Nissan - Pathfinder - Workshop Manual - 2003 - 2003

BRAKE SYSTEM SECTION BR GI MA EM LC EC FE CONTENTS PRECAUTIONS ...............................................................4 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″...............4 Precautions for SRS ″Air Bag″ and ″SEAT BELT PRE-TENSIONER″ Service.........................................4 Precautions for Brake System.....................................4 Wiring Diagrams and Trouble Diagnoses....................5 PREPARATION ...............................................................6 Special Service Tools ..................................................6 Commercial Service Tools ...........................................6 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING .....................................................7 NVH Troubleshooting Chart.........................................7 ON-VEHICLE SERVICE ..................................................8 Checking Brake Fluid Level.........................................8 Checking Brake Line ...................................................8 Changing Brake Fluid ..................................................8 Bleeding Brake System ...............................................9 BRAKE HYDRAULIC LINE ...........................................10 Hydraulic Circuit.........................................................10 Removal.....................................................................11 Inspection...................................................................11 Installation..................................................................11 PROPORTIONING VALVE ............................................12 Inspection...................................................................12 Removal and Installation ...........................................12 BRAKE PEDAL AND BRACKET..................................13 Removal and Installation ...........................................13 Inspection...................................................................13 Adjustment .................................................................13 MASTER CYLINDER.....................................................15 Removal.....................................................................15 Disassembly...............................................................16 MODELS WITHOUT VDC .........................................16 MODELS WITH VDC ................................................16 Inspection...................................................................16 Assembly ...................................................................17 MODELS WITHOUT VDC .........................................17 MODELS WITH VDC ................................................17 Installation..................................................................18 BRAKE BOOSTER........................................................19 On-vehicle Service.....................................................19 OPERATING CHECK ...............................................19 AIRTIGHT CHECK ...................................................19 Removal.....................................................................19 Inspection...................................................................19 OUTPUT ROD LENGTH CHECK ..............................19 Installation..................................................................20 VACUUM PIPING...........................................................21 Vacuum Hose ............................................................21 Removal and Installation ...........................................21 Inspection...................................................................21 HOSES AND CONNECTORS ...................................21 CHECK VALVE ........................................................21 FRONT DISC BRAKE ...................................................22 Components...............................................................22 Pad Replacement ......................................................22 Removal.....................................................................23 Disassembly...............................................................24 Inspection...................................................................24 CALIPER .................................................................24 ROTOR ...................................................................24 Assembly ...................................................................25 Installation..................................................................25 Brake Burnishing Procedure......................................25 REAR DRUM BRAKE ...................................................26 Components...............................................................26 Removal.....................................................................26 Inspection...................................................................27 WHEEL CYLINDER ..................................................27 Wheel Cylinder Overhaul...........................................28 Inspection...................................................................28 DRUM .....................................................................28 LINING ....................................................................28 Installation..................................................................28 PARKING BRAKE CONTROL ......................................30 Components...............................................................30 Removal and Installation ...........................................30 CL MT AT TF PD AX SU ST RS BT HA SC EL IDX CONTENTS Inspection...................................................................30 Adjustment .................................................................31 ABS DESCRIPTION ...............................................................32 Purpose......................................................................32 Operation ...................................................................32 ABS Hydraulic Circuit ................................................32 System Components .................................................33 System Description....................................................33 SENSOR .................................................................33 CONTROL UNIT (BUILT-IN ABS ACTUATOR AND ELECTRIC UNIT) .....................................................33 ABS ACTUATOR AND ELECTRIC UNIT ....................33 G SENSOR (4WD MODELS ONLY) ..........................34 Component Parts and Harness Connector Location .....................................................................35 Schematic ..................................................................36 Wiring Diagram - ABS - .............................................37 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ...............................................................41 Self-diagnosis ............................................................41 FUNCTION ..............................................................41 SELF-DIAGNOSIS PROCEDURE ..............................41 HOW TO READ SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES) ........................................42 HOW TO ERASE SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES) ........................................42 CONSULT-II ...............................................................43 CONSULT-II APPLICATION TO ABS..........................43 ECU (ABS CONTROL UNIT) PART NUMBER MODE .....................................................................43 CONSULT-II Inspection Procedure............................44 SELF-DIAGNOSIS PROCEDURE ..............................44 SELF-DIAGNOSTIC RESULTS MODE.......................45 DATA MONITOR PROCEDURE ................................46 ACTIVE TEST PROCEDURE ....................................47 DATA MONITOR MODE ...........................................48 ACTIVE TEST MODE ...............................................48 TROUBLE DIAGNOSIS - INTRODUCTION..................49 How to Perform Trouble Diagnoses for Quick and Accurate Repair ..................................................49 INTRODUCTION ......................................................49 TROUBLE DIAGNOSIS - BASIC INSPECTION ...........50 Preliminary Check......................................................50 Ground Circuit Check ................................................53 ABS ACTUATOR AND ELECTRIC UNIT GROUND.....53 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION ...............................................................54 Malfunction Code/Symptom Chart.............................54 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS.............................................................................56 Wheel Sensor or Rotor..............................................56 (Cont’d) DIAGNOSTIC PROCEDURE .....................................56 ABS Actuator Solenoid Valve or Solenoid Valve Relay..........................................................................59 DIAGNOSTIC PROCEDURE .....................................59 Motor Relay or Motor.................................................61 DIAGNOSTIC PROCEDURE .....................................61 Low Voltage ...............................................................63 DIAGNOSTIC PROCEDURE .....................................63 G Sensor and Circuit .................................................65 DIAGNOSTIC PROCEDURE .....................................65 Control Unit................................................................67 DIAGNOSTIC PROCEDURE .....................................67 TROUBLE DIAGNOSES FOR SYMPTOMS .................68 1. ABS Works Frequently ..........................................68 2. Unexpected Pedal Action ......................................68 3. Long Stopping Distance ........................................70 4. ABS Does Not Work..............................................70 5. Pedal Vibration and Noise.....................................71 6. Warning Lamp Does Not Come On When Ignition Switch Is Turned On .....................................72 7. Warning Lamp Stays On When Ignition Switch Is Turned On..............................................................74 8. Vehicle Vibrates Excessively When ABS Is Operating ...................................................................77 REMOVAL AND INSTALLATION .................................80 Front Wheel Sensor...................................................80 Rear Wheel Sensor ...................................................80 Front Sensor Rotor ....................................................81 REMOVAL ...............................................................81 INSTALLATION........................................................81 Rear Sensor Rotor.....................................................81 REMOVAL ...............................................................81 INSTALLATION........................................................81 G Sensor....................................................................81 ABS Actuator and Electric Unit..................................82 REMOVAL ...............................................................82 INSTALLATION........................................................82 VDC/TCS/ABS PRECAUTIONS .............................................................83 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″.............83 Precautions for SRS ″Air Bag″ and ″SEAT BELT PRE-TENSIONER″ Service.......................................83 Precautions for Brake System...................................83 Precautions for Brake Control ...................................84 Diagnosis Precaution.................................................84 CAN SYSTEM .........................................................84 Precaution for Harness Repair ..................................84 CAN SYSTEM .........................................................84 PREPARATION .............................................................86 Commercial Service Tools .........................................86 ON-VEHICLE SERVICE ................................................87 BR-2 CONTENTS Adjustment of Steering Angle Sensor Neutral Position ......................................................................87 Calibration of Decel G Sensor...................................87 GENERAL INFORMATION ...........................................89 Fail-Safe.....................................................................89 ABS SYSTEM ..........................................................89 VDC/TCS SYSTEM ..................................................89 Hydraulic Circuit Diagram..........................................89 ABS Function.............................................................89 TCS Function.............................................................90 VDC Function ............................................................90 System Diagram ........................................................90 CAN COMMUNICATION ...............................................91 System Description....................................................91 CAN Communication Unit..........................................91 TYPE 1 (ALL-MODE 4WD MODELS) .........................91 TYPE 2 (EXCEPT ALL-MODE 4WD MODELS) ...........93 TROUBLE DIAGNOSES................................................94 How to Proceed with Diagnosis ................................94 BASIC CONCEPT ....................................................94 DIAGNOSIS FLOWCHART .......................................95 ASKING COMPLAINTS ............................................96 EXAMPLE OF DIAGNOSIS SHEET ...........................96 Component Installation Location ...............................97 Schematic ..................................................................98 Wiring Diagram - VDC - ............................................99 Control Unit Input/Output Signal Standard..............104 STANDARDS BY CONSULT-II ................................104 CONSULT-II Functions ............................................106 CONSULT-II MAIN FUNCTION ................................106 SELF-DIAGNOSIS .................................................108 DATA MONITOR.................................................... 111 ACTIVE TEST ........................................................114 For Fast and Accurate Diagnosis ............................116 PRECAUTIONS FOR DIAGNOSIS ..........................116 Basic Inspection.......................................................118 BASIC INSPECTION 1: BRAKE FLUID LEVEL AND LEAK INSPECTION........................................118 BASIC INSPECTION 2: INSPECTION FOR LOOSENESS OF POWER SYSTEM TERMINALS ....118 BASIC INSPECTION 3: INSPECTION OF ABS WARNING LAMP, VDC OFF INDICATOR LAMP AND SLIP INDICATOR LAMP .................................118 Inspection 1 Wheel Sensor System ........................119 INSPECTION PROCEDURE ...................................119 Inspection 2 Engine System....................................121 Inspection 3 VDC/TCS/ABS Control Unit System...121 Inspection 4 VDC Pressure Sensor System ...........122 Inspection 5 Steering Angle Sensor System...........123 Inspection 6 Yaw Rate/Side/Decel G Sensor System .....................................................................124 (Cont’d) Inspection 7 Solenoid Valve, VDC Switch-over Solenoid Valve and Circuit ......................................126 Inspection 8 ABS Actuator Relay or ABS Motor Relay Power System ...............................................128 Inspection 9 Stop Lamp Switch and Circuit ............129 Inspection 10 ABS Actuator and Electric Unit (Control Unit) Power Circuit.....................................130 Inspection 11 When ″SHIFT POSITION ERROR″ Appears in Self-Diagnosis Results Display .............132 Inspection 12 When ″ST ANG SEN COM CIR″ Appears on Self-Diagnosis Results Display............133 Inspection 13 Brake Fluid Level of Reservoir Tank .........................................................................133 Inspection 14 CAN Communications System .........134 Inspecting Components ...........................................134 VDC OFF SWITCH ................................................134 Symptom 1 ABS Works Frequently. ........................135 Symptom 2 Unexpected Pedal Reaction ................135 Symptom 3 Long Stopping Distance.......................136 Symptom 4 ABS Does Not Work. ...........................137 Symptom 5 Pedal Vibration and Noise ...................137 Symptom 6 VDC OFF Indicator Lamp Does Not Illuminate..................................................................138 Symptom 7 SLIP Indicator Lamp Does Not Illuminate..................................................................139 Symptom 8 Vehicle Behaves Jerkily During VDC/ TCS/ABS Operation.................................................140 WHEEL SENSORS......................................................142 Removal and Installation .........................................142 REMOVAL .............................................................142 INSTALLATION......................................................142 SENSOR ROTOR ........................................................144 Removal and Installation .........................................144 REMOVAL .............................................................144 INSTALLATION......................................................144 VDC/TCS/ABS ACTUATOR........................................145 Removal and Installation .........................................145 G SENSOR ..................................................................146 Removal and Installation .........................................146 REMOVAL .............................................................146 INSTALLATION......................................................146 SERVICE DATA AND SPECIFICATIONS (SDS) .......147 General Specifications.............................................147 Disc Brake ...............................................................147 Drum Brake..............................................................147 Brake Pedal .............................................................147 Parking Brake Control .............................................148 GI MA EM LC EC FE CL MT AT TF PD AX SU ST RS BT HA SC EL IDX BR-3 PRECAUTIONS Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” NABR0206 The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS composition which is available to NISSAN MODEL R50 is as follows (The composition varies according to optional equipment.): I For a frontal collision The Supplemental Restraint System consists of driver air bag module (located in the center of the steering wheel), front passenger air bag module (located on the instrument panel on passenger side), seat belt pre-tensioners, diagnosis sensor unit, warning lamp, wiring harness and spiral cable. I For a side collision The Supplemental Restraint System consists of front side air bag module (located in the outer side of front seat), side curtain air bag module (locating in the headliner side of front and rear seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision). WARNING: I 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 should be performed by an authorized NISSAN dealer. I Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified with yellow and/or orange harness connector (and with yellow harness protector or yellow insulation tape before the harness connectors). Precautions for SRS “Air Bag” and “SEAT BELT PRE-TENSIONER” Service I I I I I I I NABR0207 Do not use electrical test equipment to check SRS circuits unless instructed to in this Service Manual. 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 and seat belt pre-tensioner to deploy. Therefore, do not work on any SRS connectors or wires until at least 3 minutes have passed. Diagnosis sensor unit must always be installed with their arrow marks “g” pointing towards the front of the vehicle for proper operation. Also check diagnosis sensor unit for cracks, deformities or rust before installation and replace as required. 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 driver and passenger air bag modules with the pad side facing upward and place side air bag module standing with stud bolt side setting bottom. Conduct self-diagnosis to check entire SRS for proper function after replacing any components. After air bag inflates, the front instrument panel assembly should be replaced if damaged. Precautions for Brake System I I I I I NABR0002 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 will ruin rubber parts of hydraulic system. SBR686C BR-4 PRECAUTIONS Precautions for Brake System (Cont’d) I Use flare nut wrench when removing and installing brake tubes. I Always torque brake lines when installing. WARNING: I Clean brakes with a vacuum dust collector to minimize risk of health hazard from powder caused by friction. GI MA EM LC Wiring Diagrams and Trouble Diagnoses When you read wiring diagrams, refer to the following: I GI-11, “HOW TO READ WIRING DIAGRAMS” I EL-11, “POWER SUPPLY ROUTING” for power distribution circuit When you perform trouble diagnoses, refer to the following: I GI-35, “HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES” I GI-24, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT” EC NABR0003 FE CL MT AT TF PD AX SU ST RS BT HA SC EL IDX BR-5 PREPARATION Special Service Tools Special Service Tools NABR0004 The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name Description KV40106500 (J25852-B) Rear wheel bearing puller Removing rear wheel sensor rotor NT724 Commercial Service Tools Tool name Description Removing and installing each brake piping a: 10 mm (0.39 in) 1 Flare nut crowfoot 2 Torque wrench NT360 Brake fluid pressure gauge Measuring brake fluid pressure NT151 Rear wheel sensor rotor drift Installing rear wheel sensor rotor a: 75 mm (2.95 in) dia. b: 63 mm (2.48 in) dia. NT509 BR-6 NABR0005 — × Rotor or drum damage — × Rotor or drum runout BR-24, 28 × Rotor or drum deformation — × Rotor or drum deflection — × Rotor or drum rust — × Rotor thickness variation BR-25 × Drum out of round BR-28 × PROPELLER SHAFT PD-4 × DIFFERENTIAL PD-4 × DRIVE SHAFT AX-3 × AXLE AX-3 × SUSPENSION SU-4 × TIRES SU-4 × ROAD WHEEL SU-4 × STEERING ST-6 × × × × × × × × × × × × NABR0085 × Rotor or drum imbalance NVH Troubleshooting Chart × BR-22 NABR0085S01 × Shims damaged NVH Troubleshooting Chart × BR-26 × BR-22, 28 Return spring damaged × Linings or pads - uneven wear NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING Noise Shake Shimmy, Judder BR-22, 28 Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts. Reference page BRAKE Possible cause and SUSPECTED PARTS Symptom ×: Applicable BR-7 Linings or pads - damaged GI MA EM LC EC FE CL MT AT TF PD AX SU ST RS BT HA SC EL IDX ON-VEHICLE SERVICE Checking Brake Fluid Level Checking Brake Fluid Level I I I NABR0006 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. If the brake warning lamp comes on, check brake fluid level switch and parking brake switch. SBR451D Checking Brake Line NABR0007 CAUTION: If leakage occurs around joints, retighten or, if necessary, replace damaged parts. 1. Check brake lines (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged parts. 2. Check for oil leakage by fully depressing brake pedal while engine is running. SBR389C Changing Brake Fluid SBR419C NABR0008 CAUTION: I Refill with new brake fluid “DOT 3”. I Always keep fluid level higher than minimum line on reservoir tank. I Never reuse drained brake fluid. I 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. 2. Connect a vinyl tube to each air bleeder valve. 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 Brake System”, BR-9. BR-8 ON-VEHICLE SERVICE Bleeding Brake System Bleeding Brake System SBR995 =NABR0009 CAUTION: I Carefully monitor brake fluid level at master cylinder during bleeding operation. I If master cylinder is suspected to have air inside, bleed air from master cylinder first. Refer to “Installation”, “MASTER CYLINDER”, BR-18. I Fill reservoir with new brake fluid “DOT 3”. Make sure it is full at all times while bleeding air out of system. I Place a container under master cylinder to avoid spillage of brake fluid. I Turn ignition switch OFF and disconnect ABS actuator and electric unit connectors or battery ground cable. I Bleed air in the following order. 1. Left rear brake 2. Right rear brake 3. Left front brake 4. Right front brake GI MA EM LC EC FE CL MT 1. 2. 3. 4. 5. 6. 7. Connect a transparent vinyl tube to air bleeder valve. Fully depress brake pedal several times. With brake pedal depressed, open air bleeder valve to release air. Close air bleeder valve. Release brake pedal slowly. Repeat steps 2. through 5. until clear brake fluid comes out of air bleeder valve. Tighten air bleeder valve. : 7 - 9 N·m (0.7 - 0.9 kg-m, 61 - 78 in-lb) SBR419C AT TF PD AX SU ST RS BT HA SC EL IDX BR-9 BRAKE HYDRAULIC LINE Hydraulic Circuit Hydraulic Circuit NABR0010 SBR058F SBR059F BR-10 BRAKE HYDRAULIC LINE Removal Removal SBR992 NABR0011 CAUTION: I 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. I All hoses must be free from excessive bending, twisting and pulling. 1. Connect vinyl tube to air bleeder valve. 2. Drain brake fluid from each air bleeder valve by depressing brake pedal. 3. Remove flare nut connecting brake tube and hose, then withdraw lock spring. 4. Cover openings to prevent entrance of dirt whenever disconnecting brake line. GI MA EM LC EC FE CL MT Inspection AT NABR0012 Check brake lines (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged parts. TF PD AX SU Installation SBR686C NABR0013 CAUTION: I Refill with new brake fluid “DOT 3”. I Never reuse drained brake fluid. 1. Tighten all flare nuts and connecting bolts. Flare nut: (M10) : 15 - 17 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb) Flare nut: (M12) : 17 - 19 N·m (1.7 - 2.0 kg-m, 12 - 14 ft-lb) Connecting bolt: : 17 - 19 N·m (1.7 - 2.0 kg-m, 12 - 14 ft-lb) 2. Refill until new brake fluid comes out of each air bleeder valve. 3. Bleed air. Refer to “Bleeding Brake System”, BR-9. ST RS BT HA SC EL IDX BR-11 PROPORTIONING VALVE Inspection Inspection SBR822BA NABR0116 CAUTION: I Carefully monitor brake fluid level at master cylinder. I Use new brake fluid “DOT 3”. I 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. I Depress pedal slowly when raising front brake pressure. I Check rear brake pressure 2 seconds after front brake pressure reaches specified value. I Disconnect harness connectors from ABS actuator and electric unit before checking. 1. Remove front LH tire. 2. Connect tool to air bleeders on front LH brake caliper and rear LH or RH brake wheel cylinder. 3. Install front LH tire. Before installing front LH tire, confirm the tool is not touching the front LH wheel. 4. Bleed air from the tool. 5. Check fluid pressure by depressing brake pedal. kPa (kg/cm2, psi) SBR823BA Applied pressure (Front brake) Output pressure (Rear brake) D1 D2 6,375 (65, 924) 3,432 - 3,825 (35 - 39, 498 - 555) If output pressure is out of specifications, replace master cylinder assembly. 6. Bleed air after disconnecting the tool. Refer to “Bleeding Brake System”, BR-9. 7. Install front LH tire. SBR705AA Removal and Installation NABR0117 Always replace together with master cylinder as an assembly. I Refer to “MASTER CYLINDER”, BR-15. BR-12 BRAKE PEDAL AND BRACKET Removal and Installation Removal and Installation NABR0016 GI MA EM LC EC FE CL SBR520E Inspection MT AT NABR0017 Check brake pedal for following items. I Brake pedal bend I Clevis pin deformation I Crack of any welded portion I Crack or deformation of clevis pin stopper TF PD AX SU Adjustment NABR0018 Check brake pedal free height from metal panel. H: Free height Refer to SDS (BR-147). D: Depressed height Refer to SDS (BR-147). Under force of 490 N (50 kg, 110 lb) with engine running C1, C2: Clearance between pedal stopper and threaded end of stop lamp switch and ASCD switch 0.3 - 1.0 mm (0.012 - 0.039 in) A: Pedal free play 1 - 3 mm (0.04 - 0.12 in) If necessary, adjust brake pedal free height. ST RS BT HA SC EL IDX SBR463CC BR-13 BRAKE PEDAL AND BRACKET Adjustment (Cont’d) 1. SBR824B Loosen lock nut and adjust pedal free height by turning brake booster input rod. Then tighten lock nut. Make sure that tip of input rod stays inside. 2. Adjust clearance “C1” and “C2” with stop lamp switch and ASCD switch respectively. Then tighten lock nuts. 3. Check pedal free play. Make sure that stop lamp is off when pedal is released. 4. Check brake pedal’s depressed height while engine is running. If depressed height is below specified value, check brake system for leaks, accumulation of air or any damage to components (master cylinder, wheel cylinder, etc.). Then make necessary repairs. BR-14 MASTER CYLINDER Removal Removal NABR0019 CAUTION: I 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. I In the case of brake fluid leakage from the master cylinder, disassemble the cylinder. Then check piston cups for deformation or 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. 3. Remove brake pipe flare nuts. 4. Remove master cylinder mounting nuts. GI MA EM LC EC FE CL MT AT TF PD AX SU ST SBR060F 1. 2. 3. 4. 5. 6. Reservoir cap Oil filter Float Reservoir tank Seal Cylinder body 7. 8. 9. 10. 11. 12. O-ring Piston stopper Secondary piston assembly Primary piston assembly Stopper cap O-ring 13. 14. 15. 16. 17. Plate Guide assembly Plate Snap ring Pressure sensor RS BT HA SC EL IDX BR-15 MASTER CYLINDER Disassembly Disassembly MODELS WITHOUT VDC 1. NABR0020 NABR0020S01 Bend claws of stopper cap outward. SBR938A 2. Remove piston stopper while piston is pushed into cylinder. 3. Remove piston assemblies. If it is difficult to remove secondary piston assembly, gradually apply compressed air through fluid outlet. 4. Draw out reservoir tank. SBR231C MODELS WITH VDC NABR0020S02 1. 2. Remove the snap ring in pushing primary piston. Holding the rod of the primary piston, remove the primary piston assembly, the plate and the guide with pulling straight to prevent the cup from being caught by the inner wall of the cylinder. 3. Remove the plate and the guide from the primary piston. CAUTION: Be careful not to damage the rod from the inner wall of the plate. BRA0561D 4. Remove piston stopper while secondary piston is pushed into cylinder. 5. Remove secondary piston assemblies. If it is difficult to remove secondary piston assembly, gradually apply compressed air through fluid outlet. 6. Draw out reservoir tank. SBR231C Inspection NABR0021 Check master cylinder inner wall for pin holes or scratches. Replace if damaged. BR-16 MASTER CYLINDER Assembly Assembly MODELS WITHOUT VDC 1. NABR0022 GI NABR0022S01 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 cylinder bore. Pay attention to alignment of secondary piston slit with valve stopper mounting hole of cylinder body. MA 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. EC I I EM LC SBR354C FE CL MT SBR940A 5. Install piston stopper while piston is pushed into cylinder. AT TF PD AX SU SBR435B MODELS WITH VDC 1. I I NABR0022S02 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 cylinder bore. Pay attention to alignment of secondary piston slit with valve stopper mounting hole of cylinder body. ST RS BT SBR061F 2. Install valve stopper while piston is pushed into cylinder. HA SC EL IDX SBR435B BR-17 MASTER CYLINDER Assembly (Cont’d) 3. Install the plate and the guide into the cylinder body. CAUTION: I Be careful not to damage the rod of the primary piston. I Pay attention to the orientation of the guide. I Do not drop the O-ring. SFIA0701E 4. Be careful not to damage the rod of the primary piston with covering the close. Then insert snap ring to cylinder with pushing primary piston. CAUTION: I Be careful to check the snap ring in the inner tip of the cylinder body. I Do not reuse the snap ring. 5. Push reservoir tank seals into cylinder body. 6. Push reservoir tank into cylinder body. BRA0561D Installation ABR190 NABR0023 CAUTION: I Refill with new brake fluid “DOT 3”. I Never reuse drained brake fluid. 1. Place master cylinder onto brake booster and secure mounting nuts lightly. 2. Torque mounting nuts. : 7.8 - 10.8 N·m (0.8 - 1.1 kg-m, 69 - 95 in-lb) 3. Fill up reservoir tank with new brake fluid. 4. Plug all ports on master cylinder with fingers to prevent air suction while releasing brake pedal. 5. Have driver depress brake pedal slowly several times until no air comes out of master cylinder. 6. Fit brake lines to master cylinder. 7. Tighten flare nuts. : 15 - 17 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb) (M10) : 17 - 19 N·m (1.7 - 2.0 kg-m, 12 - 14 ft-lb) (M12) 8. Bleed air. Refer to “Bleeding Brake System”, BR-9. BR-18 BRAKE BOOSTER On-vehicle Service On-vehicle Service OPERATING CHECK 1. 2. SBR002A 2. GI NABR0024S01 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. AIRTIGHT CHECK 1. NABR0024 NABR0024S02 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 stroke should not change after holding pedal down for 30 seconds. MA EM LC EC FE CL MT SBR365AA Removal AT NABR0025 CAUTION: I 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. I Be careful not to deform or bend brake pipes, during removal of booster. TF PD AX SU SBR242F Inspection OUTPUT ROD LENGTH CHECK 1. 2. 3. NABR0026 NABR0026S01 Apply vacuum of −66.7 kPa (−500 mmHg, −19.69 inHg) to brake booster with a hand vacuum pump. Add preload of 19.6 N (2.0 kg, 4.4 lb) to output rod. Check output rod length. Specified length: 10.275 - 10.525 mm (0.4045 - 0.4144 in) ST RS BT SBR208E HA SC EL IDX BR-19 BRAKE BOOSTER Installation Installation SBR062F =NABR0027 CAUTION: I Be careful not to deform or bend brake pipes during installation of booster. I Replace clevis pin if damaged. I Refill with new brake fluid “DOT 3”. I Never reuse drained brake fluid. I Take care not to damage brake booster mounting bolt thread when installing. Due to the narrow angle of installation, the threads can be damaged by the dash panel. 1. Before fitting booster, temporarily adjust clevis to dimension shown. 2. Fit booster, then secure mounting nuts (brake pedal bracket to brake booster) lightly. 3. Connect brake pedal and booster input rod with clevis pin. 4. Secure mounting nuts. Specification: 13 - 16 N·m (1.3 - 1.6 kg-m, 9 - 12 ft-lb) 5. Install master cylinder. Refer to “Installation” in “MASTER CYLINDER”, BR-18. 6. Adjust brake pedal height and free play. Refer to “Adjustment” in “BRAKE PEDAL AND BRACKET”, BR-13. 7. Secure lock nut for clevis. : 16 - 22 N·m (1.6 - 2.2 kg-m, 12 - 16 ft-lb) 8. Bleed air. Refer to “Bleeding Brake System”, BR-9. BR-20 VACUUM PIPING Vacuum Hose Vacuum Hose NABR0028 GI MA EM LC SBR063F EC Removal and Installation NABR0029 CAUTION: When installing vacuum hoses, pay attention to the following points. I Do not apply any oil or lubricants to vacuum hose and check valve. I Insert vacuum tube into vacuum hose as shown. FE CL MT SBR225B I AT Install check valve, paying attention to its direction. TF PD AX SU SBR064F Inspection NABR0030 HOSES AND CONNECTORS NABR0030S01 Check vacuum lines, connections and check valve for airtightness, improper attachment chafing and deterioration. ST RS BT CHECK VALVE NABR0030S02 Check vacuum with a vacuum pump. Connect to booster side Vacuum should exist. Connect to engine side Vacuum should not exist. HA SC EL IDX SBR844B BR-21 FRONT DISC BRAKE Components Components NABR0031 SBR385DC 1. 2. 3. 4. 5. 6. Main pin Pin boot Torque member fixing bolt Torque member Shim cover Inner shim 7. 8. 9. 10. 11. 12. Inner pad Pad retainer Outer pad Outer shim Connecting bolt Copper washer Pad Replacement 13. 14. 15. 16. 17. 18. Main pin bolt Bleed valve Cylinder body Piston seal Piston Piston boot NABR0032 WARNING: Clean brakes with a vacuum dust collector to minimize the hazard of airborne particles or other materials. CAUTION: I When cylinder body is open, do not depress brake pedal, or piston will pop out. I Be careful not to damage piston boot or get oil on rotor. Always replace shims when replacing pads. I If shims are rusted or show peeling of the rubber coat, replace them with new shims. I It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly. In this case, suspend cylinder body with wire so as not to stretch brake hose. I Carefully monitor brake fluid level because brake fluid will return to reservoir when pushing back piston. BR-22 FRONT DISC BRAKE Pad Replacement (Cont’d) 1. 2. Remove master cylinder reservoir cap. Remove lower pin bolt. GI MA EM LC SBR383D 3. Open cylinder body upward. Then remove pad retainers, and inner and outer shims. Standard pad thickness: 11.0 mm (0.433 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. EC FE CL MT AT TF PD AX SU SBR384D Removal NABR0033 WARNING: Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials. CAUTION: Suspend caliper assembly with wire so as not to stretch brake hose. ST RS BT Remove torque member fixing bolts and connecting bolt. It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly. In this case, suspend caliper assembly with wire so as not to stretch brake hose. HA SC EL IDX SBR386D BR-23 FRONT DISC BRAKE Disassembly Disassembly NABR0034 WARNING: Do not place your fingers in front of piston. CAUTION: Do not scratch or score cylinder wall. 1. Push out piston with dust seal with compressed air. 2. Remove piston seal with a suitable tool. SBR085A Inspection CALIPER Cylinder Body I NABR0035 NABR0035S01 NABR0035S0101 Check inside surface of cylinder for score, rust, wear, damage or presence of foreign objects. If any of the above conditions are observed, replace cylinder body. I Minor damage from rust or foreign objects may be eliminated by polishing surface with a fine emery paper. Replace cylinder body if necessary. CAUTION: Use brake fluid to clean. Never use mineral oil. Piston NABR0035S0102 Check piston for score, rust, wear, damage or presence of foreign objects. Replace if any of the above conditions are observed. CAUTION: Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign objects are stuck to sliding surface. Slide Pin, Pin Bolt and Pin Boot NABR0035S0103 Check for wear, cracks, rust or other damage. Replace if any of the above conditions are observed. ROTOR Runout SBR019B NABR0035S02 NABR0035S0201 1. Secure rotor to wheel hub with at least two nuts (M12 × 1.25). 2. Check runout using a dial indicator. Make sure that wheel bearing axial end play is within the specifications before measuring. Refer to AX-4, “Front Wheel Bearing”. Maximum runout: 0.1 mm (0.004 in) 3. If the runout is out of specification, find minimum runout position as follows: a. Remove nuts and rotor from wheel hub. b. Shift the rotor one hole and secure rotor to wheel hub with nuts. c. Measure runout. d. Repeat steps a. to c. so that minimum runout position can be found. 4. If the runout is still out of specification, turn rotor with on-car brake lathe (“MAD, DL-8700”, “AMMCO 700 and 705” or equivalent). BR-24 FRONT DISC BRAKE Inspection (Cont’d) Thickness NABR0035S0202 Thickness variation (At least 8 positions): Maximum 0.015 mm (0.0006 in) If thickness variation exceeds the specification, turn rotor with oncar brake lathe. Rotor repair limit: 26.0 mm (1.024 in) GI MA EM LC SBR020B Assembly 1. 2. 3. EC NABR0036 Insert piston seal into groove on cylinder body. With piston boot fitted to piston, insert piston boot into groove on cylinder body and install piston. Properly secure piston boot FE CL MT SBR574 Installation AT NABR0037 CAUTION: I Refill with new brake fluid “DOT 3”. I 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 Brake System”, BR-9. TF PD AX SU SBR387D Brake Burnishing Procedure NABR0086 When experiencing soft brake pedal feel at very low mileage, or after replacing the rotor, burnish the brake pad contact surfaces according to the following procedures. CAUTION: Only perform this procedure under safe road and traffic conditions. Use extreme caution. 1. Drive the vehicle on a straight smooth road at 50 km/h (31 MPH). 2. Use medium brake pedal/foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH). Adjust brake pedal/foot pressure such that vehicle stopping time equals 3 to 5 seconds. 3. To cool the brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping. 4. Repeat steps 1 to 3 10 times or more to complete the burnishing procedure. ST RS BT HA SC EL IDX BR-25 REAR DRUM BRAKE Components Components NABR0038 SBR757DA 1. 2. 3. 4. 5. 6. 7. 8. 9. Shoe hold pin Plug Back plate Check plug Spring Shoe (leading side) Air bleeder Spring Piston cup 10. 11. 12. 13. 14. 15. 16. 17. 18. Piston Boot Retainer ring Toggle lever Wave washer Shoe (trailing side) Adjuster Boot Piston Removal 19. 20. 21. 22. 23. 24. 25. 26. 27. Piston cup Wheel cylinder Adjuster lever Spring seat Shoe hold spring Retainer Adjuster spring Return spring (upper) Return spring (lower) NABR0039 WARNING: Clean brake lining with a vacuum dust collector to minimize the hazard of airborne asbestos or other materials. CAUTION: Make sure parking brake lever is released completely. 1. a. Release parking brake lever fully, then remove drum. If drum is hard to remove, the following procedures should be carried out. Remove plug. Then shorten adjuster to make clearance between brake shoe and drum as shown. SBR264CA BR-26 REAR DRUM BRAKE Removal (Cont’d) b. Tighten the two bolts gradually. GI MA EM LC SBR093A 2. After removing shoe hold pin by rotating push retainer, remove leading shoe then remove trailing shoe. Remove spring by rotating shoes in direction arrow. Be careful not to damage wheel cylinder piston boots. 3. Remove adjuster. EC FE CL MT SBR266CA 4. Disconnect parking brake cable from toggle lever. Be careful not to damage parking brake cable when separating it. AT TF PD AX SU SBR267CA 5. Remove retainer ring with a suitable tool. Then separate toggle lever and brake shoe. ST RS BT SBR093B Inspection WHEEL CYLINDER I I Check wheel cylinder for leakage. Check for wear, damage and loose conditions. Replace if any such condition exists. NABR0040 HA NABR0040S01 SC EL IDX SBR816B BR-27 REAR DRUM BRAKE Wheel Cylinder Overhaul Wheel Cylinder Overhaul I I NABR0041 Check all internal parts for wear, rust and damage. Replace if necessary. Pay attention so as not to scratch cylinder when installing pistons. SBR215B Inspection DRUM I I I SBR095A NABR0042 NABR0042S01 Maximum inner diameter: 296.5 mm (11.67 in) Out-of-roundness: 0.03 mm (0.0012 in) or less Contact surface should be fine finished with No. 120 to 150 emery paper. Using a drum lathe, lathe brake drum if it shows scoring, partial wear or stepped wear. After brake drum has been completely reconditioned or replaced, check drum and shoes for proper contact pattern. LINING NABR0042S02 Check lining thickness. Standard lining thickness: 6.1 mm (0.240 in) Lining wear limit (A): 1.5 mm (0.059 in) SBR021A Installation NABR0043 Always perform shoe clearance adjustment. Refer to BR-31. 1. Fit toggle lever to brake shoe (trailing side) with retainer ring. SBR092B 2. Apply brake grease to the contact areas (indicated by arrows and hatching) shown at left. ABR371 BR-28 REAR DRUM BRAKE Installation (Cont’d) 3. I Shorten adjuster by rotating it. Pay attention to direction of adjuster. Wheel Left Right GI Screw Depression Left-hand thread Yes Right-hand thread No MA EM LC SBR217B SBR279B 4. Connect parking brake cable to toggle lever. 5. Install all parts. Be careful not to damage wheel cylinder piston boots. 6. Check all parts are installed properly. Pay attention to direction of adjuster assembly. 7. Install brake drum. 8. When installing new wheel cylinder or overhauling wheel cylinder, bleed air. Refer to “Bleeding Brake System”, BR-9. 9. Adjust parking brake. Refer to “Adjustment”, “PARKING BRAKE CONTROL”, BR-31. EC FE CL MT AT TF PD AX SU ST RS BT HA SC EL IDX BR-29 PARKING BRAKE CONTROL Components Components NABR0044 SBR667E Removal and Installation NABR0045 1. 2. 3. To remove parking brake cable, first remove center console. Disconnect warning lamp connector. Remove bolts, slacken off and remove adjusting nut. 4. Disconnect cable. Refer to “Removal”, “REAR DRUM BRAKE”, BR-26. SBR390D SBR391D Inspection 1. 2. 3. 4. NABR0046 Check control lever for wear or other damage. Replace if necessary. Check wires for discontinuity or deterioration. Replace if necessary. Check warning lamp and switch. Replace if necessary. Check parts at each connecting portion and, if deformed or damaged, replace. BR-30 PARKING BRAKE CONTROL Adjustment Adjustment 1. a. b. 2. NABR0047 Adjust clearance between shoe and drum as follows: Release parking brake lever and loosen adjusting nut. Depress brake pedal fully at least 10 times with engine running. Pull control lever 4 - 5 notches. Then adjust control lever by turning adjusting nut. GI MA EM LC SBR042D 3. Pull control lever with specified amount of force. Check lever stroke and ensure smooth operation. Number of notches: 6 - 8 EC FE CL MT SBR073D 4. I I Bend warning lamp switchplate to ensure: Warning lamp comes on when lever is lifted “A” notches. Warning lamp goes out when lever is fully released. Number of “A” notches: 1 or less AT TF PD AX SU ST RS BT HA SC EL IDX BR-31 DESCRIPTION ABS Purpose Purpose NABR0087 The Anti-Lock Brake System (ABS) consists of electronic and hydraulic components. It allows for control of braking force so locking of the wheels can be avoided. 1) Improves proper tracking performance through steering wheel operation. 2) Eases obstacle avoidance through steering wheel operation. 3) Improves vehicle stability. Operation I I I NABR0088 When the vehicle speed is less than 10 km/h (6 MPH) this system does not work. The Anti-Lock Brake System (ABS) has a self-test function. The system turns on the ABS warning lamp for 1 second each time the ignition switch is turned “ON”. After the engine is started, the ABS warning lamp turns off. The system performs a test the first time the vehicle reaches 6 km/h (4 MPH). A mechanical noise may be heard as the ABS performs this self-test. This is a normal part of the self-test feature. If a malfunction is found during this check, the ABS warning lamp will stay on. While driving, a mechanical noise may be heard during ABS operation. This is a normal condition. ABS Hydraulic Circuit NABR0089 SBR859D 1. 2. 3. Inlet solenoid valve Outlet solenoid valve Reservoir 4. 5. 6. Pump Motor Inlet valve BR-32 7. 8. 