - - L __ ___j

[Add an additional I
1 5 m£ (0.2 US fl oz,
0.2 Imp fl oz) of
I new lubricant when
~placing liquid tan~

AHA374

HA-51 1059
 SERVICE PROCEDURES

Compressor Mounting
SEC. 274•275

~45. 60 (4.6. 6.1, 33. 44)

~~~~45. 60 (4.6. 6.1.

~45-60(4.6·6.1.
tt=:l N•m (kg-m tt-lb) 12- 16) 33-44)
33 -44)
AHA855

Belt Tension
• Refer to MA section ("Checking Drive Belts", "ENGINE
MAINTENANCE").

Fast Idle Control Device (FICO)

• Refer to EC section ("IACV-FICD Solenoid Valve",
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS").

Condenser
REMOVAL
1. Discharge refrigerant using the recovery/recycling equipment
(ACR4).
2. Remove coolant reservoir tank (3 screws).
3. Remove side marker lamps.
4. Remove front grille (5 fasteners).
5. Remove harness clip from hood lock stay, if equipped (gently
press out).
6. Remove hood lock stay plate (4 bolts) and hood lock stay
brace (2 bolts).
7. Remove hose (high-pressure) clamp bracket from radiator
core support.
8. Disconnect high-pressure hose at condenser.
9. Disconnect dual-pressure switch harness connector.
10. Disconnect high-pressure tube (liquid tank to cooling unit) at
liquid tank.
11. Remove condenser mounting bolts (2 bolts).
12. Remove condenser assembly.
CAUTION:
Carefully lift condenser without damaging radiator (fin and
tube).

1060 HA-52
 SERVICE PROCEDURES

Compressor
SEC. 274 Thermal protector
::o:J 15 - 18 (1.5- 1.8, 11 . 13)--,

::o:J 20- 24
(2.0- 2.4,
14 - 17)

Pulley
1\fl : N•m (kg-m, in-lb)
::o:J : N·m (kg-m. ft-lb)
RHA401DA

Compressor Clutch
REMOVAL
• When removing center bolt, hold clutch disc with clutch disc 111'
wrench.

AHA841

• Remove the drive plate using Tool KV99232340 .

Insert holder's three pins into the drive plate. Rotate the holder
clockwise to hook it onto the plate. Then, tighten the center bolt
to remove the drive plate.
When tightening the center bolt, insert a round bar
(screwdriver, etc.) between two of the pins (as shown in the
left-hand figure) to prevent drive plate rotation. Alter removing i't'il
the drive plate, remove the shims from either the drive shalt or
the drive plate.

• Remove the snap ring using external snap ring pliers.

IIQil:\

HA-53 1061
 SERVICE PROCEDURES
Compressor Clutch (Cont'd)
• Pulley removal
Use any commercially available pulley puller. Position the cen-
ter of it on the end of the drive shaft, and remove the pulley
assembly.
For pressed pulleys:
To prevent deformation of the pulley groove, the puller
claws should be hooked under (not into) the pulley
groove.
For machine latched pulleys:
Align the pulley puller groove with the pulley groove, and
then remove the pulley assembly.
• Remove the field coil harness clip using a screwdriver.

u /Screwdnver
• Remove the three field coil fixing screws and remove the field
coil.

~ F1eld coil

RHA074C

INSPECTION
I Snap ring

6
Shim',
Clutch disc : If the contact surface shows signs of damage due
Bolt-,

©
I £mw to excessive heat, replace clutch disc and pulley.
Pulley : Check the appearance of the pulley assembly. Check the
contact surface of the pulley for any sign of excessive grooving due
to slippage. If any sign is found, replace both the pulley and clutch

~
disc. The contact surfaces of the pulley assembly should be
cleaned with a suitable solvent before reinstallation.
! Coil : Check coil for loose connection or cracked insulation.
L_ Clutch disc ' L Coil

Pulley
RHA075C

INSTALLATION
• Install the field coil.
• Be sure to align the coil's pin with the hole in the com-
pressor's front head.
• Install the field coil harness clip using a screwdriver.

RHA076C

1062 HA-54
 SERVICE PROCEDURES
Compressor Clutch (Cont'd)
KV99234330
• Install the pulley assembly using the installer and a hand '!il~
(J-39024)
press, and then install the snap ring using snap ring pliers.

1:"1!]

• Install the drive plate on the drive shaft, together with the ~0
original shim(s). Press the drive plate down by hand.
__.-C•riveplate [;;·~

• Using the holder to prevent drive plate rotation, tighten the bolt ['.11
to 12- 15 N·m (1.2- 1.5 kg-m, 9-11 ft-lb) torque.
Ratchet wrench • After tightening the bolt, check that the pulley rotates f!"
smoothly.

Drive plate
holder

• Check clearance around the entire periphery of clutch disc.

Disc-to-pulley clearance:
0.3- 0.6 mm (0.012- 0.024 in)
If the specified clearance is not obtained, replace adjusting ~111
spacer and readjust.

BREAK-IN OPERATION
When replacing compressor clutch assembly, always conduct the
break-in operation. This is done by engaging and disengaging the
clutch about thirty times. Break-in operation raises the level of
0.3 ·0.6
(0.012- 0.024)
transmitted torque.

Unit: mm (in)
$1*
7
Spark plug gap gauge
AHA848

HA-55 1063
 SERVICE PROCEDURES

Thermal Protector
INSPECTION
• When servicing, do not allow foreign matter to get into com-
pressor.
• Check continuity between two terminals.

AHA849

1064 HA-56
 SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications
COMPRESSOR LUBRICANT
Mode! DKV-14C ZEXEL make
Model
DKV·14C
Type Vane rotary
Nissan AJC System Oil
Displacement cm 3 (cu in)/Rev 140 (8.54) Name
TypeR
Clockwise
Direction of rotation Part number KLHOO-PAGRO
(Viewed from drive end)
Capacity ml' (US fl oz, Imp fl oz)
Drive belt A type
Total in system 200 (6.8, 7.0)
Compressor (Service parts)
200 (6.8, 7.0)
charging amount

REFRIGERANT
Type R134a

Capacity kg (lb) 0.75-0.85 (1.65 -1.87)

Inspection and Adjustment

ENGINE IDLING SPEED COMPRESSOR
When AIC is ON Model DKV-14C
Refer to EC section. 0.3-0.6
Clutch disc-to-pulley clearance
BELT TENSION mm (in) (0.012- 0.024)

Refer to MA section ("Checking Drive Belts",

"ENGINE MAINTENANCE").

•
HA-57 1065
 ELECTRICAL SYSTEM

SECTION EL
CONTENTS
PRECAUTIONS .............................................................2 Wiring Diagram (For Canada) -DTRL-... ......... .42
Supplemental Restraint System (SRS) "AIR Trouble Diagnoses (For Canada) ............................. .45
BAG"........................... ........................................ 2 Bulb Specifications........ ............. .47
HARNESS CONNECTOR ................................... ............ 3 Aiming Adjustment .................................................... .47
STANDARDIZED RELAY ..... . ............ .4 EXTERIOR LAMP ............................................. ............ .49
POWER SUPPLY ROUTING ......................... . ..... 6 Back-up Lamp/Wiring Diagram -BACK/L-.............. .49
Schematic ................................................. . ..... 6 Parking, License, Tail and Stop Lamps/Wiring
Wiring Diagram -POWER- ···················· ........ 7 Diagram-TAIUL- .................................................. 50
Fuse .... . ............................ 11 Turn Signal and Hazard Warning Lamps/System
Fusible Link ...................................... . ......... 11 Description .............................................. .. ..... 52
Circuit Breaker Inspection ....... . . .................. 11 Turn Signal and Hazard Warning Lamps/Wiring
GROUND DISTRIBUTION ........... ............. . ...... 12 Diagram -TURN-................. .. ......................... 54
BATTERY .... 15 Turn Signal and Hazard Warning Lamps/Trouble
How to Handle Battery ............................................. 15 Diagnoses ............ . .. ....... 56
Service Data and Specifications (SDS) .................... 18 Combination Flasher Unit Check .. .. ............... 56
STARTING SYSTEM .......... ........ .... ............. 19 Bulb Specifications ................................. . .. ...... 57
System Description ................................................... 19 INTERIOR LAMP ............................... . ................ 58
Wiring Diagram -START-....... ................ ..... 20 Illumination/System Description ................................ 58
Starter... .. ............ ................................. ............. 22 Illumination/Schematic...................... . .............. 59
Pinion/Clutch Check ................................................ 24 Illumination/Wiring Diagram -ILL-........................... 60
Service Data and Specifications (SDS) .................... 24 Interior and MAP Lamps/
CHARGING SYSTEM................... ......... 25 Wiring Diagram -INT/L-............ .. .................... 63
System Description................................ ....... 25 Bulb Specifications..... .............. .. ....... 64
Wiring Diagram -CHARGE-.......... ..... 26 METERS AND GAUGES. ................ .. ....... 65
Trouble Diagnoses......... ................. .............. 27 System Description .......................... .. .. ....... 65
Generator..... ................................... ...... 28 Combination Meter ............................... . ......... 66
Diode Check........... .............................. 29 Speedometer, Tachometer, Temp. and Fuel
Disassembly and Assembly.. ............. ...... 30 Gauges/Wiring Diagram -METER- ......................... 68
Service Data and Specifications (SDS)... ....... 31 Inspection/Water Temperature Gauge...... ......... 69
COMBINATION SWITCH.. ................. ...... 32 Inspection/Fuel Gauge..... .. .............................. 70
Combination Switch/Check .... ..... 32 Inspection/Tachometer ............................................. 71
Combination Switch/Replacement.. ....... 33 Inspection/Speedometer and Vehicle Speed
Steering Switch/Check .. ....... 34 Sensor...... ......................................... ........... 72
HEADLAMP ............................................ . ...... 35 Inspection/Speedometer and Fuse .......................... 73
System Description (For USA) .................... 35 Fuel Tank Gauge Unit Check .. ...... .. .. ....... 74
Wiring Diagram (For USA) - H/LAMP-................... 36 Fuel Warning Lamp Sensor Check .......... 74
Trouble Diagnoses (For USA)................ ..... 37 Thermal Transmitter Check........... .. ...... 74
System Description (For Canada) ............................. 38 Oil Pressure Switch Check............ .. .............. 74
Operation (Daytime light system for Canada) ........... 39 Vehicle Speed Sensor Signal Check ........................ 75
Schematic (For Canada) ..... .................. .... .40 WARNING LAMPS ......................................... ............. 76

1066
 CONTENTS <cont'd.) (';'I

System Description........ ....... 76 Trouble Diagnoses ........................................ 123

Schematic ................................................................78 POWER WINDOW ...................................... .............. 135 i!lffi,
Wiring Diagram -WARN- ........................................ 79 Component Layout .............. . .......... 135
Diode Check..................... ............................... 82 System Description ................................................ 136 -·· i
WARNING CHIME ............... . .......... 83 Wiring Diagram -WINDOW- ............. ... 138 "l:il
System Description ................................................. 83 Trouble Diagnoses ..................... . ........... 140
Wiring Diagram -CHIME- ................................. . ... 84 POWER DOOR LOCK ........................ . ........... 141
Trouble Diagnoses ......... 85 System Description.. ........... .......... ............ 141
WIPER AND WASHER ············· ......................... 92 Schematic ............................................................... 142
System Description .................................................. 92 Wiring Diagram -D/LOCK- ................................... 144 ]K~
Wiring Diagram -WIPER-......... ............... ......... 94 Trouble Diagnoses... ..................................... 146
Trouble Diagnoses .................................................. 96 LOCATION OF ELECTRICAL UNITS. .... 150
Wiper Amplifier Check .............................................. 99 Passenger Compartment... ............................... 150 [Cl'
Installation.. . ................................... 99 Engine Compartment .................... .... 151
Washer Nozzle Adjustment .... ............... ....... 100 HARNESS LAYOUT..................... ........... 152
HORN, LIGHTER, CLOCK......... ............... ....... 101 How To Read Harness Layout......... ... 152
Wiring Diagram -HORN- ...................................... 101 Outline....... . ..................................................... 153
AUDIO ................................................. ....................... 102 Main Harness and Air Bag Harness .. ............ 154 Jf[
System Description ................................................. 102 Instrument Harness ............ .............................. .... 158
Schematic ...... ..... ............ .... 103 Engine Harness ............ . ..... 159
Wiring Diagram -AUDIO- ..................................... 104 Chassis and Tail Harness ..... . ......... 160
Trouble Diagnoses................. ......................... 107 Front Door Harness ................. ...... 161
AN~N~......................................... ........ 100 Room Lamp Harness..................... ..... 162
Location of Antenna........ ............. 109 SUPER MULTIPLE JUNCTION (SMJ) ....... Foldout page U
Window Antenna Repair ........................................ 110 Installation ........................................ Foldout page
MIRROR ................................................... .................. 112 Terminal Arrangement... ......................... Foldout page
Wiring Diagram -MIRROR- .................................... 112 JOINT CONNECTOR (J/C). .... ........ .... Foldout page IJ[j)
AUTOMATIC SPEED CONTROL DEVICE (ASCD) .... 114 Location . .... .......... .. ..................... Foldout page
Component Parts and Harness Connector Terminal Arrangement... ......................... Foldout page
Location . . ..... ......... .. . ................................ 114 FUSE BLOCK...... .............................. Foldout page 1~5':
System Description ............................................... 115 Fuse Arrangement................. ...... Foldout page
Schematic ............................................................. 117 CONTROL UNITS/MODULE ................ ...... Foldout page [~i/L
Wiring Diagram -ASCD- ............................... 118

When you read wiring diagrams:

• Read Gl section, "HOW TO READ WIRING DIAGRAMS".
When you perform trouble diagnoses, read Gl section, "HOW TO FOLLOW FLOW CHART IN
TROUBLE DIAGNOSES" and "HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL
INCIDENT".

WIRING DIAGRAM REFERENCE CHART

ECCS (Ignition system) ......................................... ;.............................................................................. EC SECTION flu'
AUTOMATIC TRANSMISSION CONTROL SYSTEM, SHIFT LOCK SYSTEM ....................................AT SECTION
ANTI-LOCK BRAKE SYSTEM ...............................................................................................................BR SECTION
SRS "AIR BAG" .....................................................................................................................................RS SECTION llii:.
HEATER AND AIR CONDITIONER .......................................................................................................HA SECTION

[[j)?{

1067
 PRECAUTIONS

Supplemental Restraint System (SRS) "AIR

BAG"
The Supplemental Restraint System "Air Bag", used along with a
seat belt, helps to reduce the risk or severity of injury to the driver
in a frontal collision. The Supplemental Restraint System consists
of an air bag module (located in the center of the steering wheel),
a diagnosis sensor unit, a crash zone sensor (4WD models),
warning lamp, wiring harness and spiral cable. Information neces-
sary to service the system safely is included in the RS section of
this Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could
increase the risk of personal injury or death in the event
of a collision which would result in air bag inflation, all
maintenance must be performed by an authorized
NISSAN dealer.
• Improper maintenance, including incorrect removal and
installation of the SRS, can lead to personal injury caused
by unintentional activation of the system.
• Do not use electrical test equipment on any circuit related
to the SRS unless instructed to in this Service Manual.
SRS wiring harnesses are covered with yellow insulation
either just before the harness connectors or for the com-
plete harness, for easy identification.

1068 EL-2
 HARNESS CONNECTOR

Description Iilli

HARNESS CONNECTOR
• All harness connectors have been modified to prevent accidental looseness or disconnection. li:j]ffil
• The connector can be disconnected by pushing or lifting the locking section.
CAUTION:
Do not pull the harness when disconnecting the connector. lf':G~

[Example]
l©

Terminal retainer If':©

~i1':

I:Q[L

Packing
{Water-proof type) ffiijjj'

Terminal retainer
ffilli'

LIFT PUSH
li'~

~
PUSH

l'l!il

rP~

~1%

PUSH ~lCJ
PUSH

i\51i'

~f§l

PUSH
(For combination meter) (For relay) ~li'

lilt!\

SEL769D

liilll:1

EL-3 1069
 STANDARDIZED RELAY

Description
NORMAL OPEN, NORMAL CLOSED AND MIXED TYPE RELAYS
Relays can be divided into three main types: normal open, normal closed and mixed type relays.
NORMAL OPEN RELAY NORMAL CLOSED RELAY MIXED TYPE RELAY

Flows. Flows.

~
~
0

-;:
Does not
flow. ¢ =

orr
---
/QOO\
,
Does not¢
flow.

'000'
"' =
sw 1
0 lr ~=0 I L..o= 0 I'
BATTERY SW 1 BATTERY sw 1 BATTERY

Flows.
Does not
Does not

z
0
- flow. ¢

=
flow.¢

-
-
;:
'OH uor "'rr
Flows.

"' ~ . ~ ,, L_....... ..
sw 1 BAJ~RY 7w1 BATTERY sw 1 BA;.;.EAY

AEL669A

TYPE OF STANDARDIZED RELAYS

1M 1 Make 1M·1B 1 Make 1 Break
2M 2 Make

1M 2M

I ~1M I 2M

L: ,, ·--:::( L:
g
0 . ~)
•'
' :; (f~)
--.... ...
~
\
( -- __
I --- r
1M-1B

c
l
:; : \/' \1
I
\,r~
"
,'.(

I
I
I
v---18

r '
I 1M

AEL309A

1070 EL-4
 STANDARDIZED RELAY
Description (Cont'd)
Type Outer view Circuit Connector symbol Case color
and connection

1M GRAY

1M BLUE
j[Ll

,-------0 0---,

1M BLUE

18~'
=
2M BROWN ~'TI'

~·~

~l

liLt,

1M-1B GRAY

AEL308A

EL-5 1071
1072

BATTERY

~
GREEN
~
BLACK BROWN ~ BROWN
FUSIBLE FUSIBLE FUSIBLE FUSIBLE
LINK LINK LINK LINK

~
lOA
EiJ
r lOA
@i]
lOA
[i] [i]A ~OA
[i]
rf11sA
y~
,liSA

~[U]
I cHJRGE I INT/L TURN MAIN H/LAMPI H/LAMPI
HORN MAFS OTRL DTRL
AUDIO
MAIN I CMPS
PGC!V
rilCIRCUIT
WBREAKER
.r:!f..l:!.Qh

D/LOCK
IGNITION SWITCH "tl
FFIAcd oN I sT 0
en
:em
:::T
n ::c
m
r7J1oA
y[i4J Jg a3 A
[i] CD en
c

j_t1 ~6~~~R
START "tl
r;- UillQJ
OTRL
0

c;· "tl
al RELAY
=-"~ !<
L-"'i"-1
::c

~
A 0
c
ABS [i4J :::!
~ACCESSORY
~RELAY
~IGNITION
~RELAY-1
t ~~ IGNITION-2
AND POWER
WINDOW
RELAY
~
" I ~~~t
IIGN/SG
TP/SW

INJECT
I
z
G)

~
r/115/\
lOA
[i2J X A
LJ~ [!__iJ

TJRN I AIT
SHIFT
SRS
ABS
CHARGE
DTRL
START
BACK/L
CHIME
METER
WARN
)> ASCD
m CANJ/V

~ = ~
PNVPSlsw I ~

~ MILIDL
 POWER SUPPLY ROUTING

Wiring Diagram -POWER- @[

....- - - - - - • - - - - EL-POWER-01

+
BATTERY
@.@)
c!J FUSIBLE
LINK
(f:j£).@)
ttll~ FUSIBLE
LINK
@1§). @>
~~ ~~
W W/8 W/R W

._ I
r------·· WI/R •~-----w+ {MAIN. MAFS.
CMPS. PGCN
r-----._-------,FUSE
w BLOCK
(iillj)
[fl FUSIBLE
LINK 15A
(~) @]
cyJ
W/B

~~~~ifi~<
~
~~~---.!':::::..;:}
. ._ _ _ _ _ _ _ _ _ _ _ _ _ W/B~Next
H/LAMP.DTRL
page

WIG . ._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ W~To EL-POWER-03

·'-----·--------·-------·W/G.D/LOCK
._._
rI
W/L W/G
. .- - - - - - L . A B S
L
WIL .j9:> To EL-POWER-03

II]]·~·~< AND POWER

WINDOW
RELAY

~~ ll4Jl ('ill§)

rr·r
B W BIG

11
• l_!::::::::B/G.ABS
w+WINDOW

B B B
_.__ _._ -:!;-
(~)(~) (~)(~)(~)

~-~-----------, ,--------------,
r-1"1(~) I I
liJ(~) :FTl(@) ~@): fi=1 @Qj) ~ (M148)
til BR
1 I (M47)
12 8 L!J
1------------...l
8
I
t 1t:ITI1 W w G
1--------------~
1 1IT' W t:tl:[j BR

ffi::::[i] ffi::::[i] ffi::::[i]

lillT lillT lillT
II
AEL299A-A

EL-7 1073
 POWER SUPPLY ROUTING
Wiring Diagram -POWER- (Cont'd)

page
P'eoedlng ~ 4w!B•--------•••----------· W/B
I
EL-POWER-02

,-------------------"-ir-"---,IGNITION
ffi
SWITCH
(iillQ)

OFF
........ _. .... ST OFF ,.._ ST OFF., . . esr
ACC ON ACC ON

ll4dl~ ~
B/Y 8/Y B/W B/L

I i 1------------------
BIW B/l
- BIW-{g>-To EL-POWER-04

BIY
m-------m<fillil
r-~~---~~--~~~~~------~-f----~--7FUSE
_.,. -- BLOCK
W/B

(~)

1DA 10A
~ [I]

OR BfW BfW GfW UY GfW

I LG!W.AUDIO

L...-. UY.WIPER

.__ _ _ _ _ _ _ GfW. {~~AUDIO, FICO,

WARN, FR02, FR02/H,

1- - - - - - - - - - - 8/W. EGRC1.
RR02, RR02/H,
VENTN,FUEL,
AACN,
{ SWN, SWLJV, EGRCN,
BYPSN
.__ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ BfW.F/PUMP

. ._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ OR.S/SIG

BIY.START, DTRL

--------------------------------------1
IT1:::ITl IT1:::ITl IT1:::ITl ~ (filliJ :
liiTf liiTf liiTf w :
I
I
I
I
I
I
I
______________________________________ JI

AEL299A-B

1074 EL-8
 POWER SUPPLY ROUTING
Wiring Diagram -POWER- (Cont'd)

EL-POWER-03
p _______....
_ _ _ _ B .HEATER, A/C

To EL-POWER-01 -<a-w-·----------· -----------·-W~Next page

~~~~edlng{~ W FUSE
BLOCK
(M143)

·c ffi
3
ACCESSORY
RELAY
(~)

c
~tb¥dl
B

BLOWER
MOTOR
RELAY
<MW
B B

-
- -
15A 10A 10A
[}] 0 ITiJ

L L lbjJJ~ B/L G/R OR W/B lbjJJ <illilJ

L!
B/L W/L
I - I+
To EL
POWER-01~
----GJ- ;;_ J
~
B AfT, SHIFT, SRS, ABS, CHARGE,
W/B+ DTRL. START. BACKIL. CHIME.
METER, WARN, ASCD, CANIN,
JOINT - VSS, PNP/SW. MIUDL

rn
CONNECTOR-2
~ . ._ _ _ _ OR +TURN

lbjdJ . ._ _ _ _ _ _ _ _ G/R.MIRROR
B

--·i-il . ._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ L .HEATER. A!C

_._
B
_._
B
_._
B
. ._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ G/R.HORN, FICO, A/C

CM49J c@> eMf§!>>

Refer to last page (Foldout page).
(M142)

0::ill<§W0::ill@9)0::ill<fiill)
~L~L~L
i=i<illill
L!..JW

AEL867A

EL-9 1075
 POWER SUPPLY ROUTING
Wiring Diagram -POWER- (Cont'd)

EL-POWER-04

POWEA-02
To EL-
--...!2r
_...4
BIW•
...._··--------------------
8/W. MAIN, FUEL, TP/SW, IGNISG, INJECT

Preceding ~W.;:.
page ~
-·-·-------------w+ CHARGE

BIW w
I
w
me~>
r-----~----_,----~~~~----------------------------------oFUSE
BLOCK
(M143)

lOA 20A lOA

I:!:II [2IJ ~

RIL L LG R/Y R/B RIG p p

LJ
1- - - - - - R/G +
P . CHIME,TAIUL,ILL

P+ CHIME

~NT/L, HORN, AUDIO,

lMAIN, MIUDL

. ._ _ _ _ _ _ _ _ _ RIB. ABS, TAIUL. ASCD

. ._ _ _ _ _ _ _ _ _ _ _ R!Y+ TURN

. ._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ LG. HORN, ASCD

. ._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ L + ABS

. ._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ RIL+ SRS

,--------------------------------------
1

: ill::::IIl [2}-:IJJ lil::[iJ

: l]]If" l]]If" l]]If"

l ~ b!dbld~~b1d~b1J~b1JIJID[gj @ill) ~ (M~6)

1
IJ'1l~~t!!H!!l~~~~IE~ 0 f
l 0 "'--=========.L--' UP

AEL868A

1076 EL-10
 POWER SUPPLY ROUTING

Fuse
• If fuse is blown, be sure to eliminate cause of problem
before installing new fuse. ic!Jc
• Use fuse of specified rating. Never use fuse of more than
specified rating.
• Do not partially install fuse; always insert it into fuse l'i~c[
holder properly.
• Remove fuse for "ELECTRICAL PARTS (BAT)" if vehicle is
O.K. Blown not used for a long period of time. l©
SEL954J

Fusible Link
A melted fusible link can be detected either by visual inspection or
by feeling with fingertip. If its condition is questionable, use circuit 1'1\l
tester or test lamp.
CAUTION:
• If fusible link should melt, it is possible that a critical ·©:L
circuit (power supply or large current carrying circuit) is
shorted. In such a case, carefully check these circuits and
eliminate cause of problem. i{Lf
• Never wrap outside of fusible link with vinyl tape.
Important: Never let fusible link touch any other wiring
harness, vinyl or rubber parts.

Circuit Breaker Inspection

For example, when current is 30A, the circuit is broken within 8 to
20 seconds. ~~~
20 f--+--+-\,'1 Circuit breakers are used in the following systems:
• Power door lock
•gf::=l=f:::~t-11~ • Power window ~cf
·~~-i~~~-t-

1
o 10 20 30 40

SBF284E

•
EL-11 1077
 GROUND DISTRIBUTION

GROUND CONNECT TO CONN. NO. CELL CODE

M15/M16 ABS CHECK CONNECTOR M154 BR-ABS
DATA LINK CONNECTOR FOR CONSULT M153 EC-MIUDL
DATA LINK CONNECTOR FOR GST M152 EC-MIUDL
DISTRIBUTOR (CAMSHAFT POSITION SENSOR) M12 EC-CMPS
DISTRIBUTOR (POWER TRANSISTOR) M12 EC-IGN/SG
ECM (EGGS CONTROL MODULE) M112 EC-MAIN EC-AP/SEN EC-FR02
EC-FR02/H EC-FUEL
REAR HEATED OXYGEN SENSOR M402 EC-RR02 EC-RR02/H
SHIELD WIRE (ABSOLUTE PRESSURE SENSOR) M24 EC-AP/SEN
SHIELD WIRE (CAMSHAFT POSITION SENSOR) M12 EC-CMPS
SHIELD WIRE (CRANKSHAFT POSITION SENSOR) E15 EC-CKPS
SHIELD WIRE (EVAP CONTROL SYSTEM PRESSURE C6 EC-PRE/SE
SENSOR)
SHIELD WIRE (FRONT HEATED OXYGEN SENSOR) M62 EC-FR02 EC-FR02/H EC-FUEL
SHIELD WIRE (MASS AIR FLOW SENSOR) M20 EC-MAFS
SHIELD WIRE (REAR HEATED OXYGEN SENSOR) M402 EC-RR02 EC-RR02/H
SHIELD WIRE (THROTTLE POSITION SENSOR) M23 EC-TPS AT-AfT
M49/M 105/M 160 ACCESSORY RELAY M149 EL-POWER
AIR BAG DIAGNOSIS SENSOR UNIT M175 RS-SRS
ASCD CONTROL UNIT M126 EL-ASCD
ASCD MAIN SWITCH N2 EL-ASCD
ASCD HOLD RELAY (With AfT) M65 EL-ASCD
ASCD HOLD RELAY (With MIT) M64 EL-ASCD
BLOWER MOTOR RELAY M150 HA-NG HA-HEATER EL-POWER
BRAKE FLUID LEVEL SWITCH M59 EL-WARN BR-ABS
BULB CHECK RELAY M63 EL-WARN
CIGARETTE LIGHTER SOCKET M119 EL-HORN
CLUTCH INTERLOCK SWITCH (With MIT) M136 EL-START
COMBINATION FLASHER UNIT M139 EL-TURN
COMBINATION METER (AIR BAG WARNING LAMP) N6 RS-SRS EL-WARN
COMBINATION METER (CLOCK) N6 EL-HORN
COMBINATION METER [CLOCK (Without tachometer)] N4 EL-HORN
COMBINATION METER [CRUISE INDICATOR (With N6 EL-ASCD
ASCD)]
COMBINATION METER (GAUGES) N4 EL-METER
COMBINATION METER (HIGH BEAM INDICATOR) NS EL-DTRL EL-H/LAMP
COMBINATION METER (SPEEDOMETER) N4 EC-VSS EL-ASCD
COMBINATION METER [TACHOMETER (With tachom- N6 EL-METER
eter)]
COMBINATION METER (TURN SIGNAL LAMP) N6 EL-TURN
COMBINATION METER [4WD INDICATOR (With 4WD)] N6 EL-WARN
DATA LINK CONNECTOR FOR GST M152 EC-MIUDL
DAYTIME LIGHT CONTROL UNIT (With DTRL) M4t EL-DTRL
DOOR MIRROR SWITCH N3 EL-MIRROR
FRONT TURN SIGNAL LAMP LH M70 EL-TURN
FRONT TURN SIGNAL LAMP RH M54 EL-TURN
GLOVE BOX LAMP SWITCH M203 EL-ILL

1078 EL-12
 GROUND DISTRIBUTION

GROUND CONNECT TO CONN. NO. CELL CODE

M49/M105/M160 HEADLAMP LH M66 EL-H/LAMP
HEADLAMP RH M51 EL-H/LAMP EL-DTRL
HIGH-MOUNTED STOP LAMP R4 EL-TAIUL
IACV-FICD SOLENOID VALVE M602 EC-FICD HA-AIC
IGNITION RELAY-1 M151 EL-POWER
IGNITION-2 AND POWER WINDOW RELAY M148 BR-ABS EL-POWER EL-WINDOW
ILLUMINATION CONTROL SWITCH M123 EL-ILL
CLUTCH INTERLOCK SWITCH (With Mff) M36 EL-START
INHIBITOR RELAY (With ASCD) M35 EL-START EL-ASCD
INHIBITOR RELAY (Without ASCD) M34 EL-START
LOCK/UNLOCK KNOB SWITCH D9 EL-D/LOCK
MAP LAMP R2 EL-INT/L
MAIN POWER WINDOW AND DOOR LOCK/UNLOCK DB EL-DLOCK EL-WINDOW
SWITCH
PARK AND NEUTRAL POSITION RELAY (with AIT) M42 EC-PNP/SW AT-AIT
POWER WINDOW AMPLIFIER Mt02 EL-WINDOW
iflr
ROOM LAMP R5 EL-INT/L
SWIRL CONTROL VALVE CONTROL VACUUM CHECK M39 EC-SNCSW
SWITCH ltl
WARNING CHIME UNIT M170 EL-CHIME
WASHER FLUID LEVEL SWITCH (Canada only) M58 EL-WARN
ll'
WIPER AMPLIFIER M4 EL-WIPER
WIPER MOTOR M3 EL-WIPER
WIPER SWITCH M132 EL-WIPER
M111 ECM (ECCS CONTROL MODULE) M112 EC-MAIN EC-IGN/SG
SHIELD WIRE (ABS CONTROL UNIT) M176 BR-ABS

EL-13 1079
 GROUND DISTRIBUTION

GROUND CONNECT TO CONN. NO. CELL CODE

M177 ABS ACTUATOR C3 BR-ABS
ABS CONTROL UNIT M176 BR-ABS
AfT DEVICE M174 AT-SHIFT
AfT DEVICE (OVERDRIVE SWITCH) M174 AT-AfT
DOOR LOCK CONTROL UNIT M178 EL-D/LOCK
DOOR SWITCH LH M171 RS-SRS EL-CHIME
FRONT PARKING LAMP LH M55 EL-TAIUL
FRONT PARKING LAMP RH M50 EL-TAIUL
FUEL TANK GAUGE UNIT (FUEL PUMP) C4 EC-F/PUMP
FUEL TANK GAUGE UNIT (LOW FUEL WARNING) C4 EL-WARN
LICENSE LAMP LH T5 EL-TAIUL
LICENSE LAMP RH T4 EL-TAIUL
LICENSE LAMP LH (With step bumper) T6 EL-TAIUL
LICENSE LAMP RH (With step bumper) T2 EL-TAIUL
REAR COMBINATION LAMP LH (BACK-UP) T7 EL-BACKIL
REAR COMBINATION LAMP RH (BACK-UP) T3 EL-BACKIL
REAR COMBINATION LAMP LH (TAIL) T7 EL-TAIUL
REAR COMBINATION LAMP RH (TAIL) T3 EL-TAIUL
REAR COMBINATION LAMP LH (TURN) T? EL-TURN
REAR COMBINATION LAMP RH (TURN) T3 EL-TURN
REAR SPEAKER AMPLIFIER M179 EL-AUDIO
SEAT BELT BUCKLE SWITCH M173 EL-CHIME EL-WARN
E6 GENERATOR EB EL-CHARGE
NEUTRAL POSITION SWITCH E18 EC-PNP/SW
POWER STEERING OIL PRESSURE SWITCH E10 EC-PST/SW
E24/E25 BATTERY E23 EL-POWER

1080 EL-14
 BATTERY

CAUTION:
• If it becomes necessary to start the engine with a booster
battery and jumper cables, use a 12-volt booster battery.
• After connecting battery cables, ensure that they are l!uffi1
tightly clamped to battery terminals for good contact.