9. Outlet valve Bypass check valve Damper DESCRIPTION ABS System Components System Components NABR0090 GI MA EM LC EC FE CL SBR447EB System Description SENSOR AT NABR0091 NABR0091S01 The sensor unit consists of a gear-shaped sensor rotor and a sensor element. The element contains a bar magnet around which a coil is wound. The front sensors are installed on the front spindles and the rear sensors are installed on the rear spindles. As the wheel rotates, the sensor generates a sine-wave pattern. The frequency and voltage increase(s) as the rotating speed increases. TF PD AX SU SBR124B CONTROL UNIT (BUILT-IN ABS ACTUATOR AND ELECTRIC UNIT) SBR676E MT NABR0091S02 The control unit computes the wheel rotating speed by the signal current sent from the sensor. Then it supplies a DC current to the actuator solenoid valve. It also controls ON-OFF operation of the valve relay and motor relay. If any electrical malfunction should be detected in the system, the control unit causes the warning lamp to light up. In this condition, the ABS will be deactivated by the control unit, and the vehicle’s brake system reverts to normal operation. (For control unit layout, refer to ABS ACTUATOR AND ELECTRIC UNIT, BR-33.) ABS ACTUATOR AND ELECTRIC UNIT The ABS actuator and electric unit contains: I An electric motor and pump I Two relays I Six solenoid valves, each inlet and outlet for — LH front — RH front — Rear I ABS control unit SBR065F BR-33 NABR0091S03 ST RS BT HA SC EL IDX DESCRIPTION ABS System Description (Cont’d) This component controls the hydraulic circuit and increases, holds or decreases hydraulic pressure to all or individual wheels. The ABS actuator and electric unit is serviced as an assembly. ABS Actuator Operation Inlet solenoid valve Outlet solenoid valve OFF (Open) OFF (Closed) Master cylinder brake fluid pressure is directly transmitted to caliper via the inlet solenoid valve. Pressure hold ON (Closed) OFF (Closed) Hydraulic circuit is shut off to hold the caliper brake fluid pressure. Pressure decrease ON (Closed) ON (Open) Caliper brake fluid is sent to reservoir via the outlet solenoid valve. Then it is pushed up to the master cylinder by pump. OFF (Closed) Master cylinder brake fluid pressure is transmitted to caliper. Normal brake operation ABS operation NABR0091S0301 Pressure increase OFF (Open) G SENSOR (4WD MODELS ONLY) NABR0091S05 The G sensor senses deceleration during braking to determine whether the vehicle is being driven on a high µ road (asphalt road, etc.) or a low µ road (snow-covered road, etc.). It then sends a signal to the ABS control unit. The reed switch turns on when it is affected by a magnetic field. During sudden deceleration (braking on a high µ road), the weight moves and the magnet in the weight moves away from the reed switch. The magnetic field then diminishes and the reed switch turns off. SBR076F BR-34 DESCRIPTION ABS Component Parts and Harness Connector Location Component Parts and Harness Connector Location GI NABR0147 MA EM LC EC FE CL MT AT TF PD AX SU ST RS BT HA SC EL SBR075F BR-35 IDX DESCRIPTION ABS Schematic Schematic NABR0093 MBR624A BR-36 DESCRIPTION ABS Wiring Diagram — ABS — Wiring Diagram — ABS — NABR0094 GI MA EM LC EC FE CL MT AT TF PD AX SU ST RS BT HA SC EL MBR625A BR-37 IDX DESCRIPTION ABS Wiring Diagram — ABS — (Cont’d) MBR626A BR-38 DESCRIPTION ABS Wiring Diagram — ABS — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU ST RS BT HA SC EL MBR479A IDX BR-39 DESCRIPTION ABS Wiring Diagram — ABS — (Cont’d) MBR584A BR-40 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ABS Self-diagnosis Self-diagnosis FUNCTION I NABR0095 NABR0095S01 When a problem occurs in the ABS, the warning lamp on the instrument panel comes on. To start the self-diagnostic results mode, ground the self-diagnostic (check) terminal located on data link connector. The location of the malfunction is indicated by the warning lamp flashing. SELF-DIAGNOSIS PROCEDURE NABR0095S02 1. 2. Drive vehicle over 30 km/h (19 MPH) for at least one minute. Turn ignition switch OFF. 3. Ground terminal 9 of data link connector with a suitable harness. Turn ignition switch ON while grounding terminal 9. Do not depress brake pedal. 4. GI MA EM LC EC FE CL MT SBR665E 5. SBR676E After 3.0 seconds, the warning lamp starts flashing to indicate the malfunction code No. (See NOTE.) 6. Verify the location of the malfunction with the malfunction code chart. Refer to BR-54. Then make the necessary repairs following the diagnostic procedures. 7. After the malfunctions are repaired, erase the malfunction codes stored in the control unit. Refer to BR-42. 8. Rerun the self-diagnostic results mode to verify that the malfunction codes have been erased. 9. Disconnect the check terminal from the ground. The self-diagnostic results mode is now complete. 10. Check warning lamp for deactivation after driving vehicle over 30 km/h (19 MPH) for at least one minute. 11. After making certain that warning lamp does not come on, test the ABS in a safe area to verify that it functions properly. NOTE: The indication terminates after 5 minutes. However, when the ignition switch is turned from OFF to ON, the indication starts flashing again. AT TF PD AX SU ST RS BT HA SC EL IDX BR-41 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ABS Self-diagnosis (Cont’d) HOW TO READ SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES) 1. 2. 3. 4. =NABR0095S03 Determine the code No. by counting the number of times the warning lamp flashes on and off. When several malfunctions occur at one time, up to three code numbers can be stored; the latest malfunction will be indicated first. The indication begins with the start code 12. After that a maximum of three code numbers appear in the order of the latest one first. The indication then returns to the start code 12 to repeat (the indication will stay on for five minutes at the most). The malfunction code chart is given on page BR-54. SBR457D HOW TO ERASE SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES) 1. 2. 3. NABR0095S04 Disconnect the check terminal from ground (ABS warning lamp will stay lit). Within 12.5 seconds, ground the check terminal three times. Each terminal ground must last more than 1 second. The ABS warning lamp goes out after the erase operation has been completed. Perform self-diagnosis again. Refer to BR-41. Only the startcode should appear, no malfunction codes. ABR256 BR-42 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ABS CONSULT-II CONSULT-II =NABR0128 CONSULT-II APPLICATION TO ABS GI NABR0128S03 MA SELF-DIAGNOSTIC RESULTS DATA MONITOR ACTIVE TEST Front right wheel sensor × × — Front left wheel sensor × × — Rear right wheel sensor × × — Rear left wheel sensor × × — DECEL G-sensor 1 × × × DECEL G-sensor 2 × × × ABS sensor × — — Stop lamp switch — × — Front right inlet solenoid valve × × × Front right outlet solenoid valve × × × Front left inlet solenoid valve × × × Front left outlet solenoid valve × × × Rear inlet solenoid valve × × × Rear outlet solenoid valve × × × Actuator solenoid valve relay × × — Actuator motor relay (ABS MOTOR is shown on the Data Monitor screen.) × × × PD ABS warning lamp — × — AX Battery voltage × × — Control unit × — — ABS operating signal — × × ITEM EM LC EC FE CL MT AT TF SU ×: Applicable —: Not applicable ECU (ABS CONTROL UNIT) PART NUMBER MODE NABR0128S04 Ignore the ECU part number displayed in the ECU PART NUMBER MODE. Refer to parts catalog to order the ECU. ST RS BT HA SC EL IDX BR-43 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ABS CONSULT-II Inspection Procedure CONSULT-II Inspection Procedure SELF-DIAGNOSIS PROCEDURE =NABR0129 NABR0129S01 1. 2. 3. 4. Turn ignition switch OFF. Connect CONSULT-II to data link connector. Start engine. Drive vehicle over 30 km/h (19 MPH) for at least one minute. 5. Stop vehicle with engine running and touch “START” on CONSULT-II screen. 6. Touch “ABS”. 7. I Touch “SELF-DIAG RESULTS”. The screen shows the detected malfunction and how many times the ignition switch has been turned ON since the malfunction. Make the necessary repairs following the diagnostic procedures. SBR665E PBR455D SBR670E 8. SBR636E 9. After the malfunctions are repaired, erase the self-diagnostic results stored in the control unit by touching “ERASE”. 10. Check warning lamp for deactivation after driving vehicle over 30 km/h (19 MPH) for at least one minute. 11. Test the ABS in a safe area to verify that it functions properly. NOTE: “SELF-DIAG RESULTS” screen shows the detected malfunction and how many times the ignition switch has been turned since the malfunction. PBR950C BR-44 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ABS CONSULT-II Inspection Procedure (Cont’d) SELF-DIAGNOSTIC RESULTS MODE Diagnostic item Diagnostic item is detected when ... NABR0129S07 GI Reference Page MA FR RH SENSOR★1 [OPEN] I Circuit for front right wheel sensor is open. (An abnormally high input voltage is entered.) BR-56 FR LH SENSOR★1 [OPEN] I Circuit for front left wheel sensor is open. (An abnormally high input voltage is entered.) BR-56 EM RR RH SENSOR★1 [OPEN] I Circuit for rear right sensor is open. (An abnormally high input voltage is entered.) BR-56 LC RR LH SENSOR★1 [OPEN] I Circuit for rear left sensor is open. (An abnormally high input voltage is entered.) BR-56 FR RH SENSOR★1 [SHORT] I Circuit for front right wheel sensor is shorted. (An abnormally low input voltage is entered.) BR-56 FR LH SENSOR★1 [SHORT] I Circuit for front left wheel sensor is shorted. (An abnormally low input voltage is entered.) BR-56 RR RH SENSOR★1 [SHORT] I Circuit for rear right sensor is shorted. (An abnormally low input voltage is entered.) BR-56 RR LH SENSOR★1 [SHORT] I Circuit for rear left sensor is shorted. (An abnormally low input voltage is entered.) BR-56 MT ABS SENSOR★1 [ABNORMAL SIGNAL] I Teeth damage on sensor rotor or improper installation of wheel sensor. (Abnormal wheel sensor signal is entered.) BR-56 AT FR RH IN ABS SOL [OPEN, SHORT] I Circuit for front right inlet solenoid valve is open. (An abnormally low output voltage is entered.) BR-59 FR LH IN ABS SOL [OPEN, SHORT] I Circuit for front left inlet solenoid valve is open. (An abnormally low output voltage is entered.) BR-59 FR RH OUT ABS SOL [OPEN, SHORT] I Circuit for front right outlet solenoid valve is open. (An abnormally low output voltage is entered.) BR-59 FR LH OUT ABS SOL [OPEN, SHORT] I Circuit for front left outlet solenoid valve is open. (An abnormally low output voltage is entered.) BR-59 RR IN ABS SOL [OPEN, SHORT] I Circuit for rear inlet solenoid valve is shorted. (An abnormally high output voltage is entered.) BR-59 RR OUT ABS SOL [OPEN, SHORT] I Circuit for rear outlet solenoid valve is shorted. (An abnormally high output voltage is entered.) BR-59 ABS ACTUATOR RELAY [ABNORMAL] I Actuator solenoid valve relay is ON, even if control unit sends off signal. I Actuator solenoid valve relay is OFF, even if control unit sends on signal. BR-59 ABS MOTOR RELAY [ABNORMAL] I Circuit for ABS motor relay is open or shorted. I Circuit for actuator motor is open or shorted. I Actuator motor relay is stuck. BR-61 EC FE CL TF PD AX SU ST RS BATTERY VOLT [VB-LOW] I Power source voltage supplied to ABS control unit is abnormally low. CONTROL UNIT I Function of calculation in ABS control unit has failed. BR-67 FR & RR G-SEN [ABNORMAL] I DECEL G sensor output is abnormally higher or lower than specifications. BR-65 HA FR & RR G-SEN TEST [ABNORMAL] I Output voltage is always constant due to G sensor malfunction. BR-65 SC G-SEN TEST [ABNORMAL] I G sensor malfunction is detected during self-diagnosis. BR-65 EL BR-63 ★1: If one or more wheels spin on a rough or slippery road for 40 seconds or more, the ABS warning lamp will illuminate. This does not indicate a malfunction. Only in the case of the short-circuit (Code Nos. 26, 22, 32 and 36), after repair the ABS warning lamp also BR-45 BT IDX ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ABS CONSULT-II Inspection Procedure (Cont’d) illuminates when the ignition switch is turned ON. In this case, drive the vehicle at speeds greater than 30 km/h (19 MPH) for approximately 1 minute as specified in “SELF-DIAGNOSIS PROCEDURE”, BR-41. Check to ensure that the ABS warning lamp goes out while the vehicle is being driven. DATA MONITOR PROCEDURE NABR0129S03 1. 2. 3. 4. Turn ignition switch OFF. Connect CONSULT-II to data link connector for CONSULT-II. Turn ignition switch ON. Touch “START” on CONSULT-II screen. 5. Touch “ABS”. 6. Touch “DATA MONITOR”. 7. Touch “SETTING” on “SELECT MONITOR ITEM” screen. PBR455D SBR670E SBR636E SBR637E BR-46 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ABS CONSULT-II Inspection Procedure (Cont’d) ACTIVE TEST PROCEDURE I I 1. 2. 3. 4. =NABR0129S04 When conducting Active test, vehicle must be stationary. When ABS warning lamp stays on, never conduct Active test. Turn ignition switch OFF. Connect CONSULT-II to data link connector. Start engine. Touch “START” on CONSULT-II screen. GI MA EM LC PBR455D 5. Touch “ABS”. EC FE CL MT SBR670E 6. Touch “ACTIVE TEST”. AT TF PD AX SU SBR636E 7. Select active test item by touching screen. ST RS BT SBR234F 8. 9. Touch “START”. Carry out the active test by touching screen key. HA SC EL IDX SBR230F BR-47 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ABS CONSULT-II Inspection Procedure (Cont’d) DATA MONITOR MODE NABR0129S08 MONITOR ITEM CONDITION SPECIFICATION FR RH SENSOR FR LH SENSOR RR RH SENSOR RR LH SENSOR Drive vehicle. (Each wheel is rotating.) Wheel speed signal (Almost the same speed as speedometer.) STOP LAMP SW Brake is depressed. Depress the pedal: ON Release the pedal: OFF FR & RR G SEN Vehicle is driven. Vehicle is stopped. Brake is applied. During sudden braking while driving on high µ roads (asphalt roads, etc.): OFF While vehicle is stopped or during constant-speed driving: ON 1. Drive vehicle at speeds over 30 km/h (19 MPH) for at least 1 minute. 2. Engine is running. Operating conditions for each solenoid valve are indicated. ABS is not operating: OFF FR RH IN SOL FR RH OUT SOL FR LH IN SOL FR LH OUT SOL RR IN SOL RR OUT SOL MOTOR RELAY ABS is not operating: OFF ABS is operating: ON ACTUATOR RELAY Ignition switch ON (Engine stops): OFF Engine running: ON WARNING LAMP Ignition switch is ON or engine is running. ABS warning lamp is turned on: ON ABS warning lamp is turned off: OFF BATTERY VOLT Power supply voltage for control unit ABS OPER SIG ABS is not operating: OFF ABS is operating: ON ACTIVE TEST MODE TEST ITEM CONDITION NABR0129S09 JUDGEMENT Brake fluid pressure control operation FR RH SOLENOID FR LH SOLENOID RR SOLENOID Engine is running. G SENSOR OUT SOL UP (Increase): OFF OFF KEEP (Hold): ON OFF DOWN (Decrease): ON ON ABS actuator motor ON: Motor runs (ABS motor relay ON) OFF: Motor stops (ABS motor relay OFF) ABS MOTOR ABS OPER SIG IN SOL Ignition switch is ON or engine is running. ON: Set ABS OPER SIG “ON” (ABS is operating.) OFF: Set ABS OPER SIG “OFF” (ABS is not operating.) Ignition switch is ON. G SENSOR ON: Set G SENSOR MONITOR “ON” (G sensor circuit is closed.) OFF: Set G SENSOR MONITOR “OFF” (G sensor circuit is open.) NOTE: Active test will automatically stop ten seconds after the test starts. (TEST IS STOPPED monitor shows ON.) BR-48 TROUBLE DIAGNOSIS — INTRODUCTION ABS How to Perform Trouble Diagnoses for Quick and Accurate Repair How to Perform Trouble Diagnoses for Quick and Accurate Repair GI INTRODUCTION MA NABR0098 SEF233G SEF234G NABR0098S01 The ABS system has an electronic control unit to control major functions. The control unit accepts input signals from sensors and instantly drives the actuators. It is essential that both kinds of signals are proper and stable. It is also important to check for conventional incidents: such as air leaks in booster lines, lack of brake fluid, or other incidents with the brake system. It is much more difficult to diagnose an incident that occurs intermittently rather than continuously. Most intermittent incidents are caused by poor electric connections or faulty wiring. In this case, careful checking of suspicious circuits may help prevent the replacement of good parts. A visual check only may not find the cause of the incidents, so a road test should be performed. Before undertaking actual checks, take a few minutes to talk with a customer who approaches with an ABS complaint. The customer is a very good source of information on such incidents; especially intermittent ones. By talking to the customer, find out what symptoms are present and under what conditions they occur. Start your diagnosis by looking for “conventional” incidents first. This is one of the best ways to troubleshoot brake incidents on an ABS controlled vehicle. Also check related Service bulletins for information. EM LC EC FE CL MT AT TF PD AX SU ST RS BT HA SC EL IDX BR-49 TROUBLE DIAGNOSIS — BASIC INSPECTION ABS Preliminary Check Preliminary Check 1 NABR0099 CHECK BRAKE FLUID Check brake fluid for contamination. Has brake fluid been contaminated? Yes © Replace. GO TO 2. No © GO TO 2. 2 CHECK BRAKE FLUID LEVEL Check brake fluid level in reservoir tank. Low fluid level may indicate brake pad wear or leakage from brake line. SBR451D Is brake fluid filled between MAX and MIN lines on reservoir tank? Yes © GO TO 3. No © Fill up brake fluid. GO TO 3. 3 CHECK BRAKE LINE Check brake line for leakage. SBR389C Is leakage present at or around brake lines, tubes or hoses or are any of these parts cracked or damaged? Yes © Repair. GO TO 4. No © GO TO 4. BR-50 TROUBLE DIAGNOSIS — BASIC INSPECTION ABS Preliminary Check (Cont’d) CHECK BRAKE BOOSTER OPERATION GI Check brake booster for operation and air tightness. Refer to “On-vehicle Service”, “BRAKE BOOSTER”, BR-19. MA 4 EM LC EC SBR058C FE Is brake booster airtight and functioning properly? Yes © GO TO 5. No © Replace. GO TO 5. CL MT 5 CHECK BRAKE PAD AND ROTOR Check brake pad and rotor. Refer to (BR-22, BR-24). AT TF PD AX SBR059C SU Are brake pads and rotors functioning properly? Yes © GO TO 6. No © Replace. ST RS BT HA SC EL IDX BR-51 TROUBLE DIAGNOSIS — BASIC INSPECTION ABS Preliminary Check (Cont’d) 6 RECHECK BRAKE FLUID LEVEL Check brake fluid level in reservoir tank again. SBR451D Is brake fluid filled between MAX and MIN lines on reservoir tank? Yes © GO TO 7. No © Fill up brake fluid. 7 CHECK WARNING LAMP ACTIVATION Check warning lamp activation. SBR677E Does warning lamp turn on when ignition switch is turned ON? Yes © GO TO 8. No © Check fuse, warning lamp bulb and warning lamp circuit. 8 CHECK WARNING LAMP DEACTIVATION Check warning lamp for deactivation after engine is started. Does warning lamp turn off when engine is started? Yes © GO TO 9. No © Go to Self-diagnosis (BR-41, BR-44). 9 DRIVE VEHICLE Drive vehicle at speeds over 30 km/h (19 MPH) for at least one minute. Does warning lamp remain off after vehicle has been driven at 30 km/h (19 MPH) for at least one minute? Yes © INSPECTION END No © Go to Self-diagnosis (BR-41, BR-44). BR-52 TROUBLE DIAGNOSIS — BASIC INSPECTION ABS Ground Circuit Check Ground Circuit Check ABS ACTUATOR AND ELECTRIC UNIT GROUND I =NABR0130 GI NABR0130S01 Check continuity between ABS actuator and electric unit connector terminals and ground. Continuity should exist. MA EM LC SBR690EA EC FE CL MT AT TF PD AX SU ST RS BT HA SC EL IDX BR-53 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION ABS Malfunction Code/Symptom Chart Malfunction Code/Symptom Chart Code No. (No. of warning lamp flashes) 12 Malfunctioning part Self-diagnosis could not detect any malfunctions. NABR0150 Reference Page — 17 ★4 G sensor and circuit BR-65 18 ★1 Sensor rotor BR-56 21 ★1 Front right sensor (open-circuit) BR-56 22 ★1 Front right sensor (short-circuit) BR-56 25 ★1 Front left sensor (open-circuit) BR-56 26 ★1 Front left sensor (short-circuit) BR-56 31 ★1 Rear right sensor (open-circuit) BR-56 32 ★1 Rear right sensor (short-circuit) BR-56 35 ★1 Rear left sensor (open-circuit) BR-56 36 ★1 Rear left sensor (short-circuit) BR-56 41 Actuator front right outlet solenoid valve BR-59 42 Actuator front right inlet solenoid valve BR-59 45 Actuator front left outlet solenoid valve BR-59 46 Actuator front left inlet solenoid valve BR-59 55 Actuator rear outlet solenoid valve BR-59 56 Actuator rear inlet solenoid valve BR-59 57 ★2 Power supply (Low voltage) BR-63 61 ★3 Actuator motor or motor relay BR-61 63 Solenoid valve relay BR-59 64 FR & RR G sensor BR-65 65 FR & RR G sensor input signal abnormal BR-65 66 FR & RR G sensor test abnormal BR-65 71 Control unit BR-67 ABS works frequently — BR-68 Unexpected pedal action — BR-68 Long stopping distance — BR-70 ABS does not work — BR-70 Pedal vibration and noise — BR-71 Warning lamp does not come on when ignition switch is turned ON. Warning lamp stays on when ignition switch is turned ON. Fuse, warning lamp bulb or warning lamp circuit Control unit BR-72 Control unit power supply circuit Warning lamp bulb circuit Control unit or control unit connector Solenoid valve relay stuck Power supply for solenoid valve relay coil BR-74 Vehicle vibrates excessively when ABS is ABS control unit to TCM circuit operating. BR-77 ★1: If one or more wheels spin on a rough or slippery road for 40 seconds or more, the ABS warning lamp will illuminate. This does not indicate a malfunction. Only in the case of the short-circuit (Code Nos. 26, 22, 32 and 36), after repair the ABS warning lamp also BR-54 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION ABS Malfunction Code/Symptom Chart (Cont’d) illuminates when the ignition switch is turned ON. In this case, drive the vehicle at speeds greater than 30 km/h (19 MPH) for approximately 1 minute as specified in “SELF-DIAGNOSIS PROCEDURE”, BR-44. Check to ensure that the ABS warning lamp goes out while the vehicle is being driven. ★2: The trouble code “57”, which refers to a low power supply voltage, does not indicate that the ABS control unit is malfunctioning. Do not replace the ABS control unit with a new one. ★3: The trouble code “61” can sometimes appear when the ABS motor is not properly grounded. If it appears, be sure to check the condition of the ABS motor ground circuit connection. GI MA EM LC EC FE CL MT AT TF PD AX SU ST RS BT HA SC EL IDX BR-55 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS ABS Wheel Sensor or Rotor Wheel Sensor or Rotor DIAGNOSTIC PROCEDURE NABR0132 Malfunction code No. 21, 22, 25, 26, 31, 32, 35, 36 or 18 NOTE: Wheel position should be distinguished by code No. except code No. 18 (sensor rotor). 1 INSPECTION START Wheel sensor inspection SBR691E © 2 GO TO 2. CHECK CONNECTOR 1. Disconnect connectors from ABS actuator and electric unit and wheel sensor of malfunction code No. Check terminals for damage or loose connection. Then reconnect connectors. 2. Carry out self-diagnosis again. Does warning lamp activate again? Yes © GO TO 3. No © INSPECTION END BR-56 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS ABS Wheel Sensor or Rotor (Cont’d) 3 GI CHECK WHEEL SENSOR ELECTRICAL 1. Disconnect ABS actuator and electric unit connector. 2. Check resistance between ABS actuator and electric unit connector E111 terminals. Code No. 21 or 22 (Front RH wheel) Terminals 10 and 25 Code No. 25 or 26 (Front LH wheel) Terminals 8 and 23 Code No. 31 or 32 (Rear RH wheel) Terminals 14 and 29 Code No. 35 or 36 (Rear LH wheel) Terminals 12 and 27 MA EM LC EC FE CL MT SBR692EB Resistance: Front 0.9 - 1.1 kΩ Rear 1.44 - 1.76 kΩ AT Is front resistance 0.9 - 1.1 kΩ and rear resistance 1.44 - 1.76 kΩ? Yes © GO TO 5. No © GO TO 4. 4 TF PD CHECK WHEEL SENSOR AX Check each sensor for resistance. SU ST SBR693E Resistance: Front 0.9 - 1.1 kΩ Rear 1.44 - 1.76 kΩ RS BT Is front resistance 0.9 - 1.1 kΩ and rear resistance 1.44 - 1.76 kΩ? Yes No © © Check the following. If NG, repair harness or connectors. I Harness connectors E111, E14, E51, B8, B69 I Harness for open or short between wheel sensor connectors and ABS actuator and electric unit Replace wheel sensor. HA SC EL IDX BR-57 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS ABS Wheel Sensor or Rotor (Cont’d) 5 CHECK TIRE Check for inflation pressure, wear and size of each tire. (See NOTE.) Are tire pressure and size correct and is tire wear within specifications? Yes © GO TO 6. No © Adjust tire pressure or replace tire(s). (See NOTE.) 6 CHECK WHEEL BEARING Check wheel bearing axial end play. (See NOTE.) Is wheel bearing axial end play within specifications? Yes © GO TO 7. No © Check wheel bearing. Refer to AX-19, AX-4, “Front wheel bearing” and “Rear wheel bearing”. 7 CHECK SENSOR ROTOR Check sensor rotor for teeth damage. (See NOTE.) Is sensor rotor free from damage? Yes © Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actuator and electric unit harness connector. Reconnect ABS actuator and electric unit harness connector. Then retest. No © Replace sensor rotor. (See NOTE.) BR-58 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS ABS ABS Actuator Solenoid Valve or Solenoid Valve Relay ABS Actuator Solenoid Valve or Solenoid Valve GI Relay DIAGNOSTIC PROCEDURE MA =NABR0133 Malfunction code No. 41, 45, 55, 42, 46, 56, 63 1 INSPECTION START EM Solenoid valve relay inspection LC EC FE CL MT AT TF SBR243F © 2 GO TO 2. PD CHECK FUSIBLE LINK Check 40A fusible link c. For fusible link layout, refer to EL-11, “POWER SUPPLY ROUTING”. AX Is fusible link OK? Yes © GO TO 3. No © GO TO 6. 3 SU CHECK CONNECTOR 1. Disconnect connector from ABS actuator and electric unit. Check terminals for damage or loose connection. Then reconnect connector. 2. Carry out self-diagnosis again. Does warning lamp activate again? Yes © GO TO 4. No © INSPECTION END 4 ST RS BT CHECK ABS ACTUATOR AND ELECTRIC UNIT GROUND CIRCUIT HA Refer to “ABS ACTUATOR AND ELECTRIC UNIT GROUND” in “Ground Circuit Check”, BR-53. Is ground circuit OK? Yes © GO TO 5. No © Repair harness or connector. SC EL IDX BR-59 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS ABS ABS Actuator Solenoid Valve or Solenoid Valve Relay (Cont’d) 5 CHECK SOLENOID VALVE POWER SUPPLY CIRCUIT 1. Disconnect ABS actuator and electric unit connector. 2. Check voltage between ABS actuator and electric unit connector E111 terminal 15 and ground. SBR695EB Does battery voltage exist? Yes © Replace ABS actuator and electric unit. No © Check the following. If NG, repair harness or connectors. I Harness connector E111 I Harness for open or short between ABS actuator and electric unit and fusible link 6 REPLACE FUSIBLE LINK Replace fusible link. Does the fusible link blow out when ignition switch is turned ON? Yes © GO TO 7. No © INSPECTION END 7 CHECK SOLENOID VALVE RELAY POWER SUPPLY CIRCUIT FOR SHORT 1. Disconnect battery cable and ABS actuator and electric unit connector. 2. Check continuity between ABS actuator and electric unit connector E111 terminal 15 and ground. SBR696EB Continuity should not exist. Does continuity exist? Yes © Check the following. If NG, repair harness or connector. I Harness connector E111 I Harness for open or short between ABS actuator and electric unit and fusible link No © Replace ABS actuator and electric unit. BR-60 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS ABS Motor Relay or Motor Motor Relay or Motor DIAGNOSTIC PROCEDURE GI =NABR0134 Malfunction code No. 61 1 MA INSPECTION START ABS motor relay inspection EM LC EC FE CL MT AT SBR067F © 2 PD CHECK FUSIBLE LINK Check 40A fusible link d. For fusible link layout, refer to EL-11, “POWER SUPPLY ROUTING”. Is fusible link OK? Yes © GO TO 3. No © GO TO 6. 3 AX SU CHECK CONNECTOR 1. Disconnect ABS actuator and electric unit connector. Check terminals for damage or loose connection. Then reconnect connector. 2. Carry out self-diagnosis again. Does warning lamp activate again? Yes © GO TO 4. No © INSPECTION END 4 TF GO TO 2. ST RS BT CHECK ABS ACTUATOR AND ELECTRIC UNIT GROUND CIRCUIT Refer to “ABS ACTUATOR AND ELECTRIC UNIT GROUND” in “Ground Circuit Check”, BR-53. HA Is ground circuit OK? SC Yes © GO TO 5. No © Repair harness or connector. EL IDX BR-61 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS ABS Motor Relay or Motor (Cont’d) 5 CHECK MOTOR RELAY POWER SUPPLY CIRCUIT 1. Disconnect ABS actuator and electric unit connector. 2. Check voltage between ABS actuator and electric unit connector E111 terminal 1 and ground. SBR698EB Does battery voltage exist? Yes © Replace ABS actuator and electric unit. No © Check the following. If NG, repair harness or connector. I Harness connector E111 I Harness for open or short between ABS actuator and electric unit and fusible link 6 REPLACE FUSIBLE LINK Replace fusible link. Does the fusible link blow out when ignition switch is turned ON? Yes © GO TO 7. No © INSPECTION END 7 CHECK ABS ACTUATOR MOTOR POWER SUPPLY CIRCUIT FOR SHORT 1. Disconnect battery cable and ABS actuator and electric unit connector. 2. Check continuity between ABS actuator and electric unit connector E111 terminal 1 and ground. SBR699EB Continuity should not exist. Does continuity exist? Yes © Check the following. If NG, repair harness or connector. I Harness connector E111 I Harness for open or short between ABS actuator and electric unit and fusible link No © Replace ABS actuator and electric unit. BR-62 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS ABS Low Voltage Low Voltage DIAGNOSTIC PROCEDURE GI NABR0135 Malfunction code No. 57 1 MA INSPECTION START ABS actuator and electric unit power supply and ground circuit inspection EM LC EC FE SBR068F © 2 GO TO 2. CL MT CHECK FUSE Check 10A fuse No. 7. For fuse layout, refer to EL-11, “POWER SUPPLY ROUTING”. Is fuse OK? Yes © GO TO 3. No © GO TO 6. 3 AT TF PD CHECK CONNECTOR 1. Disconnect ABS actuator and electric unit connector. Check terminals for damage or loose connections. Then reconnect connector. 2. Carry out self-diagnosis again. AX Does warning lamp activate again? SU Yes © GO TO 4. No © INSPECTION END 4 CHECK ABS ACTUATOR AND ELECTRIC UNIT GROUND CIRCUIT Refer to “ABS ACTUATOR AND ELECTRIC UNIT GROUND” in “Ground Circuit Check”, BR-53. ST Is ground circuit OK? Yes © GO TO 5. No © Repair harness or connector. RS BT HA SC EL IDX BR-63 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS ABS Low Voltage (Cont’d) 5 CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT 1. Disconnect ABS actuator and electric unit connector. 2. Check voltage between ABS actuator and electric unit connector E111 terminal 17 and ground. SBR701EB Does battery voltage exist when ignition switch is turned ON? Yes © Replace ABS actuator and electric unit. No © Check the following. If NG, repair harness or connector. I Harness connector E111 I Harness for open or short between ABS actuator and electric unit and fuse 6 REPLACE FUSE Replace fuse. Does the fuse blow out when ignition switch is turned ON? Yes © GO TO 7. No © INSPECTION END 7 CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT FOR SHORT 1. Disconnect battery cable and ABS actuator and electric unit connector. 2. Check continuity between ABS actuator and electric unit connector E111 terminal 17 and ground. SBR702EB Does continuity exist? Yes © Check the following. If NG, repair harness or connector. I Harness connector E111 I Harness for open or short between ABS actuator and electric unit and fuse No © Replace ABS actuator and electric unit. BR-64 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS ABS G Sensor and Circuit G Sensor and Circuit GI DIAGNOSTIC PROCEDURE =NABR0151 Malfunction code No. 17, 64, 65, 66, 68 1 MA INSPECTION START G sensor inspection EM LC EC FE SBR069F © 2 GO TO 2. MT CHECK CONNECTOR 1. Disconnect ABS actuator and electric unit and G sensor connectors. Check terminals for damage or loose connection. Then reconnect connectors. 2. Carry out self-diagnosis again. Does warning lamp active again? Yes © GO TO 3. No © INSPECTION END 3 CL AT TF PD CHECK G SENSOR POWER SUPPLY CIRCUIT AX 1. Disconnect G sensor connector B58. 2. Check voltage between G sensor connector terminals 4 and ground. SU ST RS SBR244F Does battery voltage exist? Yes © GO TO 4. No © Check the following. If NG, repair harness or connectors. I Harness connectors E111, B58 I Harness for open or short between G sensor and ABS actuator and electric unit. BT HA SC EL IDX BR-65 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS ABS G Sensor and Circuit (Cont’d) 4 CHECK G SENSOR ELECTRICAL 1. Connect G sensor body side terminal and sensor side terminal with suitable harness. 2. Check voltage between terminals 1 and 2, 1 and 3 under the following conditions. SBR245F MTBL0661 Is voltage OK? Yes © Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actuator and electric unit harness connector. Then retest. No © Replace G sensor. BR-66 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS ABS Control Unit Control Unit DIAGNOSTIC PROCEDURE GI =NABR0137 Malfunction code No. 71 1 MA INSPECTION START ABS actuator and electric unit power supply and ground circuit inspection EM LC EC FE SBR071F © 2 GO TO 2. MT CHECK CONNECTOR 1. Disconnect ABS actuator and electric unit connector. Check terminals for damage or loose connection. Then reconnect connector. 2. Carry out self-diagnosis again. Does warning lamp activate again? Yes © GO TO 3. No © INSPECTION END 3 AT TF PD CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT Check voltage. Refer to “5. CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT” in “DIAGNOSTIC PROCEDURE”, “Low Voltage”, BR-63. Does battery voltage exist when ignition switch is turned ON? Yes © GO TO 4. No © Repair. 4 CL CHECK WARNING LAMP INDICATION AX SU ST Does warning lamp indicate code No. 71 again? Yes or No Yes © Replace ABS actuator and electric unit. No © Inspect the system according to the code No. RS BT HA SC EL IDX BR-67 TROUBLE DIAGNOSES FOR SYMPTOMS ABS 1. ABS Works Frequently 1. ABS Works Frequently 1 NABR0138 CHECK BRAKE FLUID PRESSURE Check brake fluid pressure distribution. Refer to BR-12, “Inspection”, “PROPORTIONING VALVE”. Is brake fluid pressure distribution normal? Yes © GO TO 2. No © Repair. Then perform Preliminary Check. Refer to BR-50. 2 CHECK WHEEL SENSOR 1. Check wheel sensor connector for terminal damage or loose connections. 2. Perform wheel sensor mechanical check. Refer to “7. CHECK SENSOR ROTOR” in “DIAGNOSTIC PROCEDURE”, “Wheel Sensor or Rotor”, BR-56. Is wheel sensor mechanism OK? Yes © GO TO 3. No © Repair. 3 CHECK FRONT AXLE Check front axles for excessive looseness. Refer to AX-4, “Front Wheel Bearing”. Is front axle installed properly? Yes © Go to “3. CHECK WARNING LAMP INDICATION” in “2. Unexpected Pedal Action”, BR-68. No © Repair. 2. Unexpected Pedal Action 1 NABR0139 CHECK BRAKE PEDAL STROKE Check brake pedal stroke. SBR540A Is brake pedal stroke excessively large? Yes © Perform Preliminary Check. Refer to BR-50. No © GO TO 2. BR-68 TROUBLE DIAGNOSES FOR SYMPTOMS ABS 2. Unexpected Pedal Action (Cont’d) 2 GI CHECK MECHANICAL BRAKE SYSTEM PERFORMANCE Disconnect ABS actuator and electric unit connector and check whether brake is effective. MA Does brake system function properly when brake pedal is depressed? Yes © GO TO 3. No © Perform Preliminary Check. Refer to BR-50. 3 EM CHECK WARNING LAMP INDICATION LC Ensure warning lamp remains off while driving. EC FE CL MT SBR677E Is warning lamp turned off? Yes © GO TO 4. No © Carry out self-diagnosis. Refer to BR-41, BR-44. 4 CHECK WHEEL SENSOR 1. Check wheel sensor connector for terminal damage or loose connection. 2. Perform wheel sensor mechanical check. Refer to “7. CHECK SENSOR ROTOR” in “DIAGNOSTIC PROCEDURE”, “Wheel Sensor or Rotor”, BR-56. AT TF PD AX Is wheel sensor mechanism OK? Yes © Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actuator and electric unit harness connector. Reconnect ABS actuator and electric unit harness connector. Then retest. No © Repair. SU ST RS BT HA SC EL IDX BR-69 TROUBLE DIAGNOSES FOR SYMPTOMS ABS 3. Long Stopping Distance 3. Long Stopping Distance 1 =NABR0140 CHECK MECHANICAL BRAKE SYSTEM PERFORMANCE Disconnect ABS actuator and electric unit connector and check whether stopping distance is still long. Does brake system function properly when brake pedal is depressed? Yes © Perform Preliminary Check and air bleeding (if necessary). No © Go to “3. CHECK WARNING LAMP INDICATION” in “2. Unexpected Pedal Action”, BR-68. NOTE: Stopping distance may be longer for vehicles without ABS when road condition is slippery. 4. ABS Does Not Work 1 NABR0141 CHECK WARNING LAMP INDICATION Does the ABS warning lamp activate? Yes or No Yes © Carry out self-diagnosis. Refer to BR-41, BR-44. No © Go to “3. CHECK WARNING LAMP INDICATION” in “2. Unexpected Pedal Action”, BR-68. NOTE: ABS does not work when vehicle speed is under 10 km/h (6 MPH). BR-70 TROUBLE DIAGNOSES FOR SYMPTOMS ABS 5. Pedal Vibration and Noise 5. Pedal Vibration and Noise 1 NABR0142 GI INSPECTION START MA Pedal vibration and noise inspection EM LC EC SAT797A © FE GO TO 2. CL 2 CHECK SYMPTOM 1. Apply brake. 2. Start engine. MT Does the symptom appear only when engine is started? Yes © Carry out self-diagnosis. Refer to BR-41, BR-44. AT No © Go to “3. CHECK WARNING LAMP INDICATION” in “2. Unexpected Pedal Action”, BR-68. TF NOTE: ABS may operate and cause vibration under any of the following conditions. I Applying brake gradually when shifting or operating clutch. I Low friction (slippery) road. I High speed cornering. I Driving over bumps and pot holes. I Engine speed is over 5,000 rpm with vehicle stopped. PD AX SU ST RS BT HA SC EL IDX BR-71 TROUBLE DIAGNOSES FOR SYMPTOMS ABS 6. Warning Lamp Does Not Come On When Ignition Switch Is Turned On 6. Warning Lamp Does Not Come On When Ignition Switch Is Turned On 1 NABR0143 INSPECTION START Warning lamp circuit inspection SBR072F © 2 GO TO 2. CHECK FUSE Check 10A fuse No. 8. For fuse layout, refer to EL-11, “POWER SUPPLY ROUTING”. Is fuse OK? Yes © GO TO 3. No © Replace fuse. 3 CHECK WARNING LAMP ACTIVATE Disconnect ABS actuator and electric unit connector. SBR677E Does the warning lamp activate? Yes © Replace ABS actuator and electric unit. No © GO TO 4. BR-72 TROUBLE DIAGNOSES FOR SYMPTOMS ABS 6. Warning Lamp Does Not Come On When Ignition Switch Is Turned On (Cont’d) 4 GI CHECK HARNESS FOR SHORT 1. Disconnect ABS actuator and electric unit connector and combination meter connector M24. 2. Check continuity between ABS actuator and electric unit connector E111 terminal 2. MA EM LC EC SBR708EB Continuity should not exist. FE Does continuity exist? Yes © Repair harness or connectors. CL No © Check combination meter. Refer to EL-139, “WARNING LAMPS”. MT AT TF PD AX SU ST RS BT HA SC EL IDX BR-73 TROUBLE DIAGNOSES FOR SYMPTOMS ABS 7. Warning Lamp Stays On When Ignition Switch Is Turned On 7. Warning Lamp Stays On When Ignition Switch Is Turned On 1 =NABR0144 INSPECTION START ABS control unit inspection SBR073F © 2 GO TO 2. CHECK FUSE Check 10A fuse No. 7. For fuse layout, refer to EL-11, “POWER SUPPLY ROUTING”. Is fuse OK? Yes © GO TO 3. No © GO TO 8. 3 CHECK HARNESS CONNECTOR Check ABS actuator and electric unit pin terminals for damage or bad connection of ABS actuator and electric unit harness connector. Reconnect ABS actuator and electric unit harness connector. Then retest. Does warning lamp stay on when ignition switch is turned ON? Yes © GO TO 4. No © INSPECTION END 4 CHECK ABS ACTUATOR AND ELECTRIC UNIT GROUND CIRCUIT Refer to “ABS ACTUATOR AND ELECTRIC UNIT GROUND” in “Ground Circuit Check”, BR-53. Is ground circuit OK? Yes © GO TO 5. No © Repair harness or connector. BR-74 TROUBLE DIAGNOSES FOR SYMPTOMS ABS 7. Warning Lamp Stays On When Ignition Switch Is Turned On (Cont’d) CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT GI 1. Disconnect ABS actuator and electric unit connector. 2. Check voltage between ABS actuator and electric unit connector E111 terminal 17 and ground. MA 5 EM LC EC SBR701EB FE Does battery voltage exist when ignition switch is turned ON? Yes © GO TO 6. No © Check the following. If NG, repair harness or connector. I Harness connector E111 I Harness for open or short between ABS actuator and electric unit and fuse 6 CL MT AT CHECK WARNING LAMP 1. Disconnect ABS actuator and electric unit connector. 2. Connect suitable wire between ABS actuator and electric unit connector E111 terminal 2 and ground. TF PD AX SU SBR713EB Does the warning lamp deactivate? Yes © Replace ABS actuator and electric unit. No © GO TO 7. ST RS BT HA SC EL IDX BR-75 TROUBLE DIAGNOSES FOR SYMPTOMS ABS 7. Warning Lamp Stays On When Ignition Switch Is Turned On (Cont’d) 7 CHECK ABS WARNING LAMP CONTROL CIRCUIT FOR OPEN 1. Disconnect combination meter connector M24. 2. Check continuity between combination meter connector M24 terminal 10 and ABS actuator and electric unit connector E111 terminal 2. NOTE: Connect positive lead of multimeter to1combination meter connector M24 terminal 10 and negative lead to ABS actuator and electric unit connector E111 terminal 2. SBR710EB Continuity should exist. Does continuity exist? Yes © Check combination meter. Refer to EL-139, “WARNING LAMPS”. No © Repair harness or connectors. 8 REPLACE FUSE Replace fuse. Does the fuse blow out when ignition switch is turned ON? Yes © GO TO 9. No © INSPECTION END 9 CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT FOR SHORT 1. Disconnect battery cable and ABS actuator and electric unit connector. 2. Check continuity between ABS actuator and electric unit connector E111 terminal 17 and ground. SBR702EB Continuity should not exist. Does continuity exist? Yes © Check the following. If NG, repair harness or connector. I Harness connector E111 I Harness for open or short between ABS actuator and electric unit and fuse No © Replace ABS actuator and electric unit. BR-76 TROUBLE DIAGNOSES FOR SYMPTOMS ABS 8. Vehicle Vibrates Excessively When ABS Is Operating 8. Vehicle Vibrates Excessively When ABS Is Operating I I 1 GI =NABR0145 While ABS is operating, brake pedal vibrates slightly. This is not a problem. If vehicle vibration is greater in the AUTO mode than in the 2WD mode, there is the possibility of failure in the communication line between the ABS control unit and transfer control unit. Check and locate the cause of the problem. MA EM LC INSPECTION START Inspection for excessive vibration of vehicle EC FE CL MT SBR711E © 2 AT GO TO 2. CARRY OUT SELF-DIAGNOSIS TF Perform self-diagnosis for the ABS actuator and electric unit and transfer control unit. Are there any malfunctions? Yes © GO TO 3. No © GO TO 4. 3 AX INSPECTION OR REPAIR Inspect or repair the system according to the self-diagnostic item. OK © PD SU GO TO 4. ST RS BT HA SC EL IDX BR-77 TROUBLE DIAGNOSES FOR SYMPTOMS ABS 8. Vehicle Vibrates Excessively When ABS Is Operating (Cont’d) 4 CHECK CIRCUIT 1. Disconnect connectors from ABS actuator and electric unit and transfer control unit. Check terminals for damage or loose connection. 2. Check continuity between ABS actuator and electric unit connector terminal 9 and transfer control unit connector terminal 32. SBR712EA Does continuity exist? Yes © GO TO 5. No © Check the following. I Harness connectors E111, M143 I Harness for open or short between ABS actuator and electric unit and transfer control unit If NG, repair harness or connectors. 5 CHECK ABS OPERATING SIGNAL CIRCUIT 1. Reconnect only ABS actuator and electric unit connector. 2. Check continuity between transfer control unit connector terminal 32 and ground. Continuity should not exist. SBR510E Does continuity exist? Yes © Replace ABS actuator and electric unit. No © GO TO 6. BR-78 TROUBLE DIAGNOSES FOR SYMPTOMS ABS 8. Vehicle Vibrates Excessively When ABS Is Operating (Cont’d) 6 GI CHECK ABS OPERATING SIGNAL 1. Connect CONSULT-II to Data Link Connector. 2. Turn ignition switch “ON”. Set CONSULT-II in the active test mode to output an ABS operating signal. (Refer to “ACTIVE TEST PROCEDURE”, “CONSULT-II Inspection Procedure”, BR-47.) 3. An ABS operating signal lasts for 10 seconds. During the time the signal is being output, check resistance between transfer control unit connector terminal 32 and ground. Resistance: 0.5Ω, max. MA EM LC EC FE CL MT AT TF SBR680E Is resistance within specifications? Yes © CHECK transfer control unit. Refer to TF-123, “ABS OPERATION SIGNAL”. No © Replace ABS actuator and electric unit. PD AX SU ST RS BT HA SC EL IDX BR-79 =NABR0079 REMOVAL AND INSTALLATION ABS CAUTION: Be careful not to damage sensor edge and sensor rotor teeth. When removing the front or rear wheel hub assembly, disconnect the ABS wheel sensor from the assembly and move it away. Front Wheel Sensor NABR0079S01 SBR717E Rear Wheel Sensor NABR0079S02 SBR399D BR-80 REMOVAL AND INSTALLATION ABS Front Sensor Rotor Front Sensor Rotor REMOVAL 1. 2. NABR0079S03 GI NABR0079S0301 Remove the front wheel hub. Refer to AX-9, “Disassembly”. Remove the sensor rotor using suitable puller, drift and bearing replacer. MA EM LC SBR873C INSTALLATION EC NABR0079S0302 Install the sensor rotor using suitable drift and press. I Always replace sensor rotor with new one. I Pay attention to the direction of front sensor rotor as shown in figure. FE CL MT SBR400DA Rear Sensor Rotor REMOVAL I AT NABR0079S04 NABR0079S0401 Remove the sensor rotor using Tool. TF PD AX SU SRA800AA INSTALLATION NABR0079S0402 Install the sensor rotor using suitable drift and press. I Always replace sensor rotor with new one. I Pay attention to the direction of front sensor rotor as shown in figure. ST RS BT SBR402D G Sensor NABR0079S06 Always replace G sensor if bumped or dropped. Otherwise, performance characteristics of G sensor will be changed, which in turn changes ABS control performance characteristics. HA SC EL IDX SBR076F BR-81 REMOVAL AND INSTALLATION ABS ABS Actuator and Electric Unit ABS Actuator and Electric Unit NABR0079S07 SBR074F REMOVAL 1. 2. 3. 4. NABR0079S0701 Disconnect battery cable. Drain brake fluid. Refer to “Changing Brake Fluid”, BR-8. Remove mounting bracket fixing bolts and nuts. Disconnect connector, brake pipes and remove fixing nuts and actuator ground cable. INSTALLATION NABR0079S0702 CAUTION: After installation, refill brake fluid. Then bleed air. Refer to “Bleeding Brake System”, BR-9. 1. Tighten actuator ground cable. Place ground cable at a notch of mounting bracket. 2. Connect brake pipes temporarily. 3. Tighten fixing bolts and nuts. 4. Tighten brake pipes. 5. Connect connector and battery cable. BR-82 PRECAUTIONS VDC/TCS/ABS Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” GI NABR0208 The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS composition which is available to NISSAN MODEL R50 is as follows (The composition varies according to optional equipment.): I For a frontal collision The Supplemental Restraint System consists of driver air bag module (located in the center of the steering wheel), front passenger air bag module (located on the instrument panel on passenger side), seat belt pre-tensioners, diagnosis sensor unit, warning lamp, wiring harness and spiral cable. I For a side collision The Supplemental Restraint System consists of front side air bag module (located in the outer side of front seat), (located in the outer side of front seat), side curtain air bag module (locating in the headliner side of front and rear seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision). WARNING: I 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 should be performed by an authorized NISSAN dealer. I Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified with yellow and/or orange harness connector (and with yellow harness protector or yellow insulation tape before the harness connectors). Precautions for SRS “Air Bag” and “SEAT BELT PRE-TENSIONER” Service I I I I I I I MA EM LC EC FE CL MT AT TF NABR0209 Do not use electrical test equipment to check SRS circuits unless instructed to in this Service Manual. 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 and seat belt pre-tensioner to deploy. Therefore, do not work on any SRS connectors or wires until at least 3 minutes have passed. Diagnosis sensor unit must always be installed with their arrow marks “g” pointing towards the front of the vehicle for proper operation. Also check diagnosis sensor unit for cracks, deformities or rust before installation and replace as required. 