Keep clean and dry.

How to Handle Battery
METHODS OF PREVENTING DISCHARGE
The following precautions must be taken to prevent over- 1"1"
discharging a battery.
• The battery surface (particularly its top) should always be kept
clean and dry. Gl
• The terminal connections should be clean and tight.
• During every routine maintenance, check the electrolyte
level. This also applies to batteries designated as "low main- ifut'W
tenance" and "maintenance-free".
SEL189P

• When the vehicle is not going to be used over a long period of i~1i'
Remove negative ~- {i__ time, disconnect the negative battery terminal.
terminal. ~

SEL778Q

riiz~
Hydrometer
• Check the condition of the battery. Periodically check the spe-
cific gravity of the electrolyte. Keep a close check on charge
condition to prevent over-discharge.

~
Thermometer

SEL191P
I~Jir
CHECKING ELECTROLYTE LEVEL
WARNING:
Do not allow battery fluid to come in contact with skin, eyes, ~lffil
fabrics, or painted surfaces. After touching a battery, do not
touch or rub your eyes until you have thoroughly washed your
hands. If acid contacts eyes, skin or clothing, immediately
flush with water for 15 minutes and seek medical attention.
Normally the battery does not require additional water. However,
when the battery is used under severe conditions, adding distilled I[~J:&
water may be necessary during the battery life.

El-15 1081
 BATTERY
How to Handle Battery (Cont'd)
• Remove the cell plug using a suitable tool.
Suitable tool • Add distilled water up to the MAX level.
SULPHATION
A battery (with specific gravity less than 1.1 00) will completely
discharge when left unattended for a long period of time. This
will result in sulphation on the cell plates.
A sulphated battery may sometimes be brought back into ser-
MAX. level
vice by means of a slow charge, 12 hours or more. A capacity
MIN. level test should be run after the battery is charged to ensure the
battery is not damaged.
SEL779Q

SPECIFIC GRAVITY CHECK

• Check hydrometer and thermometer readings at eye level.

~
Thermometer

• When electrolyte level is too low, tilt battery case for easy
measurement.

~
Thermometer

SEL196P

• Use the chart below to correct your hydrometer reading according to electrolyte temperature.
Hydrometer temperature correction
Battery electrolyte temperature oc Battery electrolyte temperature oc
Add to specific gravity reading Add to specific gravity reading
(oF) (oF)

71 (160) 0.032 21 (70) -0.004

66 (150) 0.028 16 (60) -0.008
60 (140) 0.024 10 (50) -0.012
54 (129) 0.020 4 (39) -0.016
49 (120) 0.016 -1 (30) -0.020
43 (110) 0.012 -7 (20) -0.024
38 (100) 0.008 -12 (10) -0.028
32 (90) 0.004 -18 (0) -0.032
27 (80) 0

Corrected specific gravity Approximate charge condition Corrected specific gravity Approximate charge condition
1.260 - 1.280 Fully charged 1.170- 1.190 1/4 charged
1.230 - 1.250 3/4 charged 1.140- 1.160 Almost discharged
1.200 " 1.220 1/2 charged 1.110-1.130 Completely discharged

1082 EL-16
 BATTERY
How to Handle Battery (Cont'd)
CHARGING THE BATTERY
CAUTION:
• Do not "quick charge" a fully discharged battery.
• Keep the battery away from open flame while it is being
charged.
• When connecting the charger, connect the leads first, then
turn on the charger. Do not turn on the charger first, as
this may cause a spark.
• If battery electrolyte temperature rises above 60"C (140"F),
stop charging. Always charge battery at a temperature lC:
below 60"C (140"F).

Charging rates:

Amps Time
so 1 hour
2S 2 hours
10 S hours
s 10 hours
Do not charge at more than SO ampere rate.
Note: The ammeter reading on your battery charger will auto-
matically decrease as the battery charges. This indi-
cates that the voltage of the battery is increasing nor-
mally as the state of charge improves. The charging
amps indicated above are referred to as the initial ~lF
charge rate.
• If, after charging, the specific gravity of any two cells varies llli'
more than .050, the battery should be replaced.
• Alter the battery is charged, always pertorm a "capacity test"
as follows, to assure that the battery is serviceable.

MEMORY RESET
If the battery is disconnected or goes dead, the following items must [51'\
be reset:
• Radio AM and FM preset
• Clock

EL-17 1083
 BATIERY
How to Handle Battery (Cont'd)
• Check battery type and determine the specified current using the
following table.
Fig. 1 DISCHARGING CURRENT
SPECIFIC GRAVITY (load tester)
CHECK
Group size Current {A)

21R (USA) 245

24R (Canada) 275

CHARGING THE BATTERY

CAPACITY TEST

Test using battery checker. Test using load tester.

I

Follow manufacturer's instruc- Read load tester voltage

lions to check and determine when specified discharging SEL008Z
if battery is serviceable. current (Refer to Fig. 1.) flows
through battery for 15 sec-
O.K. N.G. onds.

Ready for use. Replace

See voltage chart.
battery.
Above minimum voltage?

~OK ~ N.G.

Ready for use. Replace

battery.

Voltage chart
Estimated electrolyte temperature "C (°F} Minimum voltage under 15 second load

21 (70) 9.6

16 (60) 9.5

10 (50) 9.4

4 (40) 9.3

-1 (30) 9.1

-7 (20) 8.9

-12 (10) 8.7

-18 (0) 8.5

Service Data and Specifications (SDS)

Applied area USA Canada

Group size 21R 24R

Capacity V-AH 12-60 12-65

Cold cranking current A 490 550

Reserve capacity minutes 88 113

1084 EL-18
 STARTING SYSTEM

System Description
MIT models
Power is supplied at all times: ~ciffi\
• to ignition switch terminal <D
• through green fusible link (located at the battery positive terminal).
With the ignition switch in the START position, power is supplied: ~[i)i
• through terminal @ of the ignition switch
• to clutch interlock relay terminals <D and @.
Ground is supplied to clutch interlock relay terminal ® when the clutch pedal is depressed through the clutch [)g
interlock switch and body grounds ® , @ and ~ .
The clutch interlock relay is energized and power is supplied:
• from terminal ® of the clutch interlock relay ~©
• to terminal <D of the starter motor windings.
The starter motor plunger closes and provides a closed circuit between the battery and the starter motor. The
starter motor is grounded to the engine block. With power and ground supplied, cranking occurs and the engine I"~
starts.

AfT models
Power is supplied at all times:
• to ignition switch terminal <D
• through green fusible link (located at the battery positive terminal).
With the ignition switch in the ON or START position, power is supplied:
• to inhibitor switch terminal <D
• through 1OA fuse (No. [j] , located in the fuse block).
With the ignition switch in the START position, power is supplied:
• from ignition switch terminal @
• to inhibitor relay terminal ® (without ASCD) or
• to inhibitor relay terminal (j) (with ASCD).
Power is supplied:
• from inhibitor switch terminal ® (with selector lever in the P or N position)
• to inhibitor relay terminal <D.
Ground is supplied:
• to inhibitor relay terminal ®
• through body grounds ® , @ , and ~ .
With power and ground supplied, the inhibitor relay is energized and power is supplied:
• from inhibitor relay terminal ® (without ASCD) or
• from inhibitor relay terminal ® (with ASCD)
• to terminal <D of the starter motor windings.
The starter motor plunger closes and provides a closed circuit between the battery and the starter motor. The [~~l
starter motor is grounded to the engine block. With power and ground supplied, cranking occurs and the engine
starts.

EL-19 1085
 STARTING SYSTEM

Wiring Diagram -START-

MfT MODELS
EL-START-01
I BA~RY I

w~;·;".,
Refer to "EL-POWER".

W/B

m
,----"--f-1'----,IGNITION
SWITCH
ST (fillg)

.....
8/Y
-, B!Y
•
B/Y

[ l'w~•
~ ~
INTERLOCK
RELAY
(M36)

UG B/P

~ CLUTCH
INTERLOCK
DEPRESSED SWITCH
~
RELEASED

~
B

~ JOINT @)
CONNECTOR-2 ~B-{1]§)

...., ~ 2
@W BATIERY ~
lbjdJ
B
• B!Y

•B •B B
-4o-
~ ~ _._
(~) c,JQs) (~)
Refer to last page (Foldout page).
@W
,-~-----------:
..BL@§) Rc~J lil@):
TL \.2) GY
: 1 (Mfl)
:29
-------------'
l..!JBI

~---------------,
I I
: R(E12) @@@) I
I
I
\.2) GY ITJ IIJ I
I
----------------'

AEL869A

1086 EL-20
 STARTING SYSTEM
Wiring Diagram -START- (Cont'd)
AfT MODELS

EL-START-02
I BA~RY I
Refer to "EL-POWERH.

rn
r~~~BLE ~: Models with ASCD
~ Models without ASCD
<iMZ>.@)
l!4Jl
W/B

ffi
r---'LT-''---, IGNITION ,.-N-~ ....
ST SWITCH R 2 •
<MiW
lbjdl
BN y

I
~
o- -~~;~--~-o~-~~s--~------ BIW• To EL-ASCD

BIW BN Y

rT"--''-i--"-, INHIBITOR
RELAY
mmm INHIBITOR
RELAY
(~) (~)
'-;,-f,;---;r;\,.,--1 ® 1,-f-.;-;rf-r.-;r+..! @
lbj:!llbj:!l~
BIP 8 UY B1P B

Ll
L-1-J;-----•UY+ToEL-ASCD

-<~>----~-~)@ '-------~-----...
t
....::
...
@>
8/Po{Q:::JoBIY~

BATTERY~ BL~_:_~-)--j~~~~Q-----1.-, i-il ___ STARTER

MOTOR
B B B
8/Y ~ ~ -:!:-
-:- (M~9) (~) (M~60)

~ @ ·-~-----------: ©T
® @ ,R(~) : 1 (iMZJ [i)(E21):
L GY \.2) GY : 2 8 L.!.J B I
-------------1
----------------.
I I
: ,R(E12) ©H1?2(~) I
1 '-.!.) GY DJ [I)
________________ !
I
I I

AEL275A-B

EL-21 1087
 STARTING SYSTEM

Starter
CALIFORNIA, USA
SEC. 233
M003T70381

9
Plate thickness:
0.25 (0.0098)
0.50 (0.0197)

r-11111''-5 • 4.4
(0.25 - 0.45,
22 -39)

Unit : mm (in)
~ : N · m (kg-m, in-lb)
ll!a@ : High-temperature grease point
AEL302A

CD Sleeve bearing 0 Packing @ Washer

® Gearcase ® Adjusting plate @ Brush H
® Pinion stopper set ® Magnetic switch assembly @ Brush holder
@) Pinion assembly @Yoke @ Sleeve bearing
® Shift lever @ Brush(+) @ Rear cover
® Plate @ Armature

1088 EL-22
 STARTING SYSTEM
Starter (Cont'd)
NON-CALIFORNIA, USA AND CANADA
SEC. 233
MOOOT60081ZC

Plate thickness:
0.25 (0.0098)

II'J2.5. 4.4
{0.25 - 0.45, 22 - 39)

. /"" ;~~'~4.4-7.1
II ~ (0.45. 0.72. 39. 62)

/~
1/~/
~~~
I~,,),
v'\~

Unit : mm (in)
~: N·m {kg-m, in-lb)
I!!Ei!l@ : High-temperature grease point

AEL303A

G) Gear case 0 Pinion stopper set @ Packing

® Shift lever ® Pinion assembly @ Yoke
® Plate ® Internal gear @ Armature
@) Packing @ Pinion shaft @ Brush holder assembly
® Adjusting plate @ Planetary gear @ Rear cover
® Magnetic switch assembly

EL-23 1089
 STARTING SYSTEM

Pinion/Clutch Check
1. Inspect pinion teeth.
• Replace pinion if teeth are worn or damaged. (Also check
condition of ring gear teeth.)
2. Inspect reduction gear teeth.
• Replace reduction gear if teeth are worn or damaged. (Also
check condition of armature shaft gear teeth.)
3. Check to see if pinion locks in one direction and rotates
smoothly in the opposite direction.
• If it locks or rotates in both directions, or unusual resistance is
evident, replace.

Service Data and Specifications (SDS)

STARTER

M003T70381 MOOOT60081ZC

Type MITSUBISHI

Non-reduction Reduction

Non-California, USA
Applied model California, USA
and Canada

System voltage v 12
No-load

Terminal voltage v 11.5 11.0

Current A 60 Max. 90 Max.

Motor revolution rpm 6,500 Min. 2,500 Min.

Minimum diameter of
commutator 314 (1 236) 28.8 (1.134)
mm (in)

Minimum length of brush

11.5 (0.453) 7.0 (0.276)
mm (in)

Brush spring tension 13.7- 25.5 11.8-23.5

N (kg, lb) (1.4- 2.6. 3.1 - 5.7) (1.20 - 2.40, 2.65 - 5.28)
Clearance of bearing metal and
armature shaft 0.2 (0.008) 0.2 (0.008)
mm (in)

Clearance between pinion front

edge and pinion stopper 0.5 . 2.0 (0.020 - 0.079) 0.5 . 2.0 (0.020 . 0 079)
mm (in)

1090 EL-24
 CHARGING SYSTEM

System Description ~I

The generator provides DC voltage to operate the vehicle's electrical system and to keep the battery charged.
The voltage output is controlled by the IC regulator.

Power is supplied at all times to generator terminal @) through:

• Black fusible link (located at the battery positive terminal).

Voltage output through generator terminal G), to charge the battery and operate the vehicle's electrical system,
is controlled by the amount of voltage detected by the IC regulator at terminal @).

Terminal ® of the generator supplies ground through body ground ® .

With the ignition switch in the ON or START position, power is supplied:
• through 1OA fuse (No. [] , located in the fuse block)
• to combination meter terminal @ for the charge warning lamp.
Ground is supplied to terminal @ of the combination meter through terminal ® of the generator. With power IPJ'
and ground supplied, the charge warning lamp will illuminate. When the generator is providing sufficient volt-
age with the engine running, the ground is opened and the charge warning lamp will go off.

If the charge warning lamp illuminates with the engine running, a fault is indicated. Refer to "Trouble
Diagnoses", "CHARGING SYSTEM", EL-27.

EL-25 1091
 CHARGING SYSTEM

Wiring Diagram - CHARGE-

EL-CHARGE-01

I BAJJRY I
Refer to "EL-POWER".
10A
FUSIBLE

rn•
LINK [DJ
(i,i£).@)

l.bjdl
w

il
w
1rh--1rf11<~>
'-.-'
w
'-j-' @)
w w

I
w
Q

E
2

Refer to last page (Foldout page).

<i@)
,-~-----------:
I I
<Iilli>.®
I 1 (i,j£} [i]@)l
:2s L!.Jst
-------------'
~--------------------,

: __r:;:l... ® @(ill @@) :

,v....w w m
J ____________________
D.J J
,

AEL870A

1092 EL-26
 CHARGING SYSTEM

Trouble Diagnoses
Before conducting an alternator test, make sure that the battery is fully charged. A 30-volt voltmeter and suit-
able test probes are necessary for the test. The alternator can be checked easily by referring to the Inspec-
tion Table.
• Before starting, inspect the fusible link.
• Use fully charged battery.
WITH IC REGULATOR

Check the fol-

lowing·
Ignition switch
-
Warning lamp
f-
Disconnect connector I Warning lamp • Warning lamp
"ON" "OFF" (S, L) and ground L rl "OFF" bulb
harness side. I • Fuse for
warning lamp

Warning lamp Damaged IC

"ON" regulator.
Replace.

Warning lamp
"ON"

Engine idling
f- Warning lamp
"ON"
r- Check the following:
• Drive belt
H Engine Idling
f- Warning lamp
"OFF"
---i OK

• B terminal connec-
tion (Check the
tightening torque)
Warning lamp
• Fuse for S terminal
"ON"
• Connector (S, L ter-
minal) connection

I
Warning lamp
"OFF"
r OK
I
Engine speed:
1,500 rpm
(Measure B ter-
minal voltage)
More than
15.5V
r-
Damaged IC
regulator.
Replace.

No generation
~ Field circuit is
open.

Warning lamp: "CHARGE" warning lamp in combination meter

* : When field circuit is open, check condition of rotor coil, rotor slip ring and brush. If necessary,
replace faulty parts with new ones.
MALFUNCTION INDICATOR
The IC regulator warning function activates to illuminate "CHARGE" warning lamp, if any of the following
symptoms occur while alternator is operating:
• B terminal is disconnected.
• S terminal is disconnected or related circuit is open.
• Field circuit is open.
• Excessive voltage is produced.

EL-27 1093
 CHARGING SYSTEM

Generator
SEC. 231
LR160-727 11]3.1-3. .
9(032-0. 40 ' 28- 35}

Rotor

JjJ 3.1 - 3.9 (0.32 - 0.40 , 28- 35)

Retainer

Front bearing

Diode ~3.1- 3.9

(0.32 - 0.40,
28- 35)
assembly

IC regulator assembly,

lj]'N·m (kg -m •in-lb)

~. N ·m (kg-m, ft-lb)
~,-.,.. AEL304A

1094 EL-28
 CHARGING SYSTEM

Diode Check ~I

MAIN DIODES
• In order to check diodes, they must be unsoldered from the stator.
• Use an ohmmeter to check condition of diodes as indicated in chart below.
• If any of the test results are not satisfactory, replace diode assembly.

Ohmmeter probes
Judgement
Positive EB Negative 8
Positive diode plate Diode terminals Diode conduCts in only one
Diodes check (Positive side)
Diode terminals Positive diode plate direction.

Negative diode plate Diode terminals Diode conducts in only one

Diodes check (Negative side)
Diode terminals Negative diode plate direction.

Positive diode plate

Negative diode plate

Diode terminals AEL326A

EL-29 1095
 CHARGING SYSTEM

Disassembly and Assembly

1. Remove rear cover.
• Heat rear cover, using heat gun, to 50'C (90'F) above room
temperature to prevent bearing damage.

2. Disconnect stator/diode.
• Cut diode terminals.
• Unsolder stator coil leads.
CAUTION:
Unsolder stator coil leads as fast as possible to avoid damag-
ing diodes.
3. Remove stator and rotor.
4. Remove bearing retainer and bearing.
5. Assemble in reverse of disassembly.

AEL819

• Insert stator coil lead into lower portion of diode terminal.

• Using pliers, crimp diode terminal around stator coil lead.
• Be sure stator coil leads do not protrude more than 3 mm
(0.118 in) past diode terminal.

L: 3mm (0.118 in) Max

AEL820

• Solder stator coil lead and diode terminals.

CAUTION:
Solder stator coil leads and diode terminals as fast as pos-
sible to avoid damaging diodes. Use 9/1 Pb/Sn solder in
assembly.

AEL821

1096 EL-30
CHARGING SYSTEM
Disassembly and Assembly (Cont'd)
REAR COVER INSTALLATION
1. Before installing front cover with pulley and rotor with rear
cover, push brush up with fingers and retain brush by insert-
ing brush lift wire into brush lift hole from outside.
2. After installing front and rear sides of generator, pull out brush
lift wire.

iH

Service Data and Specifications (SDS)

GENERATOR
Type LR160-727

Nominal rating V-A 12-60

Ground polarity Negative

Minimum revolution under no-load

Less than 1 ,000
(When 13.5 volts is applied) 'Pm

More than 17/1 ,300

Hot output current
More than 48/2,500
(When 13.5 volts is applied) A/rpm
More than 57/5,000

Regulated output voltage v 14.1- 14.7

Minimum length of brush mm {in) 6.0 (0.24)
Slip ring minimum outer diameter mm {in) More than 26.0 (1.024)

Rotor (Field coil) resistance fl 2.58

EL-31 1097
 COMBINATION SWITCH

Combination Switch/Check

WIPER

~::::!i..~i'J:' -i f)) OFF

LIGHT

'B~
1!w
1ST

OFF L
WASH
VOLUME

HI
..
~0
....,
INT

~8
(Turn)

LIGHTING SWITCH WIPER SWITCH

OFF 1ST 2ND OFF INTL0 HI WASH

0
7 --o-
1
5 88 81M oiM INTERMITTENT
WIPER VOLUME

TURN SIGNAL SWITCH

• AEL895A

1098 EL-32
 COMBINATION SWITCH

@[
Combination Switch/Replacement
Wiper and washer switch • Each switch can be replaced without removing combination
switch base. G~A

Lighting switch

AEL306A

• To remove combination switch base, remove base attaching ~·1:

screws.

~~L

AEL307A

• Before installing the steering wheel, align the turn signal can- AIf
Combination TLJm signal cel tab with the notch of combination switch. Refer to RS sec-
switch cancel tab tion ("INSTALLATION", Air Bag Module and Spiral Cable").

--
Steering wheel
guide pin

Back side of
steering wheel

)-
ARS152

•
EL-33 1099
 COMBINATION SWITCH

Steering Switch/Check

Spiral cable

Driver air bag module

HORN
SWITCH

= SPIRAL
CABLE
_ _j_
To main
~ _§_I_ harness

~ ~.
,---------112
>! I ;><'_
]_t
r+-+--------1~ ~ >!
~
IIIII I@
II I I
DRIVER

ll'----+--i8-J AIR BAG

MODULE
L___ _ __j I

-21~

j \ RESUME
OFF CANCEL HORN
22 ACCEL
~ 21
;><' 22
~~ 23
25
@
AEL896A

1100 EL-34
 HEADLAMP

System Description (For USA)

The headlamps are controlled by the lighting switch which is built into the combination switch.
Power is supplied at all times:
• through 15A fuse (No. [f2] , located in the fuse block)
• to lighting switch terminal ®, and
• through 15A fuse (No. ll3l , located in the fuse block)
• to lighting switch terminal ®.

Low beam operation

When the lighting switch is turned to the 2ND position and placed in LOW ("B") position, power is supplied:
• from lighting switch terminal ®
• to terminal CD of the LH headlamp, and
• from lighting switch terminal @)
• to terminal CD of the RH headlamp.
Terminal ® of each headlamp supplies ground through body grounds @ , ~ and ~ .
With power and ground supplied, the headlamp(s) will illuminate.

High beam operation/flash-to-pass operation

When the lighting switch is turned to the 2ND position and placed in HIGH ("A'') position or the lighting switch
is placed in the PASS ("C") position, power is supplied:
• from lighting switch terminal !J) IX'G'
• to terminal ® of the LH headlamp, and
• from lighting switch terminal ®
• to terminal ® of the RH headlamp, and "'j
• to combination meter terminal @ for the hi beam indicator.
Ground is supplied to terminal @ of the combination meter and terminal ® of each headlamp through body
grounds @ , ~ , and ~ . Ill'
With power and ground supplied, the high beams and the hi beam indicator illuminate.

EL-35 1101
 HEADLAMP

Wiring Diagram (For USA) - H/LAMP-

I 8ATIERY I EL-H/LAMP-01

r·1
I

5A Refer10"EL-POWER".
1
l_$J&J @]
RlW R

I I I
R1W R
ffi ffi
I,------;:======~;;;;;;~t~;;;;i======~r'-----1 SWITCH
LIGHTING
@>

OFF 2ND OFF 2ND

,.~

1ST

LOW
~
.PASS LOW

HIGH
'
~

HIGH
.PASS LOW
.......
HIGH
PASS LOW
.....,.,
HIGH
PASS

r~
~ I!4Jl lbj:!l ll,j=lJ

i- i .......----i-RN~~1~-----..RN
~
00 i'---i'-"------"--';-';HEADLAMP
AH
~~~~-~~
~~
BEAM
INDICATOR)
(f:j§j) l9jJI @
LOW HIGH B
m
=r m
=r 1$1@
~

I
B B
I JOINT
§)ECTOR-2 d B

~-------~--~.:;..8~8 -
8 8 8
~ _._ ~

(M4e) (~) (~)

Refer to last page (Foldout page).
<tillY
rol ~-®
_[i]_@.~ 112 3141@)
IIillii 8 8 516 7IBI w

AEL271A

1102 EL-36
 HEADLAMP

Trouble Diagnoses (For USA)

Symptom Possible cause Repair order
LH headlamps do not operate. 1. Bulb 1. Check bulb.
2. Grounds ~ . ~ and 2. Check grounds ~ . ~ and ~ .
~
3. 15A fuse 3. Check 15A fuse (No. [2] , located in fuse block). Verify
battery positive voltage is present at terminal @ of light-
ing switch.
4. Lighting switch 4. Check lighting switch.
RH headlamps do not operate. 1. Bulb 1. Check bulb.
2. Grounds~-~ and 2. Check grounds ~ . ~ and~.
~
3. 15A fuse 3. Check 15A fuse (No. [l]] , located in fuse block). Verify
battery positive voltage is present at terminal ® of light-
ing switch.
4. Lighting switch 4. Check lighting switch.
LH high beam does not operate, but 1. Bulb 1. Check bulb.
LH low beam operates. 2. Open in LH high beam circuit 2. Check R/L wire between lighting switch and LH head-
lamp for an open circuit.
3. Lighting switch 3. Check lighting switch.
LH low beam does not operate, but 1. Bulb 1. Check bulb.
LH high beam operates. 2. Open in LH low beam circuit 2. Check RIG wire between lighting switch and LH head-
lamp for an open circuit.
3. Lighting switch 3. Check lighting switch.
RH high beam does not operate, but 1. Bulb 1. Check bulb.
RH low beam operates. 2. Open in RH high beam circuit 2. Check R/Y wire between lighting switch and RH head-
lamp for an open circuit.
3. Lighting switch 3. Check lighting switch.
RH low beam does not operate, but 1. Bulb 1. Check bulb.
RH high beam operates. 2. Open in RH low beam circuit 2. Check R/B wire between lighting switch and RH head-
lamp for an open circuit.
3. Lighting switch 3. Check lighting switch.
High beam indicator does not work. 1. Bulb 1. Check bulb in combination meter.
2. Grounds~.~ and 2. Check grounds ~ . ~ and ~ .
~
3. Open in high beam circuit 3. Check RIY wire between lighting switch and combination
meter for an open circuit.

EL-37 1103
 HEADLAMP

System Description (For Canada)

The headlamp system for Canada vehicles contains a daytime light control unit that activates the high beam
headlamps at approximately half illumination whenever the engine is running. If the parking brake is applied
before the engine is started the daytime lights will not be illuminated. The daytime lights will illuminate once
the parking brake is released. Thereafter. the daytime lights will continue to operate even when the parking
brake is applied.
Power is supplied at all times:
• through 15A fuse (No. !12; , located in the fuse block)
• to daytime light control unit terminal ® and
• to lighting switch terminal ®.
Power is also supplied at all times:
• through 15A fuse (No. [l)] , located in the fuse block)
• to daytime light control unit terminal @ and
• to lighting switch terminal @.
With the ignition switch in the ON or START position, power is supplied:
• through 1OA fuse (No. IDl , located in the fuse block)
• to daytime light control unit terminal @.
With the ignition switch in the START position, power is supplied:
• through ignition switch terminal @
• to daytime light control unit terminal G).
Ground is supplied to daytime light control unit terminal ® through body grounds ~ , ~ and ~ .

HEADLAMP OPERATION
Low beam operation
When the lighting switch is moved to the 2ND position and placed in LOW ("8") position, power is supplied:
• from lighting switch terminal @
• to RH headlamp terminal G).
Ground is supplied to RH headlamp terminal ® through body grounds ~ , ~ and ~ .
Also, when the lighting switch is turned to the 2ND position and placed in LOW ("B") position, power is
supplied:
• from lighting switch terminal ®
• to LH headlamp terminal G).
Ground is supplied:
• to LH headlamp terminal ®
• from daytime light control unit terminal (j)
• through daytime light control unit terminal ®
• through body grounds ~ , ~ and ~ .
With power and ground supplied, the low beam headlamps illuminate.
High beam operation
When the lighting switch is turned to the 2ND position and placed in HIGH ("A") position, or the lighting switch
is placed in the PASS ("C") position, power is supplied:
• from lighting switch terminal ®
• to RH headlamp terminal@.
Also, when the lighting switch is moved to the 2ND position and placed in HIGH ("A'') position, or the lighting
switch is placed in the PASS ("C") position, power is supplied:
• from lighting switch terminal (j)
• to daytime light control unit terminal ®
• through daytime light control unit terminal ®
• to LH headlamp terminal @.
Ground is supplied in the same manner as low beam operation.
With power and ground supplied, the high beam headlamps illuminate.

1104 EL-38
 HEADLAMP
System Description (For Canada) (Cont'd)
DAYTIME LIGHT OPERATION
With the engine running and the lighting switch in the OFF or 1st position, power is supplied:
• to daytime light control unit terminal @
• through daytime light control unit terminal ®
• to LH headlamp terminal @
• through LH headlamp terminal ®
• to daytime light control unit terminal 0
• through daytime light control unit terminal ®
• to RH headlamp terminal @.
Ground is supplied to RH headlamp terminal ® through body grounds ® , ~ and @ .
Because the high beam headlamps are now wired in series, they operate at half illumination.

Operation (Daytime light system for Canada)

The headlamps' high beams automatically turn on after starting the
engine with the lighting switch in OFF or 1st position. Lighting II'~
switch operations other than the above are the same as conven-
tional light systems.
Engine With engine stopped With engine running
OFF 1ST 2ND OFF 1ST 2ND
Lighting switch
A B c A B c A B c A B c A B c A B c
High beam X X 0 X X 0 0 X 0 L' N 0 /\' /\' 0 0 X 0
Head lamp
Low beam X X X X X X X 0 X X X X X X X X 0 X
Parking and tail lamp X X X 0 0 0 0 0 0 X X X 0 0 0 0 0 0
License and instrument illumination lamp X X X 0 0 0 0 0 0 X X X 0 0 0 0 0 0
0: Lamp ON
X: Lamp OFF
6: Lamp dims
0: Added functions
* : When starting the engine with the parking brake released, the daytime light will come ON.
When starting the engine with the parking brake applied, the daytime light won't come ON.

EL-39 1105
 HEAD LAMP

Schematic (For Canada)

l BA TTERI I
FUSIBLE
LINK

~FUSC

~~
CHARGE
WARNING
LAMP
GENERATOR

m~-
4
6
,---- 7
IGNITION SWITCH 8
T 0 A FF
1
2 11 12 2
3
4 41-+-----+----~-1
5
s!-+-----,
sl-+-----++----~
DAYTIME' LIGHT CONTROl LJNTT

'1-t---,

9f--t----,
10 5

~ G~ :~;~~
PARKING
BRAKE
SWITCH JNnTCATOR
I AMP

AEL871A

1106 EL-40
 HEAD LAMP

NOTES

EL-41 1107
 HEADLAMP

Wiring Diagram (For Canada) -DTRL-

I BATTERY I EL-DTRL-01
•
~·-~-hA Refer to ~EL -POWER".

lf_Jml lf_j@l
i, ________
; ·~-R!Wo@>j
~Ro{9l Ne~ page

RJW R

1---r========~;;~'~=~,;;~======~'~=~'----l LIGHTING
SWITCH
@l

OFF 2ND

LOW • PASS LOW PASS LOW PASS

/

HIGH HIGH

ll4Jl lbjdl lbjdl (fill§)@)

-- I r- RIL~ ~}
RIG RIL RIB
I

( -- AN----. . . . . - -

• -::::::::::::::::1-R/8
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RIG RIL
- I RIB
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: RN D
E

F
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m lftn HEAD LAMP
LH RH
@ (M51)

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AEL273A-A

1108 EL-42
 HEAD LAMP
Wiring Diagram (For Canada) -DTRL- (Cont'd)

EL-DTRL-02

Refer to "EL-POWER".

W/B
•
••
W/B
m
wra

~
IGNITIO N

OFF~
Ac2•_.~rT ~
JOINT SWITC H
CONNECTOR-2
~ ON
lbjdJ
W/B B/Y

1$1@ (M155)

W/B

{~ -
~Y/8
A R-
Preceding
COMBINATION page
METER(CHARGE
WARNING LAMP) ~RIW~

l
@@

1TF
1$1@ (~) W/B R!W BIY R

YI/B ~mm
IGN LH FUSE ST
m
RH FUSE )DAYTIME

1·-----------Y/8 ~1!_
LIGHT
T CONTROL
· GEN-L MAIN MAIN (UNIT
~ r..;-:;";\

L.:.H:CEiiA'ii~-lLi't'-'H-'H-"E'iJIAr~i'/LT,IR.::H.:._.::LA'iit"if;-i;'~Hc:...__:oL';ijM"i;i-Pf.~'-'H--ij~:..;A:ri;~--"~, ~
ffi1(M44)
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R!L
I
RIB R/Y RJL B

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Preceding ~RIY • - - - - - - - - - - - ·
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! ~(M40) ~(M41) : ~@
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AEL872A

EL-43 1109
 HEADLAMP
Wiring Diagram (For Canada) -DTRL- (Cont'd)

EL-DTRL-03

.,------------------------,DAYTIME
LIGHT
CONTROL UNIT
(M40) , (M41)

GND PKBSW

l!.j.!l
B
~
G/Y

GIY

m
r----"-i-"----, PARKING
BRAKE
SWITCH
(M127)

,--------------------~

: .r;F,Im(M40) ~(~):
L~ \:tt1!:tV GY JI
1
____________________
GY

AEL873A

1110 EL-44
 HEADLAMP

Trouble Diagnoses (For Canada)

DAYTIME LIGHT CONTROL UNIT INSPECTION TABLE
(Data are reference values.)

Ter-
Judgement
minal Item Condition
standard
No.

1 Start signal When turning ignition switch to ST

~
Battery positive voltage

When turning ignition switch to ON from ST 1V or less

~
When turning ignition switch to OFF 1Vorless

~
2 Power source When turning ignition switch to ON Battery positive voltage

~ ~~L
When turning ignition switch to OFF Battery positive voltage

~
3 Power source [0Jif
~
When turning ignition switch to ON Battery positive voltage

When turning ignition switch to OFF Battery positive voltage

~
4 Lighting switch When turning lighting switch to HEAD Battery positive voltage
(Low beam) (2nd position)

5 Lighting switch When turning lighting switch to HIGH BEAM Battery positive voltage
(High beam)

When turning lighting switch to FLASH TO PASS Battery positive voltage

6 LH high beam When turning lighting switch to HIGH BEAM Battery positive voltage

When releasing parking brake with engine running Battery positive voltage

ID and turning lighting switch to OFF (daytime light

operation)

~
CAUTION: Block wheels and ensure selector
lever is in "N" or "P" position.

7 LH headlamp control When lighting switch is turned to HEAD 1V or less

(ground)

When releasing parking brake with engine running Approx. half battery voltage

~ and turning lighting switch to OFF (daytime light

operation)

8 RH high beam
ro CAUTION: Block wheels and ensure selector
lever is in "N" or "P" position.

When turning lighting switch to HIGH BEAM Battery positive voltage

~
ID
When releasing parking brake with engine running
and turning lighting switch to OFF (daytime light
operation)
CAUTION: Block wheels and ensure selector
lever is in "N" or "P" position.
Approx. half battery voltage

•
EL-45 1111
 HEADLAMP
Trouble Diagnoses (For Canada) (Cont'd)
Ter-
Judgement
minal Item Condition
standard
No.
9 Ground - -

10 Parking brake switch When parking brake is released Battery positive voltage

~ When parking brake is applied 1.5V or less

11 Generator When turning ignition switch to ON 1V or less

~
When engine is running Battery positive voltage

ID When turning ignition switch to OFF 1V or less

~
12 Power source When turning ignition switch to ON Battery positive voltage

~
When turning ignition switch to ST Battery positive voltage

~
When turning ignition switch to OFF 1Vorless

1112 EL-46
 HEAD LAMP

Bulb Specifications
Item Wattage (W) Bulb No.
Conventional bulb 65/55 6052
Halogen bulb 65135 H6059

Aiming Adjustment
When performing headlamp a1m1ng adjustment, use an aiming
machine, aiming wall screen or headlamp tester. Aimers should be IL·fC
~
in good repair, calibrated and operated according to their operation
manuals.
Before performing aiming adjustment, make sure of the following:
CAUTION:
• Keep all tires inflated to correct pressures.
• Place vehicle on level ground.
• See that vehicle is unloaded (except for full levels of
coolant, engine oil and fuel, and spare tire, jack, and
tools). Have the driver or equivalent weight placed in driv- CL
er's seat.
icil

LOW BEAM
1. Turn headlamp low beam ON.
2. Use adjusting screws to perform aiming adjustment. II'
• First tighten the adjusting screw all the way and then
make adjustment by loosening the screw.

WL = 1,067 (42.01) • Adjust headlamps so that upper edge and left edge of high
intensity zone are within the acceptable range as shown
at left.
• Dotted lines in illustration shown center of headlamp.
"H": Horizontal center line of headlamps.
H "We": Distance between each headlamp center.

Vertical center line

ahead of headlamps
Height of

LeN edge of high

intensity zone
II
~ = ACCEPTABLE RANGE
Unit· mm (in)
SEL914D

EL-47 1113
 HEADLAMP
Aiming Adjustment (Cont'd)
AlMER ADJUSTMENT MARK
When using a mechanical aimer, adjust adapter legs to the data
marked on the headlamps.

I@~
~
~
W-
.1[
- ~I
liJ
Example:

4H 2V

"""

rr ll
~I
SEL5011
T L__ _ _
L _____
Vertical side: 2
Horizontal side 4

1114 EL-48
 EXTERIOR LAMP

Back-up Lamp/Wiring Diagram -BACK/L- @II

EL-BACK/L-01

Refer to "EL-POWER". <I) AfT models

10A (ID : MIT models
[DJ
W/8
•
¢--:~:---.1

rrin JOINT
CONNECTOR-2
INHIBITOR
SWITCH
.--·------....
I
R/B
I
RIB

~REAR ~REAR
(M142)

~ @ COMBINATION COMBINATION
WIB LAMP LH LAMP RH
u-~-ll'~l '---r.=!"=------' (BACK-UP) (BACK-UP)
'...-'@ lbj=!l ® lbj=!l (ill

·------..
·
W/B R/B

I
W/B
B B

r~'-I-----., POSITION
---"-1
'

OTHERS
---f R
SWITCH
@)
R/B
IB

l~t------~~~;~~
~ RIB
~@)
RIB
lrTcill
1~1®
(M44)
T (M108)
RIB
RIB

+ 0 A -
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AEL908A

EL-49 1115
 EXTERIOR LAMP

Parking, License, Tail and Stop Lamps/Wiring

Diagram - TAIL/L-
I BA~ERY I EL-TAIUL-01

·---------©·
[ffi p§
10A
Referto''EL-POWER"_

RIB
ffi
ffi
,---..:.L..j--C----,sTOP
,---"-1-"----,uGHTING
SWITCH
LAMP 2ND~
SWITCH
RELEASED ~ OFF ...
DEPRESSED 1ST

•~-- ll4JI

.
P/L
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r
-- G/YojQ]o G/Y-~ PIL

G/Y lc!JI@illl
@
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G/Y 'T'@ lci:JI®
ffi nincw GD
~~~NTED ~(ill
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-{ffi:> Next page

-- -- ••
--------P/L
STOP G!Y

I ..----· --
T@
lrfu®
LAMP

,-1----------...
G/Y
,.....__, ~
P/L GIY
,.....__, ~
I
P/L

'T'~
\IY..!..!1Y
.~ILTI.n4~l~lnl~1~l------, REAR
r
~ILTI-n4~l~lnl~1~l------, REAR
r
B COMBINATION COMBINATION
mJOINT SIDE ~ LH SIDE LAMP RH
CONNECTOR-2
MARKER \.lZ...J MARKER CID
~
ll4dJ
B
ll.jdJ
B
ll.jdJ
B

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AEL909A

1116 EL-50
 EXTERIOR LAMP
Parking, License, Tail and Stop Lamps/Wiring
Diagram -TAIUL- (Cont'd) @~

~
P'eced;ng ~ P/L • - - - - - - - · ·I- - · - - - - -. .
page I <§§> With step bumper
P/L P/L
(g§): Without step bumper
~ FRONT PARKING
®FRONT PARKING
LAMP LH LAMP RH
(~) @
l!oj=!J l!oj=!J
B B

~~~~eding ~ P/L ...=;.o---:~>-----------

··----------·---------------------...
<t> --
~---------..
I~---------..
--
P/L P/L P/L P/L

m LICENSE
LAMP LH ~LICENSE ~LICENSE
LAMP RH LAMP LH ~LICENSE
LAMP RH
® @ (ill ®

~
B
~
B
~
B
~
B

._I___._- -!~o~!___..--...__.1 •
B
,..a.,@
~@

__________.
B

r[~i£)
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8
@

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I..!..EJ@@@@
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AEL874A

EL-51 1117
 EXTERIOR LAMP

Turn Signal and Hazard Warning

Lamps/System Description
TURN SIGNAL OPERATION
With the hazard switch in the OFF position and the ignition switch in the ON or START position, power is supplied:
• through 1OA fuse (No. [ill , located in the fuse block)
• to hazard switch terminal ®
• through terminal 0 of the hazard switch
• to combination flasher unit terminal CD
• through terminal ® of the combination flasher unit
• to turn signal switch terminal ®.
Ground is supplied to combination flasher unit terminal ® through body grounds ® , @ and ~ .
LH tum
With the turn signal switch in the LH position, power is supplied from turn signal switch terminal ® to:
• front turn signal lamp LH terminal ®
• rear combination lamp LH terminal ®, and
• combination meter terminal ®.
Ground is supplied:
• to front turn signal lamp LH terminal CD, and
• to combination meter terminal @
• through body grounds ® , @ and ~ .
Ground is supplied to rear combination lamp LH terminal ® through body ground <@ill) .
With power and ground supplied, the combination flasher unit controls the flashing of the LH turn signal lamps.
RH turn
With the turn signal switch in the RH position, power is supplied from turn signal switch terminal ® to:
• front turn signal lamp RH terminal ®
• rear combination lamp RH terminal ®, and
• combination meter terminal @.
Ground is supplied:
• to front turn signal lamp RH terminal CD. and
• to combination meter terminal @
• through body grounds ® , @ and ~ .
Ground is supplied to rear combination lamp LH terminal ® through body ground <@ill) .
With power and ground supplied, the combination flasher unit controls the flashing of the RH turn signal lamps.
HAZARD LAMP OPERATION
Power is supplied at all times to hazard switch terminal ® through:
• 1OA fuse (No. It .a ,located in the fuse block).
With the hazard switch in the ON position, power is supplied:
• through terminal 0 of the hazard switch
• to combination flasher unit terminal CD
• through terminal @) of the combination flasher unit
• to hazard switch terminal CD.
Ground is supplied to combination flasher unit terminal ® through body grounds ® ,@ and ~ .
Power is supplied through terminal ® of the hazard switch to
• front turn signal lamp LH terminal ®
• rear combination lamp LH terminal ®, and
• combination meter terminal ®.
Power is supplied through terminal @ of the hazard switch to
• front turn signal lamp RH terminal ®
• rear combination lamp RH terminal ®, and
• combination meter terminal @.
Ground is supplied:
• to terminal CD of the front turn signal lamps, and
• to combination meter terminal @
• through body grounds ® , @ and ~ .
Ground is supplied to rear combination lamps terminal ® through body ground <@ill) .
With power and ground supplied, the combination flasher unit controls the flashing of the hazard warning
lamps.

1118 EL-52
 EXTERIOR LAMP

NOTES

EL-53 1119
 EXTERIOR LAMP

Turn Signal and Hazard Warning Lamps/Wiring

Diagram -TURN-
EL-TURN-01
Refer to
"EL-POWER".

+
-- 1-
I+ r P / 8 . To EL-ILL

OR RIY GY!L GY/R PIB

,ffi'--'i-8.I!........!L.Jffi'-"--_----'lffi
3 ffi ffi HAZAFI.D

-- .... -- SWITCH

~\-,
.....
OFF
.....

ON OFFe
...
tON OFF ON <Mill>
---------- ~

COMBINATION
FLASHER lbjdl lbjdJ ~
P!L
~+
UNIT BRIW
('ill_;)

f:Qio -I G
L P/L. To El-ILL

~
POWER BRIW

--
·-
JOINT

OUT
~G
--
CONNECTOR-2
(~)
---
GROUND ~B cyJ --- •
FRONT TURN
SIGNAL LAMP RH
(~)

~GYI:
I I
G

G
-- - I
B

g}os ffi TURN SIGNAL

4

t
SWITCH
FRONT TURN (M133)
SIGNAL LAMP LH
(iiilQ)

~G:•
- +
3
-:~r
~
RH
t t 2

B
I
•••
g}os-e

I
+ 1-•
- • --- --- YIL GY/R

- + I
B

Refer to last page (Foldout page).

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AEL282A-A

1120 EL-54
 EXTERIOR LAMP
Turn Signal and Hazard Warning Lamps/Wiring
Diagram -TURN- (Cont'd) Cl:~

EL-TURN-02
r----;====:::::;l
I COMBINATION
METER
(TURN SIGNAL
LAMP)
TURN
RH
@,@

~ ~ ~
GY/L GY/R B

1$1----1$1-----1$1@
@§)
GY/L GY/R B

{~GY/L ..=.. !:_I· --

Preceding
page
<@-GY/R--
~

·- --
...
I
.

GY/R B GYI
I~I(M108) 1$1----------------- OJ]
@
GY/R B GYI

~--------------- ~----------------- c;J

GY/R B GYI

-- •I· ...
I I GY/

mm
GY/R B B

ffi 2

r·-·
REAR
COMBINATION
LAMP AH

B
I I
B B
TURN
(TURN SIGNAL)
TURN ~.J

~ ~ _._
(~) (M1os) (~)
Refer to last page (Foldout page).
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1 =2 D
3 4 5 6 7 8 (M109) 1112345@) ~@)
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·----------------------------'
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AEL910A

EL-55 1121
 EXTERIOR LAMP

Turn Signal and Hazard Warning

Lamps/Trouble Diagnoses
Symptom Possible cause Repair order
Turn signal and hazard warning 1. Hazard switch 1. Check hazard switch.
lamps do not operate. 2. Combination flasher unit 2. Refer to combination flasher unit check.
3. Open in combination flasher unit 3. Check wiring to combination flasher unit for open cir-
circuit cuit.
Turn signal lamps do not operate 1. 10A fuse 1. Check 1OA fuse (No. lllll , located in fuse block).
but hazard warning lamps operate. Turn ignition switch ON and verify battery positive
voltage is present at terminal @ of hazard switch.
2. Hazard switch 2. Check hazard switch.
3. Turn signal switch 3. Check turn signal switch.
4. Open in turn signal switch circuit 4. Check G wire between combination flasher unit and
turn signal switch for open circuit.
Hazard warning lamps do not oper- 1. 10A fuse 1. Check 1OA fuse (No. 1§1 , located in fuse block).
ate but turn signal lamps operate. Verify battery positive voltage is present at terminal
® of hazard switch.
2. Hazard switch 2. Check hazard switch.
3. Open in hazard switch circuit 3. Check G wire between combination flasher unit and
hazard switch for open circuit.
Front turn signal lamp LH or RH 1. Bulb 1. Check bulb.
does not operate. 2. Grounds@.~ and 2. Check grounds @ • ~ and~.
~
Rear turn signal lamp LH or RH 1. Bulb 1. Check bulb.
does not operate. 2. Ground~ 2. Check grounds ~ .
LH and RH turn indicators do not 1. Grounds@.~ and 1. Check grounds @ . ~ and~.
operate. ~
LH or RH turn indicator does not 1. Bulb 1. Check bulb in combination meter.
operate.

Test lamp (27W}

Combination Flasher Unit Check
• Before checking, ensure that bulbs meet specifications.
• Connect a battery and test lamp to the combination flasher
unit, as shown. Combination flasher unit is properly function-
ing if it blinks when power is supplied to the circuit.

Battery AEL"1"11A

1122 EL-56
EXTERIOR LAMP

Bulb Specifications
HEADLAMPS
Item Wattage (W) Bulb No.
Conventional bulb 65/55 6052
Halogen bulb 65/35 H6059

OTHER LAMPS
Item Wattage (W) Bulb No.
Front turn signal lamp 27 1156
Front parking lamp 3.8 194
Rear combination lamp
Turn signal 27 1156
S1opffail 27/8 1157
Back-up 27 1156
Rear side marker 3.4 194
License plate lamp 3.8 or 5 168 (For 3.8W lamp)
High-mounted stop lamp 2.3 2723

I~U

•
EL-57 1123
 INTERIOR LAMP

Illumination/System Description
Power is supplied at all times:
• through 1OA fuse (No. 1221 , located in the fuse block)
• to lighting switch terminal CD.
The lighting switch must be in the 1ST or 2ND position for illumination.
The illumination control switch is a thumbwheel that controls the amount of current to the illumination system.
As the amount of current increases, the illumination becomes brighter.
The glove box lamp is not controlled by the illumination control switch. The intensity of this lamp does not
change.
The clock display (if equipped) will dim when the lighting switch is turned to the 1ST or 2ND position.
The following chart shows the power and ground connector terminals for the components included in the illu-
mination system.
Component Power terminal Ground terminal
Illumination control switch ® ®
Glove box lamp CD ®
Clock• @ ®
Combination meter @ ®
ASCD main switch* @ ®
Hazard switch ® ®
AfT device indicator* ® @
Heater ® CD
Radio ® (j)
. If equipped .

With the exception of the glove box lamp, the ground for all of the components is controlled through terminals
® and ® of the illumination control switch and body grounds ® , @§:> and @ .
When the ~e box is open, glove box lamp terminal ® is grounded through glove box lamp switch and body
grounds ~ , @ and @ .

1124 El-58
 INTERIOR LAMP

Illumination/Schematic

0 HEATER (ILLUMINATION)

• e•
~ "
>
" e,
""• B ~
0
e
~
0
0
0 n
~
0
AfT DEVICE INDICATOR (ILLUMINATION)

" "" "" "" ""

~
••••
8@@@@ HAZARD SWITCH (ILLUMINATION)

ASCO MAIN SWITCH (ILLUMINATION)

BOX LAMP SWITCH

AEL297A

EL-59 1125
 INTERIOR LAMP

Illumination/Wiring Diagram -ILL-

BAITERY
EL-ILL-01

~
10A
[ill
p

I
LIGHTING
SWITCH
OFF
Ciilli)

~
'----------·-----------·--------•PIL page
P/L
1
I
PIL
•
P/L
~Next
li:I ILLUMI- ld:JI~
I~
NATION P/L
ILL ~~WJ'HOL lfl
L;r;\-,;-----;r:l-r.---;r~-!,,---_j.!@W GLOVE
~~ lbjdJ &~®LAMP

I
B P/B

.
I -- •
P/B

--

@ill)
lbjdJ
B
•
r!l
B
~ ~
B B
~
--
. __ _ _ _ _ _ _ _--;;,_ _ _ _ _ _ _ _ _ P/8 ~Next page
~) @> <iillii>
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AEL298A-A

1126 EL-60
 INTERIOR LAMP
Illumination/Wiring Diagram -ILL- (Cont'd)
1:][

EL-ILL-02

Refer to "El-POWER".
10A @:w;thASCD
m <fiJ9 : With clock

~~~~ed;ng ~ p~ iGJW

r-----------------·--·---•PIL ~~:;!
I
.
~--------$1~
GJW

G/'IN
M

PIL
- P!L

I r
---:g:---.. ffi HAZARD
SWITCH
(ILLUMINATION)
@
GNI P!L

~ ~
,-----'"T'""----:-''-T-"-, COMBINATION
METER
,.-!1-';-J"-, ASCD
MAIN
~
P/B
(ILLUMINATION) SWITCH
CLOCK {ILLUMINATION)
(DISPLAY) @.@.@
@ @)
'-:r-7-r.-'®

PIB

I ~
o---:t;As~--.1
I
PIB

l[~iED
(f@
P/B

page ~PIE
p,eced;ng__.--;;\, ·--~---- I • - - - - - - - - - - - - - - - - - •--~-• PIB~page
• J;::-..._ • Next

Refer to last page (Foldout page).

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AEL298A-8

EL-61 1127
 INTERIOR LAMP
Illumination/Wiring Diagram -ILL- (Cont'd)

EL-ILL-03

C£>: AfT models

~: With base audio
@>:With premium audio

--
t
~~~~edlng ~ Pt"t"-o-----·o--<~•-..

~ A
+

I
m@i§)
PIL

I@Qi) 8A
P/L RIL

ffi Alf DEVICE

ffi RADIO
(ILLUMINATION)
INDICATOR
(ILLUMINATION) ~
(ijill)
@

lbi=U
P/8

RADIO
(ILLUMINATION)
@§)

lbjdl
A P/8

PA 8A

Preceding~
page --..!!r P/8- - O•----···----•O·----_.
~
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4 '
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AEL298A-C

1128 EL-62
 INTERIOR LAMP

Interior and Map Lamps/ @II

Wiring Diagram -INT/L-
EL-INT/L-01
0 g -
10A
~
Refer to ·'EL-POWER". I
RIG
I
RIG
<Jill} : With map lamp

R/G
ffi ROOM
rrtil
LAMP
@)

OFF

·-
OFF
+
I ~~======~----_j
~ ~ '"2
DOOR

R/B B ~

R/G RIB
I~~ 8 I&if
ffi_--------
....... ....... ffi
-ffl- (ill)
'-.-'(~)
R/G R/B B

1- - - - - - - - - - - - - Rffi~5
...ff;;
l iii ~~
Rffi B
JOINT

~
CONNECTOR-2

R/B R/B

ffi
.-~~~---.oooR
rrtil
.-~~-----.oooR
SWITCH SWITCH
LH RH
<Mill!>
i-il
CLOSED (M171)

B B B
~ _.__ -!:--
(g4!i) (Ml05) (Ml60)
Refer to last page (Foldout page).
~

AEL875A

EL-63 1129
 INTERIOR LAMP

Bulb Specifications
Item Wattage (W) Bulb No.
Interior lamp 10
Map lamp 8

1130 EL-64
 METERS AND GAUGES

System Description rilJI

With the ignition switch in the ON or START position, power is supplied:
• through 1OA fuse (No. [l] , located in the fuse block) vi&•
IT
• to combination meter terminal @ for the water temperature gauge, fuel gauge, speedometer and '.~
tachometer (if equipped).
Ground is supplied:
• to combination meter terminal @ [and terminal @ (with tachometer)]
• through body grounds ~ , ~ and ~ .
WATER TEMPERATURE GAUGE
The water temperature gauge indicates the engine coolant temperature. The reading on the gauge is based
on the resistance of the thermal transmitter.
As the temperature of the coolant increases, the resistance of the thermal transmitter decreases. A variable ~©
ground is supplied to terminal @ (without tachometer) or ® (with tachometer) of the combination meter for
the water temperature gauge. The needle on the gauge moves from "G" to "H".
TACHOMETER
The tachometer indicates engine speed in revolutions per minute (rpm).
The tachometer is regulated by a signal:
• from terminal ® of the EGM (EGGS control module)
• to combination meter terminal @ for the tachometer.
FUEL GAUGE
The fuel gauge indicates the approximate fuel level in the fuel tank.
The fuel gauge is regulated by a variable ground signal supplied: JlJ'
• to combination meter terminal ® for the fuel gauge
• from terminal G) of the fuel tank gauge unit
• through terminal @ of the fuel tank gauge unit and
• through EGM (EGGS control module) terminal @.
SPEEDOMETER
The vehicle speed sensor provides a voltage signal to the combination meter for the speedometer.
The voltage is supplied:
• to combination meter terminals @ and @ for the speedometer
• from terminals G) and ® of the vehicle speed sensor.
The speedometer converts the voltage into the vehicle speed displayed.

EL-65 1131
 METERS AND GAUGES

Combination Meter
WITH TACHOMETER

[( )) om
IIJ ~
"'

0
"ABS" o• (@>) "BRAKE" o• ((DJ CJ

0 CJ

0
0 0 §§§ 0
0 00

0
IJ 0

0
0 000 0 0

12 36 40 30 10 9 35 34 17

- i ~

z ;:' 0
~
< w
u<
0 ~ ~ ~
!;
"c :a
~
~ ~ w
~
<
~
w w c: ~
w
~

TD'~" 7,~DCK
= ~q ')~q
<
q~ ~Q z
~Q v l>Q ~ ~~
~ ~ ~
gq ~a ~~ ~Q
~~ ~~a
~r ~( 9-- ~ .r)- ~ r ;

~~
~
~ ~
~ r u z
0
f- ~j u
0
r ~ ~
:0 ~
w
~ ~ 8
~ ~
~ ~~
~ z u
u ~ w z
~ < ~
~
< r-

'if
~
~

~
~

sPEED- <
OMETER l j
L

5 11 42 39 33 28 22 21 8 3 25 24 23 16 15 13 27 20 26 14
AEL897A

1132 EL-66
 METERS AND GAUGES
Combination Meter (Cont'd)
WITHOUT TACHOMETER

= =

~H
TEMP -~-

([

"ABS" oc (@)) "BRAKE" oc ((j))

0

0 0

0
0 0 §§§
0

000
0 0
0
0
0

1, 8
2 8
3 9

12 36 40 30 10 9 35 17

,- l ~

z
;:: 0
>-
~ w
0 ~ ~ ~
>- <
u
~
< ~ ~
w o ~

"' §a
~ w ~
< w z ~ w w ~

~q ~1 C:q
~

~c ~ ~1 ~~
ro ~ ~ ro
~·
z ~ ~
'§Q ~

Z3.p--~.p- ~ ~~a~
"- >-
~ 0
""~
~
~ ~ < z ro
~j
u

~~ T
~
~
u
0
r ~ ~

~w ~ I ~
w
>- w
~ 8
>-
0

~ ~ ~ ~
u w u
<
~
>- z
~
< ~ ~

~ j:J sPEED-
OMETER !
~ ~
<
"
5 11 42 39 28 22 21 8 31 25 24 23 16 15 13 27 ?0 26 14

AEL898A

EL-67 1133
 METERS AND GAUGES

Speedometer, Tachometer, Temp. and Fuel

Gauges/Wiring Diagram -METER-
EL-METER-01
W/B
I
~ With tachometer
Refer to "EL-POWER". Irf, I<fill§>
1DA ".-'@) <§D : Without tachometer
W/B
IT!]
W/B

I W!B
I
r----------------------------"-'1'-"----------,COMBINATION
~
METER
(@.@.
@@

B Y/G
~~
Y/R Y/R

W R W/L W
!
B

1$1---1$1-- -l$t-- -l$t--- ---------1$1---------------- --~~~It----------- -1$1cM~;,>

I t...t
Y/G YIR @)

W A W/L W B Y/G Y/A

I I
W/L W
I
B
rep~ Y/G
I
YIR

~
~ffi JOINT mi)FUEL
i
rv"s"p"'---=T"-AC-"H-", ECM (EGGS TANK THERMAL
CONTROL CONNECTOR-2 GAUGE UNIT TRANSMITTER
MODULE) @g) @ Ci!llil
<&§) II 4 II
~
GND-A
~
lbjdJ 8/G
W R 8
1~1--- jrfll (~)
".-' ".-'@ B/G
+ 1 B/G (~)
IEP@)
W R
I ~

III! !Ill
.............. I
VEHICLE

r ·-·
SPEED
SENSOR
@§)
B
I I B B
_._ -!:- ...._
(~)(M1os)(M160)
Refer to last page (Foldout page).
<&§)
1 =2 @g)
m<i;jjl> ~(M£j) 3 4 5 6 7 8 @> cflb@ (¥§).@)
~GY 9 0 11 2 1314 W GY
D
12345@) ~@
6 7 8 9 10 w ~GY

AEL876A

1134 EL-68
 METERS AND GAUGES

Inspection/Water Temperature Gauge

INSPECTION START

CHECK POWER SOURCE. Check the following items:

i. Turn ignition switch ON. • Harness continuity
2. Check voltage between terminal @ between battery terminal
AEL355A and ground. and combination meter
Battery positive voltage should exist. • Ignition relay-1
• Fusible link and fuse
OK
• Ignition switch

CHECK GAUGE OPERATION. NG Repair or replace gauge.

1. Turn ignition switch ON.
2. Connect terminal @ (with tachometer)
or @ (without tachometer) to ground
Gil'iF
with wire for less than 1 second.
AEL366A 3. Check operation of gauge.
~;::::===============~ Gauge should move smoothly to full
scale.

OK

CHECK THERMAL TRANSMITTER. Repair or replace.

Combination meter harness connectors
Perform "Thermal Transmitter Check".
With Without
Refer to EL-74.
tachometer@ tachometer @
OK

CHECK HARNESS CONTINUITY. NG Repair or replace.

Check harness continuity between termi-
nal® (with tachometer) or @ (without
tachometer) and ground.
Continuity should exist.
-=- If OK, check harness for short.

OK

Reinstall any part removed.

367
AEL A LI_ _ _ _ _IN_s_P_E_c_T_Io_N_E_N_o_ _ _ __

EL-69 1135
 METERS AND GAUGES

Inspection/Fuel Gauge
Flow chart INSPECTION START
INCIDENT
No.

Fuel gauge always reads empty [1J

llJ
2 Fuel gauge reads inaccurately IZl
CHECK POWER SOURCE. Check the following items:
3 Fuel gauge always reads full ~l 1. Turn ignition switch ON. • Harness continuity
2. Check voltage between terminal @ between battery terminal
and ground. and combination meter
Battery positive voltage should exist. • Ignition relay-1

m Combination meter harness connector@ OK

•
•
Fusible !ink and fuse
Ignition switch

[lt
i) CHECK GAUGE OPERATION. NG Repair or replace gauge.
1. Turn ignition switch ON.
@NJ 2. Connect terminal ® to ground with
wire for approx. 90 seconds.
3. Check operation of gauge.
Gauge should move smoothly to full
AEL355A scale.
OK

CHECK FUEL TANK GAUGE UNIT. NG Repair or replace.

Perform "Fuel Tank Gauge Unit Refer to FE section
Check". ("Fuel Pump and
Refer to EL-74. Gauge", "FUEL SYS-
TEM").
OK

CHECK HARNESS CONTINUITY. NG Repair or replace.

AEL368A
Check harness continuity between termi-
nal® and ground.
Continuity should exist.
If OK, check harness for short.

OK

Reinstall any part removed.