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 driver and passenger air bag modules with the pad side facing upward and place side air bag module standing with stud bolt side setting bottom. Conduct self-diagnosis to check entire SRS for proper function after replacing any components. After air bag inflates, the front instrument panel assembly should be replaced if damaged. PD AX SU ST RS BT Precautions for Brake System I I I I NABR0153 Recommended fluid is brake fluid “DOT 3”. Never reuse drained brake fluid. Be careful not to splash brake fluid on painted areas such as body. If brake fluid is splashed, wipe it off and flush area with water immediately. Never use mineral oils such as gasoline or kerosene to clean. They will ruin rubber parts and cause improper operation. HA SC EL IDX BR-83 PRECAUTIONS VDC/TCS/ABS Precautions for Brake System (Cont’d) I I I I Using a flare nut torque wrench, securely tighten brake tube flare nuts. Brake system is an important safety part. If a brake fluid leak is detected, always disassemble the affected part. If a malfunction is detected, replace part with a new one. Before working, turn ignition switch OFF and disconnect electrical connectors of ABS actuator and electric unit (control unit) or battery terminals. When installing brake piping, be sure to check torque. SBR686C Precautions for Brake Control I I I I I I I NABR0154 During VDC/TCS/ABS operation, brake pedal lightly vibrates and a mechanical noise may be heard. This is normal. Just after starting vehicle after ignition switch ON, brake pedal may vibrate or motor operating noise may be heard from engine compartment. This is a normal status of operation check. Stopping distance may be longer than that of vehicles without ABS when vehicle drives on rough, gravel, or snow-covered (fresh, deep snow) roads. When an error is indicated by ABS or another warning lamp, collect all necessary information from customer (what symptoms are present under what conditions) and check for simple causes before starting diagnostic servicing. Besides electrical system inspection, check booster operation, brake fluid level, and oil leaks. If tire size and type are used in an improper combination, or brake pads are not Genuine NISSAN parts, stopping distance or steering stability may deteriorate. If there is a radio, antenna, or antenna lead-in wire (including wiring) near control module, VDC/TCS/ABS function may have a malfunction or error. If aftermarket parts (car stereo, CD player, etc.) have been installed, check for incidents such as harness pinches, open circuits, and improper wiring. Diagnosis Precaution CAN SYSTEM I I I NABR0155S01 Do not apply voltage of 7.0V or higher to terminal to be measured. Maximum open terminal voltage of tester in use shall be 7.0V or lower. Before checking harnesses, turn ignition switch to OFF and disconnect battery negative cable. Precaution for Harness Repair CAN SYSTEM I NABR0155 NABR0156 NABR0156S01 Area to be repaired shall be soldered, and wrapped with a tape [be sure that fraying of twisted wire shall be within 110 mm (4.33 in)]. PKIA0306E BR-84 PRECAUTIONS VDC/TCS/ABS Precaution for Harness Repair (Cont’d) I Do not make a bypass connection to repaired area. (If it is done, branch part will be removed and characteristics of twisted wire will be lost.) GI MA EM LC PKIA0307E EC FE CL MT AT TF PD AX SU ST RS BT HA SC EL IDX BR-85 PREPARATION VDC/TCS/ABS Commercial Service Tools Commercial Service Tools Tool name Description 1. Flare nut crowfoot 2. Torque wrench Removing and installing each brake piping a: 10 mm (0.39 in)/12 mm (0.47 in) S-NT360 BR-86 NABR0157 ON-VEHICLE SERVICE VDC/TCS/ABS Adjustment of Steering Angle Sensor Neutral Position Adjustment of Steering Angle Sensor Neutral Position GI NABR0158 I After replacing ABS actuator and electric unit (control unit), steering angle sensor, steering components and suspension components, or after adjusting wheel alignment, make sure to adjust neutral position of steering angle sensor before running vehicle. CAUTION: To adjust neutral position of steering angle sensor, make sure to use CONSULT-II. (Adjustment cannot be done without CONSULT-II.) 1. Stop vehicle with front wheels in straight-ahead position. 2. Connect CONSULT-II and CONSULT-II CONVERTER to data link connector on vehicle, and turn ignition switch ON (do not start engine). 3. Touch “ABS”, “WORK SUPPORT” and “ST ANGLE SENSOR ADJUSTMENT” on CONSULT-II screen in this order. MA EM LC EC FE CL MT SBR112F SFIA0793E 4. Touch “START”. CAUTION: Do not touch steering wheel while adjusting steering angle sensor. 5. After approximately 10 seconds, touch “END”. (After approximately 60 seconds, it ends automatically.) 6. Turn ignition switch OFF, then turn it ON again. CAUTION: Be sure to carry out above operation. 7. Run vehicle with front wheels in straight-ahead position, then stop. 8. Select “DATA MONITOR”, “CONTROL MODULE INPUT ITEM”, and “STEERING ANGLE SIGNAL” on CONSULT-II screen. Then check that “STEERING ANGLE SIGNAL” is within 0±3.5 deg. If value is more than specification, repeat steps 1 to 5. 9. Erase memory of ABS actuator and electric unit (control unit) and ECM. 10. Turn ignition switch to OFF. AT TF PD AX SU ST RS BT Calibration of Decel G Sensor I NABR0203 After removing/installing or replacing ABS actuator and electric unit (control unit), suspension components, or after adjusting wheel alignment or replacing yaw rate/side/decel G sensor, make sure to calibrate decel G sensor before running vehicle. CAUTION: To calibrate decel G sensor, make sure to use CONSULT-II. (Adjustment cannot be done without CONSULT-II.) HA SC EL IDX BR-87 ON-VEHICLE SERVICE VDC/TCS/ABS Calibration of Decel G Sensor (Cont’d) 1. 2. 3. Stop vehicle horizontally with front wheels in straight-ahead position. Connect CONSULT-II and CONSULT-II CONVERTER to data link connector on vehicle, and turn ignition switch ON (do not start engine). Touch “ABS”, “WORK SUPPORT” and “DECEL G SEN CALIBRATION” on CONSULT-II screen in this order. SBR112F SBR231F 4. Touch “START”. CAUTION: The vehicle should be set horizontal and stationary. 5. After approximately 10 seconds, touch “END”. (After approximately 60 seconds, it ends automatically.) 6. Turn ignition switch OFF, then turn it ON again. CAUTION: Be sure to carry out above operation. 7. Run vehicle with front wheels in straight-ahead position, then stop. 8. Select “DATA MONITOR”, “CONTROL MODULE INPUT ITEM”, and “DECEL G SEN” on CONSULT-II screen. Then check that “DECEL G SEN” is within ±0.08G. If value is more than specification, repeat steps 1 to 5. 9. Erase memory of ABS actuator and electric unit (control unit) and ECM. 10. Turn ignition switch to OFF. BR-88 NABR0199 GENERAL INFORMATION VDC/TCS/ABS Fail-Safe Fail-Safe ABS SYSTEM NABR0199S01 GI NABR0199S0101 If a malfunction occurs in electrical system, ABS warning lamp, VDC OFF indicator lamp, and SLIP indicator lamp in combination meter turn ON. In this condition, the fail-safe function puts VDC/TCS/ABS and EBD into one of the following conditions. 1. Only EBD operates. Same condition as that of models without VDC/TCS/ABS. 2. VDC/TCS/ABS and EBD do not operate. All 4 wheels operate as normal brakes. NOTE: In step 1 shown above, self-diagnosis when ignition switch is turned ON and when vehicle starts at initial time is carried out. ABS self-diagnosis noise may be heard as usual. MA VDC/TCS SYSTEM EC NABR0199S0102 If a malfunction occurs in electrical system, VDC OFF indicator lamp and SLIP indicator lamp in combination meter turn on. In this condition, VDC/TCS will be deactivated and it becomes equal to that of models without VDC/TCS. However, ABS is controlled normally. If a malfunction occurs in throttle control system, VDC/TCS control will be deactivated and only ABS control will operate normally. CAUTION: If fail-safe mode is initiated, carry out self-diagnosis for VDC/TCS/ABS control system. Hydraulic Circuit Diagram EM LC FE CL MT NABR0199S02 AT TF PD AX SU ST RS BT ABS Function SBR137F HA NABR0199S03 SC 1. During ABS operation, brake pedal lightly vibrates and a mechanical noise may be heard. This is normal. 2. When starting engine, or just after starting vehicle, brake pedal may vibrate or motor operating noises may be heard from engine compartment. This is a normal status of operation check. 3. Stopping distance may be longer than that of vehicles without ABS when vehicle drives on rough, gravel, or snow-covered (fresh, deep snow) roads. 4. EBD is integrated in VDC/TCS/ABS system. BR-89 EL IDX GENERAL INFORMATION VDC/TCS/ABS TCS Function TCS Function NABR0199S04 1. ABS actuator and electric unit (control unit) detects a spin at drive wheels by comparing wheel speed signals from all 4 wheels. At this time, output from control unit controls brake fluid pressure to both LH and RH rear wheels while cutting fuel to engine and closing throttle valve to reduce engine torque. Furthermore, throttle position is continuously controlled to insure appropriate engine torque at all times. 2. Depending on road circumstances, driver may have a sluggish feel. This is normal, because optimum traction has highest priority under TCS operation. 3. When vehicle is passing through a road where surface friction coefficient varies, downshifting or depressing accelerator pedal fully may activate TCS temporarily. 4. During TCS operation, it informs driver of system operation by flashing SLIP indicator lamp. VDC Function NABR0199S05 1. In addition to TCS/ABS function, VDC detects driver’s steering operation amount and brake pedal travel from steering angle sensor and pressure sensor. Using information from yaw rate/side G-sensor and wheel sensor, VDC judges driving condition (conditions of under steer and over steer) to improve stability by controlling brake application to 4 wheels and engine output. 2. SLIP indicator lamp flashes to inform driver of VDC operation. 3. During VDC operation, body and brake pedal lightly vibrate and mechanical noises may be heard. This is normal. 4. If vehicle is rotated on turn table, or rolled and rocked on ship, ABS warning lamp, VDC OFF indicator lamp, and SLIP indicator lamp may turn ON. In this case, start engine on normal road again. If ABS warning lamp, VDC OFF indicator lamp, and SLIP indicator lamp turn OFF after restart, it is normal. 5. When driving in steep slope such as bank, ABS warning lamp, VDC OFF indicator lamp, and SLIP indicator lamp may turn ON. In this case, start engine on normal road again. If ABS warning lamp, VDC OFF indicator lamp, and SLIP indicator lamp turn OFF after restart, it is normal. System Diagram NABR0199S06 SBR113F BR-90 CAN COMMUNICATION VDC/TCS/ABS System Description System Description NABR0204 CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. CAN Communication Unit Body type Axle NABR0205 GI MA EM LC Wide/Wagon 4WD (All-mode) Engine 4WD (Part time) 2WD EC VQ35DE Transmission A/T Brake control VDC FE CL CAN communication unit ECM X X X TCM X X X MT Transfer control unit X Steering angle sensor X X X AT ABS actuator and electric unit (control unit) X X X Combination meter X X X CAN communication type (Reference page) Type 1 (BR-91) TF Type 2 (BR-93) PD X: Applicable TYPE 1 (ALL-MODE 4WD MODELS) System Diagram NABR0205S01 AX NABR0205S0101 SU ST SEL683Y RS BT HA SC EL IDX BR-91 CAN COMMUNICATION VDC/TCS/ABS CAN Communication Unit (Cont’d) Input/Output Signal Chart =NABR0205S0102 T: Transmit R: Receive Signals ECM TCM Transfer control unit ABS actuaSteering tor and elec- Combination angle sensor tric unit meter (control unit) Engine speed signal T R R Accelerator pedal position signal T R R Closed throttle position signal T R Wide open throttle position signal T R VDC operation signal R R T TCS operation signal R R T ABS operation signal R R T Output shaft revolution signal R ETC fail signal T During shifting signal R T R R T R Steering wheel angle sensor signal R T Wheel speed sensor signal R Stop lamp switch signal R R T R T MIL signal T R Engine coolant temperature signal T R Fuel consumption signal T R T R Vehicle speed signal R T Lock-up prohibition signal T R Lock-up signal R T Neutral range switch signal R T Parking range switch signal R T Overdrive control switch signal R T A/C compressor feedback signal T R Fuel level sensor signal R T A/T position indicator signal T R O/D OFF indicator signal T R BR-92 CAN COMMUNICATION VDC/TCS/ABS CAN Communication Unit (Cont’d) TYPE 2 (EXCEPT ALL-MODE 4WD MODELS) System Diagram =NABR0205S02 GI NABR0205S0201 MA EM LC EC SEL682Y FE Input/Output Signal Chart NABR0205S0202 T: Transmit R: Receive Signals ECM TCM Steering angle sensor Combination meter R Engine speed signal T R Accelerator pedal position signal T R Closed throttle position signal T R Wide open throttle position signal T R VDC operation signal R T TCS operation signal R T ABS operation signal R T Steering wheel angle sensor signal CL ABS actuator and electric unit (control unit) MT AT TF T PD AX R MIL signal T R Engine coolant temperature signal T R Fuel consumption signal T R T SU R Vehicle speed signal R T Stop lamp switch signal R Lock-up prohibition signal T R Lock-up signal R T T ST RS Neutral range switch signal R T Parking range switch signal R T Overdrive control switch signal R T A/C compressor feedback signal T R Fuel level sensor signal R T A/T position indicator signal T R O/D OFF indicator signal T R BT HA SC EL IDX BR-93 TROUBLE DIAGNOSES VDC/TCS/ABS How to Proceed with Diagnosis How to Proceed with Diagnosis BASIC CONCEPT I NABR0165 NABR0165S01 Most important point to perform diagnosis is to understand systems (control and mechanism) in vehicle thoroughly. I It is also important to clarify customer complaints before inspection. First of all, reproduce symptom, and understand it fully. Ask customer about his/her complaints carefully. In some cases, it will be necessary to check symptom by driving vehicle with customer. NOTE: Customers are not professionals. Do not assume “maybe customer means...” or “maybe customer mentioned this symptom”. SEF234G I SEF233G I I I It is essential to check symptoms right from beginning in order to repair a malfunction completely. For an intermittent malfunction, it is important to reproduce symptom based on interview with customer and past examples. Do not perform inspection on ad hoc basis. Most intermittent malfunctions are caused by poor contacts. In this case, it will be effective to shake suspected harness or connector by hand. When repairs are performed without any symptom check, no one can judge if malfunction has actually been eliminated. After diagnosis, make sure to carry out “erase memory”. Refer to BR-108. For an intermittent malfunction, move harness or harness connector by hand to check poor contact or false open circuit. Always read “GI General Information” to confirm general precautions. BR-94 TROUBLE DIAGNOSES VDC/TCS/ABS How to Proceed with Diagnosis (Cont’d) DIAGNOSIS FLOWCHART NABR0165S02 GI MA EM LC EC FE CL MT AT TF PD AX SU ST RS BT HA SC EL SBR249F BR-95 IDX TROUBLE DIAGNOSES VDC/TCS/ABS How to Proceed with Diagnosis (Cont’d) ASKING COMPLAINTS I I I NABR0165S03 Complaints against malfunction vary depending on each person. It is important to clarify customer complaints. Ask customer about what symptoms are present and under what conditions. Use information to reproduce symptom while driving. It is also important to use diagnosis sheet so as not to miss information. SBR339B EXAMPLE OF DIAGNOSIS SHEET NABR0165S04 SFIA0029E BR-96 TROUBLE DIAGNOSES VDC/TCS/ABS Component Installation Location Component Installation Location NABR0166 GI MA EM LC EC FE CL MT AT TF PD AX SU ST RS BT HA SC EL SBR114F BR-97 IDX TROUBLE DIAGNOSES VDC/TCS/ABS Schematic Schematic NABR0167 MBR627A BR-98 TROUBLE DIAGNOSES VDC/TCS/ABS Wiring Diagram — VDC — Wiring Diagram — VDC — NABR0168 GI MA EM LC EC FE CL MT AT TF PD AX SU ST RS BT HA SC EL MBR628A BR-99 IDX TROUBLE DIAGNOSES VDC/TCS/ABS Wiring Diagram — VDC — (Cont’d) MBR629A BR-100 TROUBLE DIAGNOSES VDC/TCS/ABS Wiring Diagram — VDC — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU ST RS BT HA SC EL MBR630A IDX BR-101 TROUBLE DIAGNOSES VDC/TCS/ABS Wiring Diagram — VDC — (Cont’d) MBR631A BR-102 TROUBLE DIAGNOSES VDC/TCS/ABS Wiring Diagram — VDC — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU ST RS BT HA SC EL MBR632A IDX BR-103 TROUBLE DIAGNOSES VDC/TCS/ABS Control Unit Input/Output Signal Standard Control Unit Input/Output Signal Standard STANDARDS BY CONSULT-II NABR0169 NABR0169S01 CAUTION: Items displayed are data calculated by the control unit and may indicate normal operation even if output circuit (harness) is open or shorted. Data monitor Monitor item Display content Condition Reference value in normal operation GEAR A/T gear position Vehicle running 1 to 4 SLCT LVR POSI A/T shift position Select shift position Shift position: P, R, N or D Vehicle stopped 0 [km/h (MPH)] Vehicle running (Note 1) Almost in accordance with speedometer display (within ±10%) Accelerator pedal not depressed (ignition switch is ON) 0% Depress accelerator pedal (ignition switch is ON) 0 to 100% With engine stopped 0 rpm Engine running Almost in accordance with tachometer display Straight-ahead Approx. 0 deg Steering wheel turned –756 to 756 deg Vehicle stopped Approx. 0 d/s Vehicle running –100 to 100 d/s Vehicle stopped Approx. 0 m/s2 Vehicle running –16.7 to 16.7 m/s2 FR LH SENSOR FR RH SENSOR RR LH SENSOR RR RH SENSOR Wheel speed ACCEL POS SIG Throttle actuator opening/closing is displayed (linked with accelerator pedal) ENGINE SPEED· STR ANGLE SIG YAW RATE SEN With engine running Steering angle detected by steering angle sensor Yaw rate detected by yaw rate sensor Transverse G detected SIDE G-SENSOR by side G-sensor DECEL G-SEN PRESS SENSOR BATTERY VOLT Longitudinal acceleration Vehicle stopped detected by Decel During driving G-Sen Brake fluid pressure detected by pressure sensor Approx. 0 G ±1.7 G With ignition switch turned Approx. 0 bar ON and brake pedal released With ignition switch turned ON and brake pedal depressed Battery voltage supplied to ABS actuator and Ignition switch ON electric unit (control unit) BR-104 0 to 170 bar 10 to 16V Note: Error inspection checklist — Refer to AT section. Wheel sensor circuit [Inspection 1] Refer to BR-119. Communication circuit between ABS actuator and electric unit (control unit) and ECM Engine speed signal circuit Steering angle sensor and circuit [Inspection 5] Refer to BR-123. Yaw rate sensor and circuit [Inspection 6] Refer to BR-124. Side G-sensor and circuit [Inspection 6] Refer to BR-124. Decel G sensor and circuit Pressure sensor and circuit [Inspection 4] Refer to BR-122. ABS actuator and electric unit (control unit) power supply and ground circuits [Inspection 10] Refer to BR-130. TROUBLE DIAGNOSES VDC/TCS/ABS Control Unit Input/Output Signal Standard (Cont’d) GI Data monitor Monitor item Display content Condition STOP LAMP SW OFF SW OFF switch ON/OFF status ABS warning lamp ON condition (Note 2) MOTOR RELAY Operation status of motor and motor relay OFF LAMP Brake pedal depressed ON Brake pedal not depressed OFF VDC OFF switch ON (When VDC OFF indicator lamp is ON) ON Brake pedal operation ABS WARN LAMP ACTUATOR RLY Actuator relay operation status OFF ABS warning lamp ON ON ABS warning lamp OFF OFF Ignition switch ON or engine running (ABS not operated) OFF Ignition switch ON or engine running (ABS operated) ON Vehicle stopped (Ignition switch ON) OFF Vehicle stopped (Engine running) ON When VDC OFF indicator VDC OFF indicator lamp lamp is ON status (Note 3) When VDC OFF indicator FR IN SOL FR OUT SOL RR IN SOL RR OUT SOL FLUID LEV SW EBD FAIL SIG ABS FAIL SIG TCS FAIL SIG VDC FAIL SIG SLIP indicator lamp status (Note 4) EM LC ABS warning lamp harness ABS motor, motor relay, and motor circuit [Inspection 8] Refer to BR-128. ABS actuator relay and circuit [Inspection 8] Refer to BR-128. VDC OFF indicator lamp circuit FE CL MT AT PD OFF When SLIP indicator lamp is OFF OFF AX SLIP indicator lamp circuit SU ON Solenoid and circuit [Inspection 7] Refer to BR-126. ST OFF When brake fluid level sensor ON ON When brake fluid level sensor OFF OFF Malfunctions condition (When system failed) EC ON ON When actuator (solenoid) is not active and actuator relay is active (ignition switch ON). System fail signal status Stop lamp switch circuit [Inspection 9] Refer to BR-129. TF When SLIP indicator lamp is ON Actuator (solenoid) is active (“ACTIVE TEST” with CONSULT-II) or actuator relay is Solenoid valve operation inactive (in fail-safe mode). ON/OFF status of brake fluid level sensor MA VDC OFF switch circuit VDC OFF switch OFF (When VDC OFF indicator lamp is OFF) lamp is OFF SLIP LAMP Reference value in normal operation Note: Error inspection checklist OFF Brake fluid level sensor, brake warning lamp, and circuit [Inspection 13] Refer to BR-133. EBD system ABS system TCS system VDC system RS BT HA SC EL IDX BR-105 TROUBLE DIAGNOSES VDC/TCS/ABS Control Unit Input/Output Signal Standard (Cont’d) Data monitor Monitor item Display content Condition CV1 CV2 SV1 SV2 VDC switch-over solenoid valve status Reference value in normal operation When the actuator (switchover solenoid valve) is active (“Active test” with CONSULTII) or the actuator relay is inactive (when fail-safe mode). ON When the actuator (switchover solenoid valve) is inactive or the actuator relay is active (ignition switch ON). OFF Note: Error inspection checklist Switch-over solenoid valve and circuit Note 1: Confirm tire pressure is normal. Note 2: ON/OFF timing of ABS warning lamp ON: For approximately 1 seconds after ignition switch is turned ON, or when a malfunction is detected. OFF: Approximately 1 seconds after ignition switch is turned ON (when system is in normal operation) and VDC/TCS function is not activated. (Note 3): ON/OFF timing of VDC OFF indicator lamp ON: For approximately 1 seconds after ignition switch is turned ON, or when a malfunction is detected and VDC OFF switch is ON. OFF: Approximately 1 seconds after ignition switch is turned ON (when system is in normal operation.) And when VDC OFF switch is OFF. Note 4: SLIP indicator lamp ON/OFF timing ON: For approximately 1 seconds after ignition switch is turned ON, or when a malfunction is detected and VDC/TCS function is activated while driving. OFF: Approximately 1 seconds after ignition switch is turned ON (when system is in normal operation) and VDC/TCS function is not activated. Flashing: VDC/TCS function is active during driving CONSULT-II Functions NABR0170 CONSULT-II MAIN FUNCTION NABR0170S01 In a diagnosis function (main function), there are “WORK SUPPORT”, “SELF-DIAGNOSTIC RESULTS”, “DATA MONITOR”, “CAN DIAG SUPPORT MNTR”, “ACTIVE TEST”, “FUNCTION TEST”, “ECU PART NUMBER”. Diagnostic test mode Function Reference WORK SUPPORT This mode enables a technician to adjust some devices faster and more accurately by following the indications on CONSULT-II. Refer to BR-87. SELF-DIAGNOSTIC RESULTS Self-diagnostic results can be read and erased quickly. Refer to BR-108. DATA MONITOR Input/Output data in the ABS actuator and electric unit (control unit) can be read. Refer to BR-111. CAN DIAG SUPThe results of transmit/receive diagnosis of communication can be read. PORT MNTR ACTIVE TEST Diagnostic Test Mode in which CONSULT-II drives some actuators apart from the ABS actuator and electric unit (control unit) and also shifts some Refer to BR-114. parameters in a specified range. BR-106 — TROUBLE DIAGNOSES VDC/TCS/ABS CONSULT-II Functions (Cont’d) Diagnostic test mode GI Function Reference FUNCTION TEST Conducted by CONSULT-II instead of a technician to determine whether each system is “OK” or “NG”. — MA ECU PART NUMBER ABS actuator and electric unit (control unit) part number can be read. — EM LC EC FE CL MT AT TF PD AX SU ST RS BT HA SC EL IDX BR-107 TROUBLE DIAGNOSES VDC/TCS/ABS CONSULT-II Functions (Cont’d) SELF-DIAGNOSIS Description =NABR0170S02 NABR0170S0201 If a malfunction is detected in system, ABS warning lamp, VDC OFF indicator lamp, and SLIP indicator lamp on meter turn on. In this case, perform self-diagnosis as follows: Operation Procedure 1. 2. SBR112F NABR0170S0202 Perform Refer to BR-118 using information from customer. After ignition switch is turned OFF, connect CONSULT-II and CONSULT-II CONVERTER to data link connector (data link connector is on lower instrument cover). 3. Start engine and drive at approximately 30 km/h (19 MPH) for approximately 1 minute. 4. After stopping vehicle, with engine still idling, touch “START”, “ABS”, and “SELF-DIAG RESULTS” on CONSULT-II screen in this order. CAUTION: Just after starting engine, or turning ignition switch ON, “ABS” may not be displayed on system selection screen even if “START” is touched. In this case, start self-diagnosis again from step 2. If it cannot be shown after several attempts, VDC/ TCS/ABS control unit may have malfunctioned. Repair or replace control unit. 5. Self-diagnosis result is displayed. (If necessary, touch “PRINT” to print self-diagnosis result.) I When “NO FAILURE” is shown, check ABS warning lamp, VDC OFF indicator lamp, SLIP indicator lamp. Refer to BR-116. I CONSULT-II self-diagnosis results are displayed without regard to occurrence timing. In some cases later ones (timing value is small) appear on next screen. 6. Go to appropriate “Inspection” chart according to “Display Item List”, and repair or replace as necessary. 7. Start engine and drive at approximately 30 km/h (19 MPH) for approximately 1 minute. CAUTION: Check again to make sure that there is no malfunction on other parts. 8. Turn ignition switch OFF to prepare for erasing memory. 9. Start engine and touch “START”, “ABS”, “SELF-DIAGNOSIS RESULTS”, and “ERASE MEMORY” on CONSULT-II screen in this order to erase memory. CAUTION: If memory cannot be erased, go to step 6. 10. Drive vehicle at approximately 30 km/h (19 MPH) and check that ABS warning lamp, VDC OFF indicator lamp, and SLIP indicator lamp stay off. BR-108 TROUBLE DIAGNOSES VDC/TCS/ABS CONSULT-II Functions (Cont’d) Display Item List Malfunction system Malfunction detecting condition FR LH SENSOR-1 Circuit of front LH wheel sensor is open RR RH SENSOR-1 Circuit of rear RH wheel sensor is open FR RH SENSOR-1 Circuit of front RH wheel sensor is open RR LH SENSOR-1 Circuit of rear LH wheel sensor is open FR LH SENSOR-2 Circuit of front LH wheel sensor is shorted, or sensor power voltage is unusual. Control unit cannot identify sensor pulses, because of large gap between wheel sensor and sensor rotor. RR RH SENSOR-2 Circuit of rear RH wheel sensor is shorted, or sensor power voltage is unusual. Control unit cannot identify sensor pulses, because of large gap between wheel sensor and sensor rotor. NABR0170S0203 GI Check system MA EM LC Wheel sensor and circuit [Inspection 1] Note 1 Refer to BR-119. EC FE FR RH SENSOR-2 Circuit of front RH wheel sensor is shorted, or sensor power voltage is unusual. Control unit cannot identify sensor pulses, because of large gap between wheel sensor and sensor rotor. RR LH SENSOR-2 Circuit of rear LH wheel sensor is shorted, or sensor power voltage is unusual. Control unit cannot identify sensor pulses, because of large gap between wheel sensor and sensor rotor. STOP LAMP SW Stop lamp switch circuit is open. Stop lamp switch and circuit [Inspection 9] Refer to BR-129. PRESS SEN CIRCUIT VDC pressure sensor signal line is open or shorted, or VDC pressure sensor is malfunctioning. VDC pressure sensor and circuit [Inspection 4] Refer to BR-122. ST ANGLE SEN CIRCUIT Neutral position of steering angle sensor is dislocated, or steering angle sensor is malfunctioning. Steering angle sensor and circuit [Inspection 5] Refer to BR-123. YAW RATE SENSOR Yaw rate/Side G-sensor and Yaw rate sensor has generated an error, or yaw rate sensor sig- circuit nal line is open or shorted. [Inspection 6] Refer to BR-124. FR LH IN ABS SOL Circuit of front LH IN ABS solenoid is open or shorted, or control line is open or shorted to power supply or ground. FR LH OUT ABS SOL Circuit of front LH OUT ABS solenoid is open or shorted, or control line is open or shorted to power supply or ground. RR RH IN ABS SOL Circuit of rear RH IN ABS solenoid is open or shorted, or control line is open or shorted to power supply or ground. RR RH OUT ABS SOL Circuit of rear RH OUT ABS solenoid is open or shorted, or control line is open or shorted to power supply or ground. FR RH IN ABS SOL Circuit of front RH IN ABS solenoid is open or shorted, or control line is open or shorted to power supply or ground. FR RH OUT ABS SOL Circuit of front RH OUT ABS solenoid is open or shorted, or control line is open or shorted to power supply or ground. RR LH IN ABS SOL Circuit of rear LH IN ABS solenoid is open or shorted, or control line is open or shorted to power supply or ground. RR LH OUT ABS SOL Circuit of rear LH OUT ABS solenoid is open or shorted, or control line is open or shorted to power supply or ground. CL MT AT TF PD AX SU ST RS Solenoid and circuit [Inspection 7] Refer to BR-126. BT HA SC EL IDX BR-109 TROUBLE DIAGNOSES VDC/TCS/ABS CONSULT-II Functions (Cont’d) Malfunction system CV1 CV2 SV1 Malfunction detecting condition Check system Front side of VDC switch-over solenoid valve (cut valve) is open circuit or shorted, or the control line is open or shorted to the power supply or the ground. Rear side of VDC switch-over solenoid valve (cut valve) is open circuit or sorted, or the control line is open or shorted to the VDC switch-over valve and power supply or the ground. circuit Front side of VDC switch-over solenoid valve (suction valve) is [Inspection 7] Refer to open circuit or shorted, or the control line is open or shorted to BR-126. the power supply or the ground. SV2 Rear side of VDC switch-over solenoid valve (suction valve) is open circuit or shorted, or the control line is open or shorted to the power supply or the ground. During actuator motor operation with ON, when actuator motor turns OFF or when control line for actuator motor relay is open. PUMP MOTOR (note) During actuator motor operation with OFF, when actuator motor turns ON or when control line for relay is shorted to ground. Actuator motor, motor relay, and circuit [Inspection 8] Refer to BR-128. LOW POWER VOLTAGE ABS actuator and electric unit (control unit) power supply ABS actuator and electric unit (control unit) power voltage is too and ground circuits low. [Inspection 10] Refer to BR-130. ST ANGLE SEN SIGNAL Neutral position correction of steering angle sensor is not finished. Neutral position adjustment of steering angle sensor [Inspection 12] Refer to BR-133. ST ANG SEN COM CIR CAN communication line or steering angle sensor has generated an error. Steering angle sensor and CAN communication line [Inspection 14] Refer to BR-134. SIDE G-SEN CIRCUIT Side G-sensor is malfunctioning, or signal line of side G-sensor is open or shorted. Yaw rate/Side G-sensor and circuit [Inspection 6] Refer to BR-124. CONTROLLER FAILURE Internal malfunction of ABS actuator and electric unit (control unit) ABS actuator and electric unit (control unit) [Inspection 3] Refer to BR-121. CAN COMM CIRCUIT I CAN communication line is open or shorted. I ABS actuator and electric unit (control unit) internal malfunction I Battery voltage for EMC is suddenly interrupted for approximately 0.5 seconds or more. Communication line between ABS actuator and electric unit (control unit) and other control units [Inspection 14] Note 2 Refer to BR-134. BR FLUID LEVEL LOW I Brake fluid level drops or communication line between ABS actuator and electric unit (control unit) and brake fluid level sensor is open or shorted. I Communication line between ABS actuator and electric unit (control unit) and brake fluid sensor, and brake warning lamp I Reservoir tank fluid level [Inspection 13] Refer to BR-133. VARIANT CODING I V coding is not functioning. The ABS actuator and electric unit (control unit) and circuit Note 1. If wheel sensor 2 for each wheel is indicated, check control unit power supply voltage in addition to wheel sensor circuit check. BR-110 TROUBLE DIAGNOSES VDC/TCS/ABS CONSULT-II Functions (Cont’d) Note 2. If multiple malfunctions are detected including CAN communication line [U1000], perform diagnosis for CAN communication line first. DATA MONITOR I NABR0170S03 For details of data monitor function, refer to “CONSULT-II Instruction Manual”. Operation Procedure NABR0170S0301 1. Turn ignition switch OFF. 2. Connect CONSULT-II to DDL2 data link connector. 3. Turn ignition switch ON. 4. Touch “START” on display. 5. Touch “ABS” on display. NOTE: Just after starting engine, or turning ignition switch ON, “ABS” may not be displayed on system selection screen even if “START” is touched. In this case, start self-diagnosis again from step 2. 6. Touch “DATA MONITOR”. 7. Return to monitor item selection screen, and touch any of “CONTROL UNIT INPUT ITEM”, “MAIN ITEM” or “ITEM MENU SELECTION”. Refer to BR-112. 8. Touch “START”. 9. Screen of data monitor is displayed. GI MA EM LC EC FE CL MT AT TF PD AX SU ST RS BT HA SC EL IDX BR-111 TROUBLE DIAGNOSES VDC/TCS/ABS CONSULT-II Functions (Cont’d) Display Item List =NABR0170S0302 Monitor item selection ECU input signals Main item (Monitor item selector) Selection from menu GEAR × × × Gear position judged by PNP switch signal is displayed. FR RH SENSOR (km/h (MPH)) × × × Wheel speed calculated by front RH wheel sensor signal is displayed. FR LH SENSOR (km/h (MPH)) × × × Wheel speed calculated by front LH wheel sensor signal is displayed. RR RH SENSOR (km/h (MPH)) × × × Wheel speed calculated by rear RH wheel sensor signal is displayed. RR LH SENSOR (km/h (MPH)) × × × Wheel speed calculated by rear LH wheel sensor signal is displayed. BATTERY VOLT (V) × × × Voltage supplied to ABS actuator and electric unit (control unit) is displayed. SLCT LVR POSI × × × Shift position judged by PNP switch signal. ACCEL POS SIG (%) × — × Throttle actuator opening/closing status judged by CAN communication signal is displayed. ENGINE SPEED (rpm) × × × Engine speed judged by CAN communication signal is displayed. STR ANGLE SIG (deg) × — × Steering angle detected by steering angle sensor is displayed. YAW RATE SEN (d/s) × × × Yaw rate detected by yaw rate sensor is displayed. SIDE G-SENSOR (m/s2) × — × Transverse acceleration detected by side G-sensor is displayed. PRESS SENSOR (bar) × — × Brake fluid pressure detected by pressure sensor is displayed. STOP LAMP SW (ON/OFF) × × × Stop lamp switch (ON/OFF) status is displayed. OFF SW (ON/OFF) × × × VDC OFF switch (ON/OFF) status is displayed. ABS WARN LAMP (ON/OFF) — × × ABS warning lamp (ON/OFF) status is displayed. SLIP LAMP (ON/OFF) — × × SLIP indicator lamp (ON/OFF) status is displayed. FR LH IN SOL (ON/OFF) — × × Front LH IN ABS solenoid (ON/ OFF) status is displayed. FR LH OUT SOL (ON/OFF) — × × Front LH OUT ABS solenoid (ON/ OFF) status is displayed. RR RH IN SOL (ON/OFF) — × × Rear RH IN ABS solenoid (ON/ OFF) status is displayed. Item (Unit) BR-112 Remarks TROUBLE DIAGNOSES VDC/TCS/ABS CONSULT-II Functions (Cont’d) GI Monitor item selection ECU input signals Main item (Monitor item selector) Selection from menu RR RH OUT SOL (ON/OFF) — × × Rear RH OUT ABS solenoid (ON/ OFF) status is displayed. EM FR RH IN SOL (ON/OFF) — × × Front RH IN ABS solenoid (ON/ OFF) status is displayed. LC × Front RH OUT ABS solenoid (ON/ OFF) status is displayed. Item (Unit) FR RH OUT SOL (ON/OFF) — × Remarks MA EC RR LH IN SOL (ON/OFF) — × × Rear LH IN ABS solenoid (ON/ OFF) status is displayed. RR LH OUT SOL (ON/OFF) — × × Rear LH OUT ABS solenoid (ON/ OFF) status is displayed. OFF LAMP (ON/OFF) — × × OFF Lamp (ON/OFF) status is displayed. CL MOTOR RELAY (ON/OFF) — × × ABS motor relay (ON/OFF) status is displayed. MT ACTUATOR RLY — × × ABS actuator relay (ON/OFF) status is displayed. AT DECEL G-SEN × × × FLUID LEV SW (ON/OFF) × — — ×: Applicable —: Not applicable Brake fluid level sensor (ON/OFF) status is displayed. FE TF PD AX SU ST RS BT HA SC EL IDX BR-113 TROUBLE DIAGNOSES VDC/TCS/ABS CONSULT-II Functions (Cont’d) ACTIVE TEST Operation Procedure =NABR0170S04 NABR0170S0401 CAUTION: I Do not perform active test while driving the vehicle. I Make sure to completely bleed air from brake system. I Active test cannot be performed when ABS warning lamp is on. 1. Connect the CONSULT-II connector to the vehicle-side data link connector and start the engine. 2. Touch “START” on the display. 3. Touch “ABS” and “ACTIVE TEST”. 4. 5. Test item selection screen is displayed. Touch necessary test item. 6. Touch “START” with “MAIN SIGNALS” line inverted. SBR115F SFIA2436E SBR116F SBR117F BR-114 TROUBLE DIAGNOSES VDC/TCS/ABS CONSULT-II Functions (Cont’d) 7. Active test screen is displayed. GI MA EM LC SBR118F EC Solenoid Valve 1. 2. NABR0170S0402 To perform active test of ABS functions, select major items for each test item. To perform active test of VDC/TCS functions, select item menu for each test item. For ABS solenoid valve, touch “UP”, “KEEP”, and “DOWN”. For ABS solenoid valve (ACT), touch “UP,” “ACT UP,” and “ACT KEEP”. Use screen monitor to check that solenoid valve operates as shown in Solenoid Valve Operation Chart. Refer to “Solenoid Valve Operation Chart”. SBR118F CL MT AT Solenoid Valve Operation Chart ABS solenoid valve FE NABR0170S0403 ABS solenoid valve (ACT) Operation UP KEEP DOWN UP ACT UP ACT KEEP FR RH IN SOL OFF ON ON OFF OFF OFF FR RH OUT SOL OFF OFF ON* OFF OFF OFF FR LH IN SOL OFF ON ON OFF OFF OFF FR LH OUT SOL OFF OFF ON* OFF OFF OFF RR RH IN SOL OFF ON ON OFF OFF OFF RR RH OUT SOL OFF OFF ON* OFF OFF OFF RR LH IN SOL OFF ON ON OFF OFF OFF RR LH OUT SOL OFF OFF ON* OFF OFF OFF Front RH ABS S/V Front LH ABS S/V TF PD AX SU Rear RH ABS S/V Rear LH ABS S/V ST *: ON for 1 to 2 seconds after the touch, and then OFF NOTE: I If active test is performed with brake pedal depressed, pedal stroke may change. This is normal. I “TEST STOP” is displayed approximately 10 seconds after operation starts. I After “TEST STOP” is displayed, to perform test again, repeat step 6. RS BT HA SC EL IDX BR-115 TROUBLE DIAGNOSES VDC/TCS/ABS CONSULT-II Functions (Cont’d) ABS Motor NABR0170S0404 Touch “ON” and “OFF” on the screen. Check that ABS motor relay operates as shown in table below. SFIA0593E Operation ON OFF ACTUATOR RLY ON ON MOTOR RELAY ON OFF NOTE: I If active test is performed with brake pedal depressed, pedal stroke may change. This is normal. I “TEST STOP” is displayed approximately 10 seconds after operation starts. For Fast and Accurate Diagnosis NABR0171 PRECAUTIONS FOR DIAGNOSIS I I I I I I I I I I I NABR0171S01 Before performing diagnosis, always read General Information (GI) to confirm general precautions. If ABS actuator and electric unit (control unit), steering angle sensor, steering system parts, suspension system parts, or tires have been replaced, or if alignment has been adjusted, be sure to adjust neutral position of steering angle sensor before driving. When replacing ABS actuator and electric unit (control unit), be sure labels on control units are the same color. After diagnosis is finished, be sure to erase memory. Refer to BR-108. When checking continuity and voltage between units, be sure to check for disconnection, looseness, bend, or collapse of connector terminals. If any non-standard condition is found, repair or replace connector terminals. For intermittent symptoms, possible cause is malfunction in harness, harness connector, or terminals. Move harness, harness connector, and terminals to check for poor connections. If a circuit tester is used for the check, be careful not to forcibly extend any connector terminal. To use CONSULT-II to perform self-diagnosis of ABS actuator and electric unit (control unit), active tests, or work support, first stop work, then connect CONSULT-II and select “ABS”. CONSULT-II self-diagnosis results are displayed without regard to occurrence timing. In some cases later ones (timing value is small) appear on the next screen. While self-diagnosis results of CONSULT-II shows an error, if CONSULT-II active test is performed, an engine system error may be indicated. In this case, start engine to resume the normal screen. VDC/TCS/ABS system electronically controls brake operation and engine output. The following symptoms may be caused by normal operations: Symptom Symptom description Result This is noise of motor inside VDC/TCS/ABS actuator. Slight noise may occur during VDC, TCS, and ABS operation. Motor operation noise When the vehicle speed goes over 20 km/h (12 MPH), motor and valve operating noise may be heard. It happens only once after turning ignition switch ON. This is a normal status of the system operation check. BR-116 Normal TROUBLE DIAGNOSES VDC/TCS/ABS For Fast and Accurate Diagnosis (Cont’d) Symptom System operation check noise Symptom description Result When the engine starts, slight “click” noise may be heard from engine Normal compartment. This is normal and is part of system operation check. MA TCS may activate momentarily if wheel speed changes when driving over location where friction coefficient varies, when downshifting, or when fully depressing accelerator pedal. EM For inspection of speedometer or other instruments, press VDC OFF SW to turn VDC/TCS function off. VDC/TCS operation (SLIP lamp ON) When accelerator pedal is depressed on a chassis dynamometer (fixed front-wheel type), vehicle speed will not increase. This is not normal. It is result of TCS being activated by stationary front wheels. Warning lamp may also illuminate to indicate “sensor system error”. This is also normal, and is the result of the stationary front wheels being detected. To be certain, restart engine, and drive vehicle at 30 km/h or above. Check that warning lamp does not illuminate. Normal Cancel the VDC/TCS function for the inspection on a chassis dynamometer. MT Depending on road conditions, driver may feel that feeling of acceleration is insufficient. This is because traction control, which controls the engine and brakes to achieve optimal traction, has the highest Normal priority (for safety). As a result, there may be times when acceleration is slightly less than usual for the same accelerator pedal operation. AT ×: ON —: OFF ABS warning lamp VDC OFF indicator SLIP indicator lamp lamp PD AX — — — — For Approx. 1 seconds after ignition SW is turned ON × × × — Approx. 1 seconds after ignition switch ON — — — VDC OFF SW is turned ON. (VDC function is OFF.) — × — — × × × — × × × There is a ABS actuator and electric unit (control unit) error. (Power or ground malfunction) — × × — When VDC/TCS is not functioning normally. TF Remarks Ignition SW OFF There is a VDC/TCS/ABS error. EC CL ON and OFF Timing for ABS Warning Lamp, VDC OFF Indicator Lamp, and SLIP Indicator Lamp NABR0171S0101 Condition LC FE On roads with low friction coefficients, such as snowy roads or gravel ABS operation (Longer stopping roads, vehicles with ABS may require a longer stopping distance. Normal Therefore, when driving on such roads, avoid overconfidence and distance) keep speed sufficiently low. Insufficient feeling of acceleration GI SU Turns OFF 2 seconds after engine starts. ST RS BT HA SC EL IDX BR-117 TROUBLE DIAGNOSES VDC/TCS/ABS Basic Inspection Basic Inspection NABR0172 BASIC INSPECTION 1: BRAKE FLUID LEVEL AND LEAK INSPECTION NABR0172S01 1. Check fluid level in the brake reservoir tank. If fluid level is low, refill the brake fluid. 2. Check for leakage in brake piping and around VDC/TCS/ABS actuator. If leakage or seepage is found, check as follows. I If VDC/TCS/ABS actuator connector is loose, tighten piping to specified torque. Then inspect again and confirm that there is no leakage. I If connection flare nuts or screws of VDC/TCS/ABS actuator are damaged, replace damaged parts. Then inspect again and confirm that there is no leakage. I If there is leakage or seepage at any location other than VDC/ TCS/ABS actuator connections, wipe away leakage or seepage with clean cloth. Then inspect again and confirm that there is no leakage. I If there is leakage from VDC/TCS/ABS actuator, wipe away leakage or seepage with clean cloth. Then inspect again. If there is leakage or seepage, replace VDC/TCS/ABS actuator unit. CAUTION: ABS actuator body cannot be disassembled. 3. Check brake disc rotor and pads. BASIC INSPECTION 2: INSPECTION FOR LOOSENESS OF POWER SYSTEM TERMINALS NABR0172S02 Check battery for looseness on the battery positive/negative terminals and ground connection. If looseness is detected, tighten the piping to the specified torque. Check that the battery voltage does not drop and the alternator is normal. BASIC INSPECTION 3: INSPECTION OF ABS WARNING LAMP, VDC OFF INDICATOR LAMP AND SLIP INDICATOR LAMP NABR0172S03 1. 2. 3. 4. Check that ABS warning lamp illuminates for approximately 1 seconds when ignition switch is turned ON. If it does not illuminate, inspect ABS warning lamp and circuit, and inspect combination meter. Check that VDC OFF indicator lamp illuminates for approximately 1 seconds when ignition switch is turned ON. If it does not illuminate, inspect VDC OFF indicator lamp and circuit, and inspect combination meter. Check that SLIP indicator lamp illuminates for approximately 1 seconds when ignition switch is turned ON. If it does not turn on, check SLIP indicator lamp and circuit. With engine running, turn VDC OFF switch ON and OFF. Check that VDC OFF indicator lamp turns ON and OFF. If indicator lamp does not turn ON and OFF according to switch operation, inspect VDC OFF switch and circuit. BR-118 TROUBLE DIAGNOSES VDC/TCS/ABS Inspection 1 Wheel Sensor System Inspection 1 Wheel Sensor System NABR0173 INSPECTION PROCEDURE NABR0173S01 First use CONSULT-II self-diagnosis results to determine positions of malfunctioning wheel sensors. Then inspect parts and determine which parts to replace. 1 GI MA EM STARTING INSPECTION Perform self-diagnosis. LC EC FE CL SFIA0625E OK or NG OK © Inspection is completed. NG © GO TO 2. 2 MT AT CHECKING CONNECTOR TF Disconnect control unit connector E142 and connector E14 (FR-LH), E51 (FR-RH), B8 (RR-LH), B69 (RR-RH) of wheel sensor where malfunction was detected. Check for deformation of terminals and incomplete joining of connectors. Then reconnect connector. Also check that interference with other parts has not cut wheel sensor cables. PD Drive vehicle at 30 km/h (19 MPH) or above for at least 1.0 minute. Did ABS warning lamp turn OFF? YES © Inspection is completed. NO © GO TO 3. AX SU ST RS BT HA SC EL IDX BR-119 TROUBLE DIAGNOSES VDC/TCS/ABS Inspection 1 Wheel Sensor System (Cont’d) 3 CHECKING WHEEL SENSOR CIRCUIT 1. Disconnect control unit connector E142. 2. Disconnect wheel sensor connector E14 (FR-LH), E51 (FR-RH), B8 (RR-LH), B69 (RR-RH). 3. Check resistance between terminals. (Check resistance when steering wheel is turned right and left, and when sensor harness inside wheel house is moved.) SBR119F Resistance value Power system: 0 - 0.5 Ω Signal system: 0 - 0.5 Ω GND system: ∞Ω OK or NG OK © GO TO 4. NG © Repair harness and connectors between control unit and wheel sensor. 4 TIRE INSPECTION Check air pressure, wear, and size. Are air pressure, wear, and size within standards? YES © GO TO 5. NO © Adjust air pressure or replace tire. 5 SENSOR ROTOR INSPECTION Check for damage to sensor rotor teeth and surface of rubber. OK or NG OK © GO TO 6. NG © Replace sensor rotor. 6 POWER SUPPLY CHECK FOR CONTROL UNIT SENSOR 1. Disconnect wheel sensor connector E14 (FR-LH), E51 (FR-RH), B8 (RR-LH), B69 (RR-RH). 2. Check voltage between wheel sensor harness connector E14 terminal 1 (G), E51 terminal 1 (B), B8 terminal 1 (BR), B69 terminal 1 (BR) and ground. Voltage: 8V or more OK © Replace wheel sensor. NG © Replace control unit. BR-120 TROUBLE DIAGNOSES VDC/TCS/ABS Inspection 2 Engine System Inspection 2 Engine System NABR0174 GI Inspection Procedure 1 CHECKING SELF-DIAGNOSIS RESULTS (1) MA Check self-diagnosis results. EM LC EC MTBL1338 FE Do self-diagnosis results indicate anything other than the above? YES © Perform repair or replacement for the item indicated. NO © GO TO 2. 2 CL CHECKING SELF-DIAGNOSIS RESULTS (2) MT 1. Perform ECM self-diagnosis. Repair or replace items indicated, then perform ECM self-diagnosis again. 2. Perform ABS actuator and electric unit (control unit) self-diagnosis again. AT OK or NG OK © Inspection is completed. NG © Repair or replace the items indicated. Then perform self-diagnosis again. TF PD AX SU Inspection 3 VDC/TCS/ABS Control Unit System NABR0176 Inspection Procedure 1 CHECKING SELF-DIAGNOSIS RESULTS ST Check self-diagnosis results. RS MTBL1339 BT Does anything other than “ABS CONTROLLER” appear on self-diagnosis display? YES © Repair or replace the items indicated. Then perform self-diagnosis again. NO © Replace ABS actuator and electric unit (control unit). Then perform ABS actuator and electric unit (control unit) self-diagnosis again. HA SC EL IDX BR-121 TROUBLE DIAGNOSES VDC/TCS/ABS Inspection 4 VDC Pressure Sensor System Inspection 4 VDC Pressure Sensor System NABR0177 Inspection Procedure 1 CHECKING SELF-DIAGNOSIS RESULTS (1) Check self-diagnosis results. SBR120F Does “PRESSURE SENSOR” appear on self-diagnosis display? YES © GO TO 2. NO © Inspection is completed. 2 CHECKING SELF-DIAGNOSIS RESULTS (2) 1. Disconnect VDC pressure sensor connector E137 and ABS actuator and electric unit (control unit) connectors E142. Then reconnect them securely. 2. Perform ABS actuator and electric unit (control unit) self-diagnosis again. OK or NG OK © Poor connection of connectors. Repair or replace suspect connector. Perform self-diagnosis again. NG © GO TO 3. 3 CHECKING PRESSURE SENSOR CIRCUIT 1. Disconnect VDC pressure sensor connector E137 and ABS actuator and electric unit (control unit) connectors E142. 2. Check continuity between ABS actuator and electric unit (control unit) harness connector E142 and VDC pressure sensor harness connector E137. SBR121F OK or NG OK © GO TO 4. NG © Open or short in harness. Repair or replace the suspect harness. BR-122 TROUBLE DIAGNOSES VDC/TCS/ABS Inspection 4 VDC Pressure Sensor System (Cont’d) 4 GI CHECKING PRESSURE SENSOR Check VDC pressure sensor value on “DATA MONITOR”. MA EM MTBL1340 OK or NG OK © Inspection is completed. NG © VDC pressure sensor malfunction. Replace VDC pressure sensor. LC EC FE CL MT Inspection 5 Steering Angle Sensor System AT NABR0178 Inspection Procedure 1 TF CHECKING SELF-DIAGNOSIS RESULTS (1) Check self-diagnosis results. PD AX SU SBR122F Also perform Inspection 1 for the CAN communication system. ST Does “STEERING ANGLE SENSOR” appear on self-diagnosis display? RS YES © GO TO 2. NO © Inspection is completed. BT 2 CHECKING SELF-DIAGNOSIS RESULTS (2) 1. Disconnect steering angle sensor connector E136 and ABS actuator and electric unit (control unit) connectors E142. Then reconnect them securely. 2. Perform ABS actuator and electric unit (control unit) self-diagnosis again. OK or NG OK © Poor connection of connectors. Repair or replace suspect connector. Perform self-diagnosis again. NG © GO TO 3. HA SC EL IDX BR-123 TROUBLE DIAGNOSES VDC/TCS/ABS Inspection 5 Steering Angle Sensor System (Cont’d) 3 CHECKING STEERING ANGLE SENSOR CIRCUIT 1. Disconnect ABS actuator and electric unit (control unit) harness connector E142 and steering angle sensor harness connector E136. 2. Check continuity between ABS actuator and electric unit (control unit) harness connector E142 and steering angle sensor harness connector E136. SBR125F OK or NG OK © GO TO 4. NG © Open or short in harness. Repair or replace the suspect harness. 4 DATA MONITOR CHECK Execute “DATA MONITOR” for “STEERING ANGLE SIGNAL”. Check that results are normal. MTBL1341 OK or NG OK © Perform ABS actuator and electric unit (control unit) self-diagnosis again. NG © Replace spiral cable (steering angle sensor) and adjust neutral position of steering angle sensor. Refer to BR-87. Inspection 6 Yaw Rate/Side/Decel G Sensor System Inspection Procedure BR-124 NABR0179 TROUBLE DIAGNOSES VDC/TCS/ABS Inspection 6 Yaw Rate/Side/Decel G Sensor System (Cont’d) 1 GI CHECKING SELF-DIAGNOSIS RESULTS (1) Check self-diagnosis results. MA EM LC EC SBR126F CAUTION: If vehicle is on turn-table at entrance to parking garage, or on other moving surface, VDC OFF indicator lamp may illuminate and CONSULT-II self-diagnosis may indicate yaw rate sensor system malfunction. However, in this case there is no malfunction in yaw rate sensor system. Take vehicle off of turn-table or other moving surface, and start engine. Results will return to normal. Do “YAW RATE SENSOR SYSTEM” and “SIDE G-SENSOR SYSTEM” appear on self-diagnosis display? YES © GO TO 2. NO © Inspection is completed. FE CL MT AT 2 CHECKING SELF-DIAGNOSIS RESULTS (2) 1. Disconnect yaw rate/side/decel G-sensor harness connector B163 and ABS actuator and electric unit (control unit) harness connector E142. 2. Check continuity between ABS actuator and electric unit (control unit) harness connector E142 and yaw rate/side/decel G-sensor connector B163. TF PD AX SU SBR127F ST OK or NG OK © GO TO 3. NG © Open or short in harness. Repair or replace the suspect harness. RS BT HA SC EL IDX BR-125 TROUBLE DIAGNOSES VDC/TCS/ABS Inspection 6 Yaw Rate/Side/Decel G Sensor System (Cont’d) 3 CHECKING YAW RATE/SIDE G-SENSOR CIRCUIT Check “DATA MONITOR” for yaw rate/side/decel G-sensor. Check that results are normal. MTBL1342 OK or NG OK © Perform ABS actuator and electric unit (control unit) self-diagnosis again. NG © Malfunction of yaw rate/side/decel G-sensor. Replace sensor and perform ABS actuator and electric unit (control unit) self-diagnosis again. Inspection 7 Solenoid Valve, VDC Switch-over Solenoid Valve and Circuit NABR0200 Inspection procedure 1 SELF-DIAGNOSIS RESULT CHECK 1 Check the self-diagnosis results. SBR149F Are any self-diagnosis result items above indicated? © 2 GO TO 2. SELF-DIAGNOSIS RESULT CHECK 2 1. Disconnect the ABS actuator and electric unit (control unit) connector. Securely connect them again. 2. Perform the self-diagnosis again. OK or NG OK © GO TO 3. NG © Repair or replace the poorly connected connector. BR-126 TROUBLE DIAGNOSES VDC/TCS/ABS Inspection 7 Solenoid Valve, VDC Switch-over Solenoid Valve and Circuit (Cont’d) 3 GI SOLENOID VALVE LINE CHECK 1. Disconnect the ABS actuator and electric unit (control unit) connector. 2. Check for the power supply voltage between the ABS actuator and electric unit (control unit) connector E142 and the ground. 3. Check the continuity of the ground. MA EM LC EC FE SBR150F OK or NG OK © Perform the ABS actuator and electric unit (control unit) self-diagnosis again. NG © Replace the VDC/TCS/ABS actuator assembly. CL MT AT TF PD AX SU ST RS BT HA SC EL IDX BR-127 TROUBLE DIAGNOSES VDC/TCS/ABS Inspection 8 ABS Actuator Relay or ABS Motor Relay Power System Inspection 8 ABS Actuator Relay or ABS Motor Relay Power System =NABR0201 Inspection procedure 1 SELF-DIAGNOSIS RESULT CHECK 1 Check the self-diagnosis results. MTBL1279 Are “PUMP MOTOR” and “ACTUATOR RLY” (NOTE) indicated in the self-diagnosis results? © 2 GO TO 2. NOTE: “ACTUATOR RLY” on the CONSULT-II self-diagnosis results indicates the malfunction of the actuator relay and circuit. SELF-DIAGNOSIS RESULT CHECK 2 1. Disconnect the ABS actuator and electric unit (control unit) connector. Securely connect them again. 2. Perform the self-diagnosis again. OK or NG OK © GO TO 3. NG © Repair or replace the poorly connected connector. 3 SOLENOID VALVE LINE CHECK 1. Disconnect the ABS actuator and electric unit (control unit) connector. 2. Check for the power supply voltage between the ABS actuator and electric unit (control unit) connector E142 and the ground. 3. Check the continuity of the ground. SBR150F OK or NG OK © Perform the ABS actuator and electric unit (control unit) self-diagnosis again. NG © Replace the VDC/TCS/ABS actuator assembly. BR-128 TROUBLE DIAGNOSES VDC/TCS/ABS Inspection 9 Stop Lamp Switch and Circuit Inspection 9 Stop Lamp Switch and Circuit NABR0181 GI Inspection Procedure 1 CHECKING SELF-DIAGNOSIS RESULTS MA Check self-diagnosis results. EM LC EC FE SBR128F Does “STOP LAMP SW SYSTEM” appear in self-diagnosis results display? YES © GO TO 2. NO © Inspection is completed. 2 CL MT CHECKING STOP LAMP 1. Disconnect stop lamp switch connector M31 (M/T models) or M154 (A/T models) and ABS actuator and electric unit (control unit) connector E142. 2. Reconnect connectors securely. 3. Start engine. 4. Repeat pumping brake pedal carefully several times, then perform self-diagnosis again. © GO TO 3. NO © Poor connection. Repair or replace the applicable connector. 3 TF PD Do any self-diagnosis items appear? YES AT AX CHECKING STOP LAMP SWITCH CIRCUIT SU 1. Disconnect stop lamp switch connector M31 (M/T models) or M154 (A/T models) and ABS actuator and electric unit (control unit) connector E142. 2. Check continuity between stop lamp switch harness connector M31 (M/T models) or M154 (A/T models) and ABS actuator and electric unit (control unit) harness connector E142. ST RS BT HA SBR129F OK or NG OK © Perform ABS actuator and electric unit (control unit) self-diagnosis again. NG © Open or short in harness between ABS actuator and electric unit (control unit) and stop lamp switch SC EL IDX BR-129 TROUBLE DIAGNOSES VDC/TCS/ABS Inspection 10 ABS Actuator and Electric Unit (Control Unit) Power Circuit Inspection 10 ABS Actuator and Electric Unit (Control Unit) Power Circuit NABR0182 Inspection Procedure 1 CHECKING SELF-DIAGNOSIS RESULT Check self-diagnosis results. MTBL1343 Does “LOW BATTERY VOLTAGE” appear in self-diagnosis results display? YES © GO TO 2. NO © Inspection is completed. 2 STARTING INSPECTION 1. Disconnect ABS actuator and electric unit (control unit) connector E142. Then reconnect it securely. 2. Perform self-diagnosis. Do any self-diagnosis items appear? YES © GO TO 3. NO © Poor connection. Repair or replace the applicable connector. 3 CHECKING ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) POWER SYSTEM (1) 1. Disconnect ABS actuator and electric unit (control unit) connector E142. 2. Turn ignition switch ON (but do not start engine). Check voltage between ABS actuator and electric unit (control unit) harness connector E142 and ground. SBR135F OK or NG OK © GO TO 4. NG © GO TO 5. BR-130 TROUBLE DIAGNOSES VDC/TCS/ABS Inspection 10 ABS Actuator and Electric Unit (Control Unit) Power Circuit (Cont’d) 4 GI CHECKING ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) GROUND CIRCUIT Check ABS actuator and electric unit (control unit) ground circuit. MA EM LC EC SBR130F FE OK or NG OK © Perform ABS actuator and electric unit (control unit) self-diagnosis again. NG © I Poor installation of ABS actuator and electric unit (control unit), or harness malfunction 5 CHECKING ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) POWER SYSTEM (2) CL MT 1. Check fuse 50A or 30A. 2. Check continuity between battery positive terminal and ABS actuator and electric unit (control unit) connector E142. AT TF PD AX SBR136F OK or NG OK © Check for non-standard conditions in battery (terminal looseness, low voltage, etc.) and alternator. NG © I Replace fuse 50A or 30A. I Open or short in harness. SU ST RS BT HA SC EL IDX BR-131 TROUBLE DIAGNOSES VDC/TCS/ABS Inspection 11 When “SHIFT POSITION ERROR” Appears in Self-Diagnosis Results Display Inspection 11 When “SHIFT POSITION ERROR” Appears in Self-Diagnosis Results Display =NABR0183 Inspection Procedure 1 CHECKING SELF-DIAGNOSIS RESULTS Check self-diagnosis results. MTBL1344 Does “SHIFT POSITION ERROR” appear in self-diagnosis results display? YES © GO TO 2. NO © Inspection is completed. 2 DATA MONITOR CHECK 1. Connect CONSULT-II. Start engine. 2. In “DATA MONITOR” select “ITEM MENU” and then check P position. MTBL1345 OK or NG OK © Perform ABS actuator and electric unit (control unit) self-diagnosis again. NG © GO TO 3. 3 CHECKING PARK/NEUTRAL POSITION SWITCH Perform the park/neutral position switch inspection. Refer to AT-263. Do any self-diagnosis items appear? YES © Repair the indicated items and perform ABS actuator and electric unit (control unit) selfdiagnosis again. NO © Perform ABS actuator and electric unit (control unit) self-diagnosis again. BR-132 TROUBLE DIAGNOSES VDC/TCS/ABS Inspection 12 When “ST ANG SEN COM CIR” Appears on Self-Diagnosis Results Display Inspection 12 When “ST ANG SEN COM CIR” Appears on Self-Diagnosis Results Display GI Inspection Procedure MA =NABR0180 1 CHECKING SELF-DIAGNOSIS RESULTS (1) Check self-diagnosis results. EM LC MTBL1347 EC Does anything besides “ST ANG SEN COM CIR” appear on self-diagnosis results display? YES © Inspect and repair the indicated items. Then perform self-diagnosis again. NO © Perform adjustment of steering angle sensor neutral position. Then GO TO 2. 2 FE CL CHECKING SELF-DIAGNOSIS RESULTS (2) Turn ignition switch OFF, and ON to erase self-diagnosis results, and perform ABS actuator and electric unit (control unit) self-diagnosis again. Does anything appear on self-diagnosis results display? YES © Replace steering angle sensor. Then perform adjustment of neutral position and perform self-diagnosis again. NO © Inspection is completed. MT AT TF PD AX SU Inspection 13 Brake Fluid Level of Reservoir Tank NABR0202 Inspection procedure 1 SELF-DIAGNOSIS RESULT CHECK 1 ST Check the self-diagnosis results. RS MTBL1294 BT Does the brake warning light turn on? Yes © Check the pad for wear. Check the brake fluid for leakage. No © GO TO 2. HA SC EL IDX BR-133 TROUBLE DIAGNOSES VDC/TCS/ABS Inspection 13 Brake Fluid Level of Reservoir Tank (Cont’d) 2 SELF-DIAGNOSIS RESULT CHECK 2 1. Disconnect connectors for the brake fluid level warning switch and the ABS actuator and electric unit (control unit). 2. Securely connect connectors. Perform the ABS actuator and electric unit (control unit) self-diagnosis again. Is the same self-diagnosis item indicated again? Yes © Poor connection of connector. Repair or replace the poorly connected connector. No © GO TO 3. 3 CIRCUIT CHECK BETWEEN BRAKE FLUID LEVEL WARNING SWITCH AND ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) 1. Disconnect connectors for the brake fluid level warning switch and the ABS actuator and electric unit (control unit). 2. Check for continuity between the brake fluid level warning switch (harness connector E28) and the ABS actuator and electric unit (control unit) (harness connector B142). SBR151F OK or NG OK © Perform the ABS actuator and electric unit (control unit) self-diagnosis again. NG © Repair or replace the disconnected harness. Inspection 14 CAN Communications System NABR0185 Inspection Procedure 1 CHECK CONNECTOR 1. Turn ignition switch OFF, disconnect the ABS actuator and electric unit (control unit) connector, and check the terminal for deformation, disconnection, looseness, and so on. If there is a malfunction, repair or replace the terminal. 2. Reconnect connector to perform self-diagnosis. Is “CAN COMM CIRCUIT” displayed in the self-diagnosis display items? Yes © Print out the self-diagnostic results, and refer to EL-447. No © Connector terminal connection is loose, damaged, open, or shorted. Inspecting Components VDC OFF SWITCH I NABR0175 NABR0175S01 Disconnect VDC OFF switch connector M151. Check continuity between terminal No. 2 and terminal No. 3. No. 2 to No. 3: Pressing the switch will establish continuity, releasing it will break continuity. SBR131F BR-134 TROUBLE DIAGNOSES VDC/TCS/ABS Symptom 1 ABS Works Frequently. Symptom 1 ABS Works Frequently. NABR0186 GI Inspection Procedure 1 STARTING INSPECTION MA Inspect wheel sensor system. I Sensor mounting inspection I Sensor pick-up inspection for iron chips I Sensor rotor inspection (e.g. Number of teeth, damaged teeth) I Sensor connector engagement inspection EM LC OK or NG OK © GO TO 2. NG © Repair wheel sensor and rotor system. 2 EC FE CHECKING FOR LOOSENESS Check for looseness of front axle. CL OK or NG OK © GO TO Refer to BR-135 NG © Axle inspection and repair Symptom 2 Unexpected Pedal Reaction Inspection Procedure 1 BRAKE PEDAL STROKE INSPECTION Check brake pedal stroke. Is stroke excessively long? YES © Check bleeding and brake system. NO © GO TO 2. 2 MT AT NABR0187 TF PD AX SU CHECKING PEDAL FORCE Check that brake is effective with pedal depressed. Is pedal heavy, but effective? YES © Normal NO © GO TO 3. 3 ST CONNECTOR AND PERFORMANCE INSPECTION RS Disconnect actuator relay unit connector to deactivate ABS function. Check that brake is effective. Is brake effective? YES © GO TO 4. NO © Brake line inspection 4 BT HA CHECKING ABS WARNING LAMP INDICATION Check that ABS warning lamp illuminates. OK or NG OK © Execute self-diagnosis. NG © GO TO 5. SC EL IDX BR-135 TROUBLE DIAGNOSES VDC/TCS/ABS Symptom 2 Unexpected Pedal Reaction (Cont’d) 5 CHECKING WHEEL SENSORS Inspect wheel sensor system. I Sensor mounting inspection I Check sensor pick-up for adhering iron chips. I Sensor rotor inspection (e.g. Number of teeth, damaged teeth) I Sensor connector engagement inspection OK or NG OK © Normal NG © Repair wheel sensor and rotor system. Symptom 3 Long Stopping Distance Inspection Procedure 1 STARTING INSPECTION Check that stopping distance increases only on snowy roads and gravel roads. OK or NG OK © May be longer than for vehicles without ABS. NG © GO TO 2. 2 CHECKING PERFORMANCE Disconnect actuator relay box to deactivate ABS function. Is stopping distance still long? YES © I Brake line air bleeding I Brake line inspection NO © GO TO 3. 3 CHECKING ABS WARNING LAMP INDICATION Check that ABS warning lamp illuminates. OK or NG OK © Perform self-diagnosis. NG © GO TO 4. 4 CHECKING WHEEL SENSORS Inspect wheel sensor system. I Sensor mounting inspection I Check sensor pick-up for adhering iron chips. I Sensor rotor inspection (e.g. Number of teeth, damaged teeth) I Sensor connector engagement inspection OK or NG OK © Normal NG © Repair wheel sensor and rotor system. BR-136 NABR0188 TROUBLE DIAGNOSES VDC/TCS/ABS Symptom 4 ABS Does Not Work. Symptom 4 ABS Does Not Work. NABR0189 GI Inspection Procedure 1 CHECKING ABS WARNING LAMP INDICATION MA Check that ABS warning lamp illuminates. OK or NG OK © Perform self-diagnosis. NG © GO TO 2. 2 EM LC CHECKING WHEEL SENSORS EC Inspect wheel sensor system. I Sensor mounting inspection I Check sensor pick-up for adhering iron chips. I Sensor rotor inspection (e.g. Number of teeth, damaged teeth) I Sensor connector engagement inspection FE CL OK or NG OK © Normal NG © Repair wheel sensor and rotor system. Symptom 5 Pedal Vibration and Noise Inspection Procedure 1 INSPECTION (1) Check brake system for pedal vibration or noise at engine start. OK or NG OK © Perform self-diagnosis. NG © GO TO 2. 2 MT AT NABR0190 TF PD AX SU INSPECTION (2) Check for vibration during soft braking (just placing foot on pedal). CAUTION: ABS may activate in conditions such as those listed below, when wheel speed changes. I Gear shifting I Turning at high speed I Passing through gusts of wind ST OK or NG OK © GO TO 3. NG © Normal RS BT 3 INSPECTION (3) Does vibration occur during normal braking? CAUTION: In addition to activation for sudden braking, ABS may activate in conditions such as those listed below. I Roads with low surface µ I Turning at high speed I Passing through gusts of wind OK or NG OK © GO TO 4. NG © Normal HA SC EL IDX BR-137 TROUBLE DIAGNOSES VDC/TCS/ABS Symptom 5 Pedal Vibration and Noise (Cont’d) 4 INSPECTION (4) Check for vibration when engine speed is increased while vehicle is stopped. OK or NG OK © GO TO 5. NG © Normal CAUTION: Vibration may occur when vehicle is stopped. 5 INSPECTION (5) Check for vibration when switches of electrical components are operated. OK or NG OK © Check for any wireless devices, antennas, or antenna lead near control unit (including wiring). NG © GO TO 6. 6 CHECKING ABS WARNING LAMP INDICATION Confirm ABS warning lamp turns on. OK or NG OK © Execute self-diagnosis. NG © GO TO 7. 7 CHECKING WHEEL SENSORS Inspect wheel sensor system. I Sensor mounting inspection I Sensor pick-up inspection for iron chips (e.g. Number of teeth, damaged teeth) I Sensor connector engagement inspection I Inspection of wheel sensor circuit OK or NG OK © Normal NG © Repair wheel sensor and rotor system. Symptom 6 VDC OFF Indicator Lamp Does Not Illuminate. NABR0191 Inspection Procedure BR-138 TROUBLE DIAGNOSES VDC/TCS/ABS Symptom 6 VDC OFF Indicator Lamp Does Not Illuminate. (Cont’d) 1 GI CHECKING VDC OFF INDICATOR LAMP POWER CIRCUIT Disconnect ABS actuator and electric unit (control unit) connector. Check that the voltage between ABS actuator and electric unit (control unit) harness terminal and ground is battery voltage (Approx. 12V). OK or NG OK © Malfunction of ABS actuator and electric unit (control unit). Repair or replace control unit. NG © Malfunction in combination meter system. Inspect combination meter system. EM LC Symptom 7 SLIP Indicator Lamp Does Not Illuminate. EC NABR0192 Inspection Procedure 1 MA FE CHECKING FOR BURNED-OUT SLIP INDICATOR LAMP BULB Check that there is continuity between meter power terminal and SLIP indicator lamp terminal. CL OK or NG OK © GO TO 2. NG © Open or short in SLIP indicator lamp or combination meter circuit MT AT 2 CHECKING SLIP INDICATOR LAMP POWER CIRCUIT Disconnect meter connector. Check that the voltage between meter harness terminal and ground is battery voltage (Approx. 12V). TF OK or NG OK © GO TO 3. PD NG © I Fuse inspection I Check harness and connectors between fuse block and meter. I Inspect power system (battery, ignition switch circuit). AX 3 CHECKING SLIP INDICATOR LAMP HARNESS SU 1. Disconnect ABS actuator and electric unit (control unit) and meter harness connectors. 2. Check for open circuit or short circuits in harness between meter and ABS actuator and electric unit (control unit). OK or NG OK © GO TO 4. NG © Open or short in harness. Repair or replace the suspect harness. ST RS 4 CHECKING SLIP INDICATOR LAMP CONNECTOR Check ABS actuator and electric unit (control unit) and meter harness connectors. BT OK or NG OK © Reconnect connectors and perform self-diagnosis. There is an intermediate connector in vehicle harness. Be sure to refer to vehicle wiring diagram when performing inspection. NG © Connector open, shorted or damaged. Repair or replace connector. HA SC EL IDX BR-139 TROUBLE DIAGNOSES VDC/TCS/ABS Symptom 8 Vehicle Behaves Jerkily During VDC/TCS/ABS Operation. Symptom 8 Vehicle Behaves Jerkily During VDC/TCS/ABS Operation. NABR0193 Inspection Procedure 1 CHECKING ENGINE SPEED SIGNAL On CONSULT-II, execute “DATA MONITOR” for ABS actuator and electric unit (control unit). Is engine speed at idle 400 rpm or higher? YES © Normal NO © GO TO 2. 2 CHECKING SELF-DIAGNOSIS RESULTS (1) Perform ABS actuator and electric unit (control unit) self-diagnosis. Does anything appear on self-diagnosis results display? YES © Inspect and repair items indicated. Then perform ABS actuator and electric unit (control unit) self-diagnosis again. NO © GO TO 3. 3 ECM SELF-DIAGNOSIS RESULT ITEM CHECK Perform the ECM self-diagnosis. Is the result of self-diagnosis “CRANKSHAFT POSITION SENSOR”? YES © Repair or replace crankshaft position sensor system. NO © GO TO 4. 4 CHECKING SELF-DIAGNOSIS RESULTS (2) Disconnect ABS actuator and electric unit (control unit) and ECM connectors. Then reconnect them securely. Perform the self-diagnosis again. OK or NG OK © Connector open, shorted or damaged. Repair or replace connector. NG © GO TO 5. 5 CHECKING SELF-DIAGNOSIS RESULTS (3) Perform the A/T self-diagnosis. OK or NG OK © GO TO 6. NG © Repair or replace parts at location indicated. 6 CHECKING SELF-DIAGNOSIS RESULTS (4) Perform ABS actuator and electric unit (control unit) self-diagnosis again. Does anything appear on self-diagnosis results display? YES © Repair or replace parts at location indicated. NO © GO TO 7. BR-140 TROUBLE DIAGNOSES VDC/TCS/ABS Symptom 8 Vehicle Behaves Jerkily During VDC/TCS/ABS Operation. (Cont’d) 7 CHECKING CIRCUIT BETWEEN ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) AND ECM 1. Disconnect ABS actuator and electric unit (control unit) and ECM connectors. 2. Check for open circuit or short circuits in engine speed signal harness between ABS actuator and electric unit (control unit) and ECM. 3. Check ABS actuator and electric unit (control unit) and ECM connectors. OK or NG OK © Inspection is completed. NG © Reconnect connectors and perform ABS actuator and electric unit (control unit) self-diagnosis again. GI MA EM LC EC FE CL MT AT TF PD AX SU ST RS BT HA SC EL IDX BR-141 WHEEL SENSORS VDC/TCS/ABS Removal and Installation Removal and Installation NABR0194 SBR132F REMOVAL NABR0194S01 Pay attention to the following when removing sensor. CAUTION: I As much as possible, avoid rotating sensor when removing it. Pull sensors out without pulling on sensor harness. I Take care to avoid damaging sensor edges or rotor teeth. Remove wheel sensor first before removing front or rear wheel hub. This is to avoid damage to sensor wiring and loss of sensor function. INSTALLATION NABR0194S02 Pay attention to the following when installing sensor. Tighten installation bolts and nuts to specified torques. I When installing, check that there is no foreign material such as iron chips on pick-up and mounting hole of the sensor. Check that no foreign material has been caught in the sensor rotor motor. Remove any foreign material and clean the mount. BR-142 WHEEL SENSORS VDC/TCS/ABS Removal and Installation (Cont’d) I When installing front sensor, be sure to press rubber grommets in until they lock at the three locations shown in diagram (2 at shock absorbers and 1 at body panel). When installed, harness must not be twisted. White line on harness (shaded part) must be visible from left side. GI MA EM LC EC FE CL MT AT TF PD AX SU ST RS BT HA SC EL IDX BR-143 SENSOR ROTOR VDC/TCS/ABS Removal and Installation Removal and Installation REMOVAL Front 1. 2. NABR0196 NABR0196S01 NABR0196S0101 Remove the front wheel hub. Refer to AX-7. Remove the sensor rotor using suitable puller, drift and bearing replacer. SBR873C Rear I NABR0196S0102 Remove the sensor rotor using Tool. SRA800AA INSTALLATION Front NABR0196S02 NABR0196S0201 Install the sensor rotor using suitable drift and press. I Always replace sensor rotor with new one. I Play attention to the direction of front sensor rotor as shown in figure. SBR400DA Rear NABR0196S0202 Install the sensor rotor using suitable drift and press. I Always replace sensor rotor with new one. I Pay attention to the direction of front sensor rotor as shown in figure. SBR402D BR-144 VDC/TCS/ABS ACTUATOR VDC/TCS/ABS Removal and Installation Removal and Installation NABR0197 GI MA EM LC EC FE CL MT AT TF PD AX SBR320F Pay attention to the following when removing actuator. CAUTION: I Before servicing, disconnect battery cables. I To remove brake tube, use a flare nut wrench to prevent flare nuts and brake tube from being damaged. To install, use a brake tube torque wrench (commercial service tool). I Do not remove and install actuator by holding harness. I After work is completed, bleed air from brake piping. Refer to BR-9. I When replacing ABS actuator and electric unit (control unit), calibrate steering angle sensor neutral position and decel G sensor. Refer to BR-87. SU ST RS BT HA SC EL IDX BR-145 G SENSOR VDC/TCS/ABS Removal and Installation Removal and Installation REMOVAL NABR0198 NABR0198S01 1. 2. 3. Install center console. Refer to BT-22. Remove harness connector. Remove installation bolts. Remove yaw rate/side/decel G-sensor. CAUTION: Do not drop or strike the yaw rate/side/decel G-sensor, because it has little endurance to impact. SBR134F INSTALLATION NABR0198S02 To install, follow procedure for removal in reverse order. CAUTION: Do not drop or strike the yaw rate/side/decel G-sensor, because it has little endurance to impact. BR-146 SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications General Specifications NABR0118 GI Unit: mm (in) Applied model Without VDC models Brake model Pad Length × width × thickness Rotor outer diameter × thickness 44.45 (1.7500) × 2 LT30C Lining length × width × thickness EC 22.23 (7/8) 296 × 50 × 6.1 (11.65 × 1.97 × 0.240) Drum inner diameter FE 295.0 (11.61) Bore diameter CL 25.40 (1) Valve model Control valve LC 300 × 28 (11.81 × 1.10) Cylinder bore diameter Master cylinder EM 132.0 × 52.5 × 11 (5.20 × 2.067 × 0.43) Brake model Rear brake MA AD31VC Cylinder bore diameter × number of pistons Front brake With VDC models Proportioning valve within master cylinder Split point kPa (kg/cm2, psi) × reducing ratio Booster model MT 2,942 (30, 427) × 0.2 M215T Brake booster C215T AT Pri: 230 (9.06) Sec: 205 (8.07) Diaphragm diameter Recommended brake fluid TF DOT 3 Disc Brake NABR0119 Unit: mm (in) Brake model PD AD31VC Pad wear limit Minimum thickness 2.0 (0.079) Rotor repair limit Minimum thickness 26.0 (1.024) AX SU Drum Brake NABR0120 Unit: mm (in) Brake model Lining wear limit LT30C Minimum thickness 1.5 (0.059) ST Maximum inner diameter 296.5 (11.67) Out-of-round limit 0.03 (0.0012) Drum repair limit RS Brake Pedal NABR0121 Unit: mm (in) Transmission Free height “H”* Depressed height “D”* [under force of 490 N (50 kg, 110 lb) with engine running] Clearance “C” between pedal stopper and threaded end of stop lamp switch or ASCD switch At clevis BT M/T A/T 165 - 175 (6.50 - 6.89) 175 - 185 (6.89 - 7.28) HA 65 (2.56) 70 (2.76) SC 0.3 - 1.0 (0.012 - 0.039) 1.0 - 3.0 (0.039 - 0.118) EL Pedal free play At pedal pad 1 - 3 (0.04 - 0.12) IDX *: Measured from surface of metal panel to pedal pad BR-147 SERVICE DATA AND SPECIFICATIONS (SDS) Parking Brake Control Parking Brake Control NABR0084 Unit: notch Control Type Center lever Lever stroke [under force of 196 N (20 kg, 44 lb)] 6-8 Lever stroke when warning switch comes on 1 or less BR-148 CLUTCH SECTION CL GI MA EM LC EC FE CONTENTS PRECAUTIONS ...............................................................2 Precautions ..................................................................2 PREPARATION ...............................................................3 Special Service Tools ..................................................3 Commercial Service Tools ...........................................3 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING .....................................................4 NVH Troubleshooting Chart.........................................4 CLUTCH ...................................................................4 CLUTCH SYSTEM - HYDRAULIC TYPE........................5 Components.................................................................5 On-Vehicle Inspection and Adjustment........................6 ADJUSTING CLUTCH PEDAL ....................................6 Air Bleeding Procedure................................................7 CLUTCH MASTER CYLINDER.......................................8 Components.................................................................8 Disassembly and Assembly.........................................8 Inspection.....................................................................8 OPERATING CYLINDER.................................................9 Components.................................................................9 Inspection.....................................................................9 CLUTCH RELEASE MECHANISM ...............................10 Components...............................................................10 Removal.....................................................................10 Inspection...................................................................11 Installation..................................................................11 Lubrication .................................................................11 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL....................................................................12 Components...............................................................12 Removal.....................................................................12 Inspection and Adjustment ........................................12 CLUTCH DISC.........................................................12 CLUTCH COVER .....................................................13 FLYWHEEL INSPECTION ........................................13 Installation..................................................................13 SERVICE DATA AND SPECIFICATIONS (SDS) .........15 Clutch Control System...............................................15 Clutch Master Cylinder (With damper) ......................15 Clutch Operating Cylinder .........................................15 Clutch Disc.................................................................15 Clutch Cover ..............................................................15 Clutch Pedal ..............................................................15 MT AT TF PD AX SU BR ST RS BT HA SC EL IDX PRECAUTIONS Precautions Precautions I I I I I SBR686C NACL0001 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 Tool. Use new brake fluid to clean or wash all parts of master cylinder, operating cylinder and clutch damper. I Never use mineral oils such as gasoline or kerosene. It will ruin the rubber parts of the hydraulic system. WARNING: After cleaning the clutch disc, wipe it with a dust collector. Do not use compressed air. CL-2 PREPARATION Special Service Tools Special Service Tools NACL0002 GI The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name MA Description ST20670000 ( — ) Clutch aligning bar EM Installing clutch cover and clutch disc a: 15 mm (0.59 in) dia. b: 23 mm (0.91 in) dia. c: 30 mm (1.18 in) LC EC NT405 FE MT Commercial Service Tools Tool name AT NACL0003 TF Description 1 Flare nut crowfoot 2 Torque wrench Removing and installing clutch piping a: 10 mm (0.39 in) PD AX NT360 SU BR ST RS BT HA SC EL IDX CL-3 2 OPERATING CYLINDER PISTON CUP (Damaged) CL-9 2 3 4 1 ENGINE MOUNTING (Loose) Refer to EM-60, “REMOVAL”. 5 CLUTCH DISC (Runout is excessive) CL-12 5 CLUTCH DISC (Lining broken) CL-12 5 CLUTCH DISC (Dirty or burned) CL-12 5 2 CLUTCH DISC (Oily) CL-12 2 CLUTCH DISC (Worn out) CL-12 2 CLUTCH DISC (Hardened) CL-12 5 CLUTCH DISC (Lack of spline grease) CL-13 6 3 DIAPHRAGM SPRING (Damaged) CL-13 4 PRESSURE PLATE (Distortion) CL-13 5 FLYWHEEL (Distortion) CL-13 2 2 2 7 NACL0027 CL-12 NACL0027S01 5 CLUTCH DISC (Out of true) NACL0027S0101 CL-10 1 RELEASE BEARING (Worn, dirty or damaged) NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING CL-8 NVH Troubleshooting Chart 2 MASTER CYLINDER PISTON CUP (Damaged) NVH Troubleshooting Chart CL-7 Use the chart below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, repair or replace these parts. 1 CLUTCH LINE (Air in line) 1 1 CL-6 CLUTCH Reference page Clutch grabs/chatters Clutch pedal spongy Clutch noisy SUSPECTED PARTS (Possible cause) Symptom Clutch slips Clutch does not disengage CL-4 CLUTCH PEDAL (Free play out of adjustment) CLUTCH SYSTEM — HYDRAULIC TYPE Components Components NACL0004 GI MA EM LC EC FE MT AT TF PD AX SU BR ST RS SCL910 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Clutch pedal bracket Clutch interlock switch Clutch master cylinder Fulcrum pin Bushing Clevis pin Clutch pedal Lock nut ASCD cancel switch Pedal stopper bolt 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Snap pin Assist spring Clutch disc Clutch cover Release bearing Withdrawal lever Dust boot Operating cylinder Air bleeder Clutch damper (not serviceable) 21. 22. 23. 24. 25. 26. 27. 28. 29. Clutch hose Flare nut Bushing Copper washer Snap pin Washer Withdrawal lever shaft Lock spring Heat insulator BT HA SC EL IDX CL-5 CLUTCH SYSTEM — HYDRAULIC TYPE On-Vehicle Inspection and Adjustment On-Vehicle Inspection and Adjustment ADJUSTING CLUTCH PEDAL 1. NACL0036 NACL0036S01 Adjust pedal height with pedal stopper or ASCD cancel switch. Pedal height “H”: 176 - 186 mm (6.93 - 7.32 in) SCL689 2. Adjust pedal free play with master cylinder push rod. Then tighten lock nut. Pedal free play (measured at pedal pad) “A”: 9 - 16 mm (0.35 - 0.63 in) Pedal free play means the following total measured at position of pedal pad: I Play due to clevis pin and clevis pin hole in clutch pedal. 3. Make sure that clevis pin can rotate smoothly. If not, readjust pedal free play with master cylinder push rod. SCL690 CL-6 CLUTCH SYSTEM — HYDRAULIC TYPE On-Vehicle Inspection and Adjustment (Cont’d) — Models with Clutch Interlock System — I NACL0036S0101 Adjust clearance “C” shown in the figure while fully depressing clutch pedal. Clearance C: 0.3 - 1.0 mm (0.012 - 0.039 in) GI MA EM LC EC FE MT SCL691-B Air Bleeding Procedure SCL854 AT NACL0037 CAUTION: I Check the clutch fluid level of the reservoir for shortage. I Keep clutch fluid away from the coating surface of the body or other parts. If it adheres, remove it quickly and flush the area with water. 1. Fill up master cylinder reservoir tank with new clutch fluid. 2. Connect a clear vinyl hose to air bleeder. 3. Carefully depress clutch pedal fully and release it. Repeat the cycle several times at an interval of 2 or 3 seconds. 4. While depressing clutch pedal, open air bleeder. 5. Close air bleeder. 6. Release clutch pedal, and wait for approx. 5 seconds. 7. Repeat steps 3 to 6 until no air is found in clutch fluid. TF PD AX SU BR ST RS BT HA SC EL IDX CL-7 CLUTCH MASTER CYLINDER Components Components NACL0006 SCL886 Disassembly and Assembly I NACL0007 When removing and installing stopper ring, pry it off with screwdriver while pushing push rod into cylinder. Inspection NACL0008 Check the following items, and replace if necessary. I Rubbing surface of cylinder and piston, for uneven wear, rust or damage I Piston with piston cup, for wear or damage I Return spring, for wear or damage I Dust cover, for cracks, deformation or damage I Reservoir, for deformation or damage CL-8 OPERATING CYLINDER Components Components NACL0009 GI MA EM LC EC FE MT AT TF SCL855-B PD AX SU Inspection NACL0010 Check the following items, and replace if necessary. I Rubbing surface of cylinder and piston, for uneven wear, rust or damage I Piston with piston cup, for wear or damage I Piston spring, for wear or damage I Dust cover, for cracks, deformation or damage BR ST RS BT HA SC EL IDX CL-9 CLUTCH RELEASE MECHANISM Components Components NACL0013 SCL911-A CAUTION: Keep the clutch disc facing, pressure plate and flywheel free of oil and grease. Removal 1. 2. 3. NACL0029 Remove manual transmission from the vehicle. Refer to MT-7, “Removal and Installation”. Remove withdrawal lever from inside clutch housing. Press wedge collar on clutch cover toward the engine. SCL857 4. Using a flat-head screwdriver or the like, remove release bearing from clutch cover. SCL858 CL-10 CLUTCH RELEASE MECHANISM Inspection Inspection NACL0030 Check the following items, and replace the part, if necessary. I Release bearing seizure, damages, and rough rotation. I Abnormal wear on contact surfaces of release bearing or withdrawal lever. I Dust cover cracks. GI MA EM LC SMT148A Installation EC NACL0031 1. SCL859 Apply clutch sleeve grease to the areas shown by the arrows in the figure. 2. Install the release bearing to main drive shaft. 3. Install withdrawal lever to fork support, and secure it with withdrawal lever shaft, washer, and snap pin. 4. Operate withdrawal lever to check sliding parts for smooth movement. CAUTION: Remove excessive grease coming-out. 5. Install manual transmission. Refer to MT-7, “Removal and Installation”. FE MT AT TF PD AX SU Lubrication I I NACL0016 Apply recommended grease to contact surface and rubbing surface. Too much lubricant might damage clutch disc facing. BR ST RS BT HA SCL920 SC EL IDX CL-11 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL Components Components NACL0032 SCL861 Removal NACL0033 1. Remove manual transmission from the vehicle. Refer to MT-7, “Removal and Installation”. 2. Remove release bearing from clutch cover. 3. Loosen mounting bolts on the clutch cover evenly, and remove clutch cover and clutch disc. CAUTION: Do not hold the wedge collar when handling the clutch cover. SCL862 Inspection and Adjustment CLUTCH DISC NACL0019 NACL0019S01 Check the following items, and replace if necessary. I Clutch disc, for burns, discoloration, oil or grease leakage I Clutch disc, for wear of facing Wear limit of facing surface to rivet head: 0.3 mm (0.012 in) SCL229 I 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: Less than 0.7 mm (0.028 in) Distance of runout check point (from hub center): 120 mm (4.72 in) SCL221 CL-12 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL Inspection and Adjustment (Cont’d) CLUTCH COVER I SCL863 NACL0019S04 Check parts (wedge collar and wiring) contacting the release bearing. If any worn or damaged parts are found, replace the clutch cover as an assembly. I Check release lever plate for looseness. If necessary, replace clutch cover as an assembly. I Check thrust ring of the clutch cover for wear or bending. If necessary, replace clutch cover as an assembly. I If seizure mark or discoloration is found with the mating surfaces between pressure plate and clutch disc of clutch cover, repair them with sand-paper. If surfaces are distorted or damaged, replace clutch cover as an assembly. REFERENCE: I If thrust ring is worn, chattering noise is heard when the riveted area is lightly hit with a hammer. I If thrust ring is bent, jangling noise is heard when cover is swung up and down. GI MA EM LC EC FE MT FLYWHEEL INSPECTION AT NACL0019S03 CAUTION: Do not allow any magnetic materials to contact the ring gear teeth. I Inspect contact surface of flywheel for slight burns or discoloration. Clean flywheel with emery paper. I Check flywheel runout. Maximum allowable runout: Refer to EM-73, “Flywheel/Drive plate Runout”. PD AX SU AEM100 Installation 1. SCL864 TF NACL0035 Apply specified Nissan clutch grease to clutch disc and spline of main drive shaft. CAUTION: Always apply grease. If no grease is applied, it may cause abnormal noise, insufficient disengagement, or damage to the clutch. Also, always remove excessive grease. If grease is applied excessively, it may cause sliding or juddering. 2. Install clutch disc and clutch cover. Tighten mounting bolts temporarily, and install clutch aligning bar (SST). 3. Tighten clutch cover mounting bolts evenly in the order shown in the figure by two steps. 1st step: : 10 - 19 N·m (1.0 - 2.0 kg-m, 8 - 14 ft-lb) Final step: : 35 - 44 N·m (3.5 - 4.5 kg-m, 26 - 32 ft-lb) BR ST RS BT HA SC EL IDX CL-13 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL Installation (Cont’d) 4. Check that the wire ring of clutch cover is installed securely to wedge collar pawls. 5. Turn flywheel so that the wire ring opening is positioned as shown in the figure. CAUTION: Always perform alignment of the wire ring opening. If transmission is installed without alignment, it may cause clutch disengagement failure or clutch pedal operation failure. 6. Install manual transmission. Refer to MT-7, “Removal and Installation”. SCL865 CL-14 SERVICE DATA AND SPECIFICATIONS (SDS) Clutch Control System Clutch Control System Type of clutch control NACL0028 GI Hydraulic Clutch Master Cylinder (With damper) Inner diameter MA NACL0021 EM 15.87 mm (5/8 in) Clutch Operating Cylinder Inner diameter NACL0022 LC 19.05 mm (3/4 in) Clutch Disc NACL0023 EC Unit: mm (in) Model 250 × 160 × 3.5 (9.84 × 6.30 × 0.138) Facing size (Outer dia. x inner dia. x thickness) Thickness of disc assembly FE 250 7.9 - 8.3 (0.311 - 0.327) with 7,355 N (750 kg, 1,654 lb) With load Wear limit of facing surface to rivet head 0.3 (0.012) Runout limit of facing 0.7 (0.028) Distance of runout check point (from hub center) 120 (4.72) Maximum backlash of spline (at outer edge of disc) 1.0 (0.039) MT AT TF Clutch Cover NACL0024 Unit: mm (in) Model PD 250 Set-load 7,355 N (750 kg, 1,654 lb) Diaphragm spring height 48.2 - 50.2 (1.898 - 1.976) Uneven limit of diaphragm spring toe height AX 0.6 (0.024) SU Clutch Pedal NACL0025 Unit: mm (in) Pedal height “H”* BR 176 - 186 (6.93 - 7.32) Pedal free play (at pedal pad) 9 - 16 (0.35 - 0.63) Clearance between pedal stopper rubber and threaded end of ASCD switch 0.3 - 1.0 (0.012 - 0.039) Clearance between pedal stopper rubber and threaded end of clutch interlock switch (when depressing clutch pedal fully.) 