INSPECTION END

1136 EL-70
 METERS AND GAUGES

Inspection/Tachometer

INSPECTION START

CHECK POWER SOURCE. Check the following items:

1. Turn ignition switch ON. • Harness continuity
2. Check voltage between terminal @ between battery terminal
and ground. and combination meter
AEL355A
Battery voltage should exist. • Ignition relay-1
• Fusible link and fuse
OK
• Ignition switch

CHECK ECM OUTPUT. NG Check harness and con-

1. Start engine. nector between ECM and
2. Check voltage between terminals @ combination meter, or
and @ at idle and 2,000 rpm. check ground.
Higher rpm = Higher voltage
Lower rpm = Lower voltage
Voltage should change with rpm.
AEL370A '--------.,-=,..---------'
L-------------------------~ OK

Replace tachometer.

INSPECTION END

EL-71 1137
 METERS AND GAUGES

Inspection/Speedometer and Vehicle Speed

Sensor
SYMPTOM: Speedometer stays at 0 km/h (0 MPH).

INSPECTION START

CHECK GROUND CIRCUIT OF SPEED- NG Repair harness or connec·

AEL371A OMETER. tor.
Check continuity between terminal @
(;) Combination meter harness connector@ and body ground.
Continuity should exist.
[ll OK

i) CHECK POWER SOURCE. NG Check the following items:

~ · 1. Turn ignition switch ON.

2. Check voltage between terminal @
• Harness continuity
between battery terminal
and body ground. and combination meter
Battery voltage should exist. • Ignition relay-1
• Fusible link and fuse
AEL355A OK
• Ignition switch

CHECK VEHICLE SPEED SENSOR Replace speedometer.

OUTPUT.
Combination meter harness connectors
1. Remove vehicle speed sensor from
transmission. Leave harness connector
connected.
2. Check voltage between terminal @
and @ while quickly turning vehicle
speed sensor pinion.
Voltage: Approx. 0.5V (AC)
Vehicle speed
sensor NG

CHECK VEHICLE SPEED SENSOR. NG Replace vehicle speed

Check resistance between terminals CD sensor.
and®.
Resistance: Approx. 2500.

OK

Repair harness or connector between

Speed sensor speedometer and vehicle speed sensor.
pinion
AEL372A

Vehicle speed sensor

[!j harness connector ® INSPECTION END

iv
AEL373A

1138 EL-72
 METERS AND GAUGES
Inspection/Speedometer and Vehicle Speed
Sensor (Cont'd) ~[
Vehicle speed sensor
SYMPTOM: Speedometer indication flutters.

INSPECTION START

Speed sensor pinion

~==================~
AEL061

...
Is vehicle speed sensor installed properly?
Check for looseness.

OK
- NG Install vehicle speed sen-
sor properly.

-
!;) ...

~
~ io
Vehicle speed sensor
@1
CHECK VEHICLE SPEED SENSOR.
Do you feel resistance when turning
vehicle speed sensor pinion?
No Replace vehicle speed
sensor.

~' harness connector Yes

~@)
R
NG
CHECK HARNESS CONTINUITY.
Check continuity between speedometer r--- Repair harness and con-
nector.
Combination meter terminal @ and vehicle speed sensor
harness connector@
terminal @, and between @ and G).
Continuity should exist.

w OK

Combination meter
harness connector @
I'''~
1
) Replace speedometer.

..
·

m.·. oFflilll
~r 10
'""''""'
AEL900A

Inspection/Speedometer and Fuse

SYMPTOM: Speedometer does not go back to 0 km/h (0 MPH). IZl~

INSPECTION START
I I

I Check fuse related to speedometer. NG Replace fuse.

L____ _ _ _ __ j
I ~~
OK

I Drive at over 80 km/h (50 MPH). I

NG

Replace speedometer.

EL-73 1139
 METERS AND GAUGES

Fuel Tank Gauge Unit Check

• For removal, refer to FE section ("Fuel Pump and Gauge",
"FUEL SYSTEM").
Check the resistance between terminals G) and @).
Ohmmeter Float position Resistance value
(+) (-) mm (in) (ll)
'3
'3 Full 241 (9.49) Approx. 4.5 - 5.5
Approx.
'2 G) @) '2 1/2 115 (4.53)
31.5 . 33.5
'1 Empty 8 (0.31) Approx. 80 - 83
AEL407A

Fuel Warning Lamp Sensor Check

• It will take a short time for the bulb to light.

Test
lamp~
(3W) /
ON

Test
lamp
(3W)
OFF

AEL408A

Thermal Transmitter Check

Ohmmeter Check the resistance between the terminals of thermal transmitter
and body ground.
Water temperature Resistance
Approx. 70 - 90!!
Approx. 21 · 24ll

SEL698F

Oil Pressure Switch Check

Ohmmeter
Oil pressure
Continuity
kPa (kg/cm 2 • psi)

More than 10 - 20
Engine start No
(0.1 - 0.2, 1.4 - 2.8)
Less than 1o - 20
Engine stop Yes
(0.1 - 0.2. 1.4 . 2.8)

Check the continuity between the terminals of oil pressure switch

SEL748K
and body ground.

1140 EL-74
 METERS AND GAUGES

Vehicle Speed Sensor Signal Check

1. Remove vehicle speed sensor from transmission.
2. Turn vehicle speed sensor pinion quickly and measure voltage
across G) and ®.

Volbneter
Approx. O.SV
[Alternating
cunent
l..::===~T (A.C.)]
AEL331A

EL-75 1141
 WARNING LAMPS

System Description
With the ignition switch in the ON or START position, power is supplied:
• through 1OA fuse (No. ITII, located in the fuse block)
• to combination meter terminal @, and
• to 4WD switch terminal G).
With the ignition switch in the ON or START position, power is supplied:
• through 15A fuse (No. :ill , located in the fuse block)
• to bulb check relay terminal @.
Ground is supplied:
• to combination meter terminal @,
• bulb check relay terminal ®.
• brake fluid level switch terminal @, and
• washer fluid level switch terminal @ (For Canada models only)
• through body grounds ® , @ and ~ .
Ground is supplied:
• to seat belt buckle terminal @, and
• fuel tank gauge unit terminal ®
• through body ground ~ .
AIR BAG WARNING LAMP
During prove out or when an air bag malfunction occurs, the ground path is interrupted:
• from the air bag diagnosis sensor unit terminal @
• to combination meter terminal @.
Ground is then supplied:
• through combination meter terminal @.
With power and ground supplied, the air bag warning lamp (LEOs) illuminate.
For further information, refer to RS section ("TROUBLE DIAGNOSES").
LOW FUEL LEVEL WARNING LAMP
The amount of fuel in the fuel tank is determined by the fuel level sensor in the fuel tank. A signal is sent from
fuel tank gauge unit terminal ®to combination meter terminal @.The fuel level sensor will illuminate the low
fuel level warning lamp when the fuel level is low.
With power and ground supplied, the low fuel level warning lamp illuminates.
LOW OIL PRESSURE WARNING LAMP
Low oil pressure causes oil pressure switch terminal G) to provide ground to combination meter terminal @.
With power and ground supplied, the low oil pressure warning lamp illuminates.
LOW WASHER FLUID LEVEL WARNING LAMP (For Canada models only)
When the washer fluid level is low, ground is supplied:
• to combination meter terminal @
• from washer fluid level switch terminal G).
With power and ground supplied, the low washer fluid level warning lamp illuminates.
SEAT BELT WARNING LAMP
When the driver's seat belt is unfastened, ground is supplied:
• to combination meter terminal @
• from seat belt buckle switch terminal G).
With power and ground supplied, the seat belt warning lamp illuminates.
MALFUNCTION INDICATOR LAMP
During prove out or when an engine control malfunction occurs, ground is supplied:
• to combination meter terminal @
• from ECM terminal @.
With power and ground supplied, the malfunction indicator lamp illuminates.
For further information, refer to EC section ["Malfunction Indicator Lamp (MIL)", "ON-BOARD DIAGNOSTIC
SYSTEM DESCRIPTION"].

1142 EL-76
 WARNING LAMPS
System Description (Cont'd)
ABS WARNING LAMP :lliil
During prove out or when an ABS malfunction occurs, ground is supplied:
• to combination meter terminal @
• from ABS control unit terminal ®.
With power and ground supplied, the ABS warning lamp illuminates.
For further information, refer to BR section ("Self-diagnosis", "TROUBLE DIAGNOSES").
BRAKE WARNING LAMP
When the parking brake is applied, or the brake fluid level is low, ground is supplied:
• to combination meter terminal @ L©
• from parking brake switch terminal CD, or
• brake fluid level switch terminal CD.
With power and ground supplied, the brake warning lamp illuminates. ~©
BULB CHECK RELAY (brake warning lamp prove out)
When the ignition switch is in the ON or START position, and the generator grounds terminal @, ground is I'~
supplied to the bulb check relay terminal CD.
With power and ground supplied, the bulb check relay is energized, providing a ground path for the brake
warning lamp: 1\:L
• through combination meter terminal @
• to bulb check relay terminal @.
With power and ground supplied, the brake warning lamp illuminates. i~'ii'

CHARGE WARNING LAMP

During prove out or when a generator malfunction occurs, ground is supplied:
• to combination meter terminal @
• from generator terminal ®.
With power and ground supplied, the charge warning lamp illuminates.
4WD INDICATOR LAMP (with 4-wheel drive)
When the 4WD switch is activated, power is supplied:
• from 4WD switch terminal CD
• to combination meter terminal @.
With power and ground supplied, the 4WD indicator lamp illuminates.

EL-77 1143
 WARNING LAMPS

Schematic

r-~_,~ To lighting switch

BULB CHECK RELAY

PARKING BRAKE
SWITCH

BRAKE FLUID
LEVEL SWITCH

CHARGE
11 GENERATOR

AIR BAG WARNING LAMP AIR BAG

~------------------ DIAGNOSIS
1 SENSOR UNIT
I
I
I
I
I

AEL295A

1144 EL-78
 WARNING LAMPS

Wiring Diagram -WARN- Clll

EL-WARN-01
<EQ') With 4-wheel drive

W/8

~
JOINT
CONNECTOR-2
Refer to "El-POWER".

@g)
+
~ W/8
W/8
lrf,I(M155) -- I
.J>.,._
a.-•--O~w;s~Nextpage -
'-r'@
W/8

~
1--'J'l===============:;----------~ COMBINATION
- - - -------------------IAIR8AG
:
I
:
AIR BAG LED
r.
,>.: "'
1WARNING
'LAMP
:
d
IL---.----js
-- Next page

~MALFUNCTION
(~;)A,'Nil'
\..!::!2..1

: u 1'- If-<~ : 'V~~~ATOR

I
: L ..: ~:
I

I I
L------------------- _j \
~ ~ cyJ
G!Y B R/W

l~f--------i~l-------------------1~1~;
G/Y 8 RfW
c!J@m
~@m m
D
JOINT ECM
G!Y CONNECTOR-2 (ECCS

I ~~CN~
@g) CONTROL
MODULE)

%ll
8
<filii)
(Refer to "EC-MIUDL").

AIR BAG
DIAGNOSIS
SENSOR UNIT I
(M175)
(Refer to ''RS-SRS").
i-il
Refer to last page (Foldout page).

1 11 23 5 24 13 c::::J 4 10 17 19 20 (~) @g)

9 8 3 7 18 14 2 22 6 12 15 16 21 y <'-ili:s) ,@

101 102 103 104 105 106 @1

~
107108109 11011~ 112
113 114 115 116 117 118

AEL877A

EL-79 1145
 WARNING LAMPS
Wiring Diagram -WARN- (Cont'd)

EL-WARN-02

Referto"EL-

I
POWER".

Y/8 8/W

1~1@
(M43)
Y/8
1rf.,1CM1ssl
'-.-'@)
IWI Y/B
=j=l ~ ..... To EL-ILL
(M44)@ W/8 ~ I
Preceding ......-Al-w/B .J'F2l.w!B
page~~
-=.J + Y/B
~~
P/L

r--------------------------------------------~~l:llil~3rs~l--~l~~·ro~l~ COMBINATION
Preceding Next METER
page page @.@
CHARGE 4WD
-~~Next
I ~page
BMI B/Y

,.,=-=
w
,., ,.,,
~
m
~
s
II''ji~'"~>C<
@
RELAY

l!f------------------J!I----------1'1iM~;J lbjdJ ~
1-......-----~-....iiiii---=t---...IY/8 8
I
Y/8 ~@)
Tc@ w b~N~ECTOR2

...._........-__•-•,
lrt,s I(M44) ~
1 1 1
@W

~
'T' @
Y/R
r----''-i-f11-"-----, 01 L
PRESSURE
SWITCH
=-=
IL"JI
B
GENERATOR LOW (12)
I I
( ]
® ---•
HIGH
With 4-wheel drive -:-

r---------------. Refer to last page (Foldout page).

@) @l: @W
(M1ss).@)
__.r:;::~...@ l=l® : R® ,.._®:
~w w 8 1 \JJ GY I
\..!) GY
L--------------J
~(~)
~GY
~------------------------------1
I I
I 34 33 32 O 31 30 29 CEL) I
: 282726 252423 w:
L------------------------------j
AEL878A

1146 EL-80
 WARNING LAMPS
Wiring Diagram -WARN- (Cont'd)

EL-WARN-03

Preceding
page -
,----------------------------------------,cOMBINATION
METER
@,@

ABS BRAKE FUEL SEAT WASHER

BELT

~ ~ ~ ~ ~ ~
UR B/Y BR/Y Y/PU BR/Y W

l~r--io!lJ!-----!~r--------------i~!-----------------!~r-------i~l~
UR B/Y BR/Y Y/PU BA/Y W

~~~~edlng ~B!YO ....;J ....

~ :,-
BA/Y BR/Y
IE!JI~i~
Y/PU -- •
I ~-
~ ffi DIODE BR!Y
@) ffi WARNING w
!bjdl lbjdl
SEAT
BiJl
CHIME
UNIT
@Zg)
m
,--"--j-"---,WASHER
GIY WIG FLUID

r=J b.,
LEVEL
SWITCH
LOW

G!Y WIG •--- @§)

m
.---"--i-"----, PARKING
m
,--~~--,BRAKE .--~LT~--,SEAT
HIGH

ll4Jl
BRAKE FLUID BELT B
SWITCH LEVEL BUCKLE
APPLIED~ LOW
SWITCH SWITCH

•---
RELEASED HIGH
(M59)
---• FAST-
ENED
@

UR

ffi
r--"-''--"---, ABS
ABS CONTROL
WARNING UNIT
L~~p <1lli§}
(Refer to
' - - - - - ' "BR-ABS")

Refer to last page (Foldout page).

1=2 D
3 4 5 6 7 8 @Qi) 1 2 3 4 5 (M156)
<MW-®
9 10 11 2 1314 w 6 7 8 9 10 L

123405678(~)
17 12 11 10 9 w

@
~®
\ili:tY w

AEL879A

EL-81 1147
 WARNING LAMPS

Diode Check
• Check continuity using an ohmmeter.
• Diode is functioning properly if test results are as shown in the
figure at left.
NOTE: Specifications may vary depending on the type of
tester. Before performing this inspection, be sure to
refer to the instruction manual for the tester to be
used.

SEL208R

• Diodes for warning lamps are built into the combination meter
printed circuit.
Refer to EL-66.

AEL379A

1148 EL-82
 WARNING CHIME

System Description
The warning chirne is combined with the warning chime unit.
Power is supplied at all times:
• through 1OA fuse (No. l1ll , located in the fuse block)
• to key switch terminal CD.
Power is supplied at all times:
• through 1OA fuse (No. lnl , located in the fuse block)
• to lighting switch terminal CD.
With the ignition switch in the ON or START position, power is supplied:
• through 1OA fuse (No. [l] located in the fuse block)
• to warning chime unit terminal @.
Ground is supplied to warning chime unit terminal @ through body grounds ® ,~ and ~ .
Ignition key warning chime
With the key inserted in the ignition switch in the OFF or ACC position, and the driver's door open, the warn-
ing chime will sound. A battery positive voltage signal is sent: f~
• from key switch terminal ®
• to warning chime unit terminal 0.
Ground is supplied: ©IL
• from door switch LH terminal ®
• to warning chime unit terminal @.
Door switch LH terminal CD is grounded through body ground @E) . Ui:ll'ii'
Light warning chime
With the ignition switch in the OFF or ACC position, the driver's door open, and the lighting switch in the 1ST /A'~t
or 2ND position, the warning chime will sound. A battery positive voltage signal is sent:
• from lighting switch terminal ®
• to warning chime unit terminal @. 1115
Ground is supplied:
• from door switch LH terminal ®
• to warning chime unit terminal @. ~[Ql
Door switch LH terminal CD is grounded through body ground @E) .
Seat belt warning chime
With the ignition switch turned from the OFF or ACC position to the ON position, and the seat belt unfastened IS/A
(seat belt buckle switch ON), the warning chime will sound for approximately 7 seconds.
Ground is supplied:
• from seat belt buckle switch terminal CD
• to warning chime unit terminal ®.
Seat belt buckle switch terminal ® is grounded through body ground @E) .

EL-83 1149
 WARNING CHIME

Wiring Diagram -CHIME-

BATTERY IGNITION SWITCH EL-CHIME-01

ON or START
I
•~10A ~10A 10A
Refer to "EL-POWEA".

[El @] @]
p p

ffi LIGHTING
ffi KEY
SWITCH SWITCH
<Mill> DRAWN <MilD
OFF 2ND

P!L
I
y W/B

r
m
~~------------~~------~~~'~-.
LIGHT
ffi KEY IGN WARNING
sw SW CHIME
UNIT
SEAT <Mill)
DOOR BELT
GND sw sw
lbjJJ ~ lb4Jl
B BR

.• --
BRIY

I i
·-BR/Y.ToEL-WARN
DIODE
(i@) BRIY

B lb4Jl ffi
r-----~rc----,SEAT

~
BR BELT

~
BUCKLE
JOINT SWITCH
CONNECTOA-2 DOOR UNFAST- FASTENED ~
ENED .... __ • ~
<1iliY SWITCH
LH

ll4Jl (iillj}
lb4Jl

_.
B
B

I
i-il_._ ............. I
lbjdl
B

I
_._
B
_._
B B B
-!!,.
<®> <@:s> (~) (M177)
Refer to last page (Foldout page).
<Iilli>
D D
' 3 4
6 7 8
<Mill>
w
12345@§§)
6 7 8 9 10 w

AEL278A

1150 EL-84
 WARNING CHIME

Trouble Diagnoses
SYMPTOM CHART
Main Power
Supply and
PROCEDURE Preliminary Check Diagnostic Procedure
Ground Circuit
Check

REFERENCE
EL-86 EL-86 EL-86 EL-87 El-88 EL-89 EL-90
PAGE

Main power sup-

Preliminary Preliminary Preliminary Diagnostic Diagnostic Diagnostic
SYMPTOM ply and Ground
check 1 check 2 check 3 Procedure 1 Procedure 2 Procedure 3
circuit check

Light warning
chime does not 0 0 0
activate.

Ignition key
warning chime
does not acti- 0 0 0
vate.

Seat belt warn-

ing chime does 0 0 0
not activate.
llill

EL-85 1151
 WARNING CHIME
Trouble Diagnoses (Cont'd)
PRELIMINARY CHECK
Preliminary check 1
• Light warning chime does not activate.
Does ignition key warning chime activate? ~ Go to "DIAGNOSTIC
PROCEDURE 1 - Step
No
1", EL-88.

Go to "DIAGNOSTIC PROCEDURE 1 -
Step 2", EL-88.

Preliminary check 2
• Ignition key warning chime does not activate.
Does light warning chime activate?

No
~ Go to "DIAGNOSTIC
PROCEDURE 2 - Step
1", EL-89.

Go to "DIAGNOSTIC PROCEDURE 2 -
Step 2", EL-89.

Preliminary check 3
• Seat belt warning chime does not activate.
Go to "DIAGNOSTIC PROCEDURE 3",
EL-90.

1152 EL-86
 WARNING CHIME
Trouble Diagnoses (Cont'd)
MAIN POWER SUPPLY AND GROUND CIRCUIT CHECK '1iil
~ £)
CJNN~CT

Main power supply

Warning chime Battery positive voltage existence condition
unit connector ~
Terminals Ignition switch position

r[~~~, I
OFF ACC ON
W/B
[Y] ®-® No No Yes

+ -

AEL334A

Ground circuit
~ IV 00
DISCONNtCT

Terminals Continuity
Warning chime
unit connector § ®-Ground Yes

I Ill 1,]
L,_ •
Q

~
AEL335A

EL-87 1153
 WARNING CHIME
Trouble Diagnoses (Cont'd)
m DIAGNOSTIC PROCEDURE 1
~ 18@0 SYMPTOM: Light warning chime does not activate.
Warning chime unit connector§
• Perform "PRELIMINARY CHECK - Procedure 1"" before

Hllf.] m
referring to the following flow chart.

Step 2
BR B
DOOR SWITCH INPUT SIGNAL CHECK. NG • Check door switch.
Check continuity between warning chime ~ (Reier to EL-91.)
[Q] unit harness terminals ®
and @. • Check harness continuity
+
J
between warning chime
AEL336A
Condition of driver's
Continuity
unit harness terminal ®
door and LH door switch har-
Iii DISCONMCT
®.
I)I IV
Warning chime unit connector 8
LH door is closed.
LH door is open.
No
Ye<
ness term ina I
Continuity should
exist.

[,Ill 1.] OK • Check harness continuity

between LH door switch
P/L B harness terminal CD and
body ground.
Continuity should
[YJ exist.
'--~ Note: Pay attention to
AEL337A tester polarity*.

[!]

~~;~
Iii Step 1

LIGHTING SWITCH INPUT SIGNAL

CHECK.
~ • Check lighting switch.
(Refer to EL-91.)

, Measure voltage between warning chime

®
• Check harness continuity

... ""
••
Warning
5 4 chime
unit harness terminals and @. between warning chime
unit harness terminal ®

~
Condition Voltage [V] and lighting switch har-
unit@
L1ght1ng SWitch is ON.
Lighting switch is OFF.
Approx. 12
0
ness terminal ®.
~ Continuity should
AEL375A exist.
OK
• Measure voltage
between lighting switch
harness terminal G) and
body ground.
Battery voltage should
exist.

[!]
WARNING CHIME CHECK.
1. Disconnect warning chime unit connector.
~ Replace warning chime
unit.
2. Apply 12V direct current across and ®
@,®
Does warning chime work?

Yes

INSPECTION END

*: Specifications may vary depending on the type of tester.

Before performing this inspection, refer to the instruction manual of the
tester.

1154 EL-88
 WARNING CHIME
Trouble Diagnoses (Cont'd)
r.i.1 DIAGNOSTIC PROCEDURE 2
l;;tt 10 00
DIS~ONI·IfCT

SYMPTOM: Ignition key warning chime does not activate.

§
Warning chime unit connector
• Perform "PRELIMINARY CHECK - Procedure 2" before

811£.] referring to the following flow chart.

8R 8 r.i.1 Step 2

DOOR SWITCH INPUT SIGNAL CHECK. NG • Check door switch.

[ [ill Check continuity between warning chime r---- (Refer to EL-91.)

+
J unit harness terminals ®
and @. • Check harness continuity
AEL336A between warning chime
Condrtion of driver's
door
Continuity unit harness terminal ®
§ and LH door switch har-

~ 10
OISCONNE8T
LH door is closed No
y, ness terminal @.
LH door rs open.
Continuity should
Warning chime unit connector §
exist.
H,ffi] OK
• Check harness continuity
between LH door switch
y 8 harness terminal G) and
body ground.

~~
w Continuity should
exist.

AEL338A
§

-
Step 1
[ij )'
C5 NG
''61)ti"
"0
IGNITION KEY SWITCH INPUT SIGNAL • Check ignition key
CHECK, switch.

~~~ Measure voltage between warning chime

unit harness terminals (?) and @.
(Refer to EL-91.)
• Check harness continuity

i between warning chime

0
L±tlsl4J Condition Voltage [V]
unit harness terminal

~
:7;!ng Key is inserted. Approx. 12
and key switch harness
unitS Key is drawn. 0
terminal®.
OK Continuity should
exist.
AEL915A • Measure voltage
between key switch har-
ness terminalCD and
body ground.
Battery voltage should
exist.

[ij
WARNING CHIME CHECK. No Replace warning chime
1. Disconnect warning chime unit connector. f-----. unit.
2. Apply 12V direct current across and 0
@),@
Does warning chime work?

Yes

INSPECTION END

EL-89 1155
 WARNING CHIME
Trouble Diagnoses (Cont'd)
r.:.1 DIAGNOSTIC PROCEDURE 3
~ IV U8
DISCONNECT

SYMPTOM: Seat belt warning chime does not activate.

Warning chime unit connector~ • Perform "PRELIMINARY CHECK - Procedure 3" before
referring to the following flow chart.
Hif'hl
BR/Y
r.:.1
B
SEAT BELT SWITCH INPUT SIGNAL
CHECK. ~ • Check seat belt buckle
switch.

U9 AEL339A
Check continuity between warning chime
unit harness terminals

Condition
® and @.

Continuity
(Refer to EL-91.)
• Check harness continu-
ity between warning
chime unit harness ter-
1§1 minal ®and seat belt

~};J
Unfastened Yes
,.ij buckle switch harness
Fastened No
terminal G).

~~ OK Continuity should
exist.
i~- • Check harness continu-
'~' t3±H'hl Wam;ng ity between seat belt

I~
4 ch•me
buckle switch harness
unite
- terminal ® and body
r ~
ground.
Continuity should
AEL916A
exist.

1§1

~
WARNING CHIME CHECK. Replace warning chime
1. Disconnect warning chime unit connector. unit.
2. Apply 12V direct current across @ and
0.®
Does warning chime work?

Yes

INSPECTION END

1156 EL-90
 WARNING CHIME
Trouble Diagnoses (Cont'd)
ELECTRICAL COMPONENTS INSPECTION
LH Door switch
Check continuity between terminals G) and ® when door switch
is pushed and released.
Terminal No. Condition Continuity

Door switch is pushed. No

G)-® Door switch is released. Yes

Door switch
LH connector e

jf[j'

AEL402A

Key switch
Key switch connector 8 Check continuity between terminals G) and ® when ignition key
is drawn and inserted.

~~ l Terminal No J Condition Continuity

No

LBJ
Ignition key is drawn.
G)-®
Ignition key is inserted. Yes

AEL403A

Seat belt buckle switch

Seat belt buckle
switch connector 8 Check continuity between terminals G) and ® when seat belt LH
is fastened and unfastened. ~['j!

Terminal No. Condition Continuity

Seat belt LH is fastened. No
G)-® Seat belt LH is unfas-
Yes
tened.

AEL404A

Lighting switch
Check continuity between terminals G) and ®when lighting switch
Lighting switch connector e is turned to OFF and 1st or 2nd position .
• Terminal No. Condition Continuity
5
Lighting switch is turned
No
to OFF position.
G)-® Lighting switch is turned
Yes
to 1st or 2nd position.

AEL405A

EL-91 1157
 WIPER AND WASHER

System Description
WIPER OPERATION
The wiper switch is controlled by a lever built into the combination switch.
There are three wiper switch positions:
• LO speed
• HI speed
• INT (Intermittent) (if equipped).
With the ignition switch in the ACC or ON position, power is supplied:
• through 20A fuse (No. l1J , located in the fuse block)
• to wiper motor terminal @).
Low and high speed wiper operation
Ground is supplied to wiper switch terminal ® through body grounds ® ,~ and <M® .
When the wiper switch is placed in the LO position, ground is supplied:
• through terminal @) of the wiper switch
• to wiper motor terminal ®.
With power and ground supplied, the wiper motor operates at low speed.
When the wiper switch is placed in the HI position, ground is supplied:
• through terminal ® of the wiper switch
• to wiper motor terminal ®.
With power and ground supplied, the wiper motor operates at high speed.
Auto stop operation
When the wiper switch is placed in the OFF position, the wiper motor will continue to operate until the wiper
arms reach the base of the windshield.
When the wiper switch is placed in the OFF position, ground is supplied:
• from terminal @) of the wiper switch
• to wiper motor terminal @, in order to continue wiper motor operation at low speed.
The ground path to terminal @) of the wiper switch is supplied:
• through terrninal ® of the wiper switch
• to wiper amplifier shorting connector terminal ® (without intermittent wipers), or
• to wiper amplifier terminal ® (with intermittent wipers)
• through wiper amplifier shorting connector terminal ® (without intermittent wipers), or
• through wiper amplifier terminal ® (with intermittent wipers)
• to wiper motor terminal ®
• through terminal ® of the wiper motor, and
• through body grounds ® , ~ and @ .
The ground path is interrupted and the wiper motor stops when the wiper arms reach the base of the wind-
shield.
Intermittent operation
The wiper motor operates the wiper arms one time at low speed at a set interval of approximately 4 to 12
seconds. This feature is controlled by the wiper amplifier.
When the wiper switch is placed in the INT position, ground is supplied:
• to wiper amplifier terminal @)
• from wiper switch terminal rJ)
• through wiper switch terminal ®, and
• through body grounds ® , (@§) and <M® .
The desired interval time is input:
• to wiper amplifier terminal ®
• from wiper switch terminal G).
Based on these two inputs, an intermittent ground is supplied:
• to wiper motor terminal ®
• through the wiper switch terminal @)
• to wiper switch terminal ®
• from wiper amplifier terminal ®.
With power and ground supplied, the wiper motor is activated.
The wiper motor operates at low speed at the desired time interval.

1158 EL-92
 WIPER AND WASHER
System Description (Cont'd)
·~r
WASHER OPERATION
With the ignition switch in the ACC or ON position, power is supplied:
• through 20A fuse (No. CZJ , located in the fuse block)
• to washer motor terminal G).
When the lever is pulled to the WASH position, ground is supplied:
• to washer motor terminal @, and
• to wiper amplifier terminal 0 (with intermittent wipers)
• from terminal ® of the wiper switch
• through terminal ® of the wiper switch, and
• through body grounds @ , ~ and ~ .
With power and ground supplied, the washer motor operates. Ff'
0
The wiper motor operates twice at low speed for approximately 3 seconds to clean the windshield. This feature ""'
is controlled by the wiper amplifier in the same manner as the intermittent operation.

EL-93 1159
 WIPER AND WASHER

Wiring Diagram -WIPER-

MODELS WITH INTERMITTENT WIPERS
EL-WIPER-01

Refer to "EL-POWER".
20A
0
B~L·
LIY
• ... m m
!+

• •• VARIABLE
WIPER
SWITCH

.
UY INTERMITTENT
WIPER (i,illj)

I ·-,
VOLUME
WASHER
MOTOR
-------------------- WASH ,---
(~)
~ OFF ,
'~'" _.~'-~
_, :

~
INT
~-.~·/
LO HI
~- _

D
-
U8

~ ~ ll4Jl ~ l!:jdJ l!4Jl

UY I ...
--
UR
... W/L

- -·
uw ust
I
R/L 8
I
8 B

ffi
NA, MOVE
WIPER
MOTOR
@
H
ffi

~
STOP•:--

0( ~H
L
\
+
l!4Jl
8
CONNECTOA-2
@§

~ ~
2

uw
'4=tl

-- --
UR L 8

...
I . . L --
+

• -- UY
-- - 8/L ·- I
8 + L +
--
W/L + U8
-t AIL+

mm mm m mm
"'A"'CC!C'-'':'O":FFJ'-_ _.!JG,-'Nc,JDI!...!lP-:"AR,-JK~---'-L.;,N',TJ'-_ __:WL,A'-;,SJ':H!LI::"NT:"--,wiPER
AND VOL AMPLIFIER
INT @
sw

Refer to last page (Foldout page).

(M142)

IBl
~@ 12 3 4 (i,illj)
~w 5 6 7 8 L

AEL880A

1160 EL-94
 WIPER AND WASHER
Wiring Diagram -WIPER- (Cont'd)
MODELS WITHOUT INTERMITTENT WIPERS

EL-WIPER-02

Refer to
"EL-POWER".

UY

I
•
I
UY
I
L I
~ wh WIPER
L

WIPER
MOTOR
·©L

rn
AMPLIFIER
@ SHORTING CONNECTOR
@)
~
8/L

--

UB UR LNV B/L

l'whTs~----~~t'===wh~==~----~~Tsl LO
WIPER
SWITCH
@E)
LO . . ---.,HI
/
/
/
/ ''
OFFe WASH OFF eWASH

~
I'
L
B JOINT
CONNECTOR-2 .------·.-·.-,
('ill?) T

s~s-..iiiiiii.....