0.3 - 1.0 (0.012 - 0.039) *: Measured from surface of dash lower panel to pedal pad. ST RS BT HA SC EL IDX CL-15 NOTES ELECTRICAL SYSTEM SECTION EL GI MA EM LC EC FE CONTENTS PRECAUTIONS ...............................................................5 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″...............5 Precautions for SRS ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″ Service...............................5 Precautions for Trouble Diagnosis ..............................5 Precautions for Harness Repair ..................................6 Wiring Diagrams and Trouble Diagnosis.....................6 HARNESS CONNECTOR................................................7 Description ...................................................................7 STANDARDIZED RELAY................................................9 Description ...................................................................9 POWER SUPPLY ROUTING.........................................11 Schematic ..................................................................11 Wiring Diagram - POWER - ......................................12 Inspection...................................................................18 GROUND........................................................................19 Ground Distribution....................................................19 COMBINATION SWITCH ..............................................32 Check.........................................................................32 Replacement..............................................................33 STEERING SWITCH......................................................34 Check.........................................................................34 HEADLAMP (FOR USA) ...............................................35 Component Parts and Harness Connector Location .....................................................................35 System Description....................................................35 Schematic ..................................................................38 Wiring Diagram - H/LAMP -.......................................39 CONSULT-II Inspection Procedure............................43 CONSULT-II Application Items ..................................44 Trouble Diagnoses.....................................................44 Bulb Replacement .....................................................47 Aiming Adjustment .....................................................47 HEADLAMP (FOR CANADA) - DAYTIME LIGHT SYSTEM - ......................................................................50 Component Parts and Harness Connector Location .....................................................................50 System Description....................................................50 Schematic ..................................................................54 Wiring Diagram - DTRL -...........................................55 CONSULT-II Inspection Procedure............................60 CONSULT-II Application Items ..................................60 Trouble Diagnoses.....................................................60 Bulb Replacement .....................................................65 Aiming Adjustment .....................................................65 PARKING, LICENSE AND TAIL LAMPS .....................66 System Description....................................................66 Schematic ..................................................................68 Wiring Diagram - TAIL/L -..........................................69 CONSULT-II Inspection Procedure............................73 CONSULT-II Application Items ..................................74 Trouble Diagnoses.....................................................74 STOP LAMP ..................................................................76 Wiring Diagram - STOP/L - .......................................76 BACK-UP LAMP............................................................78 Wiring Diagram - BACK/L - .......................................78 FRONT FOG LAMP.......................................................79 System Description....................................................79 Wiring Diagram - F/FOG - .........................................80 Aiming Adjustment .....................................................82 TURN SIGNAL AND HAZARD WARNING LAMPS .....83 System Description....................................................83 Wiring Diagram - TURN - ..........................................85 Trouble Diagnoses.....................................................87 Electrical Components Inspection .............................87 ILLUMINATION..............................................................88 System Description....................................................88 Schematic ..................................................................90 Wiring Diagram - ILL - ...............................................91 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS ...........................................97 System Description....................................................97 Schematic ..................................................................99 Wiring Diagram - INT/L - .........................................100 CONSULT-II Inspection Procedure..........................105 CONSULT-II Application Items ................................106 Trouble Diagnoses for Interior Lamp Timer.............108 CL MT AT TF PD AX SU BR ST RS BT HA SC IDX CONTENTS METERS AND GAUGES.............................................123 Component Parts and Harness Connector Location ...................................................................123 System Description..................................................123 Combination Meter ..................................................125 Schematic ................................................................127 Wiring Diagram - METER - .....................................128 Meter/Gauge Operation and Odo/Trip Meter Segment Check in Diagnosis Mode ........................129 Trouble Diagnoses...................................................130 Electrical Components Inspection ...........................134 COMPASS AND THERMOMETER .............................135 System Description..................................................135 Wiring Diagram - COMPAS -...................................136 Trouble Diagnoses...................................................137 Calibration Procedure for Compass ........................138 WARNING LAMPS ......................................................139 Schematic ................................................................139 Wiring Diagram - WARN - .......................................140 Fuel Warning Lamp Sensor Check .........................148 Electrical Components Inspection ...........................148 WARNING CHIME .......................................................149 Component Parts and Harness Connector Location ...................................................................149 System Description..................................................149 Wiring Diagram - CHIME - ......................................151 CONSULT-II Inspection Procedure..........................153 CONSULT-II Application Items ................................154 Trouble Diagnoses...................................................155 FRONT WIPER AND WASHER ..................................163 System Description..................................................163 Wiring Diagram - WIPER - ......................................165 Removal and Installation .........................................166 Washer Nozzle Adjustment .....................................167 Washer Tube Layout ...............................................167 REAR WIPER AND WASHER ....................................168 System Description..................................................168 Wiring Diagram - WIP/R -........................................170 Trouble Diagnoses...................................................172 Removal and Installation .........................................172 Washer Nozzle Adjustment .....................................173 Washer Tube Layout ...............................................173 Check Valve.............................................................173 HORN ...........................................................................174 Wiring Diagram - HORN - .......................................174 CIGARETTE LIGHTER................................................175 Wiring Diagram - CIGAR -.......................................175 CLOCK.........................................................................176 Wiring Diagram - CLOCK -......................................176 REAR WINDOW DEFOGGER.....................................177 Component Parts and Harness Connector Location ...................................................................177 (Cont’d) System Description..................................................177 Wiring Diagram - DEF -...........................................179 CONSULT-II Inspection Procedure..........................183 CONSULT-II Application Items ................................184 Trouble Diagnoses...................................................185 Electrical Components Inspection ...........................188 Filament Check........................................................189 Filament Repair .......................................................190 AUDIO ..........................................................................191 System Description..................................................191 Wiring Diagram - AUDIO -/Base System ................192 Schematic/BOSE System ........................................194 Wiring Diagram - AUDIO -/BOSE System...............195 Trouble Diagnoses...................................................200 Inspection.................................................................201 Audio Unit Removal and Installation .......................201 Wiring Diagram - REMOTE -...................................202 AUDIO ANTENNA .......................................................203 System Description..................................................203 Wiring Diagram - P/ANT - .......................................204 Trouble Diagnoses...................................................205 Location of Antenna.................................................205 Antenna Rod Replacement .....................................205 POWER SUNROOF.....................................................207 System Description..................................................207 Wiring Diagram - SROOF - .....................................208 CONSULT-II Inspection Procedure..........................210 CONSULT-II Application Items ................................211 Trouble Diagnoses...................................................211 DOOR MIRROR ...........................................................213 Wiring Diagram - MIRROR - ...................................213 GLASS HATCH OPENER ...........................................214 Wiring Diagram - T&FLID -......................................214 POWER SEAT .............................................................215 Wiring Diagram - SEAT - .........................................215 HEATED SEAT ............................................................217 Wiring Diagram - HSEAT - ......................................217 Seatback Heating Unit.............................................220 AUTOMATIC DRIVE POSITIONER ............................221 Component Parts and Harness Connector Location ...................................................................221 System Description..................................................222 Schematic ................................................................225 Wiring Diagram - AUT/DP - .....................................226 On Board Diagnosis ................................................231 Trouble Diagnoses...................................................233 AUTOMATIC SPEED CONTROL DEVICE (ASCD) ...256 System Description..................................................256 POWER WINDOW .......................................................257 System Description..................................................257 Schematic ................................................................260 Wiring Diagram - WINDOW - ..................................261 EL-2 CONTENTS CONSULT-II Inspection Procedure..........................266 CONSULT-II Application Items ................................267 Trouble Diagnoses...................................................267 POWER DOOR LOCK.................................................276 Component Parts and Harness Connector Location ...................................................................276 System Description..................................................276 Schematic ................................................................277 Wiring Diagram - D/LOCK -.....................................278 CONSULT-II Inspection Procedure..........................284 CONSULT-II Application Items ................................285 Trouble Diagnoses...................................................286 REMOTE KEYLESS ENTRY SYSTEM.......................299 Component Parts and Harness Connector Location ...................................................................299 System Description..................................................299 Schematic ................................................................303 Wiring Diagram - KEYLESS -..................................304 CONSULT-II Inspection Procedure..........................308 CONSULT-II Application Items ................................309 Trouble Diagnoses...................................................310 ID Code Entry Procedure ........................................323 Keyfob Battery Replacement...................................327 VEHICLE SECURITY (THEFT WARNING) SYSTEM.......................................................................328 Component Parts and Harness Connector Location ...................................................................328 System Description..................................................329 Schematic ................................................................334 Wiring Diagram - VEHSEC - ...................................336 CONSULT-II Inspection Procedure..........................342 CONSULT-II Application Item ..................................343 Trouble Diagnoses...................................................344 SMART ENTRANCE CONTROL UNIT .......................362 Description ...............................................................362 CONSULT-II .............................................................364 Schematic ................................................................366 Smart Entrance Control Unit Inspection Table ........368 HOMELINK UNIVERSAL TRANSCEIVER..................371 Wiring Diagram - TRNSCV - ...................................371 Trouble Diagnoses...................................................372 NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM - NATS) ........................................................................375 Component Parts and Harness Connetor Location ...................................................................375 System Description..................................................376 System Composition................................................376 Wiring Diagram - NATS -.........................................377 CONSULT-II .............................................................378 Trouble Diagnoses...................................................381 How to Replace NVIS (NATS) IMMU......................394 NAVIGATION SYSTEM ...............................................395 (Cont’d) Component Parts Location ......................................395 System Description..................................................396 Schematic ................................................................403 Wiring Diagram - NAVI -..........................................404 Self-diagnosis Mode ................................................407 Confirmation/Adjustment Mode ...............................410 Setting Mode............................................................420 Trouble diagnoses ...................................................428 This Condition is Not Abnormal...............................434 Program Loading .....................................................443 Initialization ..............................................................444 CAN COMMUNICATION .............................................447 System Description..................................................447 CAN Communication Unit........................................447 CAN SYSTEM (TYPE 1)..............................................452 Component Parts and Harness Connector Location ...................................................................452 System Description..................................................452 Wiring Diagram - CAN - ..........................................453 Trouble Diagnoses...................................................455 Component Inspection.............................................475 CAN SYSTEM (TYPE 2)..............................................476 Component Parts and Harness Connector Location ...................................................................476 System Description..................................................476 Wiring Diagram - CAN - ..........................................477 Trouble Diagnoses...................................................479 Component Inspection.............................................497 CAN SYSTEM (TYPE 3)..............................................498 Component Parts and Harness Connector Location ...................................................................498 System Description..................................................498 Wiring Diagram - CAN - ..........................................499 Trouble Diagnoses...................................................500 Component Inspection.............................................510 CAN SYSTEM (TYPE 4)..............................................511 Component Parts and Harness Connector Location ...................................................................511 System Description..................................................511 Wiring Diagram - CAN - ..........................................512 Trouble Diagnoses...................................................513 Component Inspection.............................................516 ELECTRICAL UNITS LOCATION...............................517 Engine Compartment...............................................517 Passenger Compartment.........................................518 HARNESS LAYOUT ....................................................520 How to Read Harness Layout .................................520 Outline......................................................................521 Main Harness...........................................................522 Engine Room Harness ............................................524 Engine Control Harness ..........................................526 Body Harness LH ....................................................528 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-3 CONTENTS Body Harness RH....................................................529 Back Door Harness .................................................530 Engine and Transmission Harness..........................531 Room Lamp Harness...............................................532 Air Bag Harness ......................................................533 Front Door Harness .................................................534 (Cont’d) Rear Door Harness..................................................535 BULB SPECIFICATIONS ............................................536 Headlamp.................................................................536 Exterior Lamp ..........................................................536 Interior Lamp............................................................536 WIRING DIAGRAM CODES (CELL CODES).............537 EL-4 PRECAUTIONS Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” GI NAEL0001 The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS composition which is available to NISSAN MODEL R50 is as follows: 쐌 For a frontal collision The Supplemental Restraint System consists of driver air bag module (located in the center of the steering wheel), front passenger air bag module (located on the instrument panel on passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. 쐌 For a side collision The Supplemental Restraint System consists of side air bag module (located in the outer side of front seat), side curtain air bag module (locating in the headliner side of front and rear seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision). WARNING: 쐌 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. 쐌 Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connector (and by yellow harness protector or yellow insulation tape before the harness connectors). Precautions for SRS “AIR BAG” and “SEAT BELT PRE-TENSIONER” Service 쐌 쐌 쐌 쐌 쐌 쐌 쐌 NAEL0485 Do not use electrical test equipment to check SRS circuits unless instructed to in this Service Manual. Before servicing the SRS, turn ignition switch “OFF”, disconnect battery ground cable and wait at least 3 minutes. For approximately 3 minutes after the cables are removed, it is still possible for the air bag and seat belt pre-tensioner to deploy. Therefore, do not work on any SRS connectors or wires until at least 3 minutes have passed. Diagnosis sensor unit must always be installed with their arrow marks “g” pointing towards the front of the vehicle for proper operation. Also check diagnosis sensor unit for cracks, deformities or rust before installation and replace as required. 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 driver and passenger air bag modules with the pad side facing upward and side air bag module standing with the stud bolt side setting bottom. Conduct self-diagnosis to check entire SRS for proper function after replacing any components. After air bag inflates, the front instrument panel assembly should be replaced if damaged. MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT Precautions for Trouble Diagnosis CAN SYSTEM 쐌 쐌 NAEL0458 HA NAEL0458S01 Do not apply voltage of 7.0V or higher to the measurement terminals. Use the tester with its open terminal voltage being 7.0V or less. SC IDX EL-5 PRECAUTIONS Precautions for Harness Repair Precautions for Harness Repair CAN SYSTEM NAEL0459 NAEL0459S01 쐌 Solder the repaired parts, and wrap with tape. [Frays of twisted line must be within 110 mm (4.33 in)] 쐌 Do not perform bypass wire connections for the repair parts. (The spliced wire will become separated and the characteristics of twisted line will be lost.) PKIA0306E PKIA0307E Wiring Diagrams and Trouble Diagnosis When you read wiring diagrams, refer to the following: 쐌 GI-11, “HOW TO READ WIRING DIAGRAMS” 쐌 EL-11, “POWER SUPPLY ROUTING” for power distribution circuit When you perform trouble diagnosis, refer to the following: 쐌 GI-35, “HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES” 쐌 GI-24, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT” Check for any Service bulletins before servicing the vehicle. EL-6 NAEL0002 HARNESS CONNECTOR Description Description HARNESS CONNECTOR (TAB-LOCKING TYPE) 쐌 쐌 NAEL0003 GI NAEL0003S01 The tab-locking type connectors help prevent accidental looseness or disconnection. The tab-locking type connectors are disconnected by pushing or lifting the locking tab(s). Refer to the illustration below. Refer to the next page for description of the slide-locking type connector. CAUTION: Do not pull the harness when disconnecting the connector. [Example] MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC SEL769D IDX EL-7 HARNESS CONNECTOR Description (Cont’d) HARNESS CONNECTOR (SLIDE-LOCKING TYPE) 쐌 =NAEL0003S02 A new style slide-locking type connector is used on certain systems and components, especially those related to OBD. 쐌 The slide-locking type connectors help prevent incomplete locking and accidental looseness or disconnection. 쐌 The slide-locking type connectors are disconnected by pushing or pulling the slider. Refer to the illustration below. CAUTION: 쐌 Do not pull the harness or wires when disconnecting the connector. 쐌 Be careful not to damage the connector support bracket when disconnecting the connector. [Example] SEL769V EL-8 STANDARDIZED RELAY Description Description NAEL0004 NORMAL OPEN, NORMAL CLOSED AND MIXED TYPE RELAYS GI NAEL0004S01 Relays can mainly be divided into three types: normal open, normal closed and mixed type relays. MA EM LC EC FE CL MT TYPE OF STANDARDIZED RELAYS 1M 1 Make 2M 2 Make 1T 1 Transfer 1M·1B 1 Make 1 Break SEL881H AT NAEL0004S02 TF PD AX SU BR ST RS BT SEL882H HA SC IDX EL-9 STANDARDIZED RELAY Description (Cont’d) GEL264 EL-10 POWER SUPPLY ROUTING Schematic Schematic NAEL0247 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL410R EL-11 IDX POWER SUPPLY ROUTING Wiring Diagram — POWER — Wiring Diagram — POWER — BATTERY POWER SUPPLY — IGNITION SW. IN ANY POSITION NAEL0248 NAEL0248S01 MEL940P EL-12 POWER SUPPLY ROUTING Wiring Diagram — POWER — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL941P IDX EL-13 POWER SUPPLY ROUTING Wiring Diagram — POWER — (Cont’d) MEL942P EL-14 POWER SUPPLY ROUTING Wiring Diagram — POWER — (Cont’d) ACCESSORY POWER SUPPLY — IGNITION SW. IN “ACC” OR “ON” NAEL0248S02 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL943P EL-15 IDX POWER SUPPLY ROUTING Wiring Diagram — POWER — (Cont’d) IGNITION POWER SUPPLY — IGNITION SW. IN “ON” AND/OR “START” NAEL0248S03 MEL411R EL-16 POWER SUPPLY ROUTING Wiring Diagram — POWER — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL412R IDX EL-17 POWER SUPPLY ROUTING Inspection Inspection FUSE 쐌 쐌 쐌 쐌 NAEL0249 NAEL0249S01 If fuse is blown, be sure to eliminate cause of problem before installing new fuse. Use fuse of specified rating. Never use fuse of more than specified rating. Do not partially install fuse; always insert it into fuse holder properly. Remove fuse for “ELECTRICAL PARTS (BAT)” if vehicle is not used for a long period of time. CEL083 FUSIBLE LINK MEL944F NAEL0249S02 A melted fusible link can be detected either by visual inspection or by feeling with finger tip. If its condition is questionable, use circuit tester or test lamp. CAUTION: 쐌 If fusible link should melt, it is possible that critical circuit (power supply or large current carrying circuit) is shorted. In such a case, carefully check and eliminate cause of problem. 쐌 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 (PTC THERMISTOR TYPE) NAEL0249S03 The PTC thermister generates heat in response to current flow. The temperature (and resistance) of the thermister element varies with current flow. Excessive current flow will cause the element’s temperature to rise. When the temperature reaches a specified level, the electrical resistance will rise sharply to control the circuit current. Reduced current flow will cause the element to cool. Resistance falls accordingly and normal circuit current flow is allowed to resume. SEL109W EL-18 GROUND Ground Distribution Ground Distribution MAIN HARNESS NAEL0250 GI NAEL0250S01 MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL074Q EL-19 IDX GROUND Ground Distribution (Cont’d) MEL075Q EL-20 GROUND Ground Distribution (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL076Q IDX EL-21 GROUND Ground Distribution (Cont’d) MEL087Q EL-22 GROUND Ground Distribution (Cont’d) ENGINE ROOM HARNESS NAEL0250S02 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL077Q EL-23 IDX GROUND Ground Distribution (Cont’d) MEL078Q EL-24 GROUND Ground Distribution (Cont’d) ENGINE CONTROL HARNESS NAEL0250S03 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL080Q EL-25 IDX GROUND Ground Distribution (Cont’d) BODY HARNESS RH NAEL0250S04 MEL081Q EL-26 GROUND Ground Distribution (Cont’d) GI MA EM LC EC FE CL MT AT TF MEL082Q PD AX SU BR ST RS BT HA SC IDX EL-27 GROUND Ground Distribution (Cont’d) BODY HARNESS LH NAEL0250S05 MEL083Q EL-28 GROUND Ground Distribution (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL911N IDX EL-29 GROUND Ground Distribution (Cont’d) MEL084Q EL-30 GROUND Ground Distribution (Cont’d) BODY HARNESS =NAEL0250S06 GI MA EM LC MEL152M EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-31 COMBINATION SWITCH Check Check NAEL0251 MEL070Q EL-32 COMBINATION SWITCH Replacement Replacement NAEL0252 For removal and installation of spiral cable, refer to RS-20, “Installation — Air Bag Module and Spiral Cable”. 쐌 Each switch can be replaced without removing combination switch base. GI MA EM LC MEL912O 쐌 To remove combination switch base, remove base attaching screw. EC FE CL MT MEL326G 쐌 Before installing the steering wheel, align the steering wheel guide pins with the screws which secure the combination switch as shown in the left figure. AT TF PD AX SU SEL151V BR ST RS BT HA SC IDX EL-33 STEERING SWITCH Check Check NAEL0253 MEL071Q EL-34 HEADLAMP (FOR USA) Component Parts and Harness Connector Location Component Parts and Harness Connector Location GI NAEL0254 MA EM LC EC FE CL MT AT TF PD SEL668Y System Description AX NAEL0255 The headlamp operation is controlled by the lighting switch which is built into the combination switch and smart entrance control unit. And the headlamp battery saver system is controlled by the smart entrance control unit. OUTLINE SU NAEL0255S01 Power is supplied at all times 쐌 to headlamp LH relay terminals 1 and 3 쐌 through 15A fuse (No. 60, located in the fuse and fusible link box), and 쐌 to headlamp RH relay terminals 1 and 3 쐌 through 15A fuse (No. 59, located in the fuse and fusible link box), and 쐌 to smart entrance control unit terminal 49 쐌 through 7.5A fuse [No. 24, located in the fuse block (J/B)]. When the ignition switch is in the ON or START position, power is supplied 쐌 to smart entrance control unit terminal 27 쐌 through 7.5A fuse [No. 11, located in the fuse block (J/B)]. When the ignition switch is in the ACC or ON position, power is supplied 쐌 to smart entrance control unit terminal 26 쐌 through 10A fuse [No. 10, located in the fuse block (J/B)] Ground is supplied 쐌 to smart entrance control unit terminals 43 and 64 쐌 through body grounds M4, M66, M111, M147 and M157. POWER SUPPLY TO LOW BEAM AND HIGH BEAM When lighting switch is in 2ND or PASS position, ground is supplied 쐌 to headlamp relay (LH and RH) terminal 2 from smart entrance control unit terminals 21 and 59 EL-35 BR ST RS BT HA SC NAEL0255S02 IDX HEADLAMP (FOR USA) System Description (Cont’d) 쐌 through smart entrance control unit terminals 22 and 60, 쐌 from lighting switch terminal 12 Headlamp relays (LH and RH) are energized and then power is supplied to headlamps (LH and RH). LOW BEAM OPERATION NAEL0255S03 When the lighting switch is turned to the 2ND position and placed in LOW (“B”) position, power is supplied 쐌 from terminal 5 of each headlamp relay 쐌 to terminal 3 of each headlamp Ground is supplied 쐌 to headlamp LH terminal 2 쐌 through lighting switch terminals 7 and 5 쐌 through body grounds E13 and E41, and 쐌 to headlamp RH terminal 2 쐌 through lighting switch terminal 10 and 8 쐌 through body grounds E13 and E41. With power and ground supplied, the headlamp(s) will illuminate. HIGH BEAM OPERATION/FLASH-TO-PASS OPERATION NAEL0255S04 When the lighting switch is turned to the 2ND position and placed in HIGH (“A”) position or PASS (“C”) position, power is supplied 쐌 from terminal 5 of each headlamp relay 쐌 to terminal 3 of each headlamp, and 쐌 to combination meter terminal 26 for the HIGH BEAM indicator. Ground is supplied 쐌 to headlamp LH terminal 1, and 쐌 to combination meter terminal 27 for the HIGH BEAM indicator 쐌 through lighting switch terminals 6 and 5 쐌 through body grounds E13 and E41, and 쐌 to headlamp RH terminal 1 쐌 through lighting switch terminals 9 and 8 쐌 through body grounds E13 and E41. With power and ground supplied, the high beams and the high beam indicator illuminate. EXTERIOR LAMP BATTERY SAVER CONTROL Except for Auto Light Control Operation NAEL0255S05 NAEL0255S0501 Headlamps will remain on for a short while after the ignition switch is turned from ON (or ACC) to OFF. Continuity between terminals 21 and 22, and between terminals 59 and 60 of smart entrance control unit will be disturbed after 5 minutes, then the headlamps will be turned off. When the lighting switch is turned from OFF to 2ND after headlamps are turned to off by the exterior lamp battery saver control, ground is supplied 쐌 to smart entrance control unit terminals 20 and 58 from lighting switch terminal 11, and then, 쐌 to headlamp LH and RH relays terminal 2 from smart entrance control unit terminals 21 and 59, 쐌 through smart entrance control unit terminals 22 and 60 and 쐌 through lighting switch terminal 12. Then headlamps illuminate again. Auto light control operation NAEL0255S0502 While the headlamps are turned ON by “AUTO” operation, the exterior lamp battery saver is activated for 5 minutes when the ignition switch is turned from ON (or ACC) to OFF, and either LH or RH front door switch is opened. The smart entrance control unit controls exterior lamp battery saver activation as follows: 쐌 When the door switch signal changes from ON to OFF while the exterior lamp battery saver is activated, the operation is discontinued, and restarts and lasts for 45 seconds, then the headlamps will be turned off. 쐌 When the door switch signal changes from OFF to ON while the exterior lamp battery saver is activated, the operation discontinued, restarts and lasts for 45 seconds, then the headlamps will be turned off. EL-36 HEADLAMP (FOR USA) System Description (Cont’d) 쐌 When the one of four door switch signals changes from OFF to ON while the exterior lamp battery saver is activated, the operation is discontinued, restarts and lasts for 5 minutes, then the headlamps will be turned off. 쐌 When all the door switch ON signals are input while the exterior lamp battery saver is activated, the saver is discontinued and restarts and lasts for 45 seconds, then the headlamps will be turned off. Exterior lamp battery saver control time can be changed using “WORK SUPPORT” mode in “HEADLAMP”. When the lighting switch is turned from OFF to 2ND after headlamps are turned to off by the exterior lamp battery saver control, ground is supplied 쐌 to smart entrance control unit terminals 20 and 58 from lighting switch terminal 11, and then, 쐌 to headlamp LH and RH relays terminal 2 from smart entrance control unit terminals 21 and 59, 쐌 through smart entrance control unit terminals 22 and 60 and 쐌 through lighting switch terminal 12. Then headlamps illuminate again. AUTO LIGHT OPERATION GI MA EM LC EC FE NAEL0255S06 The auto light control system has an auto light sensor inside instrument mask that detects outside brightness. 쐌 to smart entrance control unit terminal 23 쐌 from lighting switch terminal 42. When ignition switch is turned to ″ON″ or “START” position and 쐌 Outside brightness is darker than prescribed level. After 3 seconds delay, outside brightness becomes darker than prescribed level. Ground is supplied 쐌 to headlamp relay LH and RH terminals 2 쐌 through smart entrance control unit terminals 21, 59 and 43, 64. Then both headlamp relays and tail lamp relay are energized, headlamps (low or high) and tail lamps are illuminated according to switch position. Auto light operation allows headlamps and tail lamps to go off when 쐌 Outside brightness is brighter than prescribed level, or 쐌 After 5 seconds delay, outside brightness is brighter than prescribed level. 쐌 Ignition switch is turned to “OFF” position. (Headlamp will be turned OFF by exterior lamp battery saver control system. Refer to EL-36.) NOTE: The delay time changes (maximum of 20 seconds) as the outside brightness changes. For parking license and tail lamp auto operation, refer to “PARKING, LICENSE AND TAIL LAMPS” (EL-66). VEHICLE SECURITY SYSTEM CL MT AT TF PD AX SU BR NAEL0255S07 The vehicle security system will flash the high beams if the system is triggered. Refer to “VEHICLE SECURITY (THEFT WARNING) SYSTEM” (EL-331). ST RS BT HA SC IDX EL-37 HEADLAMP (FOR USA) Schematic Schematic NAEL0256 MEL946P EL-38 HEADLAMP (FOR USA) Wiring Diagram — H/LAMP — Wiring Diagram — H/LAMP — NAEL0257 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL947P EL-39 IDX HEADLAMP (FOR USA) Wiring Diagram — H/LAMP — (Cont’d) MEL948P EL-40 HEADLAMP (FOR USA) Wiring Diagram — H/LAMP — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL949P IDX EL-41 HEADLAMP (FOR USA) Wiring Diagram — H/LAMP — (Cont’d) MEL950P EL-42 HEADLAMP (FOR USA) CONSULT-II Inspection Procedure CONSULT-II Inspection Procedure “HEADLAMP” 1. 2. NAEL0258 GI NAEL0258S01 Turn ignition switch “OFF”. Connect “CONSULT-II” and “CONSULT-II CONVERTER” to the data link connector. MA EM LC SEL670Y 3. 4. Turn ignition switch “ON”. Touch “START (NISSAN BASED VHCL)”. EC FE CL MT SKIA3098E 5. Touch “SMART ENTRANCE”. If “SMART ENTRANCE” is not indicated, go to GI-41, “CONSULT-II Data Link Connector (DLC) Circuit”. AT TF PD AX SU SEL669Y 6. Touch “HEADLAMP”. BR ST RS BT SEL751Y 7. Select diagnosis mode. “DATA MONITOR”, “ACTIVE TEST” and “WORK SUPPORT” are available. HA SC IDX SEL400Y EL-43 HEADLAMP (FOR USA) CONSULT-II Application Items CONSULT-II Application Items “HEAD LAMP” Data Monitor NAEL0453 NAEL0453S01 NAEL0453S0101 Monitored Item Description IGN ON SW Indicates [ON/OFF] condition of ignition switch in ON position. ACC ON SW Indicates [ON/OFF] condition of ignition switch in ACC position. AUTO LIGT SW Displays status of the lighting switch as judged from the lighting switch signal. (AUTO position: ON/Other than AUTO position: OFF) AUTO LIGT SENS Displays “Illumination outside of the vehicle (close to 5V when light/close to 0V when dark)” as judged from the auto light sensor signal. LIGHT SW 1ST Displays status of the lighting switch as judged from the lighting switch signal. (1ST or 2ND position: ON/Other than 1ST and 2ND position: OFF) LIGHT SW 2ND Displays status of the lighting switch as judged from the lighting switch signal. (2ND position: ON/Other than 2ND position: OFF) DOOR SW-DR Indicates [ON/OFF] condition of front door switch LH. DOOR SW-AS Indicates [ON/OFF] condition of door switch RH. DOOR SW-RR Indicates [ON/OFF] condition of rear door switch. Active Test NAEL0453S0102 Test Item Description TAIL LAMP Tail lamp relay can be operated by on-off operation of the tail lamp. HEAD LAMP Headlamp relay can be operated by on-off operation of the headlamp. AUTO LIGHT Night time dimming signal can be operated by on-off operation. Work Support NAEL0453S0103 Work Item Description AUTO LIGHT SET Auto light sensitivity can be changed in this mode. Sensitivity can be adjusted in four modes. 쐌 NORMAL/MODE 2 (Sensitive)/MODE 3 (Desensitized)/MODE 4 (Insensitive) BATTERY SAVER SET Exterior lamp battery saver control mode can be changed in this mode. Selects exterior lamp battery saver control mode between two modes. 쐌 MODE 1 (ON)/MODE 2 (OFF) ILL DELAY SET Exterior lamp battery saver control time can be changed in this mode. Selects exterior lamp battery saver control time among eight modes. 쐌 MODE 1 (45 sec.)/MODE 2 (OFF)/MODE 3 (30 sec.)/MODE 4 (60 sec.)/ MODE 5 (90 sec.)/ MODE 6 (120 sec.)/MODE 7 (150 sec.)/MODE 8 (180 sec.) Trouble Diagnoses Symptom Neither headlamp operates. Possible cause 1. 2. 3. 4. 7.5A fuse Headlamp relay circuit Lighting switch Smart entrance control unit EL-44 NAEL0260 Repair order 1. Check 7.5A fuse [No. 24, located in fuse block (J/B)]. Verify battery positive voltage is present at terminal 49 of smart entrance control unit. 2. Check between smart entrance control unit and headlamp relays (LH and RH). 3. Check Lighting switch. 4. Check smart entrance control unit. (EL-368) HEADLAMP (FOR USA) Trouble Diagnoses (Cont’d) Symptom Headlamp LH (low and high beam) does not operate, but headlamp RH (low and high beam) does operate. 1. 2. 3. 4. Possible cause Repair order 15A fuse Headlamp LH relay Headlamp LH relay circuit Lighting switch ground circuit 1. Check 15A fuse (No. 60, located in fusible link and fuse box). Verify battery positive voltage is present at terminals 1 and 3 of headlamp LH relay. 2. Check headlamp LH relay. 3. Check the following. 쐌 Harness between headlamp LH relay and headlamp LH 쐌 Harness between headlamp LH relay and smart entrance control unit 4. Check harness between lighting switch and ground. Headlamp RH (low and high beam) 1. 15A fuse does not operate, but headlamp LH 2. Headlamp RH relay (low and high beam) does operate. 3. Headlamp RH relay circuit LH high beam does not operate, but LH low beam operates. 1. Bulb 2. Open in the LH high beam circuit 3. Lighting switch 1. Check 15A fuse (No. 59, located in fusible link and fuse box). Verify battery positive voltage is present at terminals 1 and 3 of headlamp RH relay. 2. Check headlamp RH relay. 3. Check the following. 쐌 Harness between headlamp RH relay and headlamp RH 쐌 Harness between headlamp RH relay and smart entrance control unit 4. Check harness between lighting switch and ground. 1. Check bulb. 2. Check harness between headlamp LH and lighting switch for open circuit. 3. Check lighting switch. LH low beam does not operate, but 1. Bulb LH high beam operates. 2. Open in LH low beam circuit 3. Lighting switch 1. Check bulb. 2. Check harness between headlamp LH and lighting switch for open circuit. 3. Check lighting switch. RH high beam does not operate, but RH low beam operates. 1. Bulb 2. Open in the RH high beam circuit 3. Lighting switch 1. Check bulb. 2. Check harness between headlamp RH and lighting switch for open circuit. 3. Check lighting switch. 1. Bulb 2. Open in RH low beam circuit 3. Lighting switch 1. Check bulb. 2. Check harness between headlamp RH and lighting switch for open circuit. 3. Check lighting switch. RH low beam does not operate, but RH high beam operates. High beam indicator does not work. 1. Bulb 2. Open in high beam circuit Battery saver control does not operate properly. 1. Door switch LH or RH circuit 2. Lighting switch circuit 3. Smart entrance control unit 1. Check bulb in combination meter. 2. Check the following. a. Harness between headlamp LH relay and combination meter for an open circuit b. Harness between high beam indicator and lighting switch 1. Check the following. a. Harness between smart entrance control unit and LH or RH door switch for open or short circuit. b. LH or RH door switch ground circuit. c. LH or RH door switch. 2. Check the following. a. Harness between smart entrance control unit terminals 20 or 58 and lighting switch terminal 11 for open or short circuit b. Harness between lighting switch terminal 5 and ground c. Lighting switch 3. Check smart entrance control unit. (EL-368) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-45 HEADLAMP (FOR USA) Trouble Diagnoses (Cont’d) Symptom Possible cause Repair order When outside is dark, neither tail 1. 7.5A fuse lamp nor headlamp turn on by auto 2. Lighting switch “AUTO” check light operation. 3. Lighting switch circuit check 4. Lighting switch ground circuit check 5. Auto light sensor check 6. Auto light sensor circuit check 1. Check 7.5A fuse [NO. 11 located in fuse block (J/B)]. Verify battery positive voltage is present at terminal 27 of smart entrance control unit. 2. Check lighting switch (AUTO) input signal with “CONSULT-II” in “DATA MONITOR” mode. When lighting switch is in AUTO: AUTO LIGHT SWITCH ON When lighting switch is in OFF: AUTO LIGHT SWITCH OFF 3. Check harness for open or short between smart entrance control unit and lighting switch. 4. Check harness for lighting switch and ground. 5. Check auto light sensor input signal. (With CONSULT-II) See “AUTO LIGHT SENSOR” in DATA MONITOR mode. When auto light sensor in stuck by light: More than 3V When auto light sensor is not stuck by light: Approx. 0.5V (Without CONSULT-II) Check voltage between smart entrance control unit terminal 7 and ground. Refer to smart entrance control unit. (EL-368) 6. Check the following. a. Harness for open or short between smart entrance control unit terminal 8 and auto light sensor terminal 1 b. Harness for open or short between smart entrance control unit terminal 7 and auto light sensor terminal 2 c. Harness for open or short between smart entrance control unit terminal 9 and auto light sensor terminal 3 When outside is dark, tail lamp turns on but headlamp does not turn on by auto light operation. Auto light output check Check auto light output. (With CONSULT-II) See “HEADLAMP” and “TAIL LAMP” in ACTIVE TEST mode, and headlamp switch to AUTO position. Headlamp and tail lamp should turn on. (Without CONSULT-II) Check voltage between smart entrance control unit terminals 19, 21, 57, 59 and ground. Refer to smart entrance control unit. (EL-368) When outside is dark, headlamp Auto light output check turns on but tail lamp does not turn on by auto light operation. Check auto light output. (With CONSULT-II) See “HEADLAMP” and “TAIL LAMP” in ACTIVE TEST mode, and headlamp switch to AUTO position. Headlamp and tail lamp should turn on. (Without CONSULT-II) Check voltage between smart entrance control unit terminals 19, 21, 57, 59 and ground. Refer to smart entrance control unit. (EL-368) Light does not turn off when ignition key switch is turned to “OFF” (exterior lamp battery saver control is canceled). 1. 7.5A fuse 2. IGN switch circuit 1. Check 7.5A fuse [NO. 11 located in fuse block (J/B)]. Verify battery positive voltage is present at terminal 27 of smart entrance control unit. 2. Check harness for open or short between smart entrance control unit and fuse. EL-46 HEADLAMP (FOR USA) Trouble Diagnoses (Cont’d) Symptom When outside is bright, neither tail lamps nor headlamps turn off by auto light operation. Possible cause Auto light sensor check GI Repair order Check auto light sensor input signal. (With CONSULT-II) See “AUTO LIGHT SENSOR” in DATA MONITOR mode. When auto light sensor in stuck by light: More than 3V When auto light sensor is not stuck by light: Approx. 0.5V (Without CONSULT-II) Check voltage between smart entrance control unit terminal 7 (W/G) and ground. Refer to smart entrance control unit. (EL-368) MA EM LC EC FE CL MT Bulb Replacement AT NAEL0261 The headlamp is a semi-sealed beam type which uses a replaceable halogen bulb. The bulb can be replaced from the engine compartment side without removing the headlamp body. 쐌 Grasp only the plastic base when handling the bulb. Never touch the glass envelope. 1. Disconnect the battery cable. 2. Disconnect the harness connector from the back side of the bulb. 3. Pull off the rubber cap. 4. Remove the headlamp bulb carefully. Do not shake or rotate the bulb when removing it. 5. Install in the reverse order of removal. CAUTION: Do not leave headlamp reflector without bulb for a long period of time. Dust, moisture, smoke, etc. entering headlamp body may affect the performance of the headlamp. Remove headlamp bulb from the headlamp reflector just before a replacement bulb is installed. TF PD AX SU BR ST RS BT SEL107X Aiming Adjustment NAEL0262 Before performing aiming adjustment, check the following. For details, refer to the regulations in your own country. 1) Keep all tires inflated to correct pressures. 2) Place vehicle flat surface. 3) See that there is no-load in vehicle (coolant, engine oil filled up to correct level and full fuel tank) other than the driver (or equivalent weight placed in driver’s position). HA SC IDX EL-47 HEADLAMP (FOR USA) Aiming Adjustment (Cont’d) LOW BEAM NAEL0262S01 SEL671Y 1. 2. 3. 쐌 Remove aiming adjusting screw cap. Turn headlamp low beam on. Use adjusting screws to perform aiming adjustment. First tighten the adjusting screw all the way and then make adjustment by loosening the screw. MEL222P EL-48 HEADLAMP (FOR USA) Aiming Adjustment (Cont’d) GI MA EM LC EC FE CL MT AT TF SEL376X If the vehicle front body has been repaired and/or the headlamp assembly has been replaced, check aiming. Use the aiming chart shown in the figure. 