Refer to last page (Foldout page).

@g)

~@)
till:till:J w

D
234@E)
6 7 8 L

AEL88lA

EL-95 1161
 WIPER AND WASHER

m Trouble Diagnoses
!14 IV 00
DISCONNECT

DIAGNOSTIC PROCEDURE 1
(Models with intermittent wipers)
~w;pe,amp.
connector@ SYMPTOM: Intermittent wiper does not operate.
m NG
UY CHECK POWER SUPPLY FOR WIPER
~
Check 20A fuse (No. Ill.
AMPLIFIER. located in the fuse block),

~
1. Turn ignition switch to ACC. harness and connector.
2. Measure voltage between wiper amplifier
-'? terminal ® and body ground.
AEL409A Battery voltage should exist.

OK
!;) !;)
[1t 00
CONfiECT

I) WIPER AMP. OUTPUT SIGNAL CHECK.

OK
f-----. Check wiper motor and cir-

jffiEjj
3
w;pe,amp.
connector
1. Turn ignition switch to ACC.
2. Move wiper switch to INT or OFF.
3. Measure voltage between wiper amp.
cuit.

@ harness terminal @ and body ground.

8/L J ,----

a
Condition of
Voltage [V]
w1per switch
OFF Approx. 12
~ Pointer swings from 0 to
INT
12 every 7 seconds
AEL348A

[!] OISCQ~I~fCT [!] ~NG

[lt IV 00 VOLTAGE CHECK.
NG
______. • Check wiper switch.

lffiEj w;pe, amp.

connector
1. Disconnect wiper amp. connector.
2. Turn ignition switch to ACC.
3. Measure voltage between wiper amp.
• Check wiper motor.
• Check harness continuity
between wiper amp. har·
@ harness terminal @ and body ground. ness terminal @ and
B/LJ ~ Battery voltage should exist. wiper switch harness ter·
minal ®-
OK Continuity should exist.
[YJ • Check harness continuity
between wiper sw@h
~r--- "'=" harness terminal 4 and
AEL349A wiper motor harness ter·
minal ®.
I!] Continuity should exist.

[a~ IV ~
l'ISCONNCCi
I!]
NG
INTERMITTENT SWITCH INPUT SIGNAL • Check wiper switch.
mw;pe,amp. CHECK. ~ • Check harness continuity
connector Check harness continui@between wiper between wiper amp. har·

W/L r ,---- @ amp. harness terminal 4 and body

ground.
Condition of
ness terminal @ and
wiper switch harness ter-
minal(}).
Continuity should exist.

~~1
Continuity
wiper switch
• Check harness continuity
OFF No between wiper switch
~
INT Yeo harness terminal ® and
AEL350A body ground.
OK Continuity should exist.
121 121
IV ~
OISGO~NECT

~
rm w;pe, amp.
connector
@
WIPER AMP. GROUND CIRCUIT CHECK.
Check harness continui®between wiper
amp. harness terminal 2 and body
ground.
Continuity should exist.
NG
~ tor.
Repair harness or connec·

"l ,---- OK

P.l ~

AEL351A
Replace wiper amp.

1162 EL-96
 WIPER AND WASHER
Trouble Diagnoses (Cont'd)
m CO~NECT DIAGNOSTIC PROCEDURE 2
~ IJ 00 (Models with intermittent wipers)
SYMPTOM: Intermittent time of wiper cannot be adjusted.
Wiper amp. connector @
m
mlli]
B::l_ RIL
INTERMITTENT WIPER VOLUME INPUT ~ Replace wiper amp.
I
SIGNAL CHECK.

A Q ~c
Measure resistance between wiper amp.
harness terminals ® and
ing intermittent wiper volume.
®while turn-

AEL352A
Position of wiper knob Resistance [KU]

s 0

L Approx. 1

NG

• Check intermittent wiper volume.

• Check harness continuity between
wiper amp. harness terminal ®and
wiper switch harness terminal G).
Continuity should exist.
• Check harness continuity between wiper
switch harness terminal ®
and body
ground.
Continuity should exist.

181~1

EL-97 1163
 WIPER AND WASHER
Trouble Diagnoses (Cont'd)
Pi1 f.D~NCCI DIAGNOSTIC PROCEDURE 3
[1t () 0@ (Models with intermittent wipers)
ltEREl w;pe' amp.
connector
SYMPTOM: Wiper and washer activate individually but not in
combination.
@
B
Pi1
UB
NG

a
WASHER SWITCH INPUT SIGNAL • Check wiper switch.
CHECK. ~ • Check harness continu-
[YJ 1. Turn ignition switch to ACC. ity between wiper amp.
+ - 2. Measure voltage between wiper amp. harness terminal (f)
AEL353A harness terminals (f) and ®- and wiper switch har-
ness terminal@.
m Condition of washer
Continuity should
~
COf!NECT Voltage [V]

lffiHEl 00
switch
() OFF Approx. 12
exist.
• Check harness continu-
w;pe' amp.
connector ON 0 ity between wiper switch
@ harness terminal ®
B/L B OK and body ground.
Continuity should

a [YJ
+ -
AEL354A
m
WIPER AMP. OUTPUT SIGNAL CHECK.
Measure voltage between wiper amp. har-
~
exist.

Check wiper switch.

OK
ness terminals ®
and ®
after operating
washer switch.
OV for approx. 3 seconds after washer
Replace wiper amp.
has operated.

1164 EL-98
 WIPER AND WASHER

Wiper Amplifier Check

1. Connect as shown in the figure at left.
2. If test lamp comes on when connected to terminal 0 and bat- IX~!,
Test
tery ground, wiper amplifier is normal.
lamp

Installation
1. Turn ignition ON.
2. Prior to wiper arm installation, turn on wiper switch and then [5~
turn it "OFF". Allow wiper to operate until its Auto Stop posi-
tion is reached before turning ignition off.
3. Lift the blade up and then set it down onto glass surface. Set ©L
the blade center to clearance "C" just before tightening nut.
4. Eject washer fluid. Turn on wiper switch to operate wiper motor
and then turn it "OFF".
5. Ensure that wiper blades stop within clearance "C".
Clearance "C": 20-30 mm (0.79- 1.18 in)
• Tighten windshield wiper arm nuts to specified torque .
Windshield wiper:
toJ:13- 18 N·m (1.3 -1.8 kg-m, 9-13 ft-lb)

Windshield wiper and washer

*1: 470 (18.50)

.2, 215 (8.46)
*3: 380 (14.96)

"C"~-;:=,~~ ~
*4: 180 (7.09)
*5: 60 (2.36)
•s, 225 18.861 cr;;:anoe
*7: 255 (10.04)
l
t=-i= ~=
•s: 460 (18.11)

*All the diameters of these circles are

less than 60 (2.36). Unit: mm (in)
•s -H--'-~
f-c.:=7-f-c--c.-:c8-~
I
L Lower windshield molding

AEL400A

•
El-99 1165
 WIPER AND WASHER
Installation (Cont'd)
• Before reinstalling wiper arm, clean the pivot area as illus-
trated. This will reduce possibility of wiper arm looseness.

SEL024J

Front washer
Suitable tool
Washer Nozzle Adjustment
• Adjust washer nozzle with suitable tool as shown in the figure
at left.
Adjustable range: ±1 oo

Nozzle hole
bore diameter
0.9 mm (0.035in) AEL053A

1166 EL-100
 HORN, LIGHTER, CLOCK

Wiring Diagram -HORN-

~ · With tachometer
<§!>: Without tachometer EL-HORN-01
@'WIIhASCD
<§5> Without ASCD

Refer to
15A "EL-POWER". ~~:0
0
LG RIG G/R

I
LG/B
lrpi(M128) I
C
.__.,
Iwl

~~
HORN
RELAY
(f,W
RIG
Ir;'!;,ICM155)
'-.-'@)
R/G
(@ji)

;
LG/B SPIRAL

CABLE
<i!@
I
RIG
~
CIGARETTE
LIGHTER ~
G/R

r---"""-c_---,COMBINATION (ACCESSORY)~~
BR CIGARETTE
METER
LIGHTER
I~I(Z103) (CLOCK) SOCKET
'-.-'@.) @.@.@ <Mill)
R
®®
•
O~oA~. . ..-
ll4dJ
B

~ I
~~~~RING
SWITCH
(~) +
rrh~ JOINT
CONNECTOR-2

~Q..:QoA)A-.1 I¥J
~

B
r-----~~---,HORN
•
i-il
SWITCH LGIW

~HORN
LY(M~) _._
B
_._
B
_._
B

c~39> CM~£s> <~>

Refer to last page (Foldout page).
(~)
1 2 0 3 4 (M129)
w (Miss>®
5 6 7 8 9 10 151
---------------------1
: II[Q]II@l5) ___IQI_(~):
I l2E.Iill] W ~ B I
~- ------------------- _,

AEL882A

EL-101 1167
 AUDIO

System Description
Refer to Owner's Manual for audio system operating instructions.
WITH PREMIUM AUDIO SYSTEM
Power is supplied at all times:
• through 1OA fuse (No. [OJ , located in the fuse block)
• to radio and cassette player terminal @.
Power is supplied at all times:
• through 15A fuse (No. l!l , located in the fuse block)
• to rear speaker amplifier terminal @.
With the ignition switch in the ACC or ON position, power is supplied:
• through 1OA fuse (No. [QJ , located in the fuse block)
• to radio and cassette player terminal @.
Ground is supplied through the case of the radio and cassette player.
Ground is also supplied:
• to rear speaker amplifier terminal 0
• through body ground @ .
When the system is on, remote on signal is supplied:
• from the radio and cassette player terminal @
• to the rear speaker amplifier terminal (i).
And audio signals are supplied:
• through radio and cassette player terminals (i), ®. @, @, @, @, @and@
• to terminals @, @, @) and @ of the rear speaker amplifier and the door speakers, and
• through rear speaker amplifier terminals @, @, ® and ®
• to the rear speakers.
WITH BASE AUDIO SYSTEM
Power is supplied at all times:
• through 1OA fuse (No. ,~ , located in the fuse block)
• to radio and cassette player terminal ®.
With the ignition switch in the ACC or ON position, power is supplied:
• through 1OA fuse (No. [QJ , located in the fuse block)
• to radio and cassette player terminal @.
Ground is supplied through the case of the radio and cassette player.
When the system is on, audio signals are supplied:
• through radio and cassette player terminals (i), ®. @, and @)
• to the door speakers, and
• through radio and cassette player terminals @, @, @ and @ (with rear speakers)
• to the rear speakers (with rear speakers).

1168 EL-102
 "tl
I ::0
I BATTERY I I BATTERY I
IGNITION SWITCH
ACC or ON j m
I --.- s:
c:
s:
>
c:
FUSE
~FUSE ~FUSE
c
0
en
r--c ANTENNA -<
en
1I" WINDOW '=T7ROO
"V ANTENNA -1
m
s:
6 10

RADIO AND CASSETTE PLAYER

12 14 13 11 lf> 15 2 1 4 3 8 7
en
0
T ~

rr ·d
m .,~r-·
·---~~1
(II

r;-
.....
3 l>
c:
!!!.
0
w 1 : L_____ To !!lum!nat!on o· !2
l ---- i ' ---- ~
} system
0
l_
2 1 5 12 4 11 -
REAR SPEAKER AMPLIFIER
' '
3 10 8 9

~
REAR
8
REAR
8
DOOR
~
ODOR
SPEAKER SPEAKER SPEAKER SPEAKER
LH RH LH RH
,.m ,);

..,.
r
~
~
1169

lQl
?•i
~
~'-
ro
~~
;s:w
@0
(@
c.-:J
@])
~OJ r ,_-, ~
\<;!,'
le._=IJ
cc=J
'=UTI ~ ~
c---{J
~c~
IF
CijJ
iml ~~
r
0
LuJ
~
~
Jc~~
(~b
~
 AUDIO

Wiring Diagram -AUDIO-

PREMIUM AUDIO SYSTEM

IGNITION SWITCH EL-AUDI0-01

ACCorON

Refer to "EL-POWER".

15A 10A 10A

[!] [g§J 0
GNI R/B L
I I
lril~- ------- ----1~1@1§) WINDOW
Ic_,.,,-- ANTENNA "\. /ROD
'\ ANTENNA
'T' 'T' (~)
R/8

ffi ~ -!-
L

~LBA~T~--------~IG~N~------~L--------------------_ RADIO
AND
CASSETIE
PLAYER
I (M502) , CMW

REMOTE RR RR SHIELD RR RR
ON/OFF LH+ LH- GND RH+ RH-

~~~11!i=!J~~
LG/R

~~~mj~l ~~~
BR/B ORIL
L

n •n'j' ·~~~· •·i~l ~

Pt

W/L
B PU

W
LGt

OR

r_
I
r-----
----
· · - · - ·1 -----
---
. . .I
I I I I
I
I
I
I 1-----
I
I
I
I
I
I
I
I ----
I
I
I
I
*
~r ~ ~ ~
B GNI
----
OR/L W/L w
---- OR
mm
BR/B

GND BAT
m m
REMOTE RR
~
RR
rrtil ~
RR RR
REAR
SPEAKER
ON/OFF LH+ LH- RH+ RH- AMPLIFIER
(MJI~)
I

10 8 ~ 4 2 (M116) 16 c:::J 12 @ill) 120345@1j)

976531 w 15 14 13 11 w 6 7 8 9 10 11 12 w

r---------------------~

D 0 I
I 10 8 6 4 2 (~) 16 14 12 {~) I
: 9 7 5 3 1 w 15 13 11 w :
•---------------------~

AEL883A

1170 EL-104
 AUDIO
Wiring Diagram -AUDIO- (Cont'd)

EL-AUDI0-02

L©

r-= P/L · } To EL-ILL

I r·'"•
P/L P/B

lr!JI-Icf:JI ~;
AJL AN
ffim
..-------------"-T-J'--"---j--1!-, RADIO --------------,REAR
AND SPEAKER
CASSETTE AMPLIFIER
PLAYER (iill_;)
@QY
I
FA FA FA FA RR AR RR RR
LH+ LH- RH+ AH- LH+ LH- AH+ AH-

1!4dJ!bjdJ lbjdl~ ~~ ~11j:!l

PU LG+ L d G/B G GY/R GY
~ .-L. .-L. ~ (M501)
ll4Jf &jdJ----------- ~ -~@!9 I I+ I I+
PU
.-L.
LG
+ @j)
1!4Jft!4Jl@)
+ ~ <i!iWl
L p

~-1!4Jl(D102)
GIB G
_._, ~
GY/R GY
__._, .4,-.
1~1-1~1-----------lq::Jf~q::ll(@)
<Mill>

'~ DOOR
SPEAKER
LH
® t41\ DOOR
SPEAKER
RH
(0103)

t' ''
REAR
SPEAKER
LH
(i!:jQj)
REAR
SPEAKER
RH
(~)

I0 8
976531
= 4 2 (~) rW!,
W ttlli (Mill)
L
I 2 0 3 4 5
6 7 8 9 10 11 12
@Zi)
W
[[i]__(~ @Qj),@,(~)
ITJ B B 8 8

97531
0
10 8 6 4 2 (MS02)
w

AEL293A-B
•
EL-105 1171
 AUDIO
Wiring Diagram -AUDIO- (Cont'd)
BASE AUDIO SYSTEM

To EL-ILL
EL-AUDI0-03
~. With rear speakers without power options

Refer to ~
P/L P/B
~: With rear speakers with power options
'·EL-POWER".

I I WINDOW
L_,.-----,,--ANTENNA
..,...---,,-~ROD
ANTENNA

FA FA FA FA RR RR RR RR
LH + LH- RH + RH- LH + LH- RH+ RH-

lbjdllbjdl lbjdl~ ~ ~ lbiW

PU LG L p G/B GY/R GY@
w

r
OR/L W/L

--._ ~-oI+
._ I
~--<
!==~
0 RIL

m~
W/L
PW
0
!-o:>
w
ffi ~
OR

REAR SPEAKER

+<
OP
>I G/B c
~
GY AMPLIFIER
SHORTING
~ CONNECTOR
~~ (M179)
GY/R GY+ ®

- 1=1-+ 1-o
._

I I~
._

-~ G/8
I+
G GY/R GY

IE!JI--lc!Jt----------lc!Jt- -IE}JI~;
G/B G GY/R GY

~ ~ ~~~~KER ~rTJJ ~~ls~~~:KER

LH RH
@2]) (M302)

1 10 8 =
r------------------------~
4 2
I 9 7 6 5 3 1
@1§)
W
16 = 12
15 14 13 11
@1i)
W
I
:
r.1~2"o"~3r.4~5
6789101112
(illij)
®
w
~------------------------J

IIIL(M302)' @2])' @' (~)

CIJs B B B

AEL884A

1172 EL-106
 AUDIO

Trouble Diagnoses
Symptom Possible causes Repair order

Radio inoperative (no digital 1. 10A fuse L Check 1OA fuse (No. [QJ , located in fuse block). Turn igni-
display and no sound from tion switch ON and verity battery positive voltage is present
speakers). at terminal @ of radio.
2. Poor radio case ground 2. Check radio case ground.
3. Radio 3. Remove radio for repair.
Radio controls are operational, 1. Radio output L Check radio output voltages.
but no sound is heard from 2. Radio 2. Remove radio for repair.
any speaker.

Radio presets are lost when 1. 10A fuse 1. Check 10A fuse (No. [ZQ] , located in fuse block) and verify
ignition switch is turned OFF. battery positive voltage is present at terminal® of radio.
2. Radio 2. Remove rad1o for repair.
Rear speakers are inoperative. WITH REAR SPEAKER AMPLIFIER WITH REAR SPEAKER AMPLIFIER
1. Rear speaker amplifier 15A fuse 1. Check 1SA fuse {No. LlJ , located in the fuse block) and
®
verify battery positive voltage is present at terminal of
rear speaker amplifier.
2. Poor rear amplifier ground 2. Check rear amplifier ground @It> .
3. Rear speaker amplifier 3. Check rear speaker amplifier voltages.
4. Rear speaker amplifier circuit 4. Check wires for open or short between radio, rear speaker
amplifier and rear speakers.
5. Radio 5. Remove radio for repair.
WITHOUT REAR SPEAKER AMPLIFIER WITHOUT REAR SPEAKER AMPLIFIER
1. Radio output 1. Check radio output voltages.
2. Radio 2. Remove radio for repair.

Front speakers are 1. Radio output 1. Check radio ouput voltages.

inoperative. 2. Radio 2. Remove radio for repair.
Individual speaker is noisy or 1. Speaker 1. Check speaker.
inoperative. 2. Radio/amplifier output 2. Check radio/amplifier output voltages.
3. Speaker circuit 3. Check wires for open or short between radio/amplifier and
speaker.
4. Radio 4. Remove radio for repair.
AM stations are weak or noisy 1. Antenna 1. Check antenna.
(FM stations OK). 2. Poor radio ground 2. Check radio ground.
3. Radio 3. Remove radio for repair.
FM stations are weak or noisy 1. Window antenna 1. Check window antenna.
(AM stations OK). 2. Radio 2. Remove radio for repair.

Radio generates noise in AM 1. Poor radio ground 1. Check radio ground.

and FM modes with engine 2. Loose or missing ground bonding straps 2. Check ground bonding straps.
running 3. Ignition condenser 3. Replace ignition condenser.
4. Generator 4. Check generator.
5. Ignition coil or secondary wiring 5. Check ignition coil and secondary wiring.
6. Radio 6. Remove radio for repair.

Radio generates noise in AM 1. Poor radio ground 1. Check radio ground.

and FM modes with accesso- 2. Antenna 2. Check antenna.
ries on (switch pops and motor 3. Accessory ground 3. Check accessory ground.
noise). 4. Faulty accessory 4. Replace accessory.

•
EL-107 1173
 AUDIO
Trouble Diagnoses (Cont'd)
SPEAKER INSPECTION
1. Disconnect speaker harness connector.
2. Measure the resistance between speaker terminals G) and @.
• The resistance should be 2-4 n
3. Using jumper wires, momentarily connect a 9V battery between speaker terminals G) and @.
• A momentary hum or pop should be heard
ANTENNA INSPECTION
Using a jumper wire, clip an auxiliary ground between antenna and body.
• If reception improves, check antenna ground (at body surface)
• If reception does not improve, check main feeder cable for short circuit or open circuit.
RADIO AND AMPLIFIER INSPECTION
All voltage inspections are made with:
• Ignition switch ON or ACC
• Radio ON
• Radio and amplifier connected (If either is removed for inspection, supply a ground to the case using a
jumper wire.)
RADIO VOLTAGES AMPLIFIER VOLTAGES
Voltage (V) Terminal Voltage (V)
Terminal Base Audio Premium Audio 1 10.8- 15.6
System System
2 10.8. 15.6
1 5- 7.5 2.5 - 6.5
3 4.5. 8.5
2 5- 7.5 2.5. 6.5
3 5 -7.5 2.5- 6.5 4 2.5- 6.5
4 5- 7.5 2.5 - 6.5 5 2.5 - 6.5
5 - - 6 -

6 10.8- 15.6 10.8- 15.6

7 0
7 - -
8 - - 8 4.5- 8.5
g - - g 4.5 - 8.5
10 10.8. 15.6 10.8. t5.6 10 4.5. 8.5
t1 - 0
11 2.5- 6.5
t2 - 10.8- 15.6
13 5. 7.5 2.5- 6.5 12 2.5- 6.5
14 5- 7.5 2.5. 6.5
t5 5- 7.5 2.5- 6.5
16 5. 7.5 2.5- 6.5

1174 EL-108
 ANTENNA

Location of Antenna

Fender antenna replacement

oRemoval
Window antenna
1. Remove one screw securing
(if equipped)
fender antenna assembly.
2. Disconnect fender antenna
cable connector.
3. Remove the fender antenna assembly.
~~=+==~~
Fender antenna

Fender anl'e"''" --

Window antenna
(if equipped)

l[

go
Window antenna
Fender antenna
cable connector
cable connector
(if equipped)

AEL378A
•
EL-109 1175
 ANTENNA

Window Antenna Repair

I 1 ELEMENT CHECK

c/---}1 I
1. Attach probe circuit tester (in ohm range) to each side of
antenna terminal.
I
Ohmmeter

[ill
J
SEL2501

2. If an element is broken, no continuity will exist.

f Breakpoint
I
1/1
I
,
1 / I

I
'
Ohmmeter

[ill
( )
No continuity

j Breakpoint
I
I
I / I
j

(_o"(§t'
'"--
Continuity exist
'
)

SEL2521

3. To locate a burned out point, move probe along filament. Tester

needle swings abruptly at the burned point.

:1~1
I ~-

I
'
Ohmmeter

[ill
l )
SEL2531

1176 EL-110
 ANTENNA
Window Antenna Repair (Cont'd)
ELEMENT REPAIR ~I
Repair equipment
1. Conductive silver composition (Dupont No. 4817 or equivalent) ~/(ilk
2. Ruler 30 em (11.8 in) long
3. Drawing pen
4. H~gun m
5. Alcohol
6. Cloth

Repairing procedure ~!:

Heat wire\ 1. Wipe broken heat wire and its surrounding area clean with a
cloth dampened in alcohol. F~
2. Apply a small amount of conductive silver composition to tip of
drawing pen.
Shake silver composition container before use. ©i~
3. Place ruler on glass along broken line. Deposit conductive sil-
Ruler
ver composition on break with drawing pen. Slightly overlap
Unit: mm (in) existing heat wire on both sides [preferably 5 mm (0.20 in)] of IT\11"'
Drawing pen
the break.
BE540 4. After repair has been completed, check repaired wire for con-
tinuity. This check should be conducted 10 minutes after silver ~~11
rrR epa1re d po1nt composition is deposited.
Do not touch repaired area while test is being conducted .
.l

ILl
1..@--'-
SEL012D

IR1if\
5. Apply a constant stream of hot air directly to the repaired area
,-----~ Repaired point
for approximately 20 minutes with a heat gun. A minimum dis-
tance of 3 em (1.2 in) should be kept between repaired area 11lll'i
and hot air outlet. If a heat gun is not available, let the repaired
area dry for 24 hours.

SEL013D

EL-111 1177
 MIRROR

Wiring Diagram -MIRROR-

EL-MIRROR-01
Jl_1_jl (M143)
=r(@§)
8/L Refer to "EL -POWER"

rfl10A
LtJIT:l
G/R
~~· t<@:s)
GIR
""""
~
DOOR

LGIR~t-
MIRROR SWITCH MIRROR
SWITCH
CHANGEOVER SWITCH @
--B~~ ~

•
N/
R
-~ ... ~. ,i-L ,_'e
'
D

___________!__
N/
- U
'
--------~-~~
D
N/
---'lU
R. . L
'
D

j
-·- -·-
L
N

L
---R ----- ---
N

lbjdl ~ ~~ ~
B G/B GM/ G/OR G!Y UOR

~~~--------------1~~-----------------------------------------~~~--j~,--,~~--joeo,;~;

llw.{Y
B G/8 GNI G/OR GIY UOR

JOINT
CONNECTOR-2

W
~
@W

.... G/Y~
B
.... G/OR~ Next
page

...I ,
Gtw{g>
G/8~

IB IB B
.............. ~
<~><Mf2i><till9>

Refer to last page (Foldout page)

@W
(~).@
[J
12345@
678910 w

AEL894A

1178 EL-112
 MIRROR
Wiring Diagram -MIRROR- (Cont'd)

EL-MIRROR-02 uliJ&,

~ · With power windows

<&uoR
-<9-G/Y
...... @:Wnho ut power windows

Preceding
page <:€1-G/OR
......
...... -
~G/W
<@oGIB
......
p
0
I ·- - -
I

~ @)
G!Y + If If
@!ci:J!<~>
G!Y
G!Y
@)
G!Y G/W
!~!@
@) I~I<MW
G/W
@)
G/W

G/W
GIB
!cfl!@
G/B
@)
G/B
lcfJI<MW
G/B
@)
~IL

~
+
-8-1 + + p
0 0
t

R._-+-L R~_..L

@)
"'""''"""o""s,.,..,, ®
5 6 7 8 9 10 w

AEL280A-B

EL-113 1179
 AUTOMATIC SPEED CONTROL DEVICE (ASCD)

Component Parts and Harness Connector

Location I!J ASCD main switch
IJI ASCD control unit ASCD steering switch
Indicator lamp

IJ Relay box

l'!J ASCD brake switch

Stop lamp switch
ASCD clutch switch

OJ ASCD hold relay

IJASCDpump

Inhibitor relay ASCD actuator

,.- S"op lao'p switch

ASCD brake
switch

ASCD main switch

Steering column

1180 EL-114
 AUTOMATIC SPEED CONTROL DEVICE (ASCD)

System Description
Refer to Owner's Manual for ASCD operating instructions.
When the ignition switch is in the ON or START position, power is supplied:
• through 1OA fuse (No. IIIl , located in the fuse block)
• to ASCD brake switch terminal ® (AfT models)
• to ASCD main switch terminal ® and
• to ASCD hold relay terminal ® (MIT models) or
• to ASCD hold relay terminal ® (AfT models).
With brake pedal released, power remains supplied:
• through ASCD brake switch terminal CD (AfT models) and
• to ASCD hold relay terminal ® (AfT models).
When ASCD main switch is in the ON position, power is supplied:
• from terminal ® of the ASCD main switch
• to ASCD control unit terminal 0 and
• from terminal CD of the ASCD main switch
• to ASCD hold relay terminal ® (MIT models) or
• to ASCD hold relay terminal CD (AfT models).
Ground is supplied:
• to ASCD hold relay terminal CD (MIT models) or
• to ASCD hold relay terminal ® (AfT models)
• through body grounds @ , @ED and ~ .
With power and ground supplied, the ASCD hold relay is activated, and power is supplied: [0Jll
• from terminal ® of the ASCD hold relay (MIT models) or
• from terminal ® of the ASCD hold relay (AfT models)
• to ASCD main switch terminal ®.
• to ASCD control unit terminal 0 and
• to ASCD clutch switch terminal CD (MIT models) or
• from terminal 0 of the ASCD hold relay (AfT models)
• to inhibitor relay terminal ® (AfT models).
When the ASCD main switch is released to the N (neutral) position, power remains supplied:
• to ASCD hold relay terminal ® (MIT models) or
• to ASCD hold relay terminal CD (AfT models)
• from ASCD main switch terminal CD.
• Ground is supplied:
• to ASCD control unit terminal ®
• through body grounds @ , @ED and ~ .
Inputs
At this point, the system is ready to activate or deactivate, based on inputs from the following:
• speedometer in the combination meter
• stop lamp switch
• ASCD steering switch
• inhibitor relay (AfT models)
• ASCD clutch switch (MIT models) and
• ASCD brake switch.
A vehicle speed input is supplied:
• to ASCD control unit terminal 0
• from terminal 0 of the combination meter.
Power is supplied at all times:
• to stop lamp switch terminal CD
• through 1OA fuse (No. U~ , located in the fuse block).
When the brake pedal is depressed, power is supplied:
• from terminal ® of the stop lamp switch
• to ASCD control unit terminal @.
Power is supplied at all times:
• through 1OA fuse (No. lj] , located in the fuse block)
• to horn relay terminal ®
• through terminal CD of the horn relay
• to ASCD steering switch terminal @.

EL-115 1181
 AUTOMATIC SPEED CONTROL DEVICE (ASCD)
System Description (Cont'd)
When the SET/COAST button is depressed, power is supplied:
• from terminal @ of the ASCD steering switch
• to ASCD control unit terminal ®.
When the RESUME/ACCEL button is depressed, power is supplied:
• from terminal @ of the ASCD steering switch
• to ASCD control unit terminal G).
When the CANCEL button is depressed, power is supplied:
• to ASCD control unit terminals G) and ®.
When the system is activated, power is supplied:
• to ASCD control unit terminal ®.
Power is interrupted when:
• the shift lever is placed in P or N (AfT models)
• the clutch pedal is depressed (MIT models) or
• the brake pedal is depressed.
Outputs
The ASCD pump controls the throttle drum via the ASCD wire based on inputs from the ASCD control unit.
The ASCD pump consists of a vacuum motor, an air valve, and a release valve.
Power is supplied:
• from terminal ® of the ASCD control unit
• to ASCD pump terminal @.
Ground is supplied to the vacuum motor:
• from terminal ® of the ASCD control unit
• to ASCD pump terminal @.
Ground is supplied to the air valve:
• from terminal @ of the ASCD control unit
• to ASCD pump terminal G).
Ground is supplied to the release valve:
• from terminal @ of the ASCD control unit
• to ASCD pump terminal @.
When the system is activated, power is supplied:
• from terminal @ of the ASCD control unit
• to combination meter terminal @.
Ground is supplied:
• to combination meter terminal @
• through body grounds ® , ~ and ~ .
With power and ground supplied, the CRUISE indicator illuminates.
When vehicle speed is approximately 8 km/h (5 MPH) below set speed on AfT models, ground is supplied:
• to terminal ® of the solenoid valve unit
• from ASCD control unit terminal @.
When this occurs, the overdrive is canceled.
When vehicle speed reaches approximately 3 km/h (2 MPH) above set speed, overdrive is reactivated.