쐌 Basic illuminating area for adjustment should be within the range shown on the aiming chart. Adjust headlamps accordingly. PD AX SU BR ST RS BT HA SC IDX EL-49 HEADLAMP (FOR CANADA) — DAYTIME LIGHT SYSTEM — Component Parts and Harness Connector Location Component Parts and Harness Connector Location NAEL0263 SEL668Y System Description NAEL0264 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 when the parking brake is applied. And battery saver system is controlled by the smart entrance control unit. Power is supplied at all times 쐌 to headlamp LH relay terminals 1 and 3 쐌 through 15A fuse (No. 60, located in the fuse and fusible link box), and 쐌 to headlamp RH relay terminals 1 and 3 쐌 through 15A fuse (No. 59, located in the fuse and fusible link box), and 쐌 to smart entrance control unit terminal 49 쐌 through 7.5A fuse [No. 24, located in the fuse block (J/B)]. Ground is supplied 쐌 to daytime light control unit terminal 16 and 쐌 to smart entrance control unit terminals 43 and 64 쐌 through body grounds M4, M66, M111, M147 and M157. When the ignition switch is in the ON or START position, power is also supplied 쐌 to daytime light control unit terminal 3, and 쐌 to smart entrance control unit terminal 27 쐌 through 7.5A fuse [No. 11, located in the fuse block (J/B)]. When the ignition switch is in the ACC or ON position, power is supplied 쐌 to smart entrance control unit terminal 26 쐌 through 10A fuse [No. 10, located in the fuse block (J/B)]. EL-50 HEADLAMP (FOR CANADA) — DAYTIME LIGHT SYSTEM — System Description (Cont’d) When the ignition switch is in the START position, power is supplied 쐌 to daytime light control unit terminal 2 쐌 through 7.5A fuse [No. 26, located in the fuse block (J/B)]. HEADLAMP OPERATION Power Supply to Low Beam and High Beam GI MA NAEL0264S01 NAEL0264S0101 When lighting switch is in 2ND or PASS position, ground is supplied 쐌 to headlamp relay (LH and RH) terminal 2 from smart entrance control unit terminals 21 and 59 쐌 through smart entrance control unit terminals 22 and 60 쐌 from lighting switch terminal 12. Headlamp relays (LH and RH) are energized and then power is supplied to headlamps (LH and RH). Low Beam Operation EM LC EC NAEL0264S0102 When the lighting switch is turned to 2ND and LOW (“B”) positions, ground is supplied 쐌 to terminal 2 of the headlamp LH 쐌 through daytime light control unit terminals 11 and 15 쐌 through lighting switch terminals 7 and 5 쐌 through body grounds E13 and E41. Ground is also supplied 쐌 to terminal 2 of the headlamp RH 쐌 through daytime light control unit terminals 8 and 12 쐌 through lighting switch terminals 10 and 8 쐌 through body grounds E13 and E41. With power and ground supplied, the low beam headlamps illuminate. High Beam Operation/Flash-to-pass Operation FE CL MT AT TF NAEL0264S0103 When the lighting switch is turned to 2ND and HIGH (“A”) or PASS (“C”) positions, ground is supplied 쐌 to terminal 1 of headlamp LH 쐌 through daytime light control unit terminals 10 and 13, and 쐌 to combination meter terminal 27 for the HIGH BEAM indicator 쐌 through lighting switch terminals 6 and 5 쐌 through body grounds E13 and E41. Ground is also supplied 쐌 to terminal 1 of headlamp RH 쐌 through daytime light control unit terminals 9 and 14 쐌 through lighting switch terminals 9 and 8 쐌 through body grounds E13 and E41. With power and ground supplied, the high beam headlamps and HIGH BEAM indicator illuminate. EXTERIOR LAMP BATTERY SAVER CONTROL Except for Auto Light Control Operation NAEL0264S02 PD AX SU BR ST RS NAEL0264S0201 Headlamps will remain on for a short while after the ignition switch is turned from ON (or ACC) to OFF. Continuity between terminals 21 and 22, and between terminals 59 and 60 of smart entrance control unit will be disturbed after 5 minutes, then the headlamps will be turned off. When the lighting switch is turned from OFF to 2ND after headlamps are turned to off by the exterior lamp battery saver control, ground is supplied 쐌 to smart entrance control unit terminals 20 and 58 from lighting switch terminal 11, and then, 쐌 to headlamp LH and RH relays terminal 2 from smart entrance control unit terminals 21 and 59, 쐌 through smart entrance control unit terminals 22 and 60 and 쐌 through lighting switch terminal 12. Then headlamps illuminate again. BT HA SC IDX EL-51 HEADLAMP (FOR CANADA) — DAYTIME LIGHT SYSTEM — System Description (Cont’d) Auto light control operation NAEL0264S0202 While the headlamps are turned ON by “AUTO” operation, the exterior lamp battery saver is activated for 5 minutes when the ignition switch is turned from ON (or ACC) to OFF, and either LH or RH front door switch is opened. The smart entrance control unit controls exterior lamp battery saver activation as follows: 쐌 When the door switch signal changes from ON to OFF while the exterior lamp battery saver is activated, the operation is discontinued, restarts and lasts for 45 seconds, then the headlamps will be turned off. 쐌 When the door switch signal changes from OFF to ON while the exterior lamp battery saver is activated, the operation is discontinued, restarts and lasts for 45 seconds, then the headlamps will be turned off. 쐌 When the one of four door switch signals changes from OFF to ON while the exterior lamp battery saver is activated, the operation is discontinued, restarts and lasts for 5 minutes, then the headlamps will be turned off. 쐌 When all the door switch ON signals are input while the exterior lamp battery saver is activated, the saver is discontinued and restarts and lasts for 45 seconds, then the headlamps will be turned off. Exterior lamp battery saver control time can be changed using “WORK SUPPORT” mode in “HEADLAMP”. When the lighting switch is turned from OFF to 2ND after headlamps are turned to off by the exterior lamp battery saver control, ground is supplied 쐌 to smart entrance control unit terminals 20 and 58 from lighting switch terminal 11, and then, 쐌 to headlamp LH and RH relays terminal 2 from smart entrance control unit terminals 21 and 59, 쐌 through smart entrance control unit terminals 22 and 60 and 쐌 through lighting switch terminal 12. Then headlamps illuminate again. AUTO LIGHT OPERATION NAEL0264S03 For auto light operation, refer to “HEADLAMP” (EL-37). DAYTIME LIGHT OPERATION NAEL0264S04 With the engine running, the lighting switch in the OFF or 1ST position and parking brake released, power is supplied 쐌 through daytime light control unit terminal 7 쐌 to terminal 3 of headlamp RH 쐌 through terminal 1 of headlamp RH 쐌 to daytime light control unit terminal 9 쐌 through daytime light control unit terminal 6 쐌 to terminal 3 of headlamp LH. Ground is supplied to terminal 1 of headlamp LH. 쐌 through daytime light control unit terminals 10 and 16 쐌 through body grounds E13 and E41. Because the high beam headlamps are now wired in series, they operate at half illumination. OPERATION NAEL0264S05 After starting the engine with the lighting switch in the “OFF” or “1ST” position, the headlamp high beam automatically turns on. Lighting switch operations other than the above are the same as conventional light systems. Engine With engine stopped OFF 1ST With engine running 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 O X X O O X O 왕* 왕* O 왕* 왕* O O X O Low beam X X X X X X X O X X X X X X X X O X Clearance and tail lamp X X X O O O O O O X X X O O O O O O License and instrument illumination lamp X X X O O O O O O X X X O O O O O O Headlamp EL-52 HEADLAMP (FOR CANADA) — DAYTIME LIGHT SYSTEM — System Description (Cont’d) A: “HIGH BEAM” position B: “LOW BEAM” position C: “FLASH TO PASS” position O : Lamp “ON” X : Lamp “OFF” 왕 : Lamp dims. (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 pulled, the daytime light won’t come ON. GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-53 HEADLAMP (FOR CANADA) — DAYTIME LIGHT SYSTEM — Schematic Schematic NAEL0265 MEL951P EL-54 HEADLAMP (FOR CANADA) — DAYTIME LIGHT SYSTEM — Wiring Diagram — DTRL — Wiring Diagram — DTRL — NAEL0266 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL952P EL-55 IDX HEADLAMP (FOR CANADA) — DAYTIME LIGHT SYSTEM — Wiring Diagram — DTRL — (Cont’d) MEL953P EL-56 HEADLAMP (FOR CANADA) — DAYTIME LIGHT SYSTEM — Wiring Diagram — DTRL — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL954P IDX EL-57 HEADLAMP (FOR CANADA) — DAYTIME LIGHT SYSTEM — Wiring Diagram — DTRL — (Cont’d) MEL955P EL-58 HEADLAMP (FOR CANADA) — DAYTIME LIGHT SYSTEM — Wiring Diagram — DTRL — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL956P IDX EL-59 HEADLAMP (FOR CANADA) — DAYTIME LIGHT SYSTEM — CONSULT-II Inspection Procedure CONSULT-II Inspection Procedure “HEADLAMP” NAEL0267 NAEL0267S01 Refer to “HEADLAMP (FOR USA)” (EL-43). CONSULT-II Application Items “HEADLAMP” NAEL0268 NAEL0268S01 Refer to “HEADLAMP (FOR USA)” (EL-44). Trouble Diagnoses Symptom Possible cause NAEL0269 Repair order Neither headlamp operates. 1. 2. 3. 4. 7.5A fuse Lighting switch Daytime light control unit Smart entrance control unit 1. Check the following. a. 7.5A fuse [No. 24, located in fuse block (J/B)] Verify battery positive voltage is present at terminal 49 of smart entrance control unit. b. 7.5A fuse [No. 11, located in fuse block (J/B)] Verify battery positive voltage is present at terminal 3 of daytime light control unit. 2. Check lighting switch. 3. Check daytime light control unit (EL-63). 4. Check smart entrance control unit. (EL-368) LH headlamp (low and high beam) does not operate, but RH headlamp (low and high beam) does operate. 1. 2. 3. 4. 5. 6. 7. 15A fuse Headlamp LH relay Headlamp LH relay circuit Headlamp LH ground circuit Lighting switch circuit Daytime light control unit Smart entrance control unit 1. Check 15A fuse (No. 60, located in fusible link and fuse box). Verify battery positive voltage is present at terminal 1 and 3 of headlamp LH relay. 2. Check headlamp LH relay. 3. Check the following. a. Harness between headlamp LH relay and daytime light control unit b. Harness between headlamp LH relay and smart entrance control unit 4. Check harness between headlamp LH and daytime light control unit. 5. Check harness between smart entrance control unit and lighting switch. 6. Check daytime light control unit. (EL-63) 7. Check smart entrance control unit. (EL-368) EL-60 HEADLAMP (FOR CANADA) — DAYTIME LIGHT SYSTEM — Trouble Diagnoses (Cont’d) Symptom Possible cause RH headlamp (low and high beam) 1. 15A fuse does not operate, but LH headlamp 2. Headlamp RH relay (low and high beam) does operate. 3. Headlamp RH relay circuit 4. Headlamp RH ground circuit 5. Lighting switch circuit 6. Daytime light control unit 7. Smart entrance control unit LH high beam does not operate, but LH low beam operates. Repair order 1. Check 15A fuse (No. 59, located in fusible link and fuse box). Verify battery positive voltage is present at terminals 1 and 3 of headlamp RH relay. 2. Check headlamp RH relay. 3. Check the following. a. Harness between headlamp RH relay and daytime light control unit b. Harness between headlamp RH relay and smart entrance control unit 4. Check harness between headlamp RH and daytime light control unit. 5. Check harness between smart entrance control unit and lighting switch. 6. Check daytime light control unit. (EL-63) 7. Check smart entrance control unit. (EL-368) 1. Bulb 2. Headlamp LH high beams circuit 3. Lighting switch 4. Lighting switch circuit 5. Daytime light control unit 1. Check bulb. 2. Check harness between LH headlamp and daytime light control unit. 3. Check lighting switch. 4. Check harness between daytime light control unit and lighting switch. 5. Check daytime light control unit. (EL-63) LH low beam does not operate, but 1. Bulb LH high beam operates. 2. Headlamp LH high beams circuit 3. Lighting switch 4. Lighting switch circuit 5. Daytime light control unit 1. Check bulb. 2. Check harness between LH headlamp and daytime light control unit. 3. Check lighting switch. 4. Check harness between daytime light control unit and lighting switch. 5. Check daytime light control unit. (EL-63) RH high beam does not operate, but RH low beam operates. 1. Bulb 2. Open in the RH high beams circuit 3. Lighting switch 4. Lighting switch circuit 5. Daytime light control unit 1. Check bulb. 2. Check harness between RH headlamp and daytime light control unit. 3. Check lighting switch. 4. Check harness between daytime light control unit and lighting switch. 5. Check daytime light control unit. (EL-63) 1. Bulb 2. Open in the RH high beams circuit 3. Lighting switch 4. Lighting switch circuit 5. Daytime light control unit 1. Check bulb. 2. Check harness between RH headlamp and daytime light control unit. 3. Check lighting switch. 4. Check harness between daytime light control unit and lighting switch. 5. Check daytime light control unit. (EL-63) RH low beam does not operate, but RH high beam operates. High beam indicator does not work. 1. Bulb 2. Open in high beam circuit Battery saver control does not operate properly. 1. Door switch LH or RH circuit 2. Smart entrance control unit 1. Check bulb in combination meter. 2. Check the following. a. Harness between headlamp LH relay and combination meter for an open circuit b. Harness between high beam indicator and lighting switch 1. Check the following. a. Harness between smart entrance control unit and LH or RH door switch for open or short circuit b. LH or RH door switch ground circuit c. LH or RH door switch 2. Check smart entrance control unit. (EL-368) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-61 HEADLAMP (FOR CANADA) — DAYTIME LIGHT SYSTEM — Trouble Diagnoses (Cont’d) Symptom Daytime light control does not operate properly. Possible cause 1. 2. 3. 4. 5. Fuse check Parking brake switch Parking brake switch circuit Alternator circuit Daytime light control unit Repair order 1. Check the following. a. 7.5A fuse [No. 11, located in fuse block (J/B)] Verify battery positive voltage is present at terminal 3 of daytime light control unit. b. 7.5A fuse [No. 26, located in fuse block (J/B)] Verify battery positive voltage is present at terminal 2 of daytime light control unit. 2. Check parking brake switch. 3. Check harness between parking brake switch and daytime light control unit. 4. Check harness between alternator and daytime light control unit. 5. Check daytime light control unit. (EL-63) When outside is dark, neither tail 1. 7.5A fuse lamp nor headlamp turn on by auto 2. Lighting switch “AUTO” check light operation. 3. Lighting switch circuit check 4. Lighting switch ground circuit check 5. Auto light sensor check 6. Auto light sensor circuit check 1. Check 7.5A fuse [NO. 11 located in fuse block (J/B)]. Verify battery positive voltage is present at terminal 27 of smart entrance control unit. 2. Check lighting switch (AUTO) input signal with “CONSULT-II” in “DATA MONITOR” mode. When lighting switch is in AUTO: AUTO LIGHT SWITCH ON When lighting switch is in OFF: AUTO LIGHT SWITCH OFF 3. Check harness for open or short between smart entrance control unit and lighting switch. 4. Check harness for lighting switch and ground. 5. Check auto light sensor input signal. (With CONSULT-II) See “AUTO LIGHT SENSOR” in DATA MONITOR mode. When auto light sensor in stuck by light: More than 3V When auto light sensor is not stuck by light: Approx. 0.5V (Without CONSULT-II) Check voltage between smart entrance control unit terminal 7 and ground. Refer to smart entrance control unit. (EL-368) 6. Check the following. a. Harness for open or short between smart entrance control unit terminal 8 and auto light sensor terminal 1 b. Harness for open or short between smart entrance control unit terminal 7 and auto light sensor terminal 2 c. Harness for open or short between smart entrance control unit terminal 9 and auto light sensor terminal 3 When outside is dark, tail lamp turns on but headlamp does not turn on by auto light operation. Check auto light output. (With CONSULT-II) See “HEADLAMP” and “TAIL LAMP” in ACTIVE TEST mode, and headlamp switch to AUTO position. Headlamp and tail lamp should turn on. (Without CONSULT-II) Check voltage between smart entrance control unit terminals 19, 21, 57, 59 and ground. Refer to smart entrance control unit. (EL-368) Auto light output check EL-62 HEADLAMP (FOR CANADA) — DAYTIME LIGHT SYSTEM — Trouble Diagnoses (Cont’d) Symptom Possible cause GI Repair order When outside is dark, headlamp Auto light output check turns on but tail lamp does not turn on by auto light operation. Check auto light output. (With CONSULT-II) See “HEADLAMP” and “TAIL LAMP” in ACTIVE TEST mode, and headlamp switch to AUTO position. Headlamp and tail lamp should turn on. (Without CONSULT-II) Check voltage between smart entrance control unit terminals 19, 57 and ground. Refer to smart entrance control unit. (EL-368) Light does not turn off when ignition key switch is turned to “OFF” (exterior lamp battery saver control is canceled). 1. 7.5A fuse 2. IGN switch circuit 1. Check 7.5A fuse [NO. 11 located in fuse block (J/B)]. Verify battery positive voltage is present at terminal 27 of smart entrance control unit. 2. Check harness for open or short between smart entrance control unit and fuse. When outside is bright, neither tail lamps nor headlamps turn off by auto light operation. Auto light sensor check Check auto light sensor input signal. (With CONSULT-II) See “AUTO LIGHT SENSOR” in DATA MONITOR mode. When auto light sensor in stuck by light: More than 3V When auto light sensor is not stuck by light: Approx. 0.5V (Without CONSULT-II) Check voltage between smart entrance control unit terminal 7 (W/G) and ground. Refer to smart entrance control unit. (EL-368) Wire color 1 Y/B Item Alternator Condition When turning ignition switch to “ON” EM LC EC FE CL MT AT TF DAYTIME LIGHT CONTROL UNIT INSPECTION TABLE Terminal No. MA NAEL0269S01 Voltage (Approximate values) PD Less than 1V AX 2 3 Y/R G Start signal Power source When engine is running Battery voltage When turning ignition switch to “OFF” Less than 1V BR When turning ignition switch to “ST” Battery voltage ST When turning ignition switch to “ON” from “ST” Less than 1V RS When turning ignition switch to “OFF” Less than 1V BT When turning ignition switch to “ON” Battery voltage HA When turning ignition switch to “ST” Battery voltage SC When turning ignition switch to “OFF” Less than 1V SU IDX EL-63 HEADLAMP (FOR CANADA) — DAYTIME LIGHT SYSTEM — Trouble Diagnoses (Cont’d) Terminal No. Wire color 4 R/L 5 6 7 9 10 R/W R L/R PU GY 13 14 L/W W/R 16 B 17 L/G Item Power source Power source LH hi beam RH hi beam RH hi beam (ground) LH hi beam (ground) Lighting switch (Hi beam) Condition When turning ignition switch to “ON” Battery voltage When turning ignition switch to “OFF” Battery voltage When turning ignition switch to “ON” Battery voltage When turning ignition switch to “OFF” Battery voltage When lighting switch is turned to the 2ND position with “HI BEAM” position Battery voltage 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 When lighting switch is turned to the 2ND position with “HI BEAM” position Battery voltage 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. Battery voltage When lighting switch is turned to the 2ND position with “HI BEAM” position Less than 1V 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 When lighting switch is turned to the 2ND position with “HI BEAM” position Less than 1V 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. Less than 1V When turning lighting switch to “HI BEAM” Less than 1V When turning lighting switch to “FLASH TO PASS” Less than 1V Ground Parking brake switch Voltage (Approximate values) — — When parking brake is released Battery voltage When parking brake is set Less than 1.5V EL-64 HEADLAMP (FOR CANADA) — DAYTIME LIGHT SYSTEM — Bulb Replacement Bulb Replacement NAEL0270 GI Refer to “HEADLAMP (FOR USA)” (EL-47). MA EM LC Aiming Adjustment EC NAEL0271 Refer to “HEADLAMP (FOR USA)” (EL-47). FE CL MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-65 PARKING, LICENSE AND TAIL LAMPS System Description System Description NAEL0272 The parking, license and tail lamp operation is controlled by the lighting switch which is built into the combination switch and smart entrance control unit. The battery saver system is controlled by the smart entrance control unit. Power is supplied at all times 쐌 to tail lamp relay terminals 1 and 3 쐌 through 10A fuse (No. 61, located in the fuse and fusible link box), and 쐌 to smart entrance control unit terminal 49 쐌 through 7.5A fuse [No. 24, located in the fuse block (J/B)]. When ignition switch is in ON or START position, power is supplied 쐌 to smart entrance control unit terminal 27 쐌 through 7.5A fuse [No. 11, located in the fuse block (J/B)]. When the ignition switch is in the ACC or ON position, power is supplied 쐌 to smart entrance control unit terminal 26 쐌 through 10A fuse [No. 10, located in the fuse block (J/B)]. Ground is supplied 쐌 to smart entrance control unit terminals 43 and 64 쐌 through body grounds M4, M66, M111, M147 and M157. LIGHTING OPERATION BY LIGHTING SWITCH NAEL0272S01 When lighting switch is in 1ST (or 2ND) position, ground is supplied 쐌 to tail lamp relay terminal 2 from smart entrance control unit terminals 19 and 57 쐌 through smart entrance control unit terminals 20 and 58, and 쐌 through lighting switch and body grounds E13 and E41. Tail lamp relay is then energized and the parking, license and tail lamps illuminate. LIGHTING OPERATION BY AUTO LIGHT CONTROL SYSTEM NAEL0272S02 When lighting switch is in AUTO position, ground is supplied 쐌 to tail lamp relay terminal 2 from smart entrance control unit terminals 19 and 57 쐌 through smart entrance control unit terminals 43 and 64, and 쐌 to body grounds M4, M66, M111, M147 and M157. Tail lamp relay is then energized and the parking, license and tail lamps illuminate. EXTERIOR LAMP BATTERY SAVER CONTROL Except for Auto Light Control Operation NAEL0272S03 NAEL0272S0301 Parking, license and tail lamps will remain on for a short while after the ignition switch is turned from ON (or ACC) to OFF. Continuity between terminals 19 and 20, and between terminals 57 and 58 of smart entrance control unit will be disturbed after 5 minutes, then the parking, license and tail lamps will be turned off. When the lighting switch is turned from OFF to 2ND after parking, license and tail lamps are turned to off by the exterior lamp battery saver control, ground is supplied 쐌 to smart entrance control unit terminals 20 and 58 from lighting switch terminal 11, and then, 쐌 to tail lamp relay terminal 2 from smart entrance control unit terminals 19 and 57. Then parking, license and tail lamps illuminate again. Auto light control operation NAEL0272S0302 While the parking, license and tail lamps are turned ON by “AUTO” operation, the exterior lamp battery saver is activated for 5 minutes when the ignition switch is turned from ON (or ACC) to OFF, and either LH or RH front door switch is opened. The smart entrance control unit controls exterior lamp battery saver activation as follows: 쐌 When the door switch signal changes from ON to OFF while the exterior lamp battery saver is activated, the operation is discontinued, restarts and lasts for 45 seconds, then the parking, license and tail lamps will be turned off. 쐌 When the door switch signal changes from OFF to ON while the exterior lamp battery saver is activated, the operation is discontinued, restarts and lasts for 45 seconds, then the parking, license and tail lamps will be turned off. EL-66 PARKING, LICENSE AND TAIL LAMPS System Description (Cont’d) 쐌 When the one of four door switch signals changes from OFF to ON while the exterior lamp battery saver is activated, the operation is discontinued, restarts and lasts for 5 minutes seconds, then the parking, license and tail lamps will be turned off. 쐌 When all the door switch ON signals are input while the exterior lamp battery saver is activated, the operation is discontinued, restarts and lasts for 45 seconds, then the parking, license and tail lamps will be turned off. Exterior lamp battery saver control time can be changed using “WORK SUPPORT” mode in “HEADLAMP”. When the lighting switch is turned from OFF to 2ND after parking, license and tail lamps are turned to off by the exterior lamp battery saver control, ground is supplied 쐌 to smart entrance control unit terminals 20 and 58 from lighting switch terminal 11, and then, 쐌 to tail lamp relays terminal 2 from smart entrance control unit terminals 19 and 57. Then parking, license and tail lamps illuminate again. GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-67 PARKING, LICENSE AND TAIL LAMPS Schematic Schematic NAEL0273 MEL515P EL-68 PARKING, LICENSE AND TAIL LAMPS Wiring Diagram — TAIL/L — Wiring Diagram — TAIL/L — NAEL0274 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL957P EL-69 IDX PARKING, LICENSE AND TAIL LAMPS Wiring Diagram — TAIL/L — (Cont’d) MEL958P EL-70 PARKING, LICENSE AND TAIL LAMPS Wiring Diagram — TAIL/L — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL959P IDX EL-71 PARKING, LICENSE AND TAIL LAMPS Wiring Diagram — TAIL/L — (Cont’d) MEL960P EL-72 PARKING, LICENSE AND TAIL LAMPS CONSULT-II Inspection Procedure CONSULT-II Inspection Procedure “HEADLAMP” 1. 2. NAEL0275 GI NAEL0275S01 Turn ignition switch “OFF”. Connect “CONSULT-II” and “CONSULT-II CONVERTER” to the data link connector. MA EM LC SEL670Y 3. 4. Turn ignition switch “ON”. Touch “START (NISSAN BASED VHCL)”. EC FE CL MT SKIA3098E 5. Touch “SMART ENTRANCE”. If “SMART ENTRANCE” is not indicated, go to GI-41, “CONSULT-II Data Link Connector (DLC) Circuit”. AT TF PD AX SU SEL669Y 6. Touch “HEADLAMP”. BR ST RS BT SEL751Y 7. Select diagnosis mode. “DATA MONITOR”, “ACTIVE TEST” and “WORK SUPPORT” are available. HA SC IDX SEL400Y EL-73 PARKING, LICENSE AND TAIL LAMPS CONSULT-II Application Items CONSULT-II Application Items “HEAD LAMP” Data Monitor NAEL0454 NAEL0454S01 NAEL0454S0101 Monitored Item Description IGN ON SW Indicates [ON/OFF] condition of ignition switch in ON position. ACC ON SW Indicates [ON/OFF] condition of ignition switch in ACC position. AUTO LIGT SW Displays status of the lighting switch as judged from the lighting switch signal. (AUTO position: ON/Other than AUTO position: OFF) AUTO LIGT SENS Displays “Illumination outside of the vehicle (close to 5V when light/close to 0V when dark)” as judged from the optical sensor signal. LIGHT SW 1ST Displays status of the lighting switch as judged from the lighting switch signal. (1ST or 2ND position: ON/Other than 1ST and 2ND position: OFF) LIGHT SW 2ND Displays status of the lighting switch as judged from the lighting switch signal. (2ND position: ON/Other than 2ND position: OFF) DOOR SW-DR Indicates [ON/OFF] condition of front door switch LH. DOOR SW-AS Indicates [ON/OFF] condition of door switch RH. DOOR SW-RR Indicates [ON/OFF] condition of rear door switch. Active Test NAEL0454S0102 Test Item Description TAIL LAMP Tail lamp relay can be operated by on-off operation of the tail lamp. HEAD LAMP Headlamp relay can be operated by on-off operation of the headlamp. AUTO LIGHT Night time dimming signal can be operated by on-off operation. Work Support NAEL0454S0103 Work Item Description AUTO LIGHT SET Auto light sensitivity can be changed in this mode. Sensitivity can be adjusted in four modes. 쐌 NORMAL/MODE 2 (Sensitive)/MODE 3 (Desensitized)/MODE 4 (Insensitive) BATTERY SAVER SET Exterior lamp battery saver control mode can be changed in this mode. Selects exterior lamp battery saver control mode between two modes. 쐌 MODE 1 (ON)/MODE 2 (OFF) ILL DELAY SET Auto light delay off timer period can be changed in this mode. Selects auto light delay off timer period among eight modes. 쐌 MODE 1 (45 sec.)/MODE 2 (OFF)/MODE 3 (30 sec.)/MODE 4 (60 sec.)/ MODE 5 (90 sec.)/ MODE 6 (120 sec.)/MODE 7 (150 sec.)/MODE 8 (180 sec.) Trouble Diagnoses Symptom No lamps operate (including headlamps). Possible cause 1. 7.5A fuse 2. Lighting switch 3. Smart entrance control unit EL-74 NAEL0277 Repair order 1. Check 7.5A fuse [No. 24, lacated in fuse block (J/B)]. Verify battery positive voltage is present at terminal 49 of smart entrance control unit. 2. Check lighting switch. 3. Check smart entrance control unit. (EL-368) PARKING, LICENSE AND TAIL LAMPS Trouble Diagnoses (Cont’d) Symptom No parking, license and tail lamps operate, but headlamps do operate. Exterior lamp battery saver control does not operate properly. Auto light malfunctioning Possible cause 1. 2. 3. 4. 5. 6. 10A fuse Tail lamp relay Tail lamp relay circuit Lighting switch Lighting switch circuit Smart entrance control unit 1. Driver, passenger or rear door switch circuit 2. Smart entrance control unit — Repair order 1. Check 10A fuse (No. 61, located in fusible and fuse block). Verify battery positive voltage is present at terminals 1 and 3 of tail lamp relay. 2. Check tail lamp relay. 3. Check the following. a. Harness between smart entrance control unit terminals 19 and 57 and tail lamp relay terminal 2 b. Harness between tail lamp relay terminal 5 and fuse block 4. Check lighting switch. 5. Check the following. a. Harness between lighting switch terminal 11 and smart entrance control unit terminals 20 and 58 b. Harness between lighting switch terminal 5 and ground 6. Check smart entrance control unit. (EL-368) 1. Check the following. a. Harness between smart entrance control unit and driver, passenger or rear door switch for open or short circuit b. Driver passenger or rear door switch ground circuit c. Driver, passenger or rear door switch 2. Check smart entrance control unit. (EL-368) Refer to trouble diagnosis in “HEADLAMP”. (EL-44) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-75 STOP LAMP Wiring Diagram — STOP/L — Wiring Diagram — STOP/L — NAEL0278 MEL961P EL-76 STOP LAMP Wiring Diagram — STOP/L — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL262M IDX EL-77 BACK-UP LAMP Wiring Diagram — BACK/L — Wiring Diagram — BACK/L — NAEL0279 MEL085Q EL-78 FRONT FOG LAMP System Description System Description OUTLINE NAEL0280 GI NAEL0280S01 Power is supplied at all times 쐌 to headlamp RH relay terminals 1 and 3 쐌 through 15A fuse (No. 59, located in the fuse and fusible link box), and 쐌 to smart entrance control unit terminal 49 쐌 through 7.5A fuse [No. 24, located in the fuse block (J/B)], and 쐌 to front fog lamp relay terminal 3 쐌 through 15A fuse (No. 53, located in the fuse and fusible link box). When ignition switch is in ON or START position, power is supplied 쐌 to smart entrance control unit terminal 27 쐌 through 7.5A fuse [No. 11, located in the fuse block (J/B)]. When the ignition switch is in the ACC or ON position, power is supplied 쐌 to smart entrance control unit terminal 26 쐌 through 10A fuse [No. 10, located in the fuse block (J/B)]. Ground is supplied 쐌 to smart entrance control unit terminals 43 and 64 쐌 through body grounds M4, M66, M111, M147 and M157. When lighting switch is in 2ND position, ground is supplied 쐌 to headlamp RH relay terminal 2 from smart entrance control unit terminals 21 and 59. 쐌 through smart entrance control unit terminals 22 and 60, 쐌 through lighting switch terminal 12, and 쐌 through body grounds E13 and E41. Headlamp RH relay is then energized. FOG LAMP OPERATION MA EM LC EC FE CL MT AT TF NAEL0280S02 The front fog lamp switch is built into the combination switch. The lighting switch must be in the 2ND position and LOW (“B”) position for front fog lamp operation. With the front fog lamp switch in the ON position, ground is supplied 쐌 to front fog lamp relay terminal 1 쐌 through the front fog lamp switch, lighting switch and body grounds E13 and E41. The front fog lamp relay is energized and power is supplied 쐌 from front fog lamp relay terminal 5 쐌 to terminal 1 of each front fog lamp. Ground is supplied to terminal 2 of each front fog lamp through body grounds E13 and E41. With power and ground supplied, the front fog lamps illuminate. EXTERIOR LAMP BATTERY SAVER CONTROL PD AX SU BR ST NAEL0280S03 Front fog lamps will remain on for a short while after the ignition switch is turned from ON (or ACC) to OFF. Continuity between terminals 21 and 22, and between terminals 59 and 60 of smart entrance control unit will be disturbed after 5 minutes, then the front fog lamps will be turned off. When the lighting switch is turned from OFF to 2ND after front fog lamps are turned off by the battery saver control, ground is supplied 쐌 to smart entrance control unit terminals 20 and 58 from lighting switch terminal 11, and then 쐌 to headlamp RH relay terminal 2 from smart entrance control unit terminal 21 and 59 쐌 through smart entrance control unit terminal 22 and 60 from lighting switch terminal 12. Then the front fog lamps illuminate again. NOTE: For Trouble Diagnoses for battery saver control, refer to “HEADLAMP (FOR USA)”, EL-44. RS BT HA SC IDX EL-79 FRONT FOG LAMP Wiring Diagram — F/FOG — Wiring Diagram — F/FOG — NAEL0281 MEL962P EL-80 FRONT FOG LAMP Wiring Diagram — F/FOG — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL963P IDX EL-81 FRONT FOG LAMP Aiming Adjustment Aiming Adjustment NAEL0282 Before performing aiming adjustment, make sure of the following. 1) Keep all tires inflated to correct pressure. 2) Place vehicle on level ground. 3) 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 driver’s seat. Adjust aiming in the vertical direction by turning the adjusting screw. MEL917O 1. 2. Set the distance between the screen and the center of the fog lamp lens as shown at left. Turn front fog lamps ON. MEL327G 3. 쐌 Adjust front fog lamps so that the top edge of the high intensity zone is 200 mm (7.9 in) below the height of the fog lamp centers as shown at left. When performing adjustment, if necessary, cover the headlamps and opposite fog lamp. MEL328GA EL-82 TURN SIGNAL AND HAZARD WARNING LAMPS System Description System Description TURN SIGNAL OPERATION NAEL0283 GI NAEL0283S01 With the hazard switch in the OFF position and the ignition switch in the ON or START position, power is supplied 쐌 through 7.5A fuse [No. 12, located in the fuse block (J/B)] 쐌 to hazard switch terminal 2 쐌 through terminal 1 of the hazard switch 쐌 to combination flasher unit terminal 1 쐌 through terminal 3 of the combination flasher unit 쐌 to turn signal switch terminal 1. Ground is supplied to combination flasher unit terminal 2 through body grounds M4, M66, M111, M147 and M157. MA LH Turn FE NAEL0283S0101 When the turn signal switch is moved to the LH position, power is supplied from turn signal switch terminal 3 to 쐌 front turn signal lamp LH terminal 3 쐌 combination meter terminal 25 쐌 rear combination lamp LH terminal 5. Ground is supplied to the front turn signal lamp LH terminal 1 through body grounds E13 and E41. Ground is supplied to the rear combination lamp LH terminal 6 through body grounds B11, B22 and D210. Ground is supplied to combination meter terminal 30 through body grounds M4, M66, M111, M147 and M157. With power and ground supplied, the combination flasher unit controls the flashing of the LH turn signal lamps. RH Turn NAEL0283S0102 When the turn signal switch is moved to the RH position, power is supplied from turn signal switch terminal 2 to 쐌 front turn signal lamp RH terminal 3 쐌 combination meter terminal 29 쐌 rear combination lamp RH terminal 5. Ground is supplied to the front turn signal lamp RH terminal 1 through body grounds E13 and E41. Ground is supplied to the rear combination lamp RH terminal 6 through body grounds B55 and B75. Ground is supplied to combination meter terminal 30 through body grounds M4, M66, M111, M147 and M157. With power and ground supplied, the combination flasher unit controls the flashing of the RH turn signal lamps. HAZARD LAMP OPERATION NAEL0283S02 Power is supplied at all times to hazard switch terminal 3 through: 쐌 15A fuse [No. 20, located in the fuse block (J/B)]. With the hazard switch in the ON position, power is supplied 쐌 through terminal 1 of the hazard switch 쐌 to combination flasher unit terminal 1 쐌 through terminal 3 of the combination flasher unit 쐌 to hazard switch terminal 4. Ground is supplied to combination flasher unit terminal 2 through body grounds M4, M66, M111, M147 and M157. Power is supplied through terminal 5 of the hazard switch to 쐌 front turn signal lamp LH terminal 3 쐌 combination meter terminal 25 쐌 rear combination lamp LH terminal 5. Power is supplied through terminal 6 of the hazard switch to 쐌 front turn signal lamp RH terminal 3 쐌 combination meter terminal 29 쐌 rear combination lamp RH terminal 5. EM LC EC CL MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-83 TURN SIGNAL AND HAZARD WARNING LAMPS System Description (Cont’d) Ground is supplied to terminal 1 of each front turn signal lamp through body grounds E13 and E41. Ground is supplied to terminal 6 of the rear combination lamp LH through body grounds B11, B22 and D210. Ground is supplied to terminal 6 of the rear combination lamp RH through body grounds B55 and B75. Ground is supplied to combination meter terminal 30 through body grounds M4, M66, M111, M147 and M157. With power and ground supplied, the combination flasher unit controls the flashing of the hazard warning lamps. REMOTE KEYLESS ENTRY SYSTEM OPERATION NAEL0283S03 Power is supplied at all times 쐌 to smart entrance control unit terminal 49 쐌 through 7.5A fuse [No. 24, located in the fuse block (J/B)]. Ground is supplied 쐌 to smart entrance control unit terminal 43 and 64 쐌 through body ground M4, M66, M111, M147 and M157. Refer to “REMOTE KEYLESS ENTRY SYSTEM”, EL-299. When smart entrance control unit receives LOCK or UNLOCK signal from keyfob with all doors closed, power is supplied 쐌 through terminal 47 of smart entrance control unit 쐌 to front turn signal lamp LH terminal 3 쐌 to combination meter terminal 25 쐌 to rear combination lamp LH terminal 5, and 쐌 through terminal 48 of smart entrance control unit 쐌 to front turn signal lamp RH terminal 3 쐌 to combination meter terminal 29 쐌 to rear combination lamp RH terminal 5. Ground is supplied to terminal 1 of each front turn signal lamp through body grounds E13 and E41. Ground is supplied to terminal 6 of the rear combination lamp LH through body grounds B11, B22 and D210. Ground is supplied to terminal 6 of the rear combination lamp RH through body grounds B55 and B75. Ground is supplied to combination meter terminal 30 through body grounds M4, M66, M111, M147 and M157. With power and ground supplied, the smart entrance control unit controls the flashing of the hazard warning lamps. EL-84 TURN SIGNAL AND HAZARD WARNING LAMPS Wiring Diagram — TURN — Wiring Diagram — TURN — NAEL0284 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL964P EL-85 IDX TURN SIGNAL AND HAZARD WARNING LAMPS Wiring Diagram — TURN — (Cont’d) MEL965P EL-86 TURN SIGNAL AND HAZARD WARNING LAMPS Trouble Diagnoses Trouble Diagnoses Symptom Turn signal and hazard warning lamps do not operate. Turn signal lamps do not operate but hazard warning lamps operate. Possible cause 1. 2. 3. 4. GI Repair order 1. Hazard switch 1. Check hazard switch. 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 circuit circuit. 7.5A fuse 1. Check 7.5A fuse [No. 12, located in fuse block Hazard switch (J/B)]. Turn ignition switch ON and verify battery Combination switch (turn signal) positive voltage is present at terminal 2 of hazard Open in combination switch switch. (turn signal) circuit 2. Check hazard switch. 3. Check combination switch (turn signal). 4. Check the wire between combination flasher unit terminal 3 and combination switch (turn signal) terminal 1 for open circuit. Hazard warning lamps do not oper- 1. 15A fuse ate but turn signal lamps operate. 2. Hazard switch 3. Open in hazard switch circuit Front turn signal lamp LH or RH does not operate. NAEL0285 1. Check 15A fuse [No. 20, located in fuse block (J/B)]. Verify battery positive voltage is present at terminal 3 of hazard switch. 2. Check hazard switch. 3. Check the wire between combination flasher unit terminal 3 and hazard switch terminal 4 for open circuit. 1. Bulb 2. Grounds E13 and E41 3. Open in front turn signal lamp circuit 1. Check bulb. 2. Check grounds E13 and E41. 3. Check harness between front turn signal lamp and combination switch. Rear combination lamp LH does not operate. 1. Bulb 2. Grounds B11, B22 and D210 3. Open in rear combination lamp LH circuit 1. Check bulb. 2. Check grounds B11, B22 and D210. 3. Check harness between rear combination lamp LH and hazard switch. Rear combination lamp RH does not operate. 1. Bulb 2. Grounds B55 and B75 3. Open in rear combination lamp RH circuit 1. Check bulb. 2. Check grounds B55 and B75. 3. Check harness between rear combination lamp RH and hazard switch. LH and RH turn indicators do not operate. 1. Grounds M4, M66, M111, M147 and M157 1. Check grounds M4, M66, M111, M147 and M157. LH or RH turn indicator does not operate. 1. Bulb 2. Open in turn indicator circuit 1. Check bulb in combination meter. 2. Check harness between combination meter and hazard switch. MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT Electrical Components Inspection COMBINATION FLASHER UNIT CHECK 쐌 쐌 NAEL0286 HA NAEL0286S01 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 functioning if it blinks when power is supplied to the circuit. SC IDX SEL122E EL-87 ILLUMINATION System Description System Description NAEL0287 The illumination lamp operation is controlled by the lighting switch which is built into the combination switch and smart entrance control unit. The battery saver system is controlled by smart entrance control unit. Power is supplied at all times 쐌 to tail lamp relay terminals 1 and 3 쐌 through 10A fuse (No. 61, located in the fuse and fusible link box), and 쐌 to smart entrance control unit terminal 49 쐌 through 7.5A fuse [No. 24, located in the fuse block (J/B)]. When ignition switch is in ON or START position, power is supplied 쐌 to smart entrance control unit terminal 27 쐌 through 7.5A fuse [No. 11, located in the fuse block (J/B)]. When the ignition switch is in ACC or ON position, power is supplied 쐌 to smart entrance control unit terminal 26 쐌 through 10A fuse [No. 10, located in the fuse block (J/B)]. Ground is supplied 쐌 to smart entrance control unit terminals 43 and 64 쐌 through body grounds M4, M66, M111, M147 and M157. LIGHTING OPERATION BY LIGHTING SWITCH NAEL0287S01 When lighting switch is 1ST (or 2ND) position, ground is supplied 쐌 to tail lamp relay terminal 2 from smart entrance control unit terminals 19 and 57 쐌 through smart entrance control unit terminals 20 and 58, and 쐌 through lighting switch and body grounds E13 and E41. Tail lamp relay is then energized and illumination lamps illuminate. The lighting switch must be in the 1ST or 2ND position for illumination. The illumination control switch that controls the amount of current to the illumination system. As the amount of current increases, the illumination becomes brighter. The ground for all of the components except for grove box lamp, ashtray and compass and thermometer are controlled through terminals 2 and 3 of the illumination control switch and body grounds M4, M66, M111, M145 and M157. LIGHTING OPERATION BY AUTO LIGHT CONTROL SYSTEM NAEL0287S02 When auto light operation is operated, ground is supplied 쐌 to tail lamp relay terminal 2 from smart entrance control unit terminals 19 and 57 쐌 through smart entrance control unit terminals 43 and 64, and 쐌 to body grounds M4, M66, M111, M147 and M157. Tail lamp relay is then energized and the illumination lamps illuminate. The illumination control switch that controls the amount of current to the illumination system. As the amount of current increases, the illumination becomes brighter. The following chart shows the power and ground connector terminals for the components included in the illumination system. Component Connector No. Power terminal Ground terminal Illumination control switch M19 1 3 4WD shift switch M141 7 8 1 2 Ashtray (without woody instrument finisher) Ashtray (with woody instrument finisher) B76 M155 A/T device B59 3 4 Cigarette lighter M57 3 4 Audio unit M48 8 7 R4 5 2 M35 7 8 Compass and thermometer Hazard switch EL-88 ILLUMINATION System Description (Cont’d) Component Connector No. Power terminal Ground terminal M36 5 6 M92, M93 3 5 CD auto changer M125 2 9 A/C switch illumination M45 2 1 M117, M118 8 24 A/C auto amp. M102 24 25 Clock M40 3 4 Globe box lamp M30 1 2 Combination meter M26 64 65 VDC off switch M151 4 5 Rear window defogger switch CD player Display & NAVI control unit GI MA EM LC EC FE The ground for all of the components except for compass and thermometer, glove box lamp and ashtray are controlled through terminals 2 and 3 of the illumination control switch and body grounds M4, M66, M111, M147 and M157. EXTERIOR LAMP BATTERY SAVER CONTROL Except for Auto Light Control Operation CL MT NAEL0287S03 NAEL0287S0301 Illumination lamps will remain on for a short while after the ignition switch is turned from ON (or ACC) to OFF. Continuity between terminals 19 and 20, and between terminals 57 and 58 of smart entrance control unit will be disturbed after 5 minutes, then the illumination lamp will be turned off. When the lighting switch is turned from OFF to 1ST (or 2ND) after illumination lamps are turned off by the battery saver control, ground is supplied 쐌 to smart entrance control unit terminals 20 and 58 from lighting switch terminal 11, and 쐌 to tail lamp relay terminal 2 from smart entrance control unit terminals 19 and 57. Then illumination lamps illuminate again. AT TF PD AX Auto light control operation NAEL0287S0302 While the illumination lamps are turned ON by “AUTO” operation, the exterior lamp battery saver is activated for 5 minutes when the ignition switch is turned from ON (or ACC) to OFF, and either LH or RH front door switch is opened. The smart entrance control unit controls exterior lamp battery saver activation as follows: 쐌 When the door switch signal changes from ON to OFF while the exterior lamp battery saver is activated, the operation is discontinued, restarts and lasts for 45 seconds, then the illumination lamps will be turned off. 쐌 When the door switch signal changes from OFF to ON while the exterior lamp battery saver is activated, the operation is discontinued, restarts and lasts for 45 seconds, then the illumination lamps will be turned off. 쐌 When the one of four door switch signals changes from OFF to ON while the exterior lamp battery saver is activated, the operation is discontinued, restarts and lasts for 5 minutes seconds, then the illumination lamps will be turned off. 