1182 EL-116
 BAT~ERY I
IGNITION SWITCH
ON or START 0 AIT mode I$

0
~FUSE
'1/T mode Is

~FUSE ~FUSF ASCD MAIN

swi~cH

'--iOFFi N I ON

2
6 )>
1 c
ASCD STEERING
SWITCH 3 d
s:
~
n STOP -
lnf!1HORN
RESUME/ACCEL
~RELAY LAMP
UISWITCHr-~"-
}To '"um<nec<un
,----"= ~-.-f---.
ASCD 5
system
~
'---H--o
=
CANCEL
0-0/V-
ASCD
HOLD
HOLD
RELAY I ~
= INHIBITOR
SWITCH
0
sET/coAsl
RELAY
A 1
PRND2
en
"'C
,--+L-;;=;;___.-+~ 2
en
0 m
:::r m
m CD c
3
......'
r- Ill
(')
0
~To
~• To
horn ~wl'~'~c~H~l__l_-ol_ _ _ _ _ _ _ _ _ _~--------------~
!:!:
0 z
...... L__ _ _ _ horn / l 11 4 ASCD
CLUTCH
INHTRITOR
RFI AY
-1
SWITCil :I:I
r-------------~,
0
ASCD CONTROL UNIT A r-
5 M c
13
m
p1
12 3 14 10 9 8 ASCD

A)----+----- BRAKE
SWITCH <
To
over-- 0_) 0
drive
= m
I1~1
C:iV l ~
switch

III
ASCD

II CRUISE IMETER
COMBINATION
OVER- SOLENOID
I
PUMP
I)>
SPEED-
DRIVE
CANCEL ,
VALVE
UNIT
VACUUM
MOTOR en
OMETER
-®---- (')
~
SOLENOID
VALVE
AIR
VALVE
,,_.
c
I ~
~ ~ RELEASE
VALVE

~'
"-':)
,.m VEHICLE
SPEED
SENSOR
'----,.---0
To lllumlnatlon
system

~
1183

~ lrJ~oJ ?:] Ci'!i> ]:~J 2ill

j~ ~ ~
~ IT ~~)) "l-ril [iUi; IF liiiiJ 9;
~
c~
9 rQ!i; ~ ::[pJ 2~"0 e Uil
~ IF em (F,2J c-] &;
 AUTOMATIC SPEED CONTROL DEVICE (ASCD)

Wiring Diagram -ASCD-

EL-ASCD-01

Refer to <:];> · AfT models

10A '"EL-POWER". <M) : Mff models
QIJ
W/B I1- - - - - - - - - - - - - - - - - - • • • ..- ..r::-..._
~page Next W/B

~0----~ --
W/8 ~8 BR

~ JOINT IICflf
~~ ----------="=~2 ~
IIB2llr.;:-"\
...ttl.;
r ....PIL ..0. To
EL-ILL
CONNEC- W/B BR P/L
TOR-2
(iillj)ffi ffi ffi
lhjidl
W/8
F-----"r--------"'t=========:;-"l'-----l ASCD
-------------- MAIN
OFF. ON OFF. ON SWITCH
' .,... ' ASCD MAIN ILLUMI- (@
SWITCH NATION
N N INDICATOR

®~
~B~Bl
WIB

ffi
,-----~~----,ASCD
8

ffi
BRAKE JOINT
SWITCH CONNECTOR-2
@1>0 (M142)

W!B BR l!4JI
8

U
fflASCD
HOLD
RELAY
(~l®

~lbjdl
BfoN B

_f-j. --
.~o.8ffl~1Next
. ._ _ _ _ _ _ _ _ _ _ _ _ _ _ _•BNV ~Jpage

Refer to last page (Foldout page).

€®
(iill_S). (ill)

D
2 3 4@)
6 7 8 L

AEL886A

1184 EL-118
 AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Wiring Diagram -ASCD- (Cont'd)

EL-ASCD-02
4w1s - - - - - - - - - - - - - - - -To-EL-- - - - - - - - - .
START
Preceding
page .......-cL
~ B/W - - - - - - - - - - - - -. . G)>: AfT models
t <B): MIT models
<& BIW - - - - - -. . B/P

..__•Q • W78 .J[)--..._ To

~ EL-ASCD-04
l___ ee
ll:;J

-
....-....-.--o
<f
BIW
A

.-------"-1.;-~"-I----,
Biv 1.;;;;,
ASCD
CLUTCH
SWITCH DEPRESSED -\RELEASED ...
To EL-
.-----"';='-'----, INHIBITOR
SWITCH
(M140),@ START
(~)@
•~--
Jar
~
GN

¢GN
~
y

.--"1--i-~-"-1----, A

ASCD
BRAKE
RELEASED SWITCH
(~),@
A

~
UY

<fO•uv
......
I
BIW

m
MAIN
sw
m
UY

BRAKE N.C.
sw
ASCD
CONTROL
UNIT
B
~
r·-·
I I B
~
B
-"-
(~) (~) (M~OS) @2iJ

Et=ffitt~~alt9:E~
@
@ 121310 3 9 1 2 ~ JQL@ w,n,w1•0
®
GY 14 8 4 5 7 11 B o:::ITJ L L

AEL887A

EL-119 1185
 AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Wiring Diagram -ASCD- (Cont'd)

__.................
BATTERY

I -
r"'
R
R. ~~-HORN
EL-ASCD-03

Refer to ~
~~~--------------------------,Asco

~&J
"EL-POWER"
10A
STEERING
SWITCH
[iii
<llii>
RIB UG ON
ffi
r-----~~-----,STOP HORN

C
SET/ CANCEL RESUME/
LAMP RELAY SWITCH ACCEL
SWITCH COAST
(~) SWITCH SWITCH
RELEASED @2§)
DEPRESSED

l!:jdJ l1:j:!J ~t-HORN

LG/B LGNI .. ~ eyJ ~

Lr I R

R
LB

I
LB
Y

I
Y

--------~~r-----------------1~1~~~

To
BR-ABS . G I Y • •
EL-TAIUL

I
y

~~~---------lc!!Jl-----------------j~l~~~
LG/B Y Y/L
.___.___~+ I
y
I
G!Y YIL

~ ffi ffi
BRAKE SET/ RES/ ASCD
N.O COAST ACC CONTROL
SW sw sw UNIT
(~)

~@ 12 13 1013 91 11 2 @g§) 12034~

t:ill:J GY 14 8 4 5 7 11 B 5 6 7 8 9 iO W

~--------------------~
: OIQJ}](M135) ____[JJJ_(~):
I ~ W CJTIII1ill1 B I
L-------------------1

AEL899A

1186 EL-120
 AUTOMATIC SPEED CONTROL DEVICE {ASCD)
Wiring Diagram -ASCD- {Cont'd)

To ~ _. _. ~
EL-ASCD-02~W!B •Q-<E}i~WJB-,.Y-- Next page EL-ASCD-04
I
WIB
I ~
!VEHICLE
SPEED SENSOR
<I) : NT models
~ @)
b~:ECTOR-2 l!:jJJ l!4J1
@W W R

~ !EiJ~-------!~1~~~
W/8
~
I!:fill------------- ~
W
~@
1~r----- --1~1®
R
r PIL . . To EL-ILL

W/B W R PIL

~ ~ ~ rr!iJ COMBINATION
I I I CRUISE INDICATOR
METER
@,@,
I
--& ...
SPEEDOMETER LAMP
@,@

:~
~~ILL.
~ ~ ~
8
I!4Jl
WIL BN

I ..
8
I!4Jl
PIB

L
l$--------~~
WIL BIY
LP/8 . T o EL-ILL

I I
@)@

+ ·-8~8--,

m
WIL
7 ~BIY
13 w JOINT

8
..-:-;;!:-;:::!';,---;;!,;;:'£,-,ASCD CONNECTOR-2
VEHICLE CRUISE CONTROL ()illY
SPEED LAMP UNIT
SENSOR
@W ~
GND

~
... I
-----oiiiiii.----·-··
8

•8 •
8 8
...._ ....... -:!.-
(M~9) CM~os) ('i,j~§ol
Refer to last page (Foldout page).

Et=ffi'2~'~,~~E'~"EIE'~2~
()illY
~(EJS) ~(M43) @,@)
Uill GY ~GY 14 8 4 5 7 11 8

12 11 10 0 9 8 7 @
654 321 B

AEL291A-D

EL-121 1187
 AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Wiring Diagram -ASCD- (Cont'd)

EL-ASCD-05
Preceding __..-fL.w;s ..,..
page ~

<:E) : NT models

WIG

IL..ii:i...e-
-- WIG . . ToAT-Aff

~
WIG

----------------~~~~,~~---------------.
,--- OD ASCD
CANCEL CONTROL
SIGNAL UNIT
@1§)

PUMP VACUUM AIR RELEASE

POWER MOTOR VALVE VALVE

~ ~ ~
W/8 WIPU WIL

W W/B W/PU W/L

m ~
r-~~------~~~----~~~------~~-----,ASCD
m ffi
PUMP
(~)
VACUUM AIR
MOTOR VALVE

Gflt:lCM27) &(M60)
=
~~12~1~3~10~7p9~~1~2,@1§)
GY WGv 14 8 4 5 7 11 B

AEL888A

1188 EL-122
 AUTOMATIC SPEED CONTROL DEVICE (ASCD)

CRUISE indicator operation Trouble Diagnoses

0.2 FAIL-SAFE SYSTEM
When the fail-safe system senses a malfunction, it deactivates loiffi\
ON - ASCD operation. The CRUISE indicator in the combination meter
will then flash.

OFF-

0.4
Unit_ seconds
SEL546T

Malfunction detection conditions

ASCD operation during

Detection conditions
malfunction detection
e ASCD steering (RESUMEIACCEL, CANCEL. SET/COAST) switch is stuck. • ASCD is deactivated.
• Vacuum motor ground circuit or power circuit is open or shorted. • Vehicle speed memory is can-
• Air valve ground circuit or power circuit is open or shorted. celed.
• Release valve ground circuit or power circuit is open or shorted.
• Vehicle speed sensor is faulty.
• ASCD control unit internal circuit is malfunctioning.

• ASCD brake switch or stop lamp switch is faulty. • ASCD is deactivated.

• Vehicle speed memory is not ~~l
canceled.

f)'

EL-123 1189
 AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Trouble Diagnoses (Cont'd)
Fail-safe system check
Does indicator lamp blink when ASCD Yes Go to DIAGNOSTIC PRO-
main switch is turned ON again? ~ CEDURE 5 (ASCD
STEERING SWITCH
No
CHECK), EL-129.

OK

Drive vehicle, and turn ASCD main switch

to ON.

Does indicator lamp blink when SET/ Yes Go to DIAGNOSTIC PRO-

_______.
COAST switch is pushed? CEDURE 7 (ASCD
ACTUATOR CHECK),
No
EL-131.

OK

Go to DIAGNOSTIC PRO-
CEDURE 6 (VEHICLE
SPEED SENSOR
CHECK), EL-130.

OK

Replace ASCD control unit.

Does indicator lamp blink when brake No

_______. System is OK.
pedal is depressed slowly? Check system again.
(Brake pedal should be depressed for at
least 5 seconds.)

Yes

Go to DIAGNOSTIC PROCEDURE 4
(ASCD BRAKE SWITCH CHECK),
EL-128.

1190 EL-124
 AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Trouble Diagnoses (Cont'd)
SYMPTOM CHART
PROCEDURE - Diagnostic procedure
REFERENCE PAGE EL-124 EL-126 EL-126 EL-127 EL-128 EL-129 EL-130 EL-131 EL-132
52
0
w
I 52
0 0
r- w
I
5 0
0 I
a: 0
0 r- 52 52
0 0 52
0
z ~ w w 0
52 w I I 52 w
::J 0 a:>O r--- 0 "'I
~

w 0
N
wO "'52
wo "a: w
w "'
WI wa: w Iw wo
SYMPTOM a:
::J
a:
(-')
a:w
::oi
00
a:w
::JI ""'
::J a:
O<Il
a:o
:or-
o-
a:o
::ow
a:
::J 0
a:o._
::0::;;
0 0 00 oz 0 r- O::o
-"'
u w z w I w,_ wo w>: ww w-
o::o Wo._
w 0 0 0 0<( Oz ow OW 0 -
.c
u 0
a: "'
Q_o._
0 r-
a:
Q_ ~
0--'
a:w
o._a:
0<(
a: I
0(-')
a:z
Q_-
Oo
a:w
oo
a:~
o._O
on:
a:O
E
on_ "' 0 z
w
00
o._o D-w
OD- oD-
Q_~
0::0
*"'" -::0 ---'
Or- offi -::;;
>-w >= >-o f=::J i=~ f=W >-::o i=tJ ©IL
wa: w <( W--' WW
ow 0 ::;; 8I oo 8w 0--' 8Q_ 8«
Z:;: zo zo zo zo z<;! zo zo
'*
.'!'
~
LL
~0
-o._
o_
(')O
<:W
-"'
0-
CJO
<:W
-<(
0-
CJO
<(W
-"'
o_
(-')0
<:w
-<:
0-
(')I
<:W
->
0 -
(')O
~~
0-
(-')0
<:w
-<:
0-
ASCD cannot be set. ("CRUISE"
X X X X X
indicator lamp does not blink.)
ASCD cannot be set. ("CRUISE"
X X X X X
indicator lamp blinks. '"1)
Vehicle speed does not decrease
after SET/COAST switch has been X X
pressed.
Vehicle speed does not return to the
set speed affer RESUME/ACCEL X X
switch has been pressed. ~2
Vehicle speed does not increase
after RESUME/ACCEL switch has X X
been pressed.
System is not released after CAN-
CEL switch (steering) has been X X
pressed.
Large difference between set speed
X
and actual vehicle speed.
Deceleration is greatest immediately
X
after ASCD has been set.

*1: It indicates that system is in fail-safe.

"2: If vehicle speed is greater than 48 km/h (30 MPH) after system has been released, pressing RESUMEIACCEL switch returns
vehicle speed to the set speed previously achieved. However, doing so when the ASCD main switch is turned to OFF vehicle
speed will not return to the set speed since the memory is canceled.