쐌 When all the door switch ON signals are input while the exterior lamp battery saver is activated, the operation is discontinued, restarts and lasts for 45 seconds, then the illumination lamps will be turned off. Exterior lamp battery saver control time can be changed using “WORK SUPPORT” mode in “HEADLAMP”. When the lighting switch is turned from OFF to 2ND after illumination lamps are turned to off by the exterior lamp battery saver control, ground is supplied 쐌 to smart entrance control unit terminals 20 and 58 from lighting switch terminal 11, and then, 쐌 to tail lamp relays terminal 2 from smart entrance control unit terminals 19 and 57. Then illumination lamps illuminate again. NOTE: For Trouble Diagnoses for battery saver control, refer to “PARKING, LICENSE AND TAIL LAMPS” (EL-74). EL-89 SU BR ST RS BT HA SC IDX ILLUMINATION Schematic Schematic NAEL0288 MEL966P EL-90 ILLUMINATION Wiring Diagram — ILL — Wiring Diagram — ILL — NAEL0289 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL967P EL-91 IDX ILLUMINATION Wiring Diagram — ILL — (Cont’d) MEL968P EL-92 ILLUMINATION Wiring Diagram — ILL — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL969P IDX EL-93 ILLUMINATION Wiring Diagram — ILL — (Cont’d) MEL970P EL-94 ILLUMINATION Wiring Diagram — ILL — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL971P IDX EL-95 ILLUMINATION Wiring Diagram — ILL — (Cont’d) MEL972P EL-96 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS System Description System Description POWER SUPPLY AND GROUND NAEL0290 GI NAEL0290S01 Power is supplied at all times: 쐌 through 7.5A fuse [No. 24, located in the fuse block (J/B)] 쐌 to key switch terminal 2 and 쐌 to smart entrance control unit terminal 49. When the key is removed from ignition key cylinder, power is interrupted: 쐌 through key switch terminal 1 쐌 to smart entrance control unit terminal 25. With the ignition key switch in the ON or START position, power is supplied: 쐌 through 7.5A fuse [No. 11, located in the fuse block (J/B)] 쐌 to smart entrance control unit terminal 27. Ground is supplied: 쐌 to smart entrance control unit terminals 43 and 64 쐌 through body grounds M4, M66, M111, M147 and M157. When the front driver side door is opened, ground is supplied: 쐌 through body grounds B11, B22 and D210 쐌 to front door switch (LH) terminal 2 쐌 from front door switch (LH) terminal 1 쐌 to smart entrance control unit terminal 1. When the front passenger side door is opened, ground is supplied: 쐌 through body grounds terminals B55 and B75 쐌 to front door switch (RH) terminal 2 쐌 from front door switch (RH) terminal 1 쐌 to smart entrance control unit terminal 2. When any other door (except front door) is opened, ground is supplied to smart entrance control unit terminal 3 in the same manner as the front door switch. When the front LH door is unlocked by front door key cylinder switch, ground is supplied 쐌 through body grounds M4, M66, M111, M147 and M157 쐌 to front door key cylinder switch terminal 2 쐌 through front key cylinder switch terminal 1 쐌 to power window main switch terminal 6. Power window main switch terminal 14 send unlock signal to smart entrance control unit terminal 33 with serial link communication line. When back door is unlocked by back door key cylinder switch, ground is supplied 쐌 through body grounds B11, B22 and D210 쐌 to back door key cylinder switch terminal 4 쐌 from back door key cylinder terminal 2 쐌 to smart entrance control unit terminal 10. When a signal, or combination of signals is received by the smart entrance control unit, ground is supplied: 쐌 through smart entrance control unit terminal 31 쐌 to interior lamp terminal 2. With power and ground supplied, the interior lamp illuminates. SWITCH OPERATION MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA NAEL0290S02 When interior lamp switch is ON, ground is supplied: 쐌 through case grounds of interior lamp 쐌 to interior lamp. And power is supplied: 쐌 to interior lamp terminal 1 쐌 from smart entrance control unit terminal 50. When spot lamp (LH and/or RH) is ON, ground is supplied: EL-97 SC IDX INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS System Description (Cont’d) 쐌 through body grounds M4, M66, M111, M147 and M157 쐌 to spot lamp terminal 2. And power is supplied: 쐌 to spot lamp terminal 1 쐌 from smart entrance control unit terminal 50. When vanity mirror illumination (LH and/or RH) is ON, ground is supplied: 쐌 through body grounds M4, M66, M111 and M147 쐌 to vanity mirror illuminations (LH and RH) terminals 2. And power is supplied: 쐌 to vanity mirror illuminations (LH and RH) terminals 1 쐌 from smart entrance control unit terminal 50. With power and ground supplied, interior lamps turn ON. INTERIOR LAMP TIMER OPERATION NAEL0290S03 When interior lamp switch is in the “DOOR” position, the smart entrance control unit keeps the interior lamp illuminated for about 30 seconds when: 쐌 unlock signal is supplied from door lock and unlock switch while all doors are closed and key is out of ignition key cylinder 쐌 unlock signal is supplied from keyfob or door key cylinder while driver’s door is locked and all doors are closed 쐌 key is removed from ignition key cylinder while all doors are closed 쐌 driver’s door is opened and then closed while key is out of the iginition key cylinder. (However, if the driver’s door is closed with the key inserted in the ignition key cylinder after the driver’s door is opened with the key removed, the timer is operated.) The timer is canceled when: 쐌 driver’s door is locked, 쐌 driver’s door is opened, or 쐌 ignition switch is turned ON. When driver’s door is locked, interior room lamp timer is canceled as described before. ON-OFF CONTROL NAEL0290S04 When the driver side door, front passenger door, rear LH or RH door is opened, the interior room lamp turns on while the interior room lamp switch is in the “DOOR” position. INTERIOR LAMP BATTERY SAVER NAEL0290S05 The lamp turns off automatically when interior lamp, luggage room lamp, spot lamp and/or vanity mirror illumination is illuminated with the ignition key is in OFF position, if the lamp remains lit by the door switch open signal or if the lamp switch is in ON position for more than 30 minutes. After lamps turn OFF by the battery saver system, the lamps illuminate again when: 쐌 driver’s door is locked or unlocked, 쐌 door is opened or closed, 쐌 key is removed from ignition key cylinder or inserted in ignition key cylinder. EL-98 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Schematic Schematic NAEL0291 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL407P EL-99 IDX INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Wiring Diagram — INT/L — Wiring Diagram — INT/L — NAEL0292 MEL973P EL-100 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Wiring Diagram — INT/L — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL974P IDX EL-101 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Wiring Diagram — INT/L — (Cont’d) MEL975P EL-102 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Wiring Diagram — INT/L — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL976P IDX EL-103 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Wiring Diagram — INT/L — (Cont’d) MEL977P EL-104 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS CONSULT-II Inspection Procedure CONSULT-II Inspection Procedure “INT LAMP”/“BATTERY SAVER” 1. 2. =NAEL0293 GI NAEL0293S01 Turn ignition switch “OFF”. Connect “CONSULT-II” and “CONSULT-II CONVERTER” to the data link connector. MA EM LC SEL670Y 3. 4. Turn ignition switch “ON”. Touch “START (NISSAN BASED VHCL)”. EC FE CL MT SKIA3098E 5. Touch “SMART ENTRANCE”. If “SMART ENTRANCE” is not indicated, go to GI-41, “CONSULT-II Data Link Connector (DLC) Circuit”. AT TF PD AX SU SEL669Y 6. Touch “INT LAMP” or “BATTERY SAVER”. BR ST RS BT SEL751Y 7. Select diagnosis mode. “DATA MONITOR”, “ACTIVE TEST” and “WORK SUPPORT” are available for “INT LAMP” and “BATTERY SAVER”. HA SC IDX SEL400Y EL-105 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS CONSULT-II Application Items CONSULT-II Application Items “INT LAMP” Data Monitor NAEL0294 NAEL0294S01 NAEL0294S0101 Monitored Item Description IGN ON SW Indicates [ON/OFF] condition of ignition switch. DOOR SW-RR Indicates [ON/OFF] condition of ignition switch. KEY ON SW Indicates [ON/OFF] condition of key switch. DOOR SW-DR Indicates [ON/OFF] condition of front door switch LH. DOOR SW-AS Indicates [ON/OFF] condition of front door switch RH. LOCK SW DR/AS Indicates [ON/OFF] condition of front door lock switch. UNLK SW DR/AS Indicates [ON/OFF] condition of front door lock switch. KEY CYL LK-SW Indicates [ON/OFF] condition of front door key cylinder switch. KEY CYL UN-SW Indicates [ON/OFF] condition of front door key cylinder switch. LK BUTTON/SIG Indicates [ON/OFF] condition of unlock signal from keyfob. UN BUTTON/SIG Indicates [ON/OFF] condition of unlock signal from keyfob. Active Test NAEL0294S0102 Test Item Description INT LAMP This test enables to check interior lamp operation. When “ON” on CONSULT-II screen is touched: 쐌 Interior lamp turns on when the switch is at DOOR. (Smart entrance control unit supplies power and ground to interior lamp.) IGN ILLUM This test enables to check ignition key hole illumination operation. The illumination turns on when “ON” on CONSULT-II screen is touched. STEP LAMP This test enables to check step lamp operation. The illumination turns on when “ON” on CONSULT-II screen is touched. NOTE: Even though ignition key hole illumination and step lamp are actually displayed on the CONSULT-II screen, those are not equipped, therefore, they cannot be activated. Work Support NAEL0294S0103 Work Item ROOM LAMP TIMER SET Description Interior lamp timer mode can be changed by mode setting. Selects ON-OFF of the room lamp illumination at the time the driver door is unlocked. 쐌 MODE 1 (ON)/MODE 2 (OFF) NOTE: Even though ignition keyhole illumination and step lamp are actually displayed on the CONSULT-II screen, those are not equipped, therefore, they cannot be activated. “BATTERY SAVER” Data Monitor NAEL0294S02 NAEL0294S0201 Monitored Item Description IGN ON SW Indicates [ON/OFF] condition of ignition switch. DOOR SW-RR Indicates [ON/OFF] condition of ignition switch. KEY ON SW Indicates [ON/OFF] condition of key switch. DOOR SW-DR Indicates [ON/OFF] condition of front door switch LH. EL-106 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS CONSULT-II Application Items (Cont’d) Monitored Item DOOR SW-AS Indicates [ON/OFF] condition of front door switch RH. LOCK SW DR/AS Indicates [ON/OFF] condition of front door lock switch. UNLK SW DR/AS Indicates [ON/OFF] condition of front door lock switch. KEY CYL LK-SW Indicates [ON/OFF] condition of front door key cylinder switch. KEY CYL UN-SW Indicates [ON/OFF] condition of front door key cylinder switch. LK BUTTON/SIG Indicates [ON/OFF] condition of unlock signal from keyfob. UN BUTTON/SIG Indicates [ON/OFF] condition of unlock signal from keyfob. Active Test EM LC EC FE Description This test enables to check interior lamp and spot lamp and vanity mirror illuminations operations. When touch “ON” on CONSULT-II screen. 쐌 Interior lamp turns on when the switch is in ON. (Smart entrance control unit supplies power to interior lamp.) 쐌 Spot lamp and vanity mirror illuminations turn on when the switch is in ON. (Smart entrance control unit supplies power to spot lamp, and vanity mirror illuminations.) CL MT AT Work Support NAEL0294S0203 Work Item ROOM LAMP BAT SAV SET MA NAEL0294S0202 Test Item BATTERY SAVER GI Description Description Interior lamp battery saver control period can be changed by mode setting. Selects interior lamp battery saver control period between two modes. 쐌 MODE 1 (30 minutes)/MODE 2 (60 minutes) TF PD AX SU BR ST RS BT HA SC IDX EL-107 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Trouble Diagnoses for Interior Lamp Timer Trouble Diagnoses for Interior Lamp Timer DIAGNOSTIC PROCEDURE 1 =NAEL0295 NAEL0295S01 SYMPTOM: Interior lamp timer does not operate. 1 CHECK IGNITION ON SIGNAL With CONSULT-II Check ignition switch ON signal (“IGN ON SW”) in “DATA MONITOR” mode with CONSULT-II. SEL318W Without CONSULT-II Check voltage between smart entrance control unit harness connector M122 terminal 27 (W/B) and ground. SEL003Y OK or NG OK 䊳 GO TO 2. NG 䊳 Check the following. 쐌 7.5A fuse [No. 11, located in fuse block (J/B)] 쐌 Harness for open or short between smart entrance control unit and fuse EL-108 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Trouble Diagnoses for Interior Lamp Timer (Cont’d) 2 GI CHECK FRONT DOOR SWITCH LH INPUT SIGNAL With CONSULT-II Check front door switch LH signal (“DOOR SW-DR”) in “DATA MONITOR” mode with CONSULT-II. MA EM LC EC SEL319WB Without CONSULT-II Check voltage between smart entrance control unit harness connector M121 terminal 1 (G/OR) and ground. FE CL MT AT TF SEL004YD PD OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 3. 3 AX SU CHECK FRONT DOOR SWITCH LH Check the following. 쐌 Continuity between front door switch LH connector B9 terminals 1 and 2 쐌 Continuity between front door switch LH connector B9 terminal 3 and ground BR ST RS BT SEL277Y HA OK or NG OK 䊳 Check the following. 쐌 Front door switch LH ground circuit and condition 쐌 Harness for open or short between smart entrance control unit and front door switch LH NG 䊳 Replace front door switch LH. SC IDX EL-109 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Trouble Diagnoses for Interior Lamp Timer (Cont’d) 4 CHECK FRONT DOOR SWITCH RH INPUT SIGNAL With CONSULT-II Check front door switch RH signal (“DOOR SW-AS”) in “DATA MONITOR” mode with CONSULT-II. SEL153YA Without CONSULT-II Check voltage between smart entrance control unit harness connector M121 terminal 2 (Y) and ground. SEL152YB OK or NG OK 䊳 GO TO 6. NG 䊳 GO TO 5. 5 CHECK FRONT DOOR SWITCH RH Check the following. 쐌 Continuity between front door switch RH connector B68 terminals 1 and 2 쐌 Continuity between front door switch RH connector B68 terminal 3 and ground SEL278Y OK or NG OK 䊳 Check the following. 쐌 Front door switch RH ground circuit and condition 쐌 Harness for open or short between smart entrance control unit and front door switch RH NG 䊳 Replace front door switch RH. EL-110 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Trouble Diagnoses for Interior Lamp Timer (Cont’d) 6 GI CHECK REAR AND BACK DOOR SWITCHES INPUT SIGNAL With CONSULT-II Check door switches (“DOOR SW-RR”) in “DATA MONITOR” mode with CONSULT-II. MA EM LC EC SEL154YB Without CONSULT-II Check voltage between smart entrance control unit harness connector M121 terminal 3 (R/L) and ground. FE CL MT AT TF SEL155YB PD OK or NG OK 䊳 GO TO 8. NG 䊳 GO TO 7. 7 AX SU CHECK REAR AND BACK DOOR SWITCHES 1. Disconnect door switch harness connector. 2. Check the following. 쐌 Continuity between rear door switches connector B18 and B71 terminal 1 and ground 쐌 Continuity between back door switch connector D208 terminals 1 and 2 BR ST RS BT HA SEL279Y OK or NG OK 䊳 Check the following. 쐌 Rear LH, RH and/or back door switch ground circuit or door switch ground condition 쐌 Harness for open or short between smart entrance control unit and rear LH, RH and/or back door switch NG 䊳 Replace rear LH, RH and/or back door switch. EL-111 SC IDX INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Trouble Diagnoses for Interior Lamp Timer (Cont’d) 8 CHECK KEY SWITCH INPUT SIGNAL With CONSULT-II Check key switch (“KEY ON SW”) in “DATA MONITOR” mode with CONSULT-II. SEL315W Without CONSULT-II Check voltage between smart entrance control unit harness connector M122 terminal 25 (W/R) and ground. SEL011Y OK or NG OK 䊳 GO TO 10. NG 䊳 GO TO 9. 9 CHECK KEY SWITCH (INSERT) Check continuity between terminals 1 and 2. SEL308X OK or NG OK 䊳 Check the following. 쐌 7.5A fuse [No. 24, located in fuse block (J/B)] 쐌 Harness for open or short between key switch and fuse 쐌 Harness for open or short between smart entrance control unit and key switch NG 䊳 Replace key switch. EL-112 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Trouble Diagnoses for Interior Lamp Timer (Cont’d) 10 GI CHECK DOOR LOCK/UNLOCK SWITCH INPUT SIGNAL With CONSULT-II Check door lock/unlock switch (“LOCK SW DR/AS”/“UNLK SW DR/AS”) in “DATA MONITOR” mode with CONSULT-II. MA EM LC EC SEL341W Without CONSULT-II 1. Remove key from ignition key cylinder. 2. Check the signal between smart entrance control unit harness connector M122 terminal 33 (BR) and ground with oscilloscope when door lock/unlock switch is turned “LOCK” or “UNLOCK”. 3. Make sure signals which are shown in the figure below can be detected during 10 sec. just after door lock/unlock switch is turned “LOCK” or “UNLOCK”. FE CL MT AT TF PD SEL699Y AX OK or NG OK 䊳 Door lock/unlock switch is OK. SU NG 䊳 Check the following. 쐌 Ground circuit for each front power window switch 쐌 Harness for open or short between each front power window switch and smart entrance control unit connector If above systems are normal, replace the power window main switch. BR ST RS BT HA SC IDX EL-113 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Trouble Diagnoses for Interior Lamp Timer (Cont’d) 11 CHECK DOOR KEY CYLINDER SWITCH INPUT SIGNAL (LOCK/UNLOCK SIGNAL) With CONSULT-II Check front door key cylinder switch (“KEY CYL LK-SW”/“KEY CYL UN-SW”) in “DATA MONITOR” mode with CONSULTII. SEL342W Without CONSULT-II 1. Check the signal between smart entrance control unit harness connector M122 terminal 33 (BR) and ground with oscilloscope when key inserted in front key cylinder is turned “LOCK” or “UNLOCK”. 2. Make sure signals which are shown in the figure below can be detected during 10 sec. just after key is turned “LOCK” or “UNLOCK”. SEL700Y OK or NG OK 䊳 Door key cylinder switch LH is OK. NG 䊳 GO TO 12. 12 CHECK FRONT DOOR KEY CYLINDER SWITCH INPUT SIGNAL (LOCK/UNLOCK SIGNAL) Check voltage between power window main switch harness connector D6 terminals 4 (Y/L) or 6 (LG) and ground. SEL792Y OK or NG OK 䊳 Replace smart entrance control unit. NG 䊳 GO TO 13. EL-114 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Trouble Diagnoses for Interior Lamp Timer (Cont’d) 13 GI CHECK BACK DOOR KEY CYLINDER SWITCH INPUT SIGNAL (LOCK/UNLOCK SIGNAL) With CONSULT-II Check back door key cylinder switch (“KEY CYL LK-SW”/“KEY CYL UN-SW”) in “DATA MONITOR” mode with CONSULTII. MA EM LC EC SEL342WB Without CONSULT-II Check voltage between smart entrance control unit harness connector M121 terminals 10 (LG), 11 (Y) and ground. FE CL MT AT TF PD AX SEL680Y OK or NG OK 䊳 Replace smart entrance control unit. NG 䊳 GO TO 14. SU BR ST RS BT HA SC IDX EL-115 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Trouble Diagnoses for Interior Lamp Timer (Cont’d) 14 CHECK DOOR KEY CYLINDER SWITCH 1. Disconnect door key cylinder switch harness connector. 2. Check continuity between each key cylinder switch terminals. 쐌 Front door key cylinder switch LH harness connector D9 SEL793Y 쐌 Back door key cylinder switch harness connector D201 SEL315X OK or NG OK 䊳 Check the following. 쐌 Front or back door key cylinder switch ground circuit 쐌 Harness for open or short between back door key cylinder switch and smart entrance control unit connector 쐌 Harness for open or short between front door key cylinder switch LH and power window main switch NG 䊳 Replace front or back door key cylinder switch. EL-116 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Trouble Diagnoses for Interior Lamp Timer (Cont’d) DIAGNOSTIC PROCEDURE 2 =NAEL0295S02 GI SYMPTOM: Interior lamp timer does not cancel properly. 1 CHECK IGNITION ON SIGNAL MA With CONSULT-II Check ignition switch ON signal (“IGN ON SW”) in “DATA MONITOR” mode with CONSULT-II. EM LC EC FE SEL318W CL Without CONSULT-II Check voltage between smart entrance control unit harness connector M122 terminal 27 (W/B) and ground. MT AT TF PD SEL995X OK or NG OK 䊳 GO TO 2. NG 䊳 Check the following. 쐌 7.5A fuse [No. 11, located in fuse block (J/B)] 쐌 Harness for open or short between smart entrance control unit and fuse AX SU BR ST RS BT HA SC IDX EL-117 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Trouble Diagnoses for Interior Lamp Timer (Cont’d) 2 CHECK FRONT LH DOOR SWITCH INPUT SIGNAL With CONSULT-II Check driver door switch signal (“DOOR SW-DR”) in “DATA MONITOR” mode with CONSULT-II. SEL319WB Without CONSULT-II Check voltage between smart entrance control unit harness connector M121 terminal 1 (G/OR) and ground. SEL004YD OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 3. 3 CHECK FRONT DOOR SWITCH LH Check the following. 쐌 Continuity between front door switch LH connector B9 terminals 1 and 2 쐌 Continuity between front door switch LH connector B9 terminal 3 and ground SEL277Y OK or NG OK 䊳 Check the following. 쐌 Front door switch LH ground circuit and condition 쐌 Harness for open or short between smart entrance control unit and front door switch LH NG 䊳 Replace front door switch LH. EL-118 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Trouble Diagnoses for Interior Lamp Timer (Cont’d) 4 GI CHECK DOOR LOCK/UNLOCK SWITCH INPUT SIGNAL With CONSULT-II Check door lock/unlock switch (“LOCK SW DR/AS”/“UNLK SW DR/AS”) in “DATA MONITOR” mode with CONSULT-II. MA EM LC EC SEL341W Without CONSULT-II 1. Remove key from ignition key cylinder. 2. Check the signal between smart entrance control unit harness connector M122 terminal 33 (BR) and ground with oscilloscope when door lock/unlock switch is turned “LOCK” or “UNLOCK”. 3. Make sure signals which are shown in the figure below can be detected during 10 sec. just after door lock/unlock switch is turned “LOCK” or “UNLOCK”. FE CL MT AT TF PD SEL699Y AX OK or NG OK 䊳 Door lock/unlock switch is OK. SU NG 䊳 Check the following. 쐌 Ground circuit for each front power window switch 쐌 Harness for open or short between each front power window switch and smart entrance control unit connector If above systems are normal, replace the front power window switch. BR ST RS BT HA SC IDX EL-119 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Trouble Diagnoses for Interior Lamp Timer (Cont’d) 5 CHECK DOOR KEY CYLINDER SWITCH INPUT SIGNAL (LOCK/UNLOCK SIGNAL) With CONSULT-II Check front door key cylinder switch (“KEY CYL LK-SW”/“KEY CYL UN-SW”) in “DATA MONITOR” mode with CONSULTII. SEL342W Without CONSULT-II 1. Check the signal between smart entrance control unit harness connector M122 terminal 33 (BR) and ground with oscilloscope when key inserted in front key cylinder is turned “LOCK” or “UNLOCK”. 2. Make sure signals which are shown in the figure below can be detected during 10 sec. just after key is turned “LOCK” or “UNLOCK”. SEL700Y OK or NG OK 䊳 Door key cylinder switch LH is OK. NG 䊳 GO TO 6. 6 CHECK FRONT DOOR KEY CYLINDER SWITCH INPUT SIGNAL (LOCK/UNLOCK SIGNAL) Check voltage between power window main switch harness connector D6 terminals 4 (Y/L) or 6 (LG) and ground. SEL792Y OK or NG OK 䊳 Replace smart entrance control unit. NG 䊳 GO TO 7. EL-120 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Trouble Diagnoses for Interior Lamp Timer (Cont’d) 7 GI CHECK BACK DOOR KEY CYLINDER SWITCH INPUT SIGNAL (LOCK/UNLOCK SIGNAL) With CONSULT-II Check back door key cylinder switch (“KEY CYL LK-SW”/“KEY CYL UN-SW”) in “DATA MONITOR” mode with CONSULTII. MA EM LC EC SEL342WB Without CONSULT-II Check voltage between smart entrance control unit harness connector M121 terminals 10 (LG), 11 (Y) and ground. FE CL MT AT TF PD AX SEL680Y OK or NG OK 䊳 Replace smart entrance control unit. NG 䊳 GO TO 8. SU BR ST RS BT HA SC IDX EL-121 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS Trouble Diagnoses for Interior Lamp Timer (Cont’d) 8 CHECK DOOR KEY CYLINDER SWITCH 1. Disconnect door key cylinder switch harness connector. 2. Check continuity between each key cylinder switch terminals. 쐌 Front door key cylinder switch harness connector D9 SEL793Y 쐌 Back door key cylinder switch harness connector D201 SEL315X OK or NG OK 䊳 Check the following. 쐌 Front or back door key cylinder switch ground circuit 쐌 Harness for open or short between back door key cylinder switch and smart entrance control unit connector 쐌 Harness for open or short between front door key cylinder switch and power window main switch NG 䊳 Replace front or back door key cylinder switch. EL-122 METERS AND GAUGES Component Parts and Harness Connector Location Component Parts and Harness Connector Location GI NAEL0296 MA EM LC EC FE CL SEL672Y MT System Description UNIFIED CONTROL METER 쐌 쐌 쐌 쐌 AT NAEL0297 NAEL0297S01 Speedometer, odo/trip meter, tachometer, fuel gauge and water temperature gauge are controlled totally by control unit. Digital meter is adopted for odo/trip meter.* *The record of the odo meter is kept even if the battery cable is disconnected. The record of the trip meter is erased when the battery cable is disconnected. Odo/trip meter segment can be checked in diagnosis mode. Meter/gauge can be checked in diagnosis mode. HOW TO CHANGE THE DISPLAY FOR ODO/TRIP METER NAEL0297S02 TF PD AX SU BR ST RS BT HA SC SEL175W NOTE: Turn ignition switch to the “ON” position to operate odo/trip meter. EL-123 IDX METERS AND GAUGES System Description (Cont’d) POWER SUPPLY AND GROUND CIRCUIT NAEL0297S03 Power is supplied at all times 쐌 through 7.5A fuse [No. 24, located in the fuse block (J/B)] 쐌 to combination meter terminal 62. With the ignition switch in the ON or START position, power is supplied 쐌 through 10A fuse [No. 8, located in the fuse block (J/B)] 쐌 to combination meter terminal 66. Ground is supplied 쐌 to combination meter terminal 59 쐌 through body grounds M4, M66, M111, M147 and M157. WATER TEMPERATURE GAUGE NAEL0297S04 The water temperature gauge indicates the engine coolant temperature. ECM provides an engine coolant temperature signal to the combination meter for the water temperature gauge with CAN communication line. The needle on the gauge moves from “C” to “H”. TACHOMETER NAEL0297S05 The tachometer indicates engine speed in revolutions per minute (rpm). ECM provides an engine speed signal to the combination meter for the tachometer with CAN communication line. FUEL GAUGE NAEL0297S06 The fuel gauge indicates the approximate fuel level in the fuel tank. The fuel gauge is regulated by a variable ground signal supplied 쐌 to combination meter terminal 17 for the fuel gauge 쐌 from terminal 3 of the fuel level sensor unit 쐌 through terminal 2 of the fuel level sensor unit and 쐌 through combination meter terminal 23. SPEEDOMETER Without VDC NAEL0297S07 NAEL0297S0701 The ABS actuator and electric unit (control unit) provides a voltage signal to the combination meter for the speedometer. The voltage is supplied 쐌 from combination meter terminal 15 for the speedometer 쐌 to terminal 19 of the ABS actuator and electric unit (control unit). The speedometer converts the voltage into the vehicle speed displayed. With VDC NAEL0297S0702 The ABS actuator and electric unit (control unit) provides a vehicle speed signal to the combination meter for the speedometer with CAN communication line. CAN COMMUNICATION SYSTEM NAEL0297S09 Combination meter recieves vehicle speed signal and engine coolant temperature signal etc. from some control units with can communication line. Refer to “CAN COMMUNICATION” (EL-447). EL-124 METERS AND GAUGES Combination Meter Combination Meter CHECK NAEL0298 GI NAEL0298S01 MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL073Q EL-125 IDX METERS AND GAUGES Combination Meter (Cont’d) CONSTRUCTION NAEL0298S02 SEL482Y EL-126 METERS AND GAUGES Schematic Schematic NAEL0299 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL072Q EL-127 IDX METERS AND GAUGES Wiring Diagram — METER — Wiring Diagram — METER — NAEL0300 MEL978P EL-128 METERS AND GAUGES Meter/Gauge Operation and Odo/Trip Meter Segment Check in Diagnosis Mode Meter/Gauge Operation and Odo/Trip Meter Segment Check in Diagnosis Mode DIAGNOSIS FUNCTION 쐌 쐌 2. 3. 4. 5. 6. NAEL0301 NAEL0301S01 Odo/trip meter segment can be checked in diagnosis mode. Meters/gauges can be checked in diagnosis mode. HOW TO ALTERNATE DIAGNOSIS MODE 1. GI MA EM NAEL0301S02 Turn ignition switch to ON and change odo/trip meter to “TRIP A” or “TRIP B”. Turn ignition switch to OFF. Turn ignition switch to ON when pushing odo/trip meter switch. Push odo/trip meter switch 1 second. Release odo/trip meter switch. Push odo/trip meter switch more than three times within 7 seconds. LC EC FE CL MT 7. All odo/trip meter segments should be turned on. NOTE: If some segments are not turned on, unified meter control unit with odo/trip meter should be replaced. At this point, the unified control meter is turned to diagnosis mode. AT TF PD AX SU SEL176W 8. Push odo/trip meter switch. Indication of each meter/gauge should be as shown left during pushing odo/trip meter switch if it is no malfunctioning. NOTE: It takes about a few seconds for indication of fuel gauge and water temperature gauge to become stable. BR ST RS BT SEL177W HA SC IDX EL-129 METERS AND GAUGES Trouble Diagnoses Trouble Diagnoses NAEL0302 PRELIMINARY CHECK NAEL0302S01 SEL494Y *1: Meter/Gauge Operation and Odo/ Trip Meter Segment Check in Diagnosis Mode (EL-129) *2: POWER SUPPLY AND GROUND CIRCUIT CHECK (EL-131) *3: Symptom Chart (EL-130) SYMPTOM CHART Symptom Possible causes One of speedometer/ tachometer/fuel gauge/ water temp. gauge is malfunctioning. 1. Sensor signal - Vehicle speed signal - Engine speed signal - Fuel gauge - Water temp. gauge 2. Unified meter control unit Multiple meter/gauge are malfunctioning. (except odo/trip meter) Unified meter control unit NAEL0302S02 Repair order 1. Check the sensor for malfunctioning meter/gauge. INSPECTION/VEHICLE SPEED SIGNAL WITH VDC (Refer to EL-131.) INSPECTION/VEHICLE SPEED SIGNAL WITHOUT VDC (Refer to EL-132.) INSPECTION/ENGINE SPEED SIGNAL (Refer to EL-132.) INSPECTION/FUEL LEVEL SENSOR UNIT (Refer to EL-133.) INSPECTION/WATER TEMPERATURE SIGNAL (Refer to EL-134.) 2. Replace unified meter control unit assembly. Before starting trouble diagnoses below, perform PRELIMINARY CHECK, EL-130. EL-130 METERS AND GAUGES Trouble Diagnoses (Cont’d) POWER SUPPLY AND GROUND CIRCUIT CHECK =NAEL0302S03 GI Power Supply Circuit Check NAEL0302S0301 Terminals SEL179WB MA Ignition switch position (+) (−) OFF ACC ON 62 Ground Battery voltage Battery voltage Battery voltage EM 66 Ground 0V 0V Battery voltage LC If NG, check the following. 쐌 7.5A fuse [No. 24, located in fuse block (J/B)] 쐌 10A fuse [No. 8, located in fuse block (J/B)] 쐌 Harness for open or short between fuse and combination meter EC FE CL MT AT Ground Circuit Check NAEL0302S0302 Terminals TF (+) Continuity (−) Connector Terminal (wire color) M26 59 (B) Ground PD Yes AX SU SEL747Y INSPECTION/VEHICLE SPEED SIGNAL WITH VDC NAEL0302S11 1 CHECK ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) OUTPUT BR Perform ABS actuator and electric unit (control unit) self-diagnosis. Refer to BR-106, “CONSULT-II Functions”. OK or NG OK 䊳 Replace combination meter. NG 䊳 Check ABS actuator and electric unit (control unit). Refer to BR-94, “Trouble Diagnosis”. ST RS BT HA SC IDX EL-131 METERS AND GAUGES Trouble Diagnoses (Cont’d) INSPECTION/VEHICLE SPEED SIGNAL WITHOUT =NAEL0302S04 VDC 1 CHECK ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) OUTPUT SIGNAL With CONSULT-II 1. Lift up drive wheels. 2. Start engine and drive vehicle at more than 20 km/h (12 MPH). 3. Check signal between combination meter harness connector M24 terminal 15 (G/Y) and ground when rotating wheels with engine at idle. (Use “SIMPLE OSCILLOSCOPE” in “SUB MODE” with CONSULT-II.) SEL938W Without CONSULT-II 1. Lift up drive wheels. 2. Start engine and drive vehicle at more than 20 km/h (12 MPH). 3. Check voltage between combination meter harness connector M24 terminal 15 (G/Y) and ground when rotating wheels with engine at idle. SEL939WA OK or NG OK 䊳 ABS actuator and electric unit (control unit) is OK. NG 䊳 Check the following. 쐌 Harness for open or short between ABS actuator and electric unit (control unit) and combination meter. 쐌 ABS actuator and electric unit (control unit). Refer to BR-56, “Wheel Sensor or Rotor”. INSPECTION/ENGINE SPEED SIGNAL 1 CHECK ECM SELF-DIAGNOSIS Perform ECM self-diagnosis. Refer to EC-86, “Emission-related Diagnostic Information”. OK or NG OK 䊳 Replace combination meter. NG 䊳 Perform “Diagnostic Procedure” for displayed DTC. EL-132 NAEL0302S05 METERS AND GAUGES Trouble Diagnoses (Cont’d) INSPECTION/FUEL LEVEL SENSOR UNIT 1 =NAEL0302S06 GI CHECK GROUND CIRCUIT FOR FUEL LEVEL SENSOR UNIT 1. Turn ignition switch to OFF position. 2. Disconnect combination meter connector and fuel level sensor connector. 3. Check continuity between combination meter harness connector M24 terminal 23 (B) and fuel level sensor unit harness connector B12 terminal 2 (B). 4. Check continuity between combination meter harness connector M24 terminal 23 and ground. MA EM LC EC FE SEL794Y OK or NG OK 䊳 GO TO 2. NG 䊳 Repair harness or connector. 2 CL MT AT CHECK FUEL LEVEL SENSOR UNIT TF Refer to “FUEL LEVEL SENSOR UNIT CHECK” (EL-134). OK or NG PD OK 䊳 GO TO 3. NG 䊳 Replace fuel level sensor unit. AX 3 CHECK HARNESS FOR OPEN OR SHORT 1. Disconnect combination meter connector and fuel level sensor unit connector. 2. Check continuity between combination meter terminal 17 and fuel level sensor unit terminal 3. 3. Check continuity between combination meter terminal 17 and ground. SU BR ST RS BT SEL300X OK or NG OK 䊳 Fuel level sensor unit is OK. NG 䊳 Repair harness or connector. HA SC IDX EL-133 METERS AND GAUGES Trouble Diagnoses (Cont’d) INSPECTION/WATER TEMPERATURE SIGNAL 1 NAEL0302S07 CHECK ECM SELF-DIAGNOSIS Perform ECM self-diagnosis. Refer to EC-86, “Emission-related Diagnostic Information”. OK or NG OK 䊳 Replace combination meter. NG 䊳 Perform “Diagnostic Procedure” for display DTC. Electrical Components Inspection FUEL LEVEL SENSOR UNIT CHECK 쐌 For removal, refer to FE-4, “FUEL SYSTEM”. Check the resistance between terminals 3 and 2. Ohmmeter Float position (+) 3 mm (in) (−) 2 NAEL0303 NAEL0303S02 Resistance value Ω *1 Full 95 (3.74) Approx. 4 - 6 *2 1/2 184 (7.24) 31 - 34 *3 Empty 265 (10.43) 80 - 83 YEL066K *1 and *3: When float rod is in contact with stopper. EL-134 COMPASS AND THERMOMETER System Description System Description NAEL0304 GI MA EM LC EC SEL713U This unit displays following items: 쐌 Earth magnetism and heading direction of vehicle. 쐌 Outside air temperature. 쐌 Caution for frozen road surfaces. OUTSIDE TEMPERATURE DISPLAY FE CL NAEL0304S01 Push the switch when the ignition key is in the “ACC” or “ON” position. The outside temperature will be displayed in “°F”. 쐌 Selecting the indication range Push the switch to change from “°F” to “°C”. 쐌 When the outside temperature drops below freezing point, ICE is displayed on the unit. 쐌 When the outside temperature is between 55°C (130°F) and 70°C (158°F), the display shows 55°C (130°F). 쐌 When the outside temperature is lower than −30°C (−20°F) or higher than 70°C (158°F), the display shows only “---” though it is operating. This is not a problem. 쐌 The indicated temperature on the thermometer is not readily affected by engine heat. It changes only when one of the following conditions is present. a) The temperature detected by the ambient air temperature sensor is lower than the indicated temperature on the thermometer. b) The difference in temperature detected during a period of 40 seconds is less than 1°C (1.8°F) when vehicle speed has been greater than 24 km/h (15 MPH) for more than 100 seconds. (This is to prevent the indicated temperature from being affected by engine heat or cooling fan operation during low-speed driving.) c) The ignition key has been turned to the “OFF” position for more than 4 hours. (The engine is cold.) MT DIRECTION DISPLAY ST NAEL0304S02 Push the switch when the ignition key is in the “ACC” or “ON” position. The direction will be displayed. AT TF PD AX SU BR RS BT HA SC IDX EL-135 COMPASS AND THERMOMETER Wiring Diagram — COMPAS — Wiring Diagram — COMPAS — NAEL0305 MEL979P EL-136 COMPASS AND THERMOMETER Trouble Diagnoses Trouble Diagnoses NAEL0306 PRELIMINARY CHECK FOR THERMOMETER 1 GI NAEL0306S01 MA COOL DOWN CHECK 1. Turn the ignition key switch to the “ACC” position. 2. Cool down the ambient air temperature sensor with water or ice, so that the indicated temperature falls. EM Does the indicated temperature fall? Yes 䊳 GO TO 2. No 䊳 The system is malfunctioning. Check the system following “INSPECTION/COMPASS AND THERMOMETER”. LC EC 2 WARM UP CHECK 1. Leave the vehicle for 10 minutes, so that the indicated temperature rises. 2. With the ignition key in the “ACC” position, disconnect and reconnect the ambient air temperature sensor connector. Does the indicated temperature rise? CL Yes 䊳 The system is OK. No 䊳 The system is malfunctioning. Check the system following “INSPECTION/COMPASS AND THERMOMETER”. NOTE: 쐌 When the outside temperature is between 55°C (130°F) and 70°C (158°F), the display shows 55°C (130°F). When the outside temperature is lower than −30°C (−20°F) or higher than 70°C (158°F), the display shows only “---”. 쐌 The indicated temperature on the thermometer is not readily affected by engine heat. It changes only when one of the following conditions is present. a) The temperature detected by the ambient air temperature sensor is lower than the indicated temperature on the thermometer. b) The difference in temperature detected during a period of 40 seconds is less than 1°C (1.8°F) when vehicle speed has been greater than 24 km/h (15 MPH) for more than 100 seconds. (This is to prevent the indicated temperature from being affected by engine heat or cooling fan operation during low-speed driving.) c) The ignition key has been turned to the “OFF” position for more than 4 hours. (The engine is cold.) INSPECTION/COMPASS AND THERMOMETER Symptom No display at all MT AT TF PD AX SU NAEL0306S02 Possible causes Repair order 1. 10A fuse 2. Ground circuit 3. Compass and thermometer FE 1. Check 10A fuse [No. 9, located in fuse block (J/B)]. Turn the ignition switch ON and verify that battery positive voltage is at terminal 7 of compass and thermometer. 2. Check ground circuit for compass and thermometer. 3. Replace compass and thermometer. Forward direction indication slips off the mark or incorrect. 1. In manual correction mode (Bar and display vanish.) 2. Zone variation change is not done. Compass reading remains unchanged. 1. Vehicle speed signal is not entered. 1. Check harness for open or short between combination meter 2. Compass and thermometer terminal 13 and compass and thermometer terminal 1. 2. Replace compass and thermometer. Displays wrong temperature when ambient temperature is between −30°C (−20°F) and 55°C (130°F). (See NOTE above.) 1. Check operation 2. Ambient air temperature sensor circuit 3. Vehicle speed signal is not entered. 4. Ambient air temperature sensor 5. Compass and thermometer 1. Drive the vehicle and turn at an angle of 90°. 2. Perform the zone variation change. 1. Perform preliminary check shown above. 2. Check harness for open or short between ambient air temperature sensor and compass and thermometer. 3. Check harness for open or short between combination meter terminal 13 and compass and thermometer terminal 1. 4. Replace ambient air temperature sensor. 5. Replace compass and thermometer. BR ST RS BT HA SC IDX EL-137 COMPASS AND THERMOMETER Calibration Procedure for Compass Calibration Procedure for Compass =NAEL0307 The difference between magnetic North and geographical North can sometimes be great enough to cause false compass readings. In order for the compass to operate accurately in a particular zone, it must be calibrated using the following procedure. SEL738UA CORRECTION FUNCTIONS OF COMPASS NAEL0307S01 The direction display is equipped with automatic correction function. If the direction is not shown correctly, carry out initial correction. INITIAL CORRECTION PROCEDURE FOR COMPASS NAEL0307S02 1. SEL065V Pushing the “Mode” switch for about 10 seconds will enter the initial correction mode. The direction bar starts blinking. 2. Turn the vehicle slowly in an open, safe place. The initial correction is completed in one or two turns. NOTE: In places where the terrestrial magnetism is extremely disturbed, the initial correction may start automatically. EL-138 WARNING LAMPS Schematic Schematic NAEL0308 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL980P EL-139 IDX WARNING LAMPS Wiring Diagram — WARN — Wiring Diagram — WARN — NAEL0309 MEL981P EL-140 WARNING LAMPS Wiring Diagram — WARN — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL982P IDX EL-141 WARNING LAMPS Wiring Diagram — WARN — (Cont’d) MEL983P EL-142 WARNING LAMPS Wiring Diagram — WARN — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL984P IDX EL-143 WARNING LAMPS Wiring Diagram — WARN — (Cont’d) MEL985P EL-144 WARNING LAMPS Wiring Diagram — WARN — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL986P IDX EL-145 WARNING LAMPS Wiring Diagram — WARN — (Cont’d) MEL987P EL-146 WARNING LAMPS Wiring Diagram — WARN — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL988P IDX EL-147 WARNING LAMPS Fuel Warning Lamp Sensor Check Fuel Warning Lamp Sensor Check NAEL0310 1. 2. 3. SEL062WA Turn ignition switch “OFF”. Disconnect fuel level sensor unit harness connector B12. Connect a resistor (80Ω) between fuel tank gauge unit harness connector terminals 2 and 3. 4. Turn ignition switch “ON”. The fuel warning lamp should come on. NOTE: ECM might store the 1st trip DTC P0180 during this inspection. If the DTC is stored in ECM memory, erase the DTC after reconnecting fuel tank gauge unit harness connector. Refer to EC-86, “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”. Electrical Components Inspection NAEL0311 OIL PRESSURE SWITCH CHECK MEL425F Oil pressure kPa (kg/cm2, psi) Continuity Engine start More than 10 - 20 (0.1 - 0.2, 1 - 3) NO Engine stop Less than 10 - 20 (0.1 - 0.2, 1 - 3) YES Check the continuity between the terminals of oil pressure switch and body ground. DIODE CHECK 쐌 쐌 SEL901F NAEL0311S01 NAEL0311S02 Check continuity using an ohmmeter. Diode is functioning properly if test results are as shown in the figure at left. 쐌 Check diodes at the combination meter harness connector instead of checking them on the combination meter assembly. Refer to EL-140, “WARNING LAMP” wiring diagrams. NOTE: Specification 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. EL-148 WARNING CHIME Component Parts and Harness Connector Location Component Parts and Harness Connector Location GI NAEL0312 MA EM LC EC FE CL MT AT TF PD SEL673Y AX SU System Description NAEL0313 The warning chime is controlled by the smart entrance control unit. The warning chime is located in the smart entrance control unit. Power is supplied at all times 쐌 through 7.5A fuse [No. 24, located in fuse block (J/B)] 쐌 to smart entrance control unit terminal 49 and 쐌 to key switch terminal 2, 쐌 through 10A fuse (No. 61, located in the fuse and fusible link box 쐌 to tail lamp relay terminals 1 and 3. When the ignition switch in the ON or START position, power is supplied 쐌 through 7.5A fuse [No. 11, located in the fuse block (J/B)] 쐌 to smart entrance control unit terminal 27. Ground is supplied 쐌 to smart entrance control unit terminals 43 and 64 쐌 through body grounds M4, M66, M111, M147 and M157. When a signal, or combination of signals, is received by the smart entrance control unit, the warning chime will sound. IGNITION KEY WARNING CHIME BR ST RS BT HA SC NAEL0313S01 When the key in the ignition switch in the OFF position, and the driver’s door open, the warning chime will sound. Power is supplied EL-149 IDX WARNING CHIME System Description (Cont’d) 쐌 from key switch terminal 1 쐌 to smart entrance control unit terminal 25. Ground is supplied 쐌 from front door switch LH terminal 1 쐌 to smart entrance control unit terminal 1. Front door switch LH terminal 2 is grounded through body grounds B11, B22 and D210. LIGHT WARNING CHIME NAEL0313S02 When ignition switch OFF, driver’s door open, and lighting switch in 1ST or 2ND position, warning chime will sound. Power is supplied. 쐌 from tail lamp relay terminal 2 쐌 to smart entrance control unit terminal 19 and 57. Ground is supplied 쐌 from front door switch LH terminal 1 쐌 to smart entrance control unit terminal 1. Front door switch LH terminal 2 is grounded through body grounds B11, B22 and D210. SEAT BELT WARNING CHIME NAEL0313S03 With ignition switch turned ON and seat belt unfastened (seat belt buckle switch ON), warning chime will sound for approximately 6 seconds. Ground is supplied 쐌 from seat belt buckle switch terminal 1 쐌 to smart entrance control unit terminal 28. Seat belt switch terminal 2 is grounded through body grounds B11, B22 and D210. EL-150 WARNING CHIME Wiring Diagram — CHIME — Wiring Diagram — CHIME — NAEL0314 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL989P EL-151 IDX WARNING CHIME Wiring Diagram — CHIME — (Cont’d) MEL990P EL-152 WARNING CHIME CONSULT-II Inspection Procedure CONSULT-II Inspection Procedure =NAEL0315 “KEY WARN ALM”/“LIGHT WARN ALM”/“SEAT BELT ALM” NAEL0315S01 1. 2. Turn ignition switch “OFF”. Connect “CONSULT-II” and “CONSULT-II CONVERTER” to the data link connector. GI MA EM LC SEL670Y 3. 4. Turn ignition switch “ON”. Touch “START (NISSAN BASED VHCL)”. EC FE CL MT SKIA3098E 5. Touch “SMART ENTRANCE”. If “SMART ENTRANCE” is not indicated, go to GI-41, “CONSULT-II Data Link Connector (DLC) Circuit”. AT TF PD AX SU SEL669Y 6. Touch “KEY WARN ALM”, “LIGHT WARN ALM” or “SEAT BELT ALM”. BR ST RS BT SEL023X 7. Select diagnosis mode. “DATA MONITOR” and “ACTIVE TEST” are available for the warning chime. HA SC IDX SEL322W EL-153 WARNING CHIME CONSULT-II Application Items CONSULT-II Application Items “KEY WARNING ALARM” Data Monitor NAEL0316S0101 Monitored Item Description IGN ON SW Indicates [ON/OFF] condition of ignition switch. KEY ON SW Indicates [ON/OFF] condition of key switch. DOOR SW DR Indicates [ON/OFF] condition of front door switch LH. Active Test NAEL0316S0102 Test Item Description This test is able to check key warning chime operation. Key warning chime sounds for 2 seconds after touching “ON” on CONSULT-II screen. CHIME “LIGHT WARN ALM” Data Monitor NAEL0316S02 NAEL0316S0201 Monitored Item Description LIGHT SW 1ST Indicates [ON/OFF] condition of lighting switch. IGN ON SW Indicates [ON/OFF] condition of ignition switch. DOOR SW-DR Indicates [ON/OFF] condition of front door switch LH. Active Test NAEL0316S0202 Test Item Description This test is able to check light warning chime operation. Light warning chime sounds for 2 seconds after touching “ON” on CONSULT-II screen. CHIME “SEAT BELT WARM ALM” Data Monitor NAEL0316S03 NAEL0316S0301 Monitored Item Description IGN ON SW Indicates [ON/OFF] condition of ignition switch. SEAT BELT SW Indicates [ON/OFF] condition of seat belt switch. Active Test NAEL0316S0302 Test Item CHIME NAEL0316 NAEL0316S01 Description This test is able to check seat belt warning chime operation. Seat belt warning chime sounds for 2 seconds after touching “ON” on CONSULT-II screen. EL-154 WARNING CHIME Trouble Diagnoses Trouble Diagnoses NAEL0317 SYMPTOM CHART 157 158 159 160 DIAGNOSTIC PROCEDURE 2 (KEY SWITCH INSERT SIGNAL CHECK) DIAGNOSTIC PROCEDURE 3 (SEAT BELT BUCKLE SWITCH CHECK) DIAGNOSTIC PROCEDURE 4 Light warning chime does not activate. X X Ignition key warning chime does not activate. X Seat belt warning chime does not activate. X All warning chimes do not activate. X SYMPTOM NAEL0317S01 155 DIAGNOSTIC PROCEDURE 1 (LIGHTING SWITCH INPUT SIGNAL CHECK) ) POWER SUPPLY AND GROUND CIRCUIT CHECK REFERENCE PAGE (EL- GI MA EM LC EC FE X CL X X X X X MT AT TF PD AX SU POWER SUPPLY AND GROUND CIRCUIT CHECK NAEL0317S02 Power Supply Circuit Check BR NAEL0317S0201 Terminals (+) SEL989XA Voltage Terminal (Wire color) (–) Connector M123 49 (G/R) Ground ST RS Battery voltage If NG, check the following. 쐌 7.5A fuse [No. 24, located in fuse block (J/B)] 쐌 Harness for open or short between smart entrance control unit and fuse BT HA SC IDX EL-155 WARNING CHIME Trouble Diagnoses (Cont’d) Ground Circuit Check NAEL0317S0202 Terminals (+) Continuity Connector Terminal (Wire color) M122 43 (B) M123 64 (B) (–) Ground SEL990XA EL-156 Yes WARNING CHIME Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 1 (LIGHTING SWITCH GI INPUT SIGNAL CHECK) =NAEL0317S03 1 CHECK LIGHTING SWITCH INPUT SIGNAL MA With CONSULT-II Check lighting switch (“LIGHT SW 1ST”) in “DATA MONITOR” mode with CONSULT-II. EM LC EC FE SEL991X Without CONSULT-II Check voltage between smart entrance control unit harness connector M121 terminal 19 (R/G), connector M123 terminal 57 (R) and ground. CL MT AT TF PD SEL992XA OK or NG OK 䊳 Replace smart entrance control unit. NG 䊳 Check the following. 쐌 10A fuse (No. 61, located in the fuse and fusible link box) 쐌 Harness for open or short between smart entrance control unit and tail lamp relay AX SU BR ST RS BT HA SC IDX EL-157 WARNING CHIME Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 2 (KEY SWITCH INSERT SIGNAL CHECK) =NAEL0317S04 1 CHECK KEY SWITCH INPUT SIGNAL With CONSULT-II Check key switch (“KEY ON SW”) in “DATA MONITOR” mode with CONSULT-II. SEL315W Without CONSULT-II Check voltage between smart entrance control unit harness connector M122 terminal 25 (W/R) and ground. SEL011Y OK or NG OK 䊳 Replace smart entrance control unit. NG 䊳 GO TO 2. 