EL-125 1191
 AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Trouble Diagnoses (Cont'd)
DIAGNOSTIC PROCEDURE 1
~~~ ASCD control unit connector ~
(POWER SUPPLY AND GROUND CIRCUIT CHECK)
DISCONNECT

10
00
II
4

~
8/W
II
1. Turn ignition switch ON.
2. Turn ASCD main switch ON to make
sure indicators illuminate.

OK
-
NG Go to DIAGNOSTIC PRO-
CEDURE 2 (ASCD MAIN
SWITCH CHECK).

~ ~ ~
AEL3BOA
m
CHECK POWER SUPPLY CIRCUIT FOR
ASCD CONTROL UNIT. ~ Go to DIAGNOSTIC PRO-
CEDURE 3 (ASCD HOLD

m ASCD control unit connector @> 1. Disconnect ASCD control unit con nee-
tor.
RELAY CIRCUIT CHECK),
EL-127.

~i5 2. Turn ignition switch ON.

3. Turn ASCD main switch ON.
4. Check voltage between ASCD control
IIIII [ill IIIII unit connector terminal @) and body
B ground.
Battery voltage should exist.

TITIJI
fo Q. -,;-
m
OK

AEL381A
CHECK GROUND CIRCUIT FOR ASCD ~ Repair harness.
CONTROL UNIT.
Check continuity between ASCD control
unit harness terminal @ and body
ground.

l OK

Go to next procedure.

m DIAGNOSTIC PROCEDURE 2
~
ASCD main switch
connector@ (ASCD MAIN SWITCH CHECK)
m
-
OISCONNEGT

10 B
NG

00 ffiE
CHECK POWER SUPPLY FOR ASCD Check the following:
MAIN SWITCH. • 1OA fuse (No. [j],
1. Disconnect main switch connector. located in the fuse
W/B 2. Measure voltage between main switch block)
®
~
harness terminals and @. • Harness for open or
Battery voltage should exist. short between fuse and
AEL382A ASCD main switch
OK
• Ground circuit for ASCD
main switch

~
Check ASCD main switch. Refer to Replace ASCD main
EL-134. switch.

~OK
Go to next procedure.

1192 EL-126
 AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Trouble Diagnoses (Cont'd)
m ASCD hold relay connector DIAGNOSTIC PROCEDURE 3

rir MIT models

5 ~
m
(ASCD HOLD RELAY CIRCUIT CHECK)

-
3~
W/B
CHECK POWER SUPPLY CIRCUIT FOR No Check harness for open or
WIB

~
ASCD HOLD RELAY. short between fuse and
+A- 1. Disconnect ASCD hold relay. ASCD hold relay.
2. Do approx. 12 volts exist between
®
[!ji()@) ~
AEL383A
ASCD hold relay harness terminal
(MIT models) or @ (AIT models) and
body ground?

m ASCD hold relay connector Yes

AfT models@
Mw'·~ m
lfrs B CHECK GROUND CIRCUIT FOR ASCD
HOLD RELAY.
~- Repair harness.

Does continuity exist between ASCD hold

[ill relay harness terminal G) (MIT models)
or® (AIT models) and body ground?

~IV @a ~

AEL384A [!]
Yes

[!] ASCD hold relay connector CHECK ASCD HOLD RELAY CIRCUIT. ~ Check ASCD hold relay.
Does continuity exist between ASCD hold
AfT models~ MIT models~

1lB relay harness terminals ® and @ (MIT

(~1
models) or CD and ® (AIT models)?

g~
BR

No

CHECK ASCD MAIN SWITCH.

Refer to EL·134. ~ Replace ASCD main
switch.

~~()~ AEL385A
OK

j Go to next procedure.

EL-127 1193
 AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Trouble Diagnoses (Cont'd)
DIAGNOSTIC PROCEDURE 4
~~ ASCD control unit connector ~
(ASCD CLUTCH AND BRAKE SWITCH CHECK)
OISCDNI~ECT
3 ~
18 II 5
CHECK CUT-OFF CIRCUIT FOR ASCD
NG
Check the following:

?
B

00 CONTROL UNIT.
1. Disconnect ASCD control unit connec-
tor.
• ASCD brake switch
Refer to EL-134.
• ASCD clutch switch (Mrr
[YJ 2. Turn ignition switch ON. models)
3. Turn ASCD main switch ON. Refer to EL-134.
~f..-.--- 4. Measure voltage between ASCD con- • Inhibitor switch (AIT
AEL386A trol unit connector terminals ®and models)
@ Refer to EL-134.

m When brake pedal or clutch pedal • ASCD hold relay

-~ ASCD control unit connector @ (MIT) is depressed or AfT selector Refer to EL-27.

DISCDNNFGT
G/Y
,,
r;==;1

II
lever is in ("N") or ("P") position:
Approx. OV
• Inhibitor relay
(Arr models)

IV 11
B
When both brake pedal and clutch
pedal (MIT) are released or AfT
selector lever is in any position
Refer to EL-27.
• Harness for open or
short
other than ("N") or ("P"):
Battery voltage should exist.

[YJ TOK
~'----
m
AEL387A CHECK STOP LAMP SWITCH CIRCUIT. __.
NG
Check the following:
1. Disconnect ASCD control unit connec- • Harness for open or
tor. short between ASCD
2. Check voltage between ASCD control control unit and stop
unit harness terminals @ and @. lamp switch
• 1OA fuse (No. [I]],
Voltage
Condition located in the fuse block)
[V]
• Stop lamp switch
Stop lamp I Depressed Approx. 12 Refer to EL-134.
switch I Released 0

l OK
Stop lamp switch is OK.

1194 EL-128
 AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Trouble Diagnoses (Cont'd)
DIAGNOSTIC PROCEDURE 5
m~ ASCD control unit connector §
{ASCD STEERING SWITCH CHECK)
y

l m
-
DISGOriNEGI 3
II"
IV Y/L B
I
CHECK ASCD STEERING SWITCH CIR-
CUlT FOR ASCD CONTROL UNIT.
OK
ASCO steering switch is
OK.
r-"" 1. Disconnect ASCD control unit con nee-
tor.

a
2. Check voltage between ASCD control
unit harness terminals.

Terminal No. Switch condition

AEL388A
EiJ 8 Pressed Released
SET/
COAST ® ® 12V OV
sw
RESUME/
ACCSW
Q) ® 12V ov
CANCEL ® ® 12V ov
sw Q) ® 12V ov

~ NG
CHECK POWER SUPPLY FOR ASCD ~ Check the following:
STEERING SWITCH. • 1OA fuse (No. lfii.
Does horn work? located in the fuse block)
• Horn relay
Yes • Harness for open or
short

NG
CHECK ASCD STEERING SWITCH. Replace ASCD steering
Refer to "ELECTRICAL COMPONENTS switch.
INSPECTION"". EL-134.

~OK
Check harness for open or short between
ASCD steering switch and ASCD control
unit.

Ill
EL-129 1195
 AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Trouble Diagnoses (Cont'd)
~ DIAGNOSTIC PROCEDURE 6
l:ld
DISCONNECT
ASCO control unit connector @)

W/L 3
~
(VEHICLE SPEED SENSOR CHECK)

IV 7
8 CHECK VEHICLE SPEED SENSOR ~ Vehicle speed sensor is OK.

00 CIRCUIT.
1. Insert wheel chocks and jack up
rear of vehicle.
[YJ 2. Disconnect ASCD control unit con-
+ - nectar.
AEL390A 3. Connect voltmeter between ASCD
control unit harness terminals 0
and@.
4. Slowly turn rear wheel.
5. Check deflection of voltmeter
pointer.
Note:
Before performing this procedure,
set transfer shift lever to 2WD posi~
lion. (4WD models)

NG

~
Does speedometer operate normally? Check speedometer and
vehicle speed sensor circuit.
Yes
Refer to EL-72.

Check harness for open or short

between ASCD control unit terminal
0 and combination meter terminal
0.

1196 EL-130
 AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Trouble Diagnoses (Cont'd)
r.iJ DIAGNOSTIC PROCEDURE 7
ASCD pump connector ®
(ASCD PUMP CIRCUIT CHECK)
~~iv r.iJ
1. 3. 4 CHECK ASCD PUMP. ~ Replace ASCD pump.
2 ~

1. Disconnect ASCD pump connector. I

laJ AEL902A
2. Measure resistance between ASCD
pump terminals

®
Terminals
CD
and @.

®
CD
®.@.
Resistance [n]

Approx. 3

Approx. 65
ll·©

@ Approx. 65

~OK
Check harness for open or short between
ASCD pump and ASCD control unit.

EL-131 1197
 AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Trouble Diagnoses (Cont'd)
DIAGNOSTIC PROCEDURE 8
ASCD actuator
ASCD wire
Vacuum hose {ASCD ACTUATOR/PUMP CHECK)

CHECK VACUUM HOSE. NG Repair or replace hose.

Check vacuum hose (between ASCD
actuator and ASCD pump) for breakage,
cracks or fracture.

ASCD pump OK
MEL402G
CHECK ASCD WIRE. NG Repair or replace wire.
Check wire for improper installation, rust Refer to "ASCD WIRE
formation or breaks. ADJUSTMENT'. (EL-133).

OK

CHECK ASCD ACTUATOR. NG Replace ASCD actuator.

1. Disconnect vacuum hose from ASCD
actuator.
2. Apply ·40 kPa (·0.400 bar. -0.41
Hand vacuum pump kg/cm 2 , -5.8 psi) vacuum to ASCD
actuator with hand vacuum pump.
MEL403G
ASCD wire should move to pull throttle
drum.
3. Wait 10 seconds and check for
decrease in vacuum pressure.
Vacuum pressure decrease:
ASCD pump Less than 2.7 kPa (0.0270 bar, 0.028
kglem 2 , 0.39 psi)

OK

CHECK ASCD PUMP. NG Replace ASCD pump.

1. Disconnect vacuum hose from ASCD
pump and ASCD pump connector.
2. If necessary remove ASCD pump.
3. Connect vacuum gauge to ASCD pump.
4. Apply 12V direct current to ASCD pump
and check operation.

i5 12V direct current sup-

ply terminals

Ell 8
Operation

ASCDpump
connector @J Air valve CD Close

Release
valve @ @) Close

AEL903A Vacuum
motor
@) Operate

A vacuum pressure of at least -35 kPa

(-0.350 bar, -0.36 kg/em', -5.1 psi)
should be generated.

OK

INSPECTION END

1198 EL-132
AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Trouble Diagnoses (Cont'd)
ASCD WIRE ADJUSTMENT

II)~
_--Asc;o actuator

Adjusting nut

Lock nut

II!! a- 10 N•m
(0.8 - 1.0 kg-m,
69- 87 in-lb)

AEL332A

• Be careful not to twist ASCD wire when removing it.

• Do not overly tighten ASCD wire during adjustment.
Confirm that accelerator wire is properly adjusted.
• For accelerator cable adjustment, refer to FE section
("Adjusting Accelerator Wire"', "ACCELERATOR CON- :J!j
TROL SYSTEM").
Adjust the ASCD wire as follows:
1. Loosen lock nut and tighten adjusting nut until portion A of jc]@
upper throttle lever comes into contact with lower throttle lever.
2. From that position turn back adjusting nut 0.5 to 1 turn, and
secure lock nut.
(This prevents a delay in the operation of the ASCD.)
• For ASCD brake switch adjustment, refer to BR section
("Adjustment", "BRAKE PEDAL AND BRACKET").
• For ASCD clutch switch, refer to CL section ("Adjusting Clutch
Pedal," "INSPECTION AND ADJUSTMENT").

II
EL-133 1199
 AUTOMATIC SPEED CONTROL DEVICE (ASCD)
Trouble Diagnoses (Cont'd)
ELECTRICAL COMPONENTS INSPECTION
l:j ASCDmain
switch connector ® ASCD main switch
OISCONNECT
Check continuity between terminals by pushing switch to each
IV position
"'.J
~
Terminals
Switch position
6 1 2 I 3 4 I 5
ON n n n '-' n I
[QJ ILL.
N n "--®---0
AEL397A
0---®--0
OFF I I
ASCD steenng sw1tch
[;i ASCO steering
switch connector 9 Check continuity between terminals by pushing each button
OISCO!mECT

IV rn~•@g~ Button
21
Terminal

22 23
SET/COAST 0 _{)

RESUME/ACCEL n _{)

pj CANCEL
0--- -...n
n .n
AEL917A

ASCD brake switch and stop lamp switch

ASCD brake Stop lamp
switch connector 8) switch connector 8 Continuity

,_-,Gfu~ ,--~~ Condition ASCD brake

Stop lamp switch
switch
When brake pedal is depressed No Yes
[QJ [QJ When brake pedal is released Yes No

DISCONNECT
Check each sw1tch after adJustmg brake pedal - refer to BR

~
section ("Adjustment", "BRAKE PEDAL AND BRACKET").
IV AEL892A

ASCD clutch switch {For MIT models)

~ IV
DISCONNECT

Condition Continuity
ASCD clutch When clutch pedal is depressed No
switch connector 8 When clutch pedal is released Yes
----ow: Check switch after adjusting clutch pedal - refer to CL sec-
tion ("Adjusting Clutch Pedal", "INSPECTION AND ADJUST-
MENT").
[QJ
AEL893A

Inhibitor switch (For A/T models)

~ Inhibitor switch connector
Condition Continuity
DISCONNECT
8
IV -®
When shift lever position is "N" or "P"
When shift lever position is not "N" or "P"
Yes

No

[QJ

AEL399A

1200 EL-134
 POWER WINDOW

@II
~.;, ;.:,-; .; ; d.~s;:;w; ; ;,.; -h_ _ _ _ _ _ _ _____IC~o~m!!J:pOnent Layout
i'P;;;•• ••;g:••
Power window
switch RH

Driver side switch

Lock/unlock
knob switch

LH door

Power window motor

AEL377A
actuator
EL-135 1201
 POWER WINDOW

System Description
Power is supplied at all times:
• from brown fusible link (located under relay box)
• to circuit breaker terminal CD
• through circuit breaker terminal ®
• to ignition-2 and power window relay terminal @.
With the ignition switch in the ON or START position, power is supplied:
• to ignition-2 and power window relay terminal ®.
Ground is supplied to ignition-2 and power window relay terminal CD through body grounds ® ,~ and
@.
The ignition-2 and power window relay is energized and power is supplied:
• through ignition-2 and power window relay terminal ®
• to main power window and door lock/unlock switch terminal ®.
• to power window switch RH terminal ®. and
• to power window amplifier terminals® and®.
Ground is supplied:
• to main power window and door lock/unlock switch terminal @, and
• to power window amplifier terminal CD
• through body grounds ® , ~ and @ .
MANUAL OPERATION
Door LH
WINDOW UP
When the main power window and door lock/unlock switch is pressed in the UP position, ground signal is
supplied:
• to power window amplifier terminal ®
• through main power window and door lock/unlock switch terminal @.
Then power is supplied:
• through power window amplifier terminal @
• to power window motor LH terminal ®.
Ground is supplied:
• to power window motor LH terminal CD
• from power window amplifier terminal ®.
With power and ground supplied, the motor raises the window until the switch is released.
WINDOW DOWN
When the main power window and door lock/unlock switch is pressed in the DOWN position, ground signal
is supplied:
• to power window amplifier terminal 0
• through main power window and door lock/unlock switch terminal ®.
Then power is supplied:
• through power window amplifier terminal ®
• to power window motor LH terminal G).
Ground is supplied:
• to power window motor LH terminal ®
• from power window amplifier terminal @.
With power and ground supplied, the motor lowers the window until the switch is released.

1202 EL-136
 POWER WINDOW
System Description (Cont'd)
Door RH
NOTE:
Figures in parentheses () refer to terminal Nos. arranged in order when the DOWN or UP section of
power window switch RH is pressed.
Operation by main switch
Power is supplied:
• through main power window and door lock/unlock switch terminal ((D, @)
• to power window switch RH terminal (@, G)).
The subsequent operations are the same as those outlined under "Operation by sub-switches".
Operation by sub-switches
Power is supplied:
• through power window switch RH terminal (@, @))
• to power window motor RH terminal (G), ®).
When the power window switch RH is pressed in the DOWN or UP position, ground is supplied:
• to power window motor RH terminal (@, G))
• through power window switch RH terminal (@, @)
• to power window switch RH terminal (G), @)
• through main power window and door lock/unlock switch terminal (@, (D)
• to main power window and door lock/unlock switch terminal (@))
• through body grounds @ , ~ , and <§g) .
Then, the motor raises or lowers the window until the switch is released.
AUTO FEATURE
The power window AUTO feature enables the driver to lower the driver's window without holding the window
switch in the down position. I~T'
The AUTO feature only operates on the driver's window downward movement.
When the main power window and door lock/unlock switch is pressed and released in the AUTO position,
ground signal is supplied: f[S
• to power window amplifier terminal ®
• through main power window and door lock/unlock switch terminal G).
Power is supplied:
• to power window motor LH terminal G)
• through power window amplifier terminal ®
Ground is supplied:
• to power window motor LH terminal ®
• through power window amplifier terminal @)
Then, the door LH window will travel to the fully open position.

LOCK FEATURE
The power window lock is designed to lock-out passenger window operation.
When the lock switch is pressed to the LOCK position, ground of the main power window and door lock/unlock
switch is disconnected. This prevents the passenger power window motor from operating.

EL-137 1203
 POWER WINDOW

Wiring Diagram -WINDOW-

EL-WINDOW-01

T FUSIBLE
LINK
@
Refer to "EL~POWER"

~
W/8

~
CIRCUIT
BREAKER
@Q§)

l.bjdl
W/G
•
WIG
m

8 y

ToBA·ABS·Y-I.....J

. -- 1+

•.•
rI I
8 8 8
..L ..L ..L
c~l<§">c~o)

0
!1!11@ 1234@
ttl BR 5 6 7 8 w

AEL28tA-A

1204 EL-138
 POWER WINDOW
Wiring Diagram -WINDOW- (Cont'd)

EL-WINDOW-02 ~lut1,
Preceding....-A~-w.;;;..·------------..iiiiiii.
page ~ •
..................oiiiiiiiii.ioioi-·
w
,~,(~)
@)
w
m MAIN
POWER
WINDOW

. ,,
AND
, DOOR

~
~'
~
LOCK LOCK/
AVTO SWITCH N
--:..-u-ia~-- -T~ u D
UNLOCK

' D ro-' u LOCK ~ UNLOCK U

__ ------------
SWITCH

FRONTRH
@)
N N
I FRONTLH
I
~ l!i!l lb4Jl
W/R UOR L s uv: uwl
lrt,~----lrf,~-------ffi® jrf,~-------lrh--------ffi® Au1r
....... ....... ....... <Mill> ....... ....... '-r'@W
W/R UOR L B UY UW

m
I· I· I·
WIR

AUTO
UOR

ffi
DOWN
ffi
UP
L

POWER
I...............
__ ...
• ---·
, I uv

UY
ffiffiffi
uw

UW
w@
iEfJ~- lt:iJI- -1~1co;~;)
W

DOWN
WINDOW POWER
AMPLIFIER
WINDOW
@'@ SWITCH
UP DOWN RH
@Z)
~ ~ D

LJ13t URt FRONT

,¢,------jc!Jj<MW
@)
RH

LJ13
ffi ______ ffi
UR
~ ~
. - - - : - , __ __.-,POWER ffi ______ ffit
t
LJ13 UR

~:.......!._-=====~@)
WINDOW
MOTOR
LH i-i,
_._
B
...._
B B
~
.---~._----~L-,POWER
WINDOW
MOTOR
RH

(~)(M105HM1so) L::.....!_-====-_j@Q§)

D 2 c::::::J 12
12 3 4@'@,@ 1 2 o 3 4@ ,..r::;:)..,@),(DiP:s) 45131467@)
6 7 8 w w 5678910w l.2..l!.ls 8
3 1 w
l~li~

AEL281A-B

EL-139 1205
 POWER WINDOW

Trouble Diagnoses
Symptom Possible causes Repair order

None of the power windows can be operated 1. Brown fusible link and circuit breaker. 1. Check brown fusible link (located under the relay
from any switch. box) and the circuit breaker. Turn ignition switch ON
and verify battery positive voltage is present at termi-
nal ® of both power window switches.

2. Grounds to ignition-2 and power win- 2. Check grounds @D . ~ and~.

dow relay.

3. lgnition-2 and power window relay 3. Check ignition-2 and power window relay.

4. Grounds to main power window and 4. Check grounds @D , ~ , and ~ .

door lock/unlock switch.

Driver side power window cannot be oper- 1. Driver side power window motor LH 1. Check driver side power window motor LH circuit.
ated but passenger window can be operated. circuit.

2. Driver side power window motor LH. 2. Check driver side power window motor LH.

3. Power to power window amplifier. 3. Turn ignition switch ON and verify battery positive
voltage is present at terminals ® and ® of power
window amplifier.

4. Ground to power window amplifier. 4. Check grounds @D , ~ , and @9:> .

5. Driver side power window switch. 5. Check main power window and door lock/unlock
switch.

6. Power window switch circuit. 6. Check wires between main power window and door
lock/unlock switch and power window amplifier for
open/short circuits.

7. Power window amplifier. 7. Replace power window amplifier.

Passenger power window cannot be oper~ 1. Power window switch RH. 1. Check power window switch RH.
ated.

2. Power window motor RH. 2. Check power window motor RH.

3. Main power window and door lock/ 3. Check main power window and door lock/unlock
unlock switch. switch.

4. Power window circuit. 4. Check wires between main power window and door
lock/unlock switch and passenger power window
switch and motor for open/short circuits.

Passenger power window cannot be oper- 1. Main power window and door lock/ 1. Check main power window and door lock/unlock
ated by main switch but can be operated by unlock switch. switch (lock must be in unlock position).
passenger's switch.

2. Power to main power window and door 2. Turn ignition switch ON and verify battery positive
lock/unlock switch. voltage is present at terminal @ of main power win-
dow and door lock/unlock switch.

Passenger power window cannot be oper- 1. Power window switch RH. 1. Check power window switch RH.
ated by passenger switch but can be oper-
ated by main switch.

2. Power to power window switch RH. 2. Turn ignition switch ON and verify battery positive
voltage is present at terminal ® of power wmdow
switch RH.

1206 EL-140
 POWER DOOR LOCK

System Description
Power is supplied at all times:
• through brown fusible link (located under the relay box)
• to circuit breaker terminal CD
• through circuit breaker terminal ®
• to door lock control unit terminal ®.
Ground is supplied:
• to door lock control unit terminal ®
• through body ground ~ .
INPUT
When the lock/unlock knob switch is moved to the UNLOCK or LOCK position, ground is supplied:
• to door lock control unit terminal CD or ®
• from lock/unlock knob switch terminal @ or CD
• through lock/unlock knob switch terminal ®
• through body grounds ® , ~ and <@D .
When the main power window and door lock/unlock switch is moved to the UNLOCK or LOCK position, ground
is supplied:
• to door lock control unit terminal CD or ®
• from main power window and door lock/unlock switch terminal @ or @
• through main power window and door lock/unlock switch terminal @ or 0
• through body grounds ® , ~ and <@D .
OUTPUT
Unlock
Power is supplied:
• from door lock control unit terminal 0
• to door lock actuator LH terminal @, and
• to door lock actuator RH terminal CD.
Ground is supplied:
• from door lock control unit terminal @
• to door lock actuator LH terminal CD. and
• to door lock actuator RH terminal @.
With power and ground supplied, the door actuators move to the unlocked position.
Lock
Power is supplied:
• from door lock control unit terminal @
• to door lock actuator LH terminal CD. and
• to door lock actuator RH terminal @.
Ground is supplied:
• from door lock control unit terminal 0
• to door lock actuator LH terminal @, and
• to door lock actuator RH terminal CD.
With power and ground supplied, the door actuators move to the locked position.

EL-141 1207
 POWER DOOR LOCK

Schematic

I BATTERY I MAIN POWER WINDOW

AND DOOR LOCK/UNLOCK
SWITCH
K N N K
4
1\11 fUSIBLE 1
~LINK 13
14

[u~
flRCUIT
BREAKER

..__ _ _ _ To tgnltlon-2 and

T poweJ" window relay LOCK/UNLOCK KNOB
SWITCH
K N N K
2 5
DOOR LOCK CONTROL UNIT l
3 4 6

-
~ ACTUATOR ~ ACTUATOR
DOOR r- DOOR
LOCK LOCK
llLH ~ RH

~ JJ
AEL289A

1208 EL-142
 POWER DOOR LOCK

NOTES

©IL

EL-143 1209
 POWER DOOR LOCK

Wiring Diagram -D/LOCK-

EL-D/LOCK-01

- I
WIB

CIRCUIT
BREAKER
lbjJl @Q§) Referto "EL-POWER".

OO
- WiG
I
· - - - W i G . To EL-WINDOW
I
WiG

ffi )DOOR
BAT
LOCK
CONTROL
LOCK LOCK (UNIT
ACTUATOR ACTUATOR GND <Mill>
lbiJl lbjJl ll4ll
-
I I -
VIR~

•
I
v:~
•
8

V/8 ViR
I
VIR
I
VIB

ir!Jt··--1~1<MW
@) leiJt·······1ciJI~
<@>
V/8 VIR ViR V/8

ffi ffi

ViB

~@
t!! BR

[J
1 2 3 •®
s6 1 a w

AEL288A-A

1210 EL-144
 POWER DOOR LOCK
Wiring Diagram -D/LOCK- (Cont'd)

EL-D/LOCK-02
r------,oooR
LOCK
CONTROL
UNIT ~,J!iU

UNLOCK LOCK @1§)

lbjdii!4Jl loG
B/R B1Y

!ciJ!
8/R
!c}J!t~:';
BN ~IG

!-1-------... IF~

I i---1------1
8/R BN B/R BIY
©1
ffiffi LOCK/UNLOCK
~ ~
MAIN
KNOB POWER 11111
,.., SWITCH
N I N
WINDOW

•
N
, @ , , AND DOOR

UNLOCK LOCK UNLOCK LOCK •

UNLOCK
--------------
'
LOCK
LOCK/UNLOCK
SWITCH
@ "'11

11F

!Pill

~'"'

11llfl

~1i'

~~·

[]
,.,.®,@1§) 1 2 0 3 4 @) 1 2 3 4@ 11!11'
t:tl:ltil w 5 6 7 8 9 10 w 5 6 7 8 w

[X]~
2 =1121
14 5 1311416171
13 111 I I

AEL288A·B

EL-145 1211
 POWER DOOR LOCK

Trouble Diagnoses
~i) MAIN POWER SUPPLY AND GROUND CIRCUIT CHECK

'IT Main power supply for door lock control unit

2 Door lock control unit
connector8 Terminals Battery voltage existence

WIG @ - Ground (GND) Yes

ooLJ*
~
AEL356A

Ground circuit for door lock control unit

~i) Terminals Continuity
®-Ground Yes
D
IL _JI Door lock control unit
6 connector8

J~
[ill
_____.!:

AEL357A

1212 EL-146
 POWER DOOR LOCK
Trouble Diagnoses (Cont'd)
DIAGNOSTIC PROCEDURE
m~ "'"'cr
~ I) SYMPTOM: Power door locks cannot be operated by door
lock/unlock switches.

0
1
Door lock control unit
m
5 connector~ OK
CHECK SIGNAL OF DOOR LOCK/
BN B/R UNLOCK SWITCH. ~@ (Go to next page.)

S-F~
Check voltage between control unit termi-
nal CD ®
or and ground.

AEL359A Door lock/

Voltage
Tenninals unlock switch
m DISCON~En operation
(V)

~ IV @·GND
Lock 0
12

iW
Nand Unlock
Unlock 0
Ma;n powerw;ndow
CD. GND Nand Lock 12
and door lock/unlock
switch connector@ NG
B B
!;)[!]

w~ AEL360A
CHECK GROUND CIRCUIT FOR LOCK/
UNLOCK SWITCHES. ~ Repair ground harness of
door lock/unlock switch.
1. Disconnect door lock/unlock switch.
2. Check continuity between door lock!
[!]~
OISGO~NECT

IV m
unlock switch terminal(s) and ground.
Main power window and door lock!
unlock switch
:::::). Lock/unlock knob Between terminals @, @) and
2 ) switch connector @
ground.
B [!] Lock/unlock knob switch
Between terminal ®and ground.

J~
[ill Continuity should exist.
____!: NG
AEL918A
lil131
lil Main power window and door CHECK DOOR LOCK/UNLOCK 10\ Repair harness between
®
-
lock/unlock switch connector SWITCHES. door lock/unlock switch

,_ 1. Disconnect door lock/unlock switch.

2. Check continuity.
and control unit connector.

4 4 1413
I lil Main power window and door lock/
unlock switch

Operation Terminals Continuity

B [!it iv l[Cill]
AEL362A
131
Lock
Unlock
~.
®1·~
(!),

Lock/unlock knob switch

~
Yes

131~ Lock/unlock knob

switch connector ®
Operation
Lock
Terminals
(1). 0
Continuity

Yes
Unlock ®·®
~
DISCONNECT

IV NG
,...-'

~J
Replace door lock/unlock switch.

1~:%

AEL363A

EL-147 1213
 POWER DOOR LOCK
Trouble Diagnoses (Cont'd)

Iii~ Y/R li[]i Door lock control ®

CONNECT
,..-.JCH, unit connector @
Iii T
I) Y/8
CHECK DOOR LOCK ACTUATOR CIA-
CUlT.
Check voltage for door lock actuator.

~
Door lock actuator LH and RH

Door lock/unlock Terminals Voltage NG

Replace door lock control
switch operation $ 8 (V) ~ unit.
~ Lock (!I GND
AEL364A BatteJY voltage
Unlock ~ GND

[!!~
Door lock actuator connector

DISCONNECT 1, 3
tm 3,1
l.Ho9J
RH:B
[!I
OK

NG
I() ~ ~
CHECK DOOR LOCK ACTUATOR.
1. Disconnect door lock actuator.
2. Apply 12V direct current to door lock
[------- Repair harness between
control unit connector and
door lock actuator.
actuator and check operation.
~

~
Door lock/unlock Terminals
switch operation $ 8
Lock 1 3
AEL358A LH
Unlock 3 1
Lock 3 1
RH
Unlock 1 3

~OK
Replace malfunctioning power door lock
actuator.

1214 EL-148
 POWER DOOR LOCK

NOTES @II

EL-149 1215
 LOCATION OF ELECTRICAL UNITS

Passenger Compartment

lgnition~2 and power window relay

Accessory relay Circuit breaker

Power window amplifier

Blower motor relay

ECM (ECCS control module)

ASCD clutch switch

Clutch interlock switch

Fuse block

SMJ

Warning chime unit

Rear speaker amplifier

Door lock control unit

Air bag diagnosis sensor unit

AEL911A

1216 EL-150
 LOCATION OF ELECTRICAL UNITS

Engine Compartment

Daytime light control unit

(For Canada)

Fuel pump <el•oy--._ ~-B,•Ib check relay

ASCD hold relay

Inhibitor relay (without ASCD)

Inhibitor relay (with ASCD)
Clutch interlock relay (with MID

Park and neutral position relay {with All)

AEL314A

EL-151 1217
 HARNESS LAYOUT

How To Read Harness Layout

Example:
E2 ® GY/2: Brake fluid level switch

T --r:nector color/Cavity

I Connector number

Grid reference

The following Harness Layouts use a map style grid to help locate connectors on the drawings:
• Main Harness and Air Bag Harness
To use the grid reference
1) Find the desired connector number on the connector list.
2) Find the grid reference.
3) On the drawing, lind the crossing of the grid reference letter column and number row.
4) Find the connector number in the crossing zone.
5) Follow the line (if used) to the connector.

CONNECTOR SYMBOL
Main symbols of connectors (In Harness Layout) are indicated below.

Waterproof type Standard type

Connector type
Male Female Male Female

• Cavity: Less than 4

@ ({jV ~ ~
• Relay connector

• Cavity: From 5 to 8
~. ~ ~ ~
•
~ ~ ~ ~
Cavity: More than 9

• Ground: terminal etc .

-
f11?

1218 EL-152
 HARNESS LAYOUT

Outline

Instrument harness

Tail harness

Chassis harness

Door harness LH

Air bag harness

AEL315A

EL-153 1219
1220

A B c E F G

2 2
@Relay box

§)
*§) :I:
s::: l>
@

~Y
@ !!!. ::0
m /
::I z
(§) m
,...
.....'
(11
3
@l @ 3111..
:I:
::I
CD
C/)
C/)
,...
""' Ill
Ill ~
Ill 0
::I c:
a. -1

4 40l
..
;!::

Ill
CQ

Air bag harness I ..

:I:
Ill
::I
CD
Ill
Ill

~ 11@1"~ I ~ (@) \ ( ~ 1\~.Jm~

~ A I B I c I DIE IF I G
 D1 *® GY/6 : EVAP canister purge volume control valve D2 ~ GY/8: Inhibitor switch 82 § GY/2: Front parking lamp RH
D1 @ W/6 : Wiper motor D2 @) GY/3 : Solenoid valve unit 83 @) 8/3 : Headlamp RH
E1 ® W/8 : Wiper amplifier D1 *@) GY/2: Inhibitor switch 83 (§) GY/2: Dual-pressure switch
F2 *@B/2 : Injector No. 4 C1 (§! GY/4: To@ (with 4-wheel drive) 83 8 GY/2: Front turn signal lamp RH
E2 *@B/2 : Injector No. 3 C1 @ - : Relay box D5 8 GY/2 : Front parking lamp LH
E1 *@GY/4: IACV~AAC solenoid valve and to@l A2 @ U4 : Fuel pump relay E3 *~ GY/2 : Resistor
E2 *@ GY/2: EGA temperature sensor A2 *i§) U4 : ECCS relay F3 (§! W/2 : Washer motor
F2 *@B/2 : EGRC·solenoid valve A3 @ U4 : Air conditioner relay F3 ~ 8/2 : Washer fluid level switch (for Canada}
Relay box
E2 *@B/2 : Injector No.2 A3 (§) U4 : Inhibitor relay (without ASCD) F2 ~ GY/2 : Brake fluid level switch
E2 *(§) 8/2 : Injector No. 1 A3 @ GY/6: Inhibitor relay (with ASCD) F3 {§ GY/4: ASCD pump (wi1h ASCD)
03 *@) GY/6: Distributor (camshaft position sensor) A3 @ U4 : Clutch interlock relay (with Mff) E2 *@GY/4: To EiJ
E3 *@ GY/2 : Distributor (ignition coil) A3 @ GY/3: Horn relay J F3 *~ GY/3: Front heated oxygen sensor
E3 8 GY/1 : A/C compressor C1 § BR/2 : Fusible link F3 @) U4 : Bulb check relay
03 *@- : Engine ground C1 *!§) B/2 : Swirl control valve control vacuum check switch F4 ~ U4 : ASCD hold relay (with Mff)
03 *@- : Engine ground 81 @ GY/6: Daytime light control unit (with DTRL) F4 1§1 BR/6: ASCD hold relay (with AIT) ~~
-- l:J
m
D3 (§)B/1 : Thermal transmitter B2 @) GY/8: Daytime light control unit (with DTRL) 05 (§) 8/3 : Headlamp LH ::s z
r
E3 *~ GY/2: Engine coolant temperature sensor C1 *(§) U4 :Park and neutral position relay C5 I§) B/3 : Headlamp LH (with DTRL) xm
Ill (/)
.....' 03 *(§) G/2 : EVAP canister purge control solenoid valve C2 *@GY/S:To@ D5 1§1 B/1 : Horn .., (/)
c.n 02 *@ BR/4 : Mass air flow sensor D2 *{§JB/8 :To@ @ ~ r
c.n D5 GY/2: Front turn signal lamp LH
02 *(§> GY/2: Intake air temperature sensor C2 I8JGY/1 :To@ E3 *E'JGY/4 :To@ g: ~
02 *@ GY/3 : Throttle position switch C3 I8JBi2 :To@ E2 *E'JGY/4:To@ Ill 0
03 * (§) BR/3 : Throttle position sensor B4 *@) 8/2 : Fusible link D2 *~ PU/2 : IACV-FICD solenoid valve
::s c:
C.-I
E1 *(@) GY/3: Absolute pressure sensor B4 @ W/3 : Fusible link
E1 *(@B/2 : MAP/8ARO switch solenoid valve C2 *<§) - : Body ground Air Bag Harness
..,l>
C1 @ GY/4: To (§! (w~h 4-wheel drive) Ill
Ill
C4 @ GY/2: Crash zone sensor (with 4-wheel drive) IC
:I:
..,
Ill
::s
(1)
rn
rn
.-.
0

-
0
::s
* : Be sure to connect and lock the connectors securely after repair work.
)>
m Failure to do so may cause the on-board diagnostic system to light up 0::
._.
§ the MIL as an open circuit detection. (Refer to EC Section.)
~
1221

~ (i~LDJ 0J/J ~c mru

~
i1li dl'J @Ql
ill" COil ~ ©
""
'ig! IF [iij]
2-:::?, J!~ 9 e~m ~J :;!E) ~·:J ::r~ (Q]
"" 9 !f-' cmJ e;--=5) IQ) ~ ~~ ~
1222

D E F G
Body ground

0
~;
-·
:Ill z
m J:m
r- 3 3 Ill (/)
......
' .... (/)
(To
Ol ; r-
g: ~
Ill 0
:I c
C.-I
....~
4 4 m
Ill
IC
J:
Ill
....
:I
(D
Ill
Ill
......
5 sO

ii;
§
**: This harness runs along the
frame on the underbody.

c
-c:
0
:I

._.
~ B F G
 E2 @ W/2 : Blower motor ~§~ : Wiper switch E5 8 8/3 : Door switch LH
E3 ~ W/8 : Power window amplifier ~@- : Turn signal switch E4 l§ijiU4 :To@)

~~-
E2 i§JW/6 :To(§) : Lighting switch E5 §8/2 : Seat belt buckle switch
E2 i§JW/6 :To!§) ~s- : To spiral cable 04 §9 W/6 :AfT device
E2*i§J- : Body ground 811§)~ : Clutch interlock switch F4 8 Y/24 : Air bag diagnosis sensor unit
E2 § W/2 :Circuit breaker ~@~ : ASCD brake switch (with ASCD) D5 ~ W/17: ABS control unit
G4 @)8/1 : Door switch RH ~sM : Stop lamp switch D4 8 - : Body ground
E4 *i§JW110:To@ 81i§)M : Combination flasher unit E5 ~ W/6 : Door lock control unit
E4*i§IW/14:To@ ~@~ : ASCD clutch switch (with Mn) E4 ~ W/12: Rear speaker amplifier
E3 *(§0 8/27 :Joint connector-1 U8- :To@ D1 8 W/2 :To ~§ill
E4 § - : Body ground g@~ :Joint connector-2 D3 (§) W/2 :Glove box lamp
F4 *@ SMJ : ECM (ECCS control module) g~~ :Fuse block E3 (§ BR/2 :Glove box lamp switch
01 ~ W/4 :Thermo control amplifier ~8M :Toi§l E4 @j)U4 :To@
E2 €§) W/6 : Fan resistor 83 @W/1 :Toi§J G4 (§8/2 : Rear speaker RH
D1 ~§ill W/2 :To
(§Y W/10: To@
8 83 @W/1 :Toi§J
Fuse block
F5 1§18/2 : Rear speaker LH ~~
-· :tl
m
C3 (with premium audio) 83 @)W/3 :To@ C4 *~ GY/4 : Rear heated oxygen sensor ::I z
r
Radio and cassette player (wi1h base audio) A1 8 BR/6 : lgnition-2 and power window relay C3 ~ W/10: To §(with premium audio) ::t:m
Ill w
....
' D3 @ W/6 :To (§\ (with premium audio) A1 ~ U4 :Accessory relay D3 (§ W/10: Radio and cassette player ... w
Ul
..... Radio and cassette player (with base audio) A1 (§) U4 : Blower motor relay (with premium audio)
8
ill r
g: ~
C1 ~§ill 8/2 : Cigarette lighter socket 81 §) U4 : lgnition-1 relay D3 i§IW/6 :To
C1 ~ W/3 :Air conditioner switch (with NC) D3 (@ W/6 : Radio and cassette player
A3 (§31WI16 : DatalinkconnectorforGST
(premium audio) Ill0
C1 l§i)8/6 :Fan switch 83 @GY/14: Data link connector for CONSULT ::Ic
Q.-1
C1 (§§) W/8 : Hazard switch 83 @) U6 : ABS check connector
C1 @ W/6 : Illumination control switch U*@SMJ :To@
~
...
C1 ~ W/2 : Heater (illumination) M @U10 :Diode Ill
Ill
81 @ 8/20 : ASCD control unit A2 @)w/10 :To@ (with power windows and power door locks) cc
C1 @)W/1 : Parking brake switch Al ~ W/6 :To@ (without power windows and power door locks) J:
81 ~§ill W/10: To 1§1 U @W/8 :To@ ...
Ill
::I
81 ~§ill W/10: To I§) A4 *@ - : Body ground CD
Ill
C3 * t§ W/6 : Ignition switch A4 ~ W/8 :Warning chime unit Ill
82 (§!) W/2 : Key switch .....
0
Diode@

-
0
::I
Warning chime unit • Door switch LH
,.m * : Be sure to connect and lock the connectors securely after repair work.
Failure to do so may cause the on-board diagnostic system to light up
ABS control unit Brake fluid level switch
._. a:
:;; Combination meter Parking brake switch
the MIL as an open circuit detection. {Refer to EC Section.)
t Solenoid valve unit AfT device
(overdrive switch)
1223

~ cum
§
~ ~
[@
""]
Zl
w 9
@iJ
Zl
;!jjJ
~-:> ~ ""g ~ ~ ~
""] ~"
F ITiW ~ ~ ; §
2:0
@»
1224

oo 0
a :I:

-...
:::J )>
Ill :II
m r:: z
r- m
.....• 3 en
en
-...
(I)
c.n :::J
r-
[Jl~
011
:I:
Ill ~
0
:::J
(I) c::
Ill -1
Ill

*§SMJ :To(§} (SMJ) *@ B/12 :Combination meter

® W/6 : ASCD main switch @ W/8 : Combination meter
@ W/1 0: Door mirror switch *@W/12: Combination meter
* ® B/1 0 : Combination meter * : Be sure to connect and lock the connectors securely after repair work.
Failure to do so may cause the on-board diagnostic system to light up
,.m the MIL as an open circuit detection. (Refer to EC section.)

~
 Body ground

::I:
m >
::I ::0
IC
m ::I
z
m
r;- ID
en
...... *@B/8 :To@
::I: en
U1
(I) @B/2 :To@ ...Ill::I I'""
@GY/1 :To@
ID
Ill
~
@GY/S:To@
Ill 0
@ - : Battery positive tenninal c
-1
@ - : Body ground
@ W/2 :Generator
@ - : Generator
® B/1 : Oil pressure switch
@) 8/2 : Power steering oil pressure switch
@) - : Generator
@ GY/1 :Starter motor @ 8/2 : Position switch (MIT models) @ - : Body ground
@ - : Starter motor *@!) B/2 : Neutral position switch (Mrr models) @ - : Engine ground
*@ BR/2 : Swir1 control valve control solenoid valve @ W/1 : 4WD switch (4WD MIT models)
*@ GY/2: Crankshaft position sensor (OBD) @ - : 4WD sw~ch (4WD MIT models)
*€!l GY/2: Vehicle speed sensor (2WD MIT models) *@B/1 :To@ * : Be sure to connect and lock the connectors
~ *@tt GY/2: Vehicle speed sensor (2WD AfT models) @)G12:To@ securely after repair work. Failure to do so may
"'~ *@)ttt GY/2: Vehicle speed sensor (4WD MIT models) cause the on-board diagnostic system to light up
)> (§) - : Battery negative tenninal the MIL as an open circuit detection. (Refer to EC Section.)
1225

g 9 @]] C)j ©2' w

~ ~ ~
9
~~ ~' '-"D WJ ~ dPJ "'"
!RJ ~ ""{ ~
9
C;'?l
F ""
lml
ljlnl
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r
<tc)
lr}]l
~
~
~
~
1226

Tail Harness
@GY/8:To@
® GY/2 : License lamp RH (With step bumper:)
® W/6 : Rear combination lamp RH
® GY/2 : License lamp RH (Without step bumper)
® GY/2 : License lamp LH (Without step bumper)
® GY/2 : License lamp LH (With step bumper)
® W/6 : Rear combination lamp LH

:I:
0 )>
:::r ::0
Ill
m Ill z
Ill m
...'
r-
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iii"
Ill
en
en
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g 0
c:
:I: -1
...
Ill
:I
m
Ill
Chassis Harness
'@W/14: To if§l
'@WI10:Toif§l
@ GY/4: ABS actuator
*@ GY/6 : Fuel tank gauge unit
@ GY/2 : Rear sensor
*@ GY/3: EVAP control system pressure sensor
,.
m * : Be sure to connect and Jock the connectors securely after repair work.
*@ G/2 :Vacuum cut valve bypass valve
*@ B/2 : EVAP canister vent control valve
~ Failure to do so may cause the on-board diagnostic system to light up
~ the MIL as an open circuit detection. (Refer to EC section.) @GY/S:To@
 HARNESS LAYOUT

Door harness LH
Front Door Harness

@W/10oTo@
@W/6 oToi§j)
@W/8 oToi§j)
® B/2 : Door speaker LH
@ W/3 : LH side door mirror
® B/2 : Power window motor LH
@ W/14: Main power window and door lock/unlock switch
® GY/3 : Lock/unlock knob switch
(§) W/4 : Door lock actuator LH

AEL323A

Door harness RH

(§)W/6 oToi§j)
/§)W/6 oToi§j)
i§j)B/2 : Door speaker RH
@)W/3 : RH side door mirror
8 @812 : Power window motor RH
(§ r§}W/6 : Power window switch RH
@ i§j)W/4 : Door lock actuator RH

II
AEL324A

EL-161 1227
 HARNESS LAYOUT

Room Lamp Harness

@W/6 :To(§)
@ W/2 : Map lamp (With map lamp)
@ BR/2 : High~mounted stop lamp
@ W/3 : Room lamp

AEL325A

1228 EL-162
 SUPER MULTIPLE JUNCTION (SMJ)

INSTALLATION
To install SMJ, tighten bolts until orange "fulltight" mark appears
OODDDDDDOD and then retighten to specified torque as required.
lit]: 3- 5 N·m
DDDDDODDDD CAUTION:
(0.3 - 0.5 kg-m, 26 - 43 in-lb)

Do not overtighten bolt, otherwise, it may be damaged.

Fuse block

AEL346A

Behind fuse block

SMJ (Main harness-Instrument harness)

[1!13- 5 N•m
(0.3- 0.5 kg-m, 26 • 43 in-lb) AELS4?A
SUPER MULTIPLE JUNCTION (SMJ)

Terminal Arrangement

MAIN HARNESS

/ I A1 I 81 I C1 I
D1
I E1 I F1

A2 B2 C2 "--- E2 F2
D2
A3 83 C3 E3

A4 84 C4
D3
E4 F4

AS BS CS "--- ES FS

~
A6
"---
~ ~
~
"---
A9
"---
~
A11
tJ ~
F8
;:::
F9
f.-

F11
<MW

A12 612 C12 f.- E12 F12

D14
A13 813 C13 E13 F13

A14 814 C14 E14

D1S
A1S 61S C1S f.- E1S F1S
D16
A16 816 C16 E16 F16

A16 816 C16 E16 F16

D16
A1S 81S C1S f.- E15 F15
D15
A14 814 C14 E14

A13 813 C13 E13 F13

D14
A12 612 C12 f.- E12 F12

A11 F11
f.- f.-
~

..
~
A9 F9
I= ;::: @
~ ~
~ ~
F6
A6

AS 8S CS I- E5 F5
D3
A4 84 C4 E4 F4

A3 83 C3 E3
D2
A2 82 C2 f.- E2 F2
D1
I A1 I 81 I C1 I I E1 I F1
/
INSTRUMENT HARNESS

AEL344A
 JOINT CONNECTOR (J/C)

Location

J/C-1 @ (Located under passenger seat)

J/C-2 @9 (Taped to main hamess below SMJ)

AEL342A

Terminal Arrangement

J/C-1 J/C-2

26 25 24X 23 22 21 20 19 26 25 24 X 23 22 21 20 19
18 17 16 15 14 13 12 11 10 18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1

AEL343A
 FUSE BLOCK

Fuse Arrangement

FUSE BLOCK (!ill})

c:J[!JWJ~[:ll[!l[:l:l[!J[:ll~~
~ ~~IE~~llil~~~l'l!l!!l 0

AEL341A
 CONTROL UNITS/MODULE

AIRBAG DIAGNOSIS SENSOR UNIT

20 19 17 10 4 c:::J 13 24 5 23 11 i ~
21 16 15 12 6 22 2 1418 7 3 8 9 t....ll
View from harness side

ABS CONTROL UNIT

876504321
9 10 1112 13 14 15 16 17

View from harness side

ECM (EGGS CONTROL MODULE)

I
~
1 2 3 ~
101 102 103 104 105 106
~ 53~55 ~
107 108 109 110 111112
113 114 115 116 117 118
5 6 7 8 91 10
111 12 13 14
I1.§J 16 17 18
:
19
w, 144 45 46 57 58 59 60 61
47 48 62 63 64 65
I2.!Jgj 66 67 68 69
70

View from harness side

AEL345A
ALPHABETICAL INDEX @~

SECTION IDX

1229
 ALPHABETICAL INDEX

ASCD (automatic speed control device) ............... EL-114

A NT - Wiring diagram ................................................ AT-6
NT mode switch............ .............................. ..... AT-22
AACN- Wiring diagram ....................................... EC-221 AfT removal and installation......... ................... AT-40
ABS - Wiring diagram........ ................ BR-39 NT shift lock system ................... ...... AT-30
ABS (anti-lock brake system) ................................. BR-30 NT shift lock system - Wiring diagram ................... AT-31
Absolute pressure sensor .......... . ........ EC-100 NT trouble diagnoses................. ........................ AT-12
NC - Wiring diagram ................... . ........... HA-31 Audio....... ................ ............. .... EL-102
NC air flow ................................. . .......... HA-13 AUDIO - Wiring diagram ...................................... EL-1 04
NC component layout... ............. . ......... HA-12 Audio and A/C control removal and installation -
NC compressor clutch removal and installation .... HA-53 See Instrument panel ....................................... BT-10
NC compressor mounting ..................................... HA-52 Auto lock free running hub ................... . ............... FA-18
NC compressor precaution ...................................... HA-6 Automatic speed control system- See ASCD ....... EL-114
NC compressor special service tool. ....................... HA-6 Automatic transmission fluid replacement ............. MA-17
NC control linkage adjustment (manual NC) ......... HA-42 Automatic transmission number .............................. GI-37
NC control operation (manual NC). ........... HA-14 Auxiliary air control (AAC)...... ......... EC-221
NC diagnostic work flow (manual NC) ................. HA-15 Axle housing (rear)... ............. ...................... RA-5
NC harness layout (manual NC) ........ . ........ HA-28
NC HFC134a (R134a) system identification ............ HA-3
NC HFC134a (R134a) system introduction ..... HA-3 B
NC HFC134a (R134a) system precaution ..... HA-4
NC HFC134a (R134a) system service Back window ....... .............. ........... BT-28
procedure............... ... .. .. ...... .................. ... HA-48 BACKIL- Wiring diagram.. ................................ EL-49
NC HFC134a (R134a) system service tools ........... HA-7 Back-up lamp...................... ........ EL-49
NC HFC134a system service equipment Back-up lamp switch (MIT) . .................................. MT-4
precaution .................. .. ...................... HA-9 Ball joint front axle ................................................. FA-44
NC lubricant (R134a) ........... . ...... HA-50 Battery..... ................. ....................... EL-15
NC operational check.......................... ....... HA-16 Baulk ring (MIT)...... ........................ ......... MT-8
NC performance chart..................... ................ HA-24 Blower motor........ ............ ......... . . HA-41
NC performance test diagnoses... ....... HA-22 Blower relay....... ................ .. HA-42
NC relay......................................... ......... HA-42 Blower resistor.. ....... .......... .. HA-41
NC service data specification ............................... HA-57 Body alignment... ........... ...... ... BT-34
NC switch ............................................................... HA-41 Body mounting ......... .... .. .......... .. BT-33
NC symptom chart (manual NC) ..... ........ . ..... HA-18 Boring/honing cylinder block..... ............ .. .. EM-35
NC trouble diagnoses (manual NC) ..................... HA-15 BPT valve...... .............................................. EC-184
Accelerator control system ............. . ................. FE-2 Brake booster.. ........... .. .. .. BR-16
Accelerator wire adjustment....... .................... FE-2 Brake control valve (Proportioning valve).. ......... BR-8
Air bag ................................................................... RS-10 Brake fluid change ..................... . .......... BR-4
Air bag disposal. .................................................... RS-13 Brake fluid level. ................................................... MA-20
Air bag precautions ................. . .......... GI-2 Brake fluid level and line check ....... . .......... BR-4
Air bleeding for brake system .. ............. ......... BR-5 Brake hydraulic line ................................................ BR-6
Air bleeding (hydraulic clutch) ... ........................ CL-6 Brake inspection.. .............. MA-20
Air cleaner filter replacement .......................... MA-12 Brake lines and cables inspection ........................ MA-20
Air conditioner- wiring diagram......... . HA-31 Brake master cylinder.............. .. BR-13
Air conditioner cut control . .. ........... .. ..... EC-18 Brake pedal .... ...... ................ .. .... BR-11
Air conditioning - See NC ..... ........... .. ............... HA-11 Bumper, front.......... ................. .. ... BT-6
Air control cable adjustment............. ........ HA-43 Bumper, rear .......... ............ . ........................... BT-7
Air flow meter - See Mass air flow sensor ............. EC-93 BYPSN -Wiring diagram ............................. EC-276
Air mix door control linkage adjustment.. ............... HA-43
Alternator ..................................... . ......... EL-28
Angular tightening application ......... . ................ EM-2 c
Antenna............................................ ..EL-109
Anti-lock brake system - See ABS ... . ................ BR-30 Cab body ....................................... . ............. BT-32
Anti-lock brake system - Wiring diagram ................ BR-39 Camshaft inspection ............ .... .... ...... .. ............ EM-19
AP/SEN - Wiring diagram ............. . EC-1 00 Camshaft position sensor (CMPS)............. .. .. EC-171
ASCD - Wiring diagram................. ....... EL -118 Canister- See EVAP canister ............................... EC-20

1230 IDX-2
 ALPHABETICAL INDEX

CANIN- Wiring diagram ....................................... EC-199 Coupling sleeve (MfT) ............................................. MT-8 ~~~
Cargo space .............................................................. GI-38 Crank angle sensor built into distributor - See
Center bearing assembly (propeller shaft) ............... PD-11 Camshaft position sensor ................................. EC-171
Center bearing disassembly (propeller shaft) ......... PD-1 0 Crankcase ventilation system - See positive ~G~ffil
CHARGE - Wiring diagram ...................................... EL-26 crankcase ventilation . ....... .... . ............ . ........ EC-24
Charging system ...................................................... EL-25 Crankshaft.... ................................................... EM-36
Chassis and body maintenance .............................. MA-16 Crankshaft position sensor (OBD) ........................ EC-166
CHIME - Wiring diagram ......................................... EL-84 Crankshaft position sensor (OBD) cog chipping ... EC-262
Cigarette lighter............. ................................... EL-1 01 Crash zone sensor .................................................... RS-9 !l©
Circuit breaker.. ................................................. EL-11 Cruise control- SeeASCD........................... EL-114
CKPS- Wiring diagram....... .............. EC-166, EC-262 Cylinder block.............. ......................... .......... EM-32
Clearance lamp ....................................................... EL-50 Cylinder block boring ............................................... EM-35 [[((;;
Clock...................................... ....................... EL-101 Cylinder head.................. ................................... EM-16
Closed loop control .............................................. EC-134 Cylinder head bolt tightening ................................. EM-26
Closed throttle position switch ........... .. ....... EC-226
Clutch cover............... ........................... CL-13
Clutch damper..................................... .... CL-9 D
Clutch disc .............................................................. CL-12
Clutch fluid levei ...................................................... MA-16 Data link connector for Consult................... ... EC-53
Clutch master cylinder ............................................... CL-7 Daytime light system ............................................... EL-38 u;u-J
Clutch operating cylinder..................... ............. CL-8 Daytime running light- See Daytime light
Clutch pedal...................... ............................. CL-4 system ................................................................ EL-38
Clutch release bearing...... . .................... CL-10 Defroster door control rod adjustment .................... HA-43 J'J
Clutch withdrawal lever...... ............................. CL-10 Diagnosis sensor unit.. ............................. ................ RS-9
CMPS - Wiring diagram...... .......................... EC-171 Diagnostic trouble code (DTC) chart ...................... EC-75
Collision diagnosis...................... ........... RS-37 Diagnostic trouble code (DTC) for ECCS OBD 'if!'
Combination lamp, front, removal and system................. .................................. EC-2
installation ..................................... . ..... BT-6 Differential carrier
Combination lamp, rear, removal and assembly ...................... PD-30, PD-52, PD-75, PD-96 IPlJ
installation .................................................. . .... BT-7 Differential carrier disassembly ...... PD-36, PD-58, PD-81
Combination meter. ................................................ EL-66 Differential gear oil replacement.. ......................... MA-19
.?/~\
Combination meter (needle type) ............................. EL-66 Dimensions ................................................................ GI-38
Combination meter removal and installation - Distributor ignition (DI) system ................................ EC-17
See Instrument panel ......................................... BT-1 0 D/LOCK- Wiring diagram ...................................... EL-144
Combination switch .................................................. EL-32 Dome light - See Interior lamp.. .............. ......... EL-63
Compression pressure ............................................. EM-7 Door, front. ................................................................ BT-9
Compressor clutch removal and installation ........... HA-53 Door glass ................................................................. BT-9 !Jill
Compressor mounting ............................................. HA-52 Door lock .................................................................... BT-9
Compressor precaution... ................................. HA-6 Door mirror .............................................................. BT-30
Compressor special service tool ............................. HA-6 Door trim .................................................................. BT-13 @IJ
Connecting rod ...................................................... EM-34 Drive belt inspection ................................................ MA-1 0
Connecting rod bearing clearance ......................... EM-38 Drive pinion diff. inspection ............ PD-40, PD-62, PD-85
Connecting rod bushing clearance ........................ EM-39 Drive pinion height .......................... PD-47, PD-70, PD-92 11].3
Console box - See Instrument panel .......... BT-1 0 Drive plate runout... ................................................. EM-39
CONSULT for ECCS .......................... ...... EC-53 Drive shaft (front) ..................................................... FA-28
CONSULT general information ................................ GI-33 DTRL- Wiring diagram ............................................ EL-42 iJT
Control lever (MfT) ................................................ MT-1 0 Dual pressure switch ............................................. HA-41
Control lever transfer ................................................ TF-7
Control valve (AfT)....... .......................... ............ AT-61
Converter housing installation ................................. AT-41 E
Coolant mixture ratio.. ....................................... MA-9
Coolant replacement..... ...................................... MA-11 ECCS basic inspection ............................................ EC-72
Cooling circuit (engine). ......................................... LC-7 ECCS circuit diagram ................................ c ••••••••••••••• EC-9
Cooling fan ............................................................... LC-12 ECCS component parts location ............................. EC-11
Counter gear (MfT) ................................................. MT-8 ECCS fail-safe system ............................................ EC-76
Counter gear transfer ........... .................................... TF-9 ECCS on board diagnostic system ......................... EC-34

IDX-3 1231
 ALPHABETICAL INDEX

ECCS relay.... ............................ ....................... EC-89 Fluids ....................................................................... MA-8

ECCS symptom matrix chart........................ .... EC-77 Flywheel (clutch) ...................................................... CL-13
ECCS system diagram and chart .......................... EC-1 0 Flywheel runout ...................................................... EM-39
ECM inpuVoutput signal ......................................... EC-83 Fork rod (MIT) .... .. .. ............. .. ........................ MT-1 0
ECTS - Wiring diagram............. ...... EC-113, EC-124 Forward clutch ......................................................... AT-79
EGR control (EGRC) - BPT valve ........................ EC-184 F/PUMP - Wiring diagram ..................................... EC-309
EGR control (EGRC) - solenoid valve .................. EC-267 Freeze frame data ................................................... EC-36
EGR control valve................... .. .............. EC-182 FR02- Wiring diagram.. .. ............................... EC-129
EGR temperature sensor ..................................... EC-271 FR02/H - Wiring diagram ..................................... EC-135
EGRC1 -Wiring diagram.......... .. ..................... EC-176 Front axle .............................................................. FA-15
EGRCN - Wiring diagram......... .. ................... EC-267 Front bumper................................................. .... BT-6
EGR/TS - Wiring diagram .................................... EC-271 Front combination lamp removal and
Electrical diagnoses......................... .. ......... GI-18 installation ................................................ . .. .. BT-6
Electrical unit ............... .................. .. ..... EL-150 Front disc brake ...................................................... BR-19
Electrical units location.. .. ................ EL-150 Front door............... . .................... BT-9
Engine compartment ............................................... BT-35 Front drive shaft transfer ........................................... TF-9
Engine control module (ECM) ................................. EC-6 Front final drive disassembly (4WD) ....................... PD-18
Engine coolant temperature sensor Front final drive pre-inspection (4WD) .................... PD-18
(ECTS) ................................................ EC-113, EC-124 Front final drive removal and installation (4WD) ... PD-15
Engine oil filter replacement... ............... MA-13 Front heated oxygen sensor (H02S) heater ....... EC-135
Engine oil precautions ............................................... GI-5 Front oxygen sensor (028)....... ............... EC-129
Engine oil replacement... ....................................... MA-13 Front seat ............................................................... BT-23
Engine outer component parts ................................ EM-6 Front seat belt ........................................................ RS-3
Engine removal ...................................................... EM-29 Front suspension .................................................... FA-34
Engine room - See Engine compartment ................ BT-35 Front washer .......................................................... EL-93
Engine serial number ................................................ GI-37 Front wiper .............................................................. EL-92
EVAP canister ......................................................... EC-20 FUEL- Wiring diagram .......................... EC-148, EC-153
EVAP canister purge control valve ...................... EC-199 Fuel cut control (at no load & high engine
EVAP canister purge volume control valve .......... EC-281 speed) ................................................................. EC-19
EVAP canister vent control valve ........................ EC-207 Fuel filter replacement. ......................................... MA-12
EVAP control system pressure sensor ................. EC-212 Fuel gauge..................... .. ............................ EL-70
EVAP control system purge flow monitoring Fuel injection system .............................. EC-148, EC-153
diagnosis .......................................................... EC-288 Fuel injector...... ............................... .. ........ EC-303
EVAP control system (small leak) diagnosis ........ EC-189 Fuel line inspection ................ .......... .. ........... MA-12
EVAP shut valve ...................................................... EC-21 Fuel precautions.... .......................... .. .............. GI-6
EVAP vapor lines inspection .................................. MA-15 Fuel pressure check ............................................... EC-25
Evaporative emission (EVAP) system .................... EC-20 Fuel pressure regulator. .. .. .......... .... ........ .. EC-25
Exhaust gas recirculation (EGR) valve ................ EC-176 Fuel pressure release ........................................... EC-25
Exhaust system ........................................................ FE-7 Fuel pump............................. .................. . EC-309
Exhaust system inspection .................................... MA-16 Fuel pump and gauge.......... .. .. ...... .. ........ .. ..... FE-6
Extension tube diff ................................................. PD-21 Fuel pump relay.... ................. ................ . EC-312
Exterior.......................... .. .............................. BT-17 Fuel system............ ................... .. .... FE-3
Exterior lamp ......................................................... EL-49 Fuel tank vacuum relief valve...................... .. EC-21
Fuel temperature sensor ....................................... EC-158
Fuse ......................................................................... EL-11
F Fuse block ................................................... Foldout page
Fusible link .............................................................. EL-11
Fan switch ............................................................. HA-41
Fast idle cam (FIG) inspection and adjustment.. .... EC-27
FICO - Wiring diagram ........................................ EC-317 G
Final drive disassembly ................... PD-36, PD-58, PD-81
Final drive pre-inspection ................ PD-36, PD-58, PD-81 Garage jack and safety stand .................................. GI-40
Final drive removal and installation ....................... PD-16 Gauges ................................................................. EL-65
Finisher, rear panel .................................................. BT-13 Gears (MIT) ............................................................. MT-8
Floor trim .. .. ........................ .... .. .. .. .................... BT-13 Generator ................................................................ EL-28
Flow charts................. .. ...................................... GI-30 Generic scan tool (GST) ....................................... EC-66

1232 IDX-4
 ALPHABETICAL INDEX

Glass ........................................................................ BT-9 Intake door control linkage adjustment........ ... HA-43 <:il
Governer valve assembly..... . ................ AT-72 Intake manifold............................ .................. ..... EM-6
Grease .................................................................... MA-8 Interior.......................................................... ... BT-13
Ground clearance .. ............................. GI-38 Interior lamp...................... .................... EL-58
Ground distribution ..... . ....................... EL-12 INT/L- Wiring diagram ............................................ EL-63

H J

Harness connector ............ . ..... EL-3 Jacking points .......................................................... GI-39

Harness layout .. ......................... EL -152 Joint connector (J/C) ......... ................. Foldout page
Hazard warning lamp ............................................ EL -52 Journal bearing assembly (propeller shaft) ............ PD-12 c;c;
Headlamp ........... ........................................... EL-35 Journal bearing disassembly (propeller shaft) ......... PD-11
Headlamp aiming control ........................................ EL-47 Jump seat................. .............. .. . .............. BT-24
Headlining - See Roof trim ...................................... BT-15
Heated oxygen sensor (H02S) ............................. EC-129
Heated oxygen sensor (H02S) (front) .................. EC-129 K
Heated oxygen sensor (rear) ................................ EC-139
HEATER - Wiring diagram ...................................... HA-30 Knuckle spindle ...................................... . ..... FA-25
Heater system - Wiring diagram ............................. HA-30
Height (Dimensions).......... ................................ GI-38
HFC134a (R134a) system identification .................. HA-3 L
HFC134a (R134a) system introduction ..................... HA-3
HFC134a (R134a) system precaution ...................... HA-4 Leaf spring (rear)... ...................................... RA-10
HFC134a (R134a) system service procedure ........ HA-48 Length (Dimensions) ............................................... GI-38
HFC134a (R134a) system service tools ................... HA-7 License lamp...... ... ................ .......... .. ................ EL-50 ]f
HFC134a system service equipment precaution ...... HA-9 Lifting points ............................................................ GI-39
High clutch............. . ....................... AT-77 Limited slip diff. adjustment... ..................... PD-65, PD-88
H/LAMP - Wiring diagram ....................................... EL-36 Limited slip diff. assembly.. ........ PD-43, PD-67, PD-89 F't!
Hood...................................... ........................ BT-6 Limited slip diff. disassembly ......... PD-42, PD-63, PD-86
Horn.......................................... ............. EL-101 Limited slip dill. inspection ............. PD-42, PD-64, PD-87
fLi~
HORN- Wiring diagram ........................................ EL-101 Line pressure test (AfT).......... ................... ... AT-27
How to erase DTC for ECCS OBD system ........... EC-43 Liquid gasket application ......................................... EM-2
Hydraulic lash adjuster inspection ......................... EM-28 Location of electrical units ................................... EL-150 ~Jji,
Lock, door..... ..... ... ................ .......... ............... BT-9
Low and reverse brake .......................................... AT-83
LSV (Load sensing valve) ....................................... BR-9 llci
Lubricant (R134a) A/C ........................................... HA-50
IACV-AAC valve inspection.............. ... EC-225 Lubricants ........................ ........ .............................. MA-8
IACV-FICD solenoid valve... ... EC-317 Lubrication circuit (engine)....... .................. ..... LC-4 l)j
IATS- Wiring diagram.............................. ........ EC-107 Lubrication-locks, hinges and hood latches ........... MA-22
Idle air control valve (IACV) ..................... .. EC-221
Idle mixture ratio...................... ................ .... EC-28
Idle speed........ ................ .. .. .. ................... .. .. .... EC-28 M
Ignition coil ............................................... EC-261
Ignition timing .. .............. ..................... ... EC-28 [01
MAFS - Wiring diagram .... . ...................... EC-93
Ignition wire inspection.......... .................. EC-165 Magnet clutch ....................... . ...................... HA-53
IGN/SG - Wiring diagram ..................................... EC-256 MAIN - Wiring diagram ......... . ........ EC-89
ILL- Wiring diagram ................................................ EL-60 Main drive gear (MIT)............. ................ . MT-8
Illumination .............................................................. EL-58 Main gear transfer....... .. TF-9
Inhibitor switch .......................................... AT-23, EC-232 Mainshaft (MIT) ............. .. ...... ..................... MT-8 ~l
INJECT- Wiring diagram ..................................... EC-303 Main shaft transfer .................................................... TF-9
lnjector .........................c ........................................ EC-305 Maintenance .............. . .MA-3
Injector removal and installation ............................. EC-26 Maintenance (engine) .......................... . ....... MA-10
Instrument panel. ...................................................... BT-1 0 Manual lock free running hub ....................... FA-17
Intake air temperature sensor ............................. EC-1 07 Manual steering gear ... ....................... ST-14

IDX-5 1233
 ALPHABETICAL INDEX

Manual transmission number .......... .............. . ... GI-37 Parking lamp .......................................................... EL-50
Manual transmission oil replacement.. ................... MA-16 Park/Neutral position switch .................................. EC-232
Map lamp... .. ............................................. EL -63 PCV filter replacement ........................................... MA-15
MAP/BARO switch solenoid valve ....................... EC-237 PCV (positive crankcase ventilation) ..................... EC-24
Mass air flow sensor (MAFS) ................................ EC-93 PGC/V - Wiring diagram ....................................... EC-281
Master cylinder (brake)...................... .. ...... BR-13 Pilot bushing replacement.. ..................................... EM-41
Master cylinder (clutch) ............................................ CL-7 Pinion bearing preload dill. ..................................... PD-25
Meter ...................................................................... EL-65 Pinion gear height dill. ....... PD-25, PD-47, PD-70, PD-92
METER - Wiring diagram ............................. EL-68 Piston assembly...... .. ................................ EM-39
MIL & Data link connectors circuit ....................... EC-321 Piston pin inspection .............................................. EM-33
MIUDL- Wiring diagram ...................................... EC-321 Piston ring inspection .............................................. EM-34
MIRROR- Wiring diagram ..................................... EL-112 Piston to bore clearance ......................................... EM-35
Mirror, door ....................... .. ...... BT-30 POWER- Wiring diagram .......................................... EL-7
Mirror, out side ....................................................... BT-30 Power door lock.......... .. ................................. EL-141
Misfire...................................................... .. EC-162 Power door mirror... .. ................................. EL-112
Mode door control linkage adjustment.. .................. HA-43 Power steering fluid level .............................. ST-5, MA-21
Model variation ........................................................ GI-34 Power steering gear ................................................. ST-20
Molding - See Exterior ............ .. ................. BT-17 Power steering hydraulic pressure ............................. ST-8
MIT overhaul ........................................................... MT-7 Power steering oil pressure switch ............ .......... EC-313
MIT removal and installation..... .. ..................... MT-5 Power steering oil pump ....................................... ST-35
Mud guard - See Exterior ....................................... BT-17 Power steering system bleeding ................... ST-6
Multipart fuel injection (MFI) system ...................... EC-15 Power supply routing ................................................. EL-6
Multipart fuel injection precautions ............................. GI-6 Power transistor .................................................... EC-261
Power transistor & ignition coil. ............................ EC-256
Power window ........................................................ EL-135
N Precautions (General)...... ................ .. ............... GI-3
PRE/SE - Wiring diagram .................................... EC-212
Neutral position switch ........................................ EC-232 Pressure plate- See Clutch cover ........................... CL-13
Neutral position switch (MIT) ........ .. ................ ..... MT-4 Pressure test (A/T) ................................................... AT-27
Propeller shaft .......................................................... PD-7
Propeller shaft inspection ....................................... MA-18
0 Propeller shaft on vehicle service ............................. PD-9
Propeller shaft vibration ............................................ PD-9
Oil change (capacity) .............................................. MA-8 PST/SW - Wiring diagram ................................... EC-313
Oil change (interval) ................................................ MA-6
Oil pan (engine). ................... .. ........ EM-8
Oil pressure (engine) ................................................ LC-5
R
Oil pressure relief valve (engine) .............................. LC-6
Oil pump (A/T) ........................................................ AT-57 R134a- See HFC134a .................. . ...... HA-3
Oil pump (engine) ...................................... LC-5 Radiator ......................................... . .. ... LC-11
Oil pump regulator valve (engine). .. .................... LC-6 Radiator fan - See Cooling fan ...... . .. ................ LC-12
Oil seal replacement (engine) ................................ EM-14 Radio - See Audio ................ . .. ........... EL-102
Oil seal replacement (front final drive 4WD) .......... PD-13 Rear axle........................................... .. ............ RA-5
Oil seal replacement (front of final drive) ............... PD-13 Rear axle (drum brake type) ..................................... RA-3
Operating cylinder (clutch).... .............. .. ............... CL-8 Rear body ................................................................. BT-32
Out side mirror ....................................................... BT-30 Rear bumper ............................................................ BT-7
Overdrive control switch ......................................... AT-22 Rear combination lamp removal and installation ....... BT-7
Overrun clutch .. .. .. .. .. ....... .. ............... .. .. AT-79 Rear cover packing replacement dill ...................... PD-14
Oversize piston................ .................... .. EM-35 Rear drum brake ..................................................... BR-24
Oxygen sensor (02S) (front) ................................ EC-129 Rear heated oxygen sensor (H02S) .................... EC-139
Rear heated oxygen sensor (H02S) heater ......... EC-143
Rear panel finisher ................................................. BT-13
p
Rear seat belt ............................................ RS-3
Rear side window ..................................................... BT-29
Pantograph jack ...................................................... GI-39 Rear suspension ....................................................... RA-9
Parking brake control ............ ...... .. .................. BR-28 Rear wheel anti-lock brake system (R-ABS) .......... BR-30

1234 IDX-6
 ALPHABETICAL INDEX

Rear window ............................................................ BT-28 Stabilizer bar (front) .................................................. FA-39 iill~
Refrigerant connection precaution ............................ HA-5 Stall test (AfT) .......................................................... AT-25
Refrigerant discharging evacuating charging .......... HA-48 Standardized relay ..................................................... EL-4
Refrigerant general precaution............. ............... HA-4 START- Wiring diagram .......................................... EL-20
Refrigerant lines ...................................................... HA-47 Start signal ............................................................ EC-306
Refrigeration cycle .................................................... HA-11 Starter ....................................................................... EL-22
Release bearing (clutch) .......................................... CL-10 Starting system ......................................................... EL-19
Resistor ................................................................. EC-261 Steering gear and linkage inspection ...................... MA-21
Reverse clutch .......................................................... AT-73 Steering gear oil level ............................................. MA-21
Reverse gear (M!T) ................................................. MT-8 Steering knuckle ....................................................... FA-25
Reverse idler shaft (M!T) .......................................... MT-8 Steering linkage ........................................................ ST-38
Reverse lamp switch (M!T) - See Back-up lamp Steering switch ......................................................... EL-34 Iilii;:
switch (M!T) .......................................................... MT-4 Steering wheel and column ...................................... ST-1 0
Ring gear diff. inspection ................ PD-40, PD-62, PD-85 Steering wheel play .................................................... ST-7
Road wheel size ........................................................ GI-38 Steering wheel turning force ...................................... ST-7 ~
Roof trim .................................................................. BT-15 Stop lamp ................................................................. EL-50
Room lamp ............................................................... EL-63 Striking rod (M!T) .................................................... MT-10
Room lamp - See Interior lamp ................................ EL-63 Sunroof ..................................................................... BT-25 ©!L
Rotor disc (front) ...................................................... FA-24 Supplement restraint system - Wiring diagram ....... RS-20
RR02- Wiring diagram ......................................... EC-139 Supplemental Restraint System ................................ RS-6
RR02/H- Wiring diagram ..................................... EC-143 SNCSW - Wiring diagram .................................... EC-251
Swirl control valve control solenoid valve ............. EC-243
Swirl control valve control vacuum check ffi\'ii'
s switch ................................................................ EC-251
SWLN - Wiring diagram ....................................... EC-243
SAE J1930 terminology list.. .................................... GI-45 SWN - Wiring diagram ......................................... EC-237 'ii'~
Screw jack ................................................................GI-39 Symbols and abbreviations ......................................... GI-8
Seal- See Exterior ................................................... BT-17 Synchronizer (M!T) .................................................... MT-8
Seat belt, front.. ......................................................... RS-3 System readiness test (SAT) code ......................... EC-36 ~~
Seat belt inspection ............................................... MA-23
Seat belt, rear. ........................................................... RS-3
Seat, front.. ............................................................... BT-23
T
Self-diagnostic results ............................................. EC-47
SHIFT- Wiring diagram ........................................... AT-31 Tachometer .............................................................. EL-71
Shift control (M!T) .................................................... MT-10 Tail lamp ................................................................... EL-50
Shift control (TF) ...................................................... TF-1 0 TAIUL- Wiring diagram ........................................... EL-50
Shift fork (M!T) ........................................................ MT-1 0 Tank fuel temperature sensor ............................... EC-158
Shift lock system ...................................................... AT-30 TCV - Wiring diagram ........................................... EC-295
Shift schedule ........................................................... AT-14 Temperature control cable and linkage
Shock absorber (front) ............................................. FA-36 adjustment .......................................................... HA-43 i§l'ii'
Shock absorber (rear) ............................................. RA-10 Tension rod (front) .................................................... FA-42
Side bearing preload diff ............................. PD-46, PD-69 TFTS- Wiring diagram .......................................... EC-158
Side bearing preload (front final drive 4WD) .......... PD-24 Thermal protector .................................................... HA-42
Side shaft diff .......................................................... PD-21 Thermo control amp ................................................ HA-42
Side trim ................................................................... BT-13 Thermostat ................................................................. LC-9
Side window - See Rear side window ..................... BT-29 Three way catalyst ................................................ EC-186 ~'ii'
SMJ (super multiple junction) ....................... Foldout page Three way catalyst precautions .................................. GI-6
Spare tire size ........................................................... GI-38 Throttle bodies ........................................................... EM-6 lilt'\
Spark plug replacement.. ....................................... MA-14 Throttle chambers ..................................................... EM-6
Speedometer ........................................................... EL-72 Throttle drum adjustment ........................................... FE-2
Spiral cable ............................................................. RS-1 0 Throttle position sensor adjustment. ....................... EC-72 lil!L
Spot lamp ................................................................ EL-63 Throttle position sensor (TPS) ............................... EC-118
SRS - See Supplemental Restraint System ............. RS-6 Throwout bearing- See Clutch release bearing ...... CL-10
SRS - Wiring diagram ............................................. RS-20 Tie-rod ...................................................................... ST-38
SRS Trouble diagnoses .......................................... RS-17 Tie-rod ball joints ...................................................... ST-38
S/SIG - Wiring diagram ......................................... EC-306 Tightening torque of standard bolts .......................... GI-44

IDX-7 1235
 ALPHABETICAL INDEX

Timing chain ........................................................... EM-1 0 Vehicle recovery (freeing a stuck vehicle) ............... GI-43
Tire rotation ........................................................... MA-19 Vehicle speed sensor (VSS) ........... .................. EC-217
Tire size ..................................................................... GI-38 Ventilator door control rod adjustment.. ................. HA-42
Tooth contact dill ............................. PD-51, PD-74, PD-95 VENTN - Wiring diagram. .. ..................... EC-207
Tooth contact (front final drive 4WD) ...................... PD-29 Viscosity number (SAE) ............................................ MA-9
Torque converter clutch solenoid valve ................... AT-20 VSS - Wiring diagram .... .. ......................... EC-217
Torque converter installation.......... ............... AT-41
Torque convertor clutch solenoid valve ................. EC-295
Torsion bar spring ..................................................... FA-36 w
Tow truck towing ....................................................... GI-42
Towing point........................... .................. .. ...... GI-43 WARN - Wiring diagram .......................................... EL-79
TPS- Wiring diagram ........................................... EC-118 Warning chime .............. ........................ .. ...... EL-83
TP/SW - Wiring diagram ...................................... EC-226 Warning lamps ........................................... . .. EL-76
Transfer case ............................................................. TF-8 Washer, front.... .......... ...... .. .......... .. . EL-93
Transfer fluid replacement ...................................... MA-18 Water cock control rod adjustment ......................... HA-43
Transfer oil replacement......... .............. .. ..... MA-18 Water pump ............................................................. LC-8
Transfer overhaul ................................... ................. TF-8 Water temperature gauge ........................................ EL -69
Transfer removal and installation ............................. TF-6 Weatherstrip- See Exterior.......... .. ....................... BT-17
Transfer serial number ............................................. GI-37 Wheel alignment (front)................ .. ............... .. FA-8
Transmission case (MIT) ........................................... MT-7 Wheel balance ....................................................... MA-19
Transmission serial number..... .......... GI-37 Wheel bearing (front axle).................. .. ......... FA-6
Tread-FR&RR (Dimensions)........ .. ......... GI-38 Wheel bearing (rear) .............................................. RA-4
Trim.. .......................... .. ........ BT-13 Wheel hub (front) ................................................... FA-24
TURN - Wiring diagram .......................................... EL-54 Wheel sensors (ABS) ............................................ BR-30
Turn signal lamp .............. . ................................... EL-52 Wheel size ................................................................GI-38
Two trip detection logic ......................................... EC-34 Wheelbase (Dimensions) ......................................... GI-38
Two-pole lift................ .. ................................ GI-41 Wide open & closed throttle position (CTP)
switch ............................................................... EC-226
Width (Dimensions).......... ................ .. ...... GI-38
u WINDOW- Wiring diagram.. .. ........ EL-138
Window antenna... .. ......................... EL-109
Under body .............................................................. BT-36 Window, back............................. .. ......... BT-28
Upper link (front susp.) ............................................ FA-40 Window, door. ........................................................... BT-9
Window, rear .......................................................... BT-28
Window, rear side ................................................... BT-29
v Window, side - See Rear side window ..... .............. BT-29
Windshield........................ .. .......................... BT-26
Vacuum cut valve .................................................. EC-280 Windshield washer- See Front washer ................ EL-93
Vacuum cut valve bypass valve ..... EC-276 Windshield wiper- See Front wiper.... .. .......... EL-92
Vacuum hose (brake system) ............................... BR-18 WIPER- Wiring diagram... .. .......... EL-94
Vacuum hose drawing (ECCS) .. . .. ................... EC-13 Wiper and washer..... .. ....................... EL-92
Valve clearance .................................................... EM-21 Wiper, front................. ............. .. .. EL-92
Valve guide ............................................................ EM-21 Wiring diagrams............. ..................... .. ............. GI-9
Valve seat... ........................................................... EM-22 Withdrawal lever (clutch)....................... .. ........ CL-10
Valve spring ........................................................... EM-24 Wrist pin - See Piston pin inspection ...................... EM-33
Vehicle identification number .................................. GI-36

1236 IDX-8