2 CHECK KEY SWITCH (INSERT) Check continuity between terminals 1 and 2. SEL308X OK or NG OK 䊳 Check the following. 쐌 7.5A fuse [No. 24, located in fuse block (J/B)] 쐌 Harness for open or short between key switch and fuse 쐌 Harness for open or short between smart entrance control unit and key switch NG 䊳 Replace key switch. EL-158 WARNING CHIME Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 3 (SEAT BELT BUCKLE GI SWITCH CHECK) =NAEL0317S05 1 CHECK SEAT BELT BUCKLE SWITCH INPUT SIGNAL MA With CONSULT-II Check seat belt buckle switch (“SEAT BELT SW”) in “DATA MONITOR” mode with CONSULT-II. EM LC EC FE SEL317W Without CONSULT-II 1. Turn ignition switch “ON”. 2. Check voltage between smart entrance control unit harness connector M122 terminal 28 (B/Y) and ground. CL MT AT TF PD SEL994X AX OK or NG OK 䊳 Replace smart entrance control unit. NG 䊳 GO TO 2. 2 SU CHECK SEAT BELT BUCKLE SWITCH BR Check continuity between terminals 1 and 2 when seat belt is fastened and unfastened. ST RS BT HA SEL381X OK or NG OK 䊳 Check the following. 쐌 Seat belt buckle switch ground circuit 쐌 Harness for open or short between smart entrance control unit and seat belt buckle switch NG 䊳 Replace seat belt buckle switch. SC IDX EL-159 WARNING CHIME Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 4 1 NAEL0317S06 CHECK IGNITION ON SIGNAL With CONSULT-II Check ignition switch ON signal (“IGN ON SW”) in “DATA MONITOR” mode with CONSULT-II. SEL318W Without CONSULT-II Check voltage between smart entrance control unit harness connector M122 terminal 27 (W/B) and ground. SEL995X OK or NG OK 䊳 GO TO 2. NG 䊳 Check the following. 쐌 7.5A fuse [No. 11, located in fuse block (J/B)] 쐌 Harness for open or short between smart entrance control unit and fuse EL-160 WARNING CHIME Trouble Diagnoses (Cont’d) 2 GI CHECK DOOR SWITCH INPUT SIGNAL With CONSULT-II Check driver door switch signal (“DOOR SW-DR”) in “DATA MONITOR” mode with CONSULT-II. MA EM LC EC SEL319W Without CONSULT-II Check voltage between smart entrance control unit harness connector M121 terminal 1 (G/OR) and ground. FE CL MT AT TF SEL996X PD OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 3. 3 AX SU CHECK DRIVER SIDE DOOR SWITCH Check continuity between terminals 1 and 2. BR ST RS BT SEL383X OK or NG OK NG 䊳 䊳 Check the following. 쐌 Driver side door switch ground circuit and condition 쐌 Harness for open or short between smart entrance control unit and front door switch LH HA SC Replace front door switch LH. IDX EL-161 WARNING CHIME Trouble Diagnoses (Cont’d) 4 CHECK WARNING CHIME With CONSULT-II Perform “CHIME” in “ACTIVE TEST” mode with CONSULT-II. SEL320W OK or NG OK 䊳 System is OK. NG 䊳 Replace smart entrance control unit. EL-162 FRONT WIPER AND WASHER System Description System Description WIPER OPERATION NAEL0318 GI NAEL0318S01 The front wiper switch is controlled by a lever built into the combination switch. There are three wiper switch positions: 쐌 LO speed 쐌 HI speed 쐌 INT (Intermittent) With the ignition switch in the ACC or ON position, power is supplied 쐌 through 20A fuse [No. 19, located in the fuse block (J/B)] 쐌 to front wiper motor terminal 1, and 쐌 to front wiper switch terminal 15. Low and High Speed Wiper Operation MA EM LC EC NAEL0318S0101 Ground is supplied to front wiper switch terminal 17 through body grounds E13 and E41. When the wiper switch is placed in the LO position, ground is supplied 쐌 through terminal 14 of the front wiper switch 쐌 to front wiper motor terminal 5. With power and ground supplied, the front wiper motor operates at low speed. When the front wiper switch is placed in the HI position, ground is supplied 쐌 through terminal 16 of the front wiper switch 쐌 to front wiper motor terminal 3. With power and ground supplied, the front wiper motor operates at high speed. Auto Stop Operation FE CL MT AT NAEL0318S0102 With front wiper switch turned OFF, front wiper motor will continue to operate until wiper arms reach windshield base. When wiper arms are not located at base of windshield with front wiper switch OFF, ground is provided 쐌 from terminal 14 of the front wiper switch 쐌 to front wiper motor terminal 5, in order to continue front wiper motor operation at low speed. Ground is also supplied 쐌 to terminal 13 of the front wiper switch 쐌 through front wiper motor terminal 4 쐌 through terminal 6 of the front wiper motor, and 쐌 through body grounds E13 and E41. When wiper arms reach base of windshield, front wiper motor terminals 1 and 4 are connected instead of terminals 4 and 6. Wiper motor will then stop wiper arms at the PARK position. TF Intermittent Operation ST NAEL0318S0103 The front wiper motor operates the wiper arms one time at low speed at a set interval of approximately 2 to 13 seconds. This feature is controlled by the wiper amplifier built in the front wiper switch. When the front wiper switch is placed in the INT position, ground is supplied 쐌 to wiper amplifier (INT SW) 쐌 from front wiper switch terminal 17 쐌 through body grounds E13 and E41, 쐌 to front wiper motor terminal 5 쐌 through the front wiper switch terminal 14 and 쐌 through wiper amplifier (OUTPUT). WASHER OPERATION NAEL0318S02 With the ignition switch in the ACC or ON position, power is supplied 쐌 through 20A fuse [No. 19, located in the fuse block (J/B)] 쐌 to front washer motor terminal 1. When the lever is pulled to the WASH position, ground is supplied 쐌 to front washer motor terminal 2 쐌 through terminal 18 of the front wiper switch EL-163 PD AX SU BR RS BT HA SC IDX FRONT WIPER AND WASHER System Description (Cont’d) 쐌 through terminal 17 of the front wiper switch, and 쐌 through body grounds E13 and E41. With power and ground supplied, the front washer motor operates. When the lever is pulled to the WASH position for one second or more, the front wiper motor operates at low speed for approximately 3 seconds to clean windshield. This feature is controlled by the wiper amplifier in the same manner as the intermittent operation. EL-164 FRONT WIPER AND WASHER Wiring Diagram — WIPER — Wiring Diagram — WIPER — NAEL0319 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL991P EL-165 IDX FRONT WIPER AND WASHER Removal and Installation Removal and Installation WIPER ARMS 1. 2. 3. 4. SEL543TA 쐌 쐌 NAEL0320 NAEL0320S01 Prior to wiper arm installation, turn on wiper switch to operate wiper motor and then turn it “OFF” (Auto Stop). Lift the blade up and then set it down onto glass surface to set the blade center to clearance “L1” & “L2” immediately before tightening nut. Eject washer fluid. Turn on wiper switch to operate wiper motor and then turn it “OFF”. Ensure that wiper blades stop within clearance “L1” & “L2”. Clearance “L1”: 29 - 39 mm (1.14 - 1.54 in) Clearance “L2”: 32 - 42 mm (1.26 - 1.65 in) Tighten wiper arm nuts to specified torque. Front wiper: 21 - 26 N·m (2.1 - 2.7 kg-m, 15 - 20 ft-lb) Before reinstalling wiper arm, clean up the pivot area as illustrated. This will reduce possibility of wiper arm looseness. SEL024J WIPER LINKAGE NAEL0320S02 MEL840F EL-166 FRONT WIPER AND WASHER Removal and Installation (Cont’d) Removal 1. 2. 3. Be NAEL0320S0201 Remove 4 bolts that secure wiper motor. Detach wiper motor from wiper linkage at ball joint. Remove wiper linkage. careful not to break ball joint rubber boot. NAEL0320S0202 Grease ball joint portion before installation. Installation is the reverse order of removal. LC EC Washer Nozzle Adjustment 쐌 MA EM Installation 쐌 1. GI NAEL0321 Adjust washer nozzle with suitable tool as shown in the figure at left. Adjustable range: ±10° FE CL MT MEL582Q Unit: mm (in) MEL583Q *1 251 (9.88) *6 459 (18.07) *2 351 (13.82) *7 256 (10.08) *3 165 (6.50) *8 67 (2.64) *4 269 (10.59) *9 42 (1.65) *5 167 (6.57) AT TF PD AX *A: The diameters of these circles are less than 80 mm (3.15 in). *B: The diameters of these circles are less than 138 × 80 mm (5.43 × 3.15 in). *C: The diameters of these circles are less than 96 × 80 mm (3.78 × 3.15 in). *D: The diameters of these circles are less than 90 × 80 mm (3.54 × 3.15 in). SU BR ST RS BT Washer Tube Layout NAEL0322 HA SC IDX MEL074H EL-167 REAR WIPER AND WASHER System Description System Description WIPER OPERATION Power Supply and Ground NAEL0323 NAEL0323S01 NAEL0323S0101 Power is supplied at all times 쐌 through 10A fuse [No. 5, located in fuse block (J/B)] 쐌 to rear wiper motor terminal 1. With ignition switch in the ACC or ON position, power is supplied 쐌 through 10A fuse [No. 29, located in the fuse block (J/B)] 쐌 to rear wiper motor terminal 4. When the glass hatch switch is OPEN, ground is supplied 쐌 to rear wiper motor terminal 6 쐌 through glass hatch switch terminals 1 and 2 쐌 through body grounds B11, B22 and D210. Ground is supplied 쐌 to rear wiper motor terminal 8 쐌 through body grounds B11, B22 and D210. Wiper Operation NAEL0323S0102 When the rear wiper switch is turned ON, ground is supplied 쐌 to rear wiper motor terminal 2 쐌 through combination switch terminals 22 and 24 쐌 through body grounds E13 and E41. Then, power is supplied 쐌 to rear wiper motor terminal 4. Ground is supplied 쐌 to rear wiper motor terminal 8 쐌 through body grounds B11, B22 and D210. With power and ground supplied, the wiper motor operates. Auto Stop Operation NAEL0323S0103 With rear wiper switch turned OFF, rear wiper motor will continue to operate until wiper arm reaches rear wiper stopper. Then wiper motor turns the other way and wiper arm moves once until wiper arm reaches stopper. Intermittent Operation NAEL0323S0104 The rear wiper motor operates the wiper arms at low speed approximately every 7 seconds. When the wiper switch is placed in the INT position, ground is supplied 쐌 to rear wiper motor terminal 3 쐌 through rear wiper switch terminals 21 and 24 쐌 through body grounds E13 and E41. Then, power is supplied 쐌 to rear wiper motor terminal 4. Ground is supplied 쐌 to rear wiper motor terminal 8 쐌 through body grounds B11, B22 and D210. With power and ground supplied, rear wiper operates at intermittent. WIPER OPERATION PROHIBIT CONTROL NAEL0323S02 When glass hatch is open with back door key cylinder while rear wiper is operated, wiper operation is stopped. (Wiper operation prohibit control) When glass hatch is closed and rear wiper switch turns from OFF and then rear wiper switch is turned to ON, wiper operation prohibit control is canceled. WASHER OPERATION NAEL0323S03 When the rear wiper switch is turned to WASH position, ground is supplied EL-168 REAR WIPER AND WASHER System Description (Cont’d) 쐌 to rear wiper motor terminal 5 쐌 through terminals 23 and 24 쐌 through body grounds E13 and E41. Then, power is supplied 쐌 to rear washer motor terminal 2 쐌 through 10 A fuse [No. 29, located in the fuse block (J/B)]. Ground is supplied 쐌 to rear washer motor terminal 1 쐌 through rear wiper switch terminals 23 and 24 쐌 through body grounds E13 and E41. With power and ground supplied, the rear washer motor operates. When the rear wiper switch is turned to WASH position for 0.4 seconds or more, the rear wiper motor operates approximately 3 times after the rear wiper switch is released. GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-169 REAR WIPER AND WASHER Wiring Diagram — WIP/R — Wiring Diagram — WIP/R — NAEL0324 MEL992P EL-170 REAR WIPER AND WASHER Wiring Diagram — WIP/R — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL993P IDX EL-171 REAR WIPER AND WASHER Trouble Diagnoses Trouble Diagnoses NAEL0325 REAR WIPER MOTOR INSPECTION TABLE NAEL0325S01 (Data are reference values.) Terminal No. Item 1 Power supply (BAT) 2 ON switch Condition Voltage (Approximate value) — Battery voltage Rear wiper switch ON OFF or INT 3 Intermittent switch Rear wiper switch INT OFF, ON or WASH 4 Power supply (ACC) 5 Washer switch — Rear wiper switch Glass hatch switch WASH Glass hatch Open Closed 7 8 Park switch Trunk lid opener switch Ground Battery voltage Less than 1V Battery voltage Battery voltage OFF, ON or INT 6 Less than 1V — Less than 1V Battery voltage Less than 1V 5V ON 11.5V OFF Battery voltage — NOTE: Power to the rear wiper motor will be interrupted when the rear glass hatch is opened. In that case, conduct the inspection of the rear wiper motor with the rear glass hatch closed, unless otherwise indicated. Removal and Installation WIPER ARMS 1. 2. 3. NAEL0326 NAEL0326S01 Prior to wiper arm installation, turn on wiper switch to operate wiper motor and then turn it “OFF” (Auto Stop). Install wiper arm to portion A as in figure below and tighten wiper arm nut to specification. Then, set wiper arm to portion B. : 13 - 18 N·m (1.3 - 1.8 kg-m, 9 - 13 ft-lb) MEL066G 쐌 Before reinstalling wiper arm, clean up the pivot area as illustrated. This will reduce possibility of wiper arm looseness. SEL024J EL-172 REAR WIPER AND WASHER Washer Nozzle Adjustment Washer Nozzle Adjustment 쐌 NAEL0327 Adjust washer nozzle with suitable tool as shown in the figure at left. Adjustable range: ±10° (In any direction) GI MA EM LC MEL584Q EC FE CL MT MEL034G Washer Tube Layout AT NAEL0328 TF PD AX SU MEL067G Check Valve 쐌 NAEL0329 A check valve is provided in the washer fluid line. Be careful not to connect check valve to washer tube in the wrong direction. BR ST RS BT SEL411H HA SC IDX EL-173 HORN Wiring Diagram — HORN — Wiring Diagram — HORN — NAEL0330 MEL994P EL-174 CIGARETTE LIGHTER Wiring Diagram — CIGAR — Wiring Diagram — CIGAR — NAEL0331 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL995P EL-175 IDX CLOCK Wiring Diagram — CLOCK — Wiring Diagram — CLOCK — NAEL0332 MEL996P EL-176 REAR WINDOW DEFOGGER Component Parts and Harness Connector Location Component Parts and Harness Connector Location GI NAEL0333 MA EM LC EC FE CL MT AT TF PD SEL674Y AX SU System Description NAEL0334 The rear window defogger system is controlled by the smart entrance control unit. The rear window defogger operates only for approximately 15 minutes. Power is supplied at all times 쐌 to rear window defogger relay terminal 3 쐌 through 20A fuse (No. 56, located in the fuse and fusible link box) and 쐌 to rear window defogger relay terminal 6 쐌 through 20A fuse (No. 57, located in the fuse and fusible link box) 쐌 to smart entrance control unit terminal 49 쐌 through 7.5A [No. 24, located in fuse block (J/B)]. With the ignition switch in the ON or START position, power is supplied 쐌 through 7.5A fuse [No. 11, located in the fuse block (J/B)] 쐌 to the rear window defogger relay terminal 1, and 쐌 to smart entrance control unit terminal 27. Ground is supplied 쐌 to terminal 1 of the rear window defogger switch (with auto A/C and NAVI, with manual A/C) or 쐌 to terminal 32 of A/C auto amp. (with auto A/C and without NAVI) and 쐌 to smart entrance control unit terminals 43 and 64 쐌 through body grounds M4, M66, M111, M147 and M157. When the rear window defogger switch is turned ON, ground is supplied EL-177 BR ST RS BT HA SC IDX REAR WINDOW DEFOGGER System Description (Cont’d) 쐌 through terminal 2 of the rear window defogger switch (without A/C and NAVI, with manual A/C) or 쐌 through terminal 31 of A/C auto amp. (with auto A/C and without NAVI) 쐌 to smart entrance control unit terminal 14. Terminal 37 of the smart entrance control unit then supplies ground to the rear window defogger relay terminal 2. With power and ground supplied, the rear window defogger relay is energized. Power is supplied 쐌 through terminals 5 and 7 of the rear window defogger relay 쐌 to the rear window defogger. The rear window defogger has an independent ground. With power and ground supplied, the rear window defogger filaments heat and defog the rear window. When the system is activated, the rear window defogger indicator illuminates in the rear window defogger switch. Power is supplied 쐌 to terminal 3 of the rear window defogger switch (with auto A/C and NAVI, with manual A/C) or 쐌 to terminal 30 of A/C auto amp. (with auto A/C and without NAVI) 쐌 from terminal 7 of the rear window defogger relay. Terminal 4 of the rear window defogger switch (with auto A/C and NAVI, with manual A/C) or terminal 32 of A/C auto amp. (with auto A/C and without NAVI) is grounded through body grounds M4, M66, M111, M147 and M157. EL-178 REAR WINDOW DEFOGGER Wiring Diagram — DEF — Wiring Diagram — DEF — WITH AUTO A/C AND NAVI, WITH MANUAL A/C NAEL0335 GI NAEL0335S01 MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL997P EL-179 IDX REAR WINDOW DEFOGGER Wiring Diagram — DEF — (Cont’d) MEL998P EL-180 REAR WINDOW DEFOGGER Wiring Diagram — DEF — (Cont’d) WITH AUTO A/C AND WITHOUT NAVI NAEL0335S02 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL999P EL-181 IDX REAR WINDOW DEFOGGER Wiring Diagram — DEF — (Cont’d) MEL001Q EL-182 REAR WINDOW DEFOGGER CONSULT-II Inspection Procedure CONSULT-II Inspection Procedure “REAR DEFOGGER” 1. 2. NAEL0336 GI NAEL0336S01 Turn ignition switch “OFF”. Connect “CONSULT-II” and “CONSULT-II CONVERTER” to the data link connector. MA EM LC SEL670Y 3. 4. Turn ignition switch “ON”. Touch “START (NISSAN BASED VHCL)”. EC FE CL MT SKIA3098E 5. Touch “SMART ENTRANCE”. If “SMART ENTRANCE” is not indicated, go to GI-41, “CONSULT-II Data Link Connector (DLC) Circuit”. AT TF PD AX SU SEL669Y 6. Touch “REAR DEFOGGER”. BR ST RS BT SEL023X 7. Select diagnosis mode. “DATA MONITOR” and “ACTIVE TEST” are available. HA SC IDX SEL322W EL-183 REAR WINDOW DEFOGGER CONSULT-II Application Items CONSULT-II Application Items “REAR DEFOGGER” Data Monitor NAEL0337S0101 Monitored Item Description IGN ON SW Indicates [ON/OFF] condition of ignition switch. REAR DEF SW Indicates [ON/OFF] condition of rear window defogger switch. Active Test NAEL0337S0102 Test Item REAR DEFOGGER NAEL0337 NAEL0337S01 Description This test is able to check rear window defogger operation. Rear window defogger activates when “ON” on CONSULT-II screen is touched. EL-184 REAR WINDOW DEFOGGER Trouble Diagnoses Trouble Diagnoses DIAGNOSTIC PROCEDURE NAEL0338 NAEL0338S01 SYMPTOM: Rear window defogger does not activate, or does not go off after activating. 1 GI CHECK REAR WINDOW DEFOGGER OUTPUT SIGNAL MA EM With CONSULT-II Select “ACTIVE TEST” in “REAR DEFOGGER” with CONSULT-II. LC EC FE CL SEL353W MT Without CONSULT-II 1. Turn ignition switch to ON position. 2. Check voltage between smart entrance control unit harness connector M122 terminal 37 (G/B) and ground. AT TF PD AX SEL997X OK or NG OK NG 䊳 䊳 SU Check the following. 쐌 Rear window defogger relay (Refer to EL-188.) 쐌 Rear window defogger circuit 쐌 Rear window defogger filament (Refer to EL-189.) BR GO TO 2. ST RS BT HA SC IDX EL-185 REAR WINDOW DEFOGGER Trouble Diagnoses (Cont’d) 2 CHECK DEFOGGER RELAY COIL SIDE CIRCUIT 1. Disconnect smart entrance control unit connector. 2. Turn ignition switch to ON position. 3. Check voltage between smart entrance control unit harness connector M122 terminal 37 (G/B) and ground. SEL998X OK or NG OK 䊳 GO TO 3. NG 䊳 Check the following. 쐌 7.5A fuse [No. 11, located in the fuse block (J/B)] 쐌 Rear window defogger relay 쐌 Harness for open or short between fuse and rear window defogger relay 쐌 Harness for open or short between rear window defogger relay and smart entrance control unit EL-186 REAR WINDOW DEFOGGER Trouble Diagnoses (Cont’d) 3 GI CHECK REAR WINDOW DEFOGGER SWITCH INPUT SIGNAL With CONSULT-II Select “REAR DEF SW” in “DATA MONITOR” mode with CONSULT-II. MA EM LC EC SEL352W Without CONSULT-II Check voltage between smart entrance control unit harness connector M121 terminal 14 (OR) and ground. FE CL MT AT TF SEL685Y PD OK or NG OK 䊳 GO TO 4. NG 䊳 Check the following. 쐌 Rear window defogger switch (Refer to EL-188.) 쐌 Harness for open or short between smart entrance control unit and rear window defogger switch 쐌 Rear window defogger switch ground circuit AX SU BR 4 CHECK POWER SUPPLY AND IGNITION INPUT SIGNAL Check voltage between smart entrance control unit harness connector M122 terminal 27 (W/B), M123 terminal 49 (G/R) and ground. ST RS BT HA SEL001Y SC OK or NG OK 䊳 GO TO 5. NG 䊳 Check the following. 쐌 7.5A fuse [No. 11 or No. 24, located in the fuse block (J/B)] 쐌 Harness for open or short between smart entrance control unit and fuse EL-187 IDX REAR WINDOW DEFOGGER Trouble Diagnoses (Cont’d) 5 CHECK CONTROL UNIT GROUND CIRCUIT Check continuity between smart entrance control unit harness connector M122 terminal 43 (B), M123 terminal 64 (B) and ground. SEL002Y Yes 䊳 Replace smart entrance control unit. No 䊳 Repair harness or connectors. Electrical Components Inspection NAEL0339 REAR WINDOW DEFOGGER RELAY NAEL0339S01 Check continuity between terminals 3 and 5, 6 and 7. Condition Continuity 12V direct current supply between terminals 1 and 2 Yes No current supply No SEC202B REAR WINDOW DEFOGGER SWITCH Auto A/C and NAVI, and With Manual A/C NAEL0339S02 NAEL0339S0201 Check continuity between terminals when rear window defogger switch is pushed and released. Terminals Condition Continuity Rear window defogger switch is pushed Yes Rear window defogger switch is released No 1-2 SEL430TB EL-188 REAR WINDOW DEFOGGER Electrical Components Inspection (Cont’d) With Auto A/C and Without NAVI =NAEL0339S0202 Check voltage between A/C auto amp. and ground, when rear window switch is pushed and released. Terminals (+) Connector Condition Terminal (Wire color) SEL760Y M102 31 (OR) Voltage (V) (−) GI MA EM LC Rear window defogger switch is pushed 0 Rear window defogger switch is released Battery voltage EC Ground FE CL MT Filament Check 1. AT NAEL0340 Attach probe circuit tester (in volt range) to middle portion of each filament. TF PD AX SU SEL263 2. 3. If a filament is burned out, circuit tester registers 0 or 12 volts. To locate burned out point, move probe to left and right along filament. Test needle will swing abruptly when probe passes the point. BR ST RS BT HA SC IDX SEL265 EL-189 REAR WINDOW DEFOGGER Filament Check (Cont’d) 쐌 When measuring voltage, wrap tin foil around the top of the negative probe. Then press the foil against the wire with your finger. SEL122R Filament Repair REPAIR EQUIPMENT 1) 2) 3) 4) 5) 6) NAEL0341 NAEL0341S01 Conductive silver composition (Dupont No. 4817 or equivalent) Ruler 30 cm (11.8 in) long Drawing pen Heat gun Alcohol Cloth REPAIRING PROCEDURE NAEL0341S02 1. Wipe broken heat wire and its surrounding area clean with a cloth dampened in alcohol. 2. Apply a small amount of conductive silver composition to tip of drawing pen. Shake silver composition container before use. 3. Place ruler on glass along broken line. Deposit conductive silver composition on break with drawing pen. Slightly overlap existing heat wire on both sides [preferably 5 mm (0.20 in)] of the break. BE540 4. After repair has been completed, check repaired wire for continuity. This check should be conducted 10 minutes after silver composition is deposited. Do not touch repaired area while test is being conducted. SEL012D 5. Apply a constant stream of hot air directly to the repaired area for approximately 20 minutes with a heat gun. A minimum distance of 3 cm (1.2 in) should be kept between repaired area and hot air outlet. If a heat gun is not available, let the repaired area dry for 24 hours. SEL013D EL-190 AUDIO System Description System Description NAEL0342 GI Refer to Owner’s Manual for audio system operating instructions. BASE SYSTEM NAEL0342S01 Power is supplied at all times 쐌 through 15A fuse [No. 4, located in the fuse block (J/B)] 쐌 to audio unit terminal 6, and 쐌 to CD player terminal 4 (with CD player). With the ignition switch in the ACC or ON position, power is supplied 쐌 through 10A fuse [No. 10, located in the fuse block (J/B)] 쐌 to audio unit terminal 10, and 쐌 to CD player terminal 1 (with CD player). Ground is supplied through the case of the audio unit. When the audio unit power knob is pushed to the ON position, audio signals are supplied 쐌 through audio unit terminals 1, 2, 3, 4, 13, 14, 15 and 16 쐌 to the front and rear speakers. BOSE SYSTEM MA EM LC EC FE CL NAEL0342S02 Power is supplied at all times 쐌 through 15A fuse [No. 4, located in the fuse block (J/B)] 쐌 to audio unit terminal 6, 쐌 to audio amp. relay terminal 3, 쐌 to rear speaker amp. terminal 11 and 쐌 to AUX box terminal 7 (with rear TV). With the ignition switch in the ACC or ON position, power is supplied 쐌 through 10A fuse [No. 10, located in the fuse block (J/B)] 쐌 to audio unit terminal 10, 쐌 to AUX box terminal 6 (with rear TV). Ground is supplied through the case of the audio unit. Ground is supplied 쐌 to audio amp. relay terminal 2, 쐌 to front door speaker LH terminal 5 and 쐌 to front door speaker RH terminal 5 쐌 through body grounds M4, M66, M111, M147 and M157 쐌 to rear speaker amp. terminal 24 and 쐌 to AUX box terminal 8 (with rear TV) 쐌 through body grounds B11, B22 and D210 쐌 to rear TV switch terminal 3 쐌 through body grounds M4, M66, M111, M147 and M157. When the audio unit POWER button is pressed, power is supplied to rear speaker amp. terminal 9 and audio amp. relay terminal 1 from audio unit terminal 12. Then audio amp. relay is energized and power is supplied 쐌 to front door speaker LH terminal 4 and 쐌 to front door speaker RH terminal 4. Audio signals are supplied 쐌 through audio unit terminals 1, 2, 3, 4, 13, 14, 15 and 16 쐌 to terminals 2 and 6 of the LH and RH front speakers and terminals 5, 7, 18 and 20 of the rear speaker amp. 쐌 to LH and RH tweeters through terminals 1 and 3 of the front door speakers 쐌 to rear LH and RH speakers through terminals 1, 2, 25 and 26 of the rear speaker amp. MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-191 AUDIO Wiring Diagram — AUDIO —/Base System Wiring Diagram — AUDIO —/Base System NAEL0343 MEL355N EL-192 AUDIO Wiring Diagram — AUDIO —/Base System (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL038M IDX EL-193 AUDIO Schematic/BOSE System Schematic/BOSE System NAEL0344 MEL002Q EL-194 AUDIO Wiring Diagram — AUDIO —/BOSE System Wiring Diagram — AUDIO —/BOSE System NAEL0345 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL003Q EL-195 IDX AUDIO Wiring Diagram — AUDIO —/BOSE System (Cont’d) MEL004Q EL-196 AUDIO Wiring Diagram — AUDIO —/BOSE System (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL005Q IDX EL-197 AUDIO Wiring Diagram — AUDIO —/BOSE System (Cont’d) MEL006Q EL-198 AUDIO Wiring Diagram — AUDIO —/BOSE System (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL007Q IDX EL-199 AUDIO Trouble Diagnoses Trouble Diagnoses NAEL0346 AUDIO UNIT NAEL0346S01 Symptom Possible causes Repair order Audio unit inoperative (no digital display and no sound from speakers). 1. 10A fuse 2. Poor audio unit case ground 3. Audio unit 1. Check 10A fuse [No. 10, located in fuse block (J/B)]. Turn ignition switch ON and verify that battery positive voltage is present at terminal 10 of audio unit. 2. Check audio unit case ground. 3. Remove audio unit for repair. Audio unit presets are lost when ignition switch is turned OFF. 1. 15A fuse 2. Audio unit 1. Check 15A fuse [No. 4, located in fuse block (J/B)] and verify that battery positive voltage is present at terminal 6 of audio unit. 2. Remove audio unit for repair. AM stations are weak or noisy (FM stations OK). 1. Antenna 2. Poor audio unit ground 3. Audio unit 1. Check antenna. 2. Check audio unit ground. 3. Remove audio unit for repair. FM stations are weak or noisy (AM stations OK). 1. Window antenna 2. Audio unit 1. Check window antenna. 2. Remove audio unit for repair. Audio unit generates noise 1. Poor audio unit ground in AM and FM modes with 2. Loose or missing ground bonding engine running. straps 3. Ignition condenser or rear window defogger noise suppressor condenser 4. Alternator 5. Ignition coil or secondary wiring 6. Audio unit 1. Check audio unit ground. 2. Check ground bonding straps. 3. Replace ignition condenser or rear window defogger noise suppressor condenser. 4. Check alternator. 5. Check ignition coil and secondary wiring. 6. Remove audio unit for repair. Audio unit generates noise in AM and FM modes with accessories on (switch pops and motor noise). 1. 2. 3. 4. 1. 2. 3. 4. Poor audio unit ground Antenna Accessory ground Faulty accessory Check audio unit ground. Check antenna. Check accessory ground. Replace accessory. BASE SYSTEM NAEL0346S02 Symptom Individual speaker is noisy or inoperative. Possible causes 1. 2. 3. 4. Repair order 1. Check speaker. 2. Check audio unit output voltages. 3. Check wires for open or short between audio unit and speaker. 4. Remove audio unit for repair. Speaker Audio unit output Speaker circuit Audio unit BOSE SYSTEM NAEL0346S03 Symptom Audio unit controls are operational, but no sound is heard from any speaker. Possible causes Repair order 1. 15A fuse 2. Audio unit output 3. Audio unit 1. Check 15A fuse [No. 4, located in fuse block (J/B)]. Verify battery positive voltage is present at terminal 3 of audio amp. relay. 2. Check audio unit output voltage (Terminal 12). 3. Remove audio unit for repair. All front speakers are inop- 1. Audio amp. relay erative. 2. Audio amp. relay ground 3. Amp. ON signal 1. Check audio amp. relay. 2. Check audio amp. relay ground (Terminal 2). 3. Turn ignition switch ACC and audio unit ON. Verify battery positive voltage is present at terminal 1 of audio amp. relay. Individual front speaker is noisy or inoperative. 1. 2. 3. 4. 1. 2. 3. 4. Speaker ground Power supply Audio unit output Speaker EL-200 Check speaker ground (Terminal 5). Check power supply for speaker (Terminal 4). Check audio unit output voltage for speaker. Replace speaker. AUDIO Trouble Diagnoses (Cont’d) Symptom Both rear speakers are inoperative. Individual rear speaker is noisy or inoperative. Possible causes 1. 2. 3. 4. 1. 2. 3. 4. Poor rear speaker amp. ground Power supply Amp. ON signal Rear speaker amp. Speaker Audio unit/amp. output Speaker circuit Audio unit 1. Check rear speaker amp. ground circuit. 2. Check power supply for rear speaker amp. (Terminal 11). 3. Turn ignition switch ACC and audio unit ON. Verify battery positive voltage is present at terminal 9 of rear speaker amp. 4. Remove rear speaker amp. for repair. 1. Check speaker. 2. Check audio unit/amp. output. 3. Check wires for open or short between audio unit/ amp. and speakers. 4. Remove audio unit for repair. Inspection AUDIO UNIT AND AMP. All 쐌 쐌 쐌 GI Repair order NAEL0347 MA EM LC EC FE NAEL0347S01 voltage inspections are made with: Ignition switch ON or ACC Audio unit ON Audio unit and amps. connected (If audio unit or amp. is removed for inspection, supply a ground to the case using a jumper wire.) ANTENNA NAEL0347S02 1. Using a jumper wire, clip an auxiliary ground between antenna and body. 쐌 If reception improves, check antenna ground (at body surface). 쐌 If reception does not improve, check main feeder cable for short circuit or open circuit. Audio Unit Removal and Installation MT AT TF NAEL0348 1. Lock the CD changer unit mechanism (if so equipped) prior to removing a malfunctioning CD changer unit. Refer to “LOCKING CD CHANGER UNIT MECHANISM”, EL-201. 2. Remove CD changer unit. Refer to BT-22, “INSTRUMENT PANEL ASSEMBLY”. LOCKING CD CHANGER UNIT MECHANISM CL PD AX NAEL0348S01 CAUTION: 쐌 Prior to removing a malfunctioning CD changer unit that will be shipped for repair, the changer mechanism MUST BE LOCKED to prevent the mechanism from being damaged during shipping. 쐌 If a CD is jammed or unable to be removed from the unit, do NOT lock the changer mechanism. If the unit is to be shipped for repair, carefully package the unit to prevent vibration and shock. 1. Eject and remove any CDs from the CD changer unit. 2. Turn ignition switch OFF. Wait until CD changer unit display is off and mechanism stops moving (mechanism sound stops). 3. Press any one of the disc selection buttons once. When a display shows on the CD changer unit, press the same disc selection button again within 5 seconds. 쐌 The changer mechanism will lock itself within 10 seconds. 4. After mechanism stops moving (mechanism sound stops), disconnect the CD changer unit connectors. NOTE: After installing a new or remanufactured CD changer unit, switching the CD changer unit ON will automatically unlock the mechanism. A special unlocking procedure is not required. SU BR ST RS BT HA SC IDX EL-201 AUDIO Wiring Diagram — REMOTE — Wiring Diagram — REMOTE — NAEL0349 MEL008Q EL-202 AUDIO ANTENNA System Description System Description NAEL0350 Power is supplied at all times 쐌 through 7.5A fuse [No. 24, located in the fuse block (J/B)] 쐌 to power antenna terminal 6. Ground is supplied to the power antenna terminal 2 through body grounds M4, M66, M111, M147 and M157. When the audio unit is turned to the ON position, battery positive voltage is supplied 쐌 through audio unit terminal 5 쐌 to power antenna terminal 4. The antenna raises and is held in the extended position. When the audio unit is turned to the OFF position, battery positive voltage is interrupted 쐌 from audio unit terminal 5 쐌 to power antenna terminal 4. The antenna retracts. GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-203 AUDIO ANTENNA Wiring Diagram — P/ANT — Wiring Diagram — P/ANT — NAEL0351 MEL009Q EL-204 AUDIO ANTENNA Trouble Diagnoses Trouble Diagnoses NAEL0352 POWER ANTENNA Symptom Power antenna does not operate. GI NAEL0352S01 Possible causes MA Repair order 1. 7.5A fuse 2. Audio unit signal 3. Grounds M4, M66, M111, M147 and M157 1. Check 7.5A fuse [No. 24, located in fuse block (J/B)]. Verify that battery positive voltage is present at terminal 6 of power antenna. 2. Turn ignition switch and audio unit ON. Verify that battery positive voltage is present at terminal 4 of power antenna. 3. Check grounds M4, M66, M111, M147 and M157. Location of Antenna EM LC EC NAEL0353 FE CL MT AT TF PD AX SU BR ST RS YEL067K BT Antenna Rod Replacement REMOVAL 1. NAEL0354 HA NAEL0354S01 Remove antenna nut and antenna base. SC IDX MEL036G EL-205 AUDIO ANTENNA Antenna Rod Replacement (Cont’d) 2. Withdraw antenna rod while raising it by operating antenna motor. MEL037G INSTALLATION 1. 2. 3. 4. 5. NAEL0354S02 Lower antenna rod by operating antenna motor. Insert gear section of antenna rope into place with it facing toward antenna motor. As soon as antenna rope is wound on antenna motor, stop antenna motor. Insert antenna rod lower end into antenna motor pipe. Retract antenna rod completely by operating antenna motor. Install antenna nut and base. MEL038G EL-206 POWER SUNROOF System Description System Description OUTLINE NAEL0355 GI NAEL0355S01 Electric sunroof system consists of 쐌 Sunroof switch 쐌 Sunroof motor 쐌 Smart entrance control unit Smart entrance control unit controls retained power operation. OPERATION MA EM NAEL0355S02 The sunroof can be tilted up or down with the tilt switch. The sunroof can be opened or closed automatically with the sunroof switch. RETAINED POWER OPERATION LC EC NAEL0355S04 When the ignition switch is turned to OFF position from ON or START position, power is supplied for 45 seconds 쐌 to power window relay terminal 2 쐌 from smart entrance control unit terminal 46. Ground is always supplied 쐌 to power window relay terminal 1 쐌 through body grounds M4, M66, M111, M147 and M157. When power and ground are supplied, power window relay continues to be energized, and the electrical sunroof can be operated. When power is supplied, the electrical sunroof can be operated. The retained power operation is canceled when the driver or passenger side door is opened. RAP signal period can be changed by CONSULT-II. (EL-211) INTERRUPTION DETECTION FUNCTION FE CL MT AT TF NAEL0355S05 The CPU of sunroof motor monitors the sunroof motor operation and the sunroof position (full closed or other) for sunroof by the signals from encoder and limit switch in sunroof motor. When sunroof motor detects interruption during the following close operation, 쐌 automatic close operation when ignition switch is in the “ON” position 쐌 automatic close operation during retained power operation sunroof switch controls the motor for open and the sunroof will operate about 150 mm (5.91 in). PD AX SU BR ST RS BT HA SC IDX EL-207 POWER SUNROOF Wiring Diagram — SROOF — Wiring Diagram — SROOF — NAEL0356 MEL010Q EL-208 POWER SUNROOF Wiring Diagram — SROOF — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL011Q IDX EL-209 POWER SUNROOF CONSULT-II Inspection Procedure CONSULT-II Inspection Procedure “RETAINED PWR” =NAEL0357 NAEL0357S01 1. 2. Turn ignition switch “OFF”. Connect “CONSULT-II” and “CONSULT-II CONVERTER” to the data link connector. 3. 4. Turn ignition switch “ON”. Touch “START (NISSAN BASED VHCL)”. 5. Touch “SMART ENTRANCE”. If “SMART ENTRANCE” is not indicated, go to GI-41, “CONSULT-II Data Link Connector (DLC) Circuit”. 6. Touch “RETAINED PWR”. 7. Select diagnosis mode. “DATA MONITOR”, “ACTIVE TEST” and “WORK SUPPORT” are available. SEL670Y SKIA3098E SEL669Y SEL751Y SEL400Y EL-210 POWER SUNROOF CONSULT-II Application Items CONSULT-II Application Items “RETAINED PWR” Data Monitor NAEL0455S0101 MA Description IGN ON SW Indicates [ON/OFF] condition of ignition switch. DOOR SW-DR Indicates [ON/OFF] condition of front door switch LH. DOOR SW-AS Indicates [ON/OFF] condition of front door switch RH. EM LC Active Test NAEL0455S0102 Test Item EC Description This test is able to supply RAP signal (power) from smart entrance control unit to power window system, power sunroof system. Those systems can be operated when turning on “RETAINED PWR” on CONSULT-II screen even if the ignition switch is tuned OFF. NOTE: During this test, CONSULT-II can be operated with ignition switch “OFF” position. “RETAINED PWR” should be turned “ON” or “OFF” on CONSULT-II screen when ignition switch is ON. Then turn ignition switch OFF for checking retained power operation. CONSULT-II might be stuck if “RETAINED PWR” is turned “ON” or “OFF” on CONSULT-II screen when ignition switch is OFF. FE CL MT AT Work Support NAEL0455S0103 Work Item RETAINED PWR SET GI NAEL0455S01 Monitored Item RETAINED PWR NAEL0455 Description RAP signal’s power supply period can be changed by mode setting. Selects RAP signal’s power supply period between three steps. 쐌 MODE 1 (45 sec.)/MODE 2 (OFF)/MODE 3 (2 min.) TF PD AX SU Trouble Diagnoses NAEL0456 Symptom Possible cause Repair order Power sunroof cannot be operated using any switch. 1. 7.5A fuse, 40A fusible link and M145 circuit breaker 2. Power window relay ground circuit 3. Sunroof motor ground circuit 4. Power window relay 5. Sunroof motor circuit 6. Sunroof switch 7. Sunroof switch circuit 8. Sunroof motor 1. Check 7.5A fuse [No. 11, located in fuse block (J/B)], 40A fusible link (letter f, located in fuse and fusible link box) and M145 circuit breaker. Turn ignition switch “ON” and verify battery positive voltage is present at terminals 2 and 3 of power window relay and terminal 1 of sunroof motor. 2. Check power window relay ground circuit. 3. Check sunroof motor ground circuit. 4. Check power window relay. 5. Check the wire between power window relay and sunroof motor. 6. Check sunroof switch. 7. Check harness between sunroof switch and sunroof motor. 8. Check sunroof motor. Power sunroof cannot be operated using one of the sunroof switches. 1. Sunroof switch 2. Sunroof switch circuit BR ST RS BT HA SC 1. Check sunroof switch. 2. Check the harness between sunroof motor and sunroof switch. IDX EL-211 POWER SUNROOF Trouble Diagnoses (Cont’d) Symptom Power sunroof cannot be opened or closed fully. Possible cause 1. Full closed position not initialized 2. Sunroof slide mechanism 3. Sunroof switch 4. Sunroof switch circuit 5. Sunroof motor Retained power operation does not 1. RAP signal circuit operate properly. 2. Driver or passenger side door switch circuit 3. Smart entrance control unit EL-212 Repair order 1. 2. a. b. c. 3. 4. Initialize full closed position. Check the following. Check obstacles in sunroof, etc. Check worn or deformed sunroof. Check sunroof sash tilted too far inward or outward. Check sunroof switch. Check harness between sunroof motor and sunroof switch. 5. Replace sunroof motor. 1. Check RAP signal. a. (With CONSULT-II) Check RAP signal with CONSULT-II. Use “ACTIVE TEST” mode, “RETAINED PWR” in “SMART ENTRANCE”. (Refer to EL-211.) If NG, go to the step b. below. b. Verify 12 positive voltage from smart entrance control unit is present at terminal 2 of power window relay: 쐌 Within 45 seconds after ignition switch turns off. 쐌 When front door LH and RH is closed. 2. Check harness between smart entrance control unit and driver or passenger side door switch. Check driver or passenger side door switch. Check driver or passenger side door switch. 3. Check smart entrance control unit. (EL-368) DOOR MIRROR Wiring Diagram — MIRROR — Wiring Diagram — MIRROR — NAEL0360 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL012Q EL-213 IDX GLASS HATCH OPENER Wiring Diagram — T&FLID — Wiring Diagram — T&FLID — NAEL0460 MEL048Q EL-214 POWER SEAT Wiring Diagram — SEAT — Wiring Diagram — SEAT — NAEL0361 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL830L EL-215 IDX POWER SEAT Wiring Diagram — SEAT — (Cont’d) MEL601F EL-216 HEATED SEAT Wiring Diagram — HSEAT — Wiring Diagram — HSEAT — NAEL0362 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL013Q EL-217 IDX HEATED SEAT Wiring Diagram — HSEAT — (Cont’d) MEL014Q EL-218 HEATED SEAT Wiring Diagram — HSEAT — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL015Q IDX EL-219 HEATED SEAT Seatback Heating Unit Seatback Heating Unit NAEL0363 SBT314 EL-220 AUTOMATIC DRIVE POSITIONER Component Parts and Harness Connector Location Component Parts and Harness Connector Location GI NAEL0364 MA EM LC EC FE CL MT AT TF PD SEL701Y AX SU BR ST RS BT HA SC IDX EL-221 AUTOMATIC DRIVE POSITIONER System Description System Description =NAEL0365 OPERATIVE CONDITION NAEL0365S01 The drive position can be set in 2 ways, manually and automatically. Manual Operation NAEL0365S0101 The driver’s seat can be adjusted for sliding, reclining, front cushion height and rear cushion height with the LH power seat switches. The manual operation can be adjusted with the IGN key in any position. Automatic Operation NAEL0365S0102 The driver’s seat is adjusted to the proper positions for the driver automatically, in 3 different ways: MEMORY AUTOMATIC SET, AUTOMATIC EXITING SETTING and AUTOMATIC SET RETURN. (Automatic Drive Positioner = ADP) CONDITIONS INHIBITING AUTOMATIC OPERATION NAEL0365S02 Automatic memory setting procedures are suspended under any of the following conditions: 1) When vehicle speed is more than 7 km/h (4 MPH). 2) When driver’s side power seat switch is turned on. 3) When any two of the switches (set switch and memory switches 1 and 2) are turned ON. 4) When cancel switch is turned on. 5) When selector lever is in any position other than “P”. 6) When ignition switch is turned to “START” position. (Operation resumes when ignition switch is returned to “ON”.) 7) When detention switch malfunction is detected: 쐌 Detention switch failure is sensed when detention switch remains off for at least 2 seconds at a vehicle speed of greater than 7 km/h (4 MPH). FAIL-SAFE SYSTEM Output Failure NAEL0365S03 NAEL0365S0301 When the ignition switch is in the ON position, if any of the parts (indicated in the following chart) move more than the specified amount within a period “T2” when no “ON” input is sent from any of the switches (indicated in the following chart), or an output from the automatic drive positioner is not produced, an output failure is sensed. Motor operation will be suspended automatically, and all automatic operations will be ineffective. (In this case, the motor will not operate manually.) OPERATED PORTION T2 Allowable measurement Seat sliding Approx. 2.5 sec. Within 6 mm (0.24 in) Seat reclining Same as above Change angle within 1° Absolving NAEL0365S0302 When moving selector lever back to “P” position after having moved it to any position except “P”, fail-safe operation will be canceled. INITIALIZATION NAEL0365S04 After reconnecting battery cable, perform initialization procedure A or B. If initialization has not been performed, automatic drive positioner will not operate. PROCEDURE A 1) Insert key in the ignition key cylinder. (Ignition switch is in “OFF” position.) 2) Open , close , open driver side door. (Do not perform with the door switch operation.) 3) End PROCEDURE B 1) Drive the vehicle at more than 25 km/h (16 MPH). 2) End EL-222 AUTOMATIC DRIVE POSITIONER System Description (Cont’d) MEMORY AUTOMATIC SET =NAEL0365S05 Two drive positions can be retained in the memory. Press memory switch to set driver’s seat to preset position. GI MA EM LC EC FE CL MT AT TF PD SEL592W NOTE: 쐌 When memory switch for which driver’s seat positions are already retained in memory is pressed, new seat positions will be retained in memory in place of the previously set positions. 쐌 Drive position is erased from the memory when battery cable is disconnected more than 30 seconds. After connecting battery cable, perform initialization procedures. AX SU BR ST RS BT HA SC SEL593W EL-223 IDX AUTOMATIC DRIVE POSITIONER System Description (Cont’d) NOTE: 1) Do not keep cancel switch pressed as it will not operate. 2) Automatic exiting setting will be performed. 3) The driver’s seat position (see the following Table) operates in the order of priority. The order of priority Operated portion 1 Seat sliding 2 Seat reclining 3 Seat front lifting 4 Seat rear lifting AUTOMATIC EXITING SETTING NAEL0365S06 “Exiting” positions: Driver’s seat ... Slides about 40 mm (1.57 in) rear from normal sitting position. SEL594W AUTOMATIC SET RETURN NAEL0365S07 With driver’s seat set to the “exiting” position, operating one of the following procedures moves it to the position previously retained in memory. SEL595W EL-224 AUTOMATIC DRIVE POSITIONER Schematic Schematic NAEL0366 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL016Q EL-225 IDX AUTOMATIC DRIVE POSITIONER Wiring Diagram — AUT/DP — Wiring Diagram — AUT/DP — NAEL0367 MEL017Q EL-226 AUTOMATIC DRIVE POSITIONER Wiring Diagram — AUT/DP — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL018Q IDX EL-227 AUTOMATIC DRIVE POSITIONER Wiring Diagram — AUT/DP — (Cont’d) MEL019Q EL-228 AUTOMATIC DRIVE POSITIONER Wiring Diagram — AUT/DP — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL186M IDX EL-229 AUTOMATIC DRIVE POSITIONER Wiring Diagram — AUT/DP — (Cont’d) MEL187M EL-230 AUTOMATIC DRIVE POSITIONER On Board Diagnosis On Board Diagnosis NAEL0368 GI MA EM LC EC SEL354X HOW TO PERFORM SELF-DIAGNOSIS NAEL0368S01 FE CL MT AT TF PD AX SU BR ST RS BT HA SC SEL596W *1: If no malfunction is indicated, self-diagnosis will end after the vehicle speed sensor diagnosis is performed. *2: Diagnosis ends after self-diagnostic results have been indicated for 10 minutes if left unattended. EL-231 IDX AUTOMATIC DRIVE POSITIONER On Board Diagnosis (Cont’d) MALFUNCTION CODE TABLE =NAEL0368S02 In this mode, a malfunction code is indicated by the number of flashes from the automatic drive positioner indicator lamps (indicator lamp 1, indicator lamp 2) as shown below. SEL597WA Code No. Detected items Diagnostic procedure Reference page 1 Seat sliding PROCEDURE 2 (Sliding encoder check) PROCEDURE 6 (Sliding motor check) 2 Seat reclining 3 Seat lifting front Code No. Detected items Diagnostic procedure Reference page EL-238 EL-246 4 Seat lifting rear PROCEDURE 5 [Lifting encoder (rear) check] PROCEDURE 9 [Lifting motor (rear) check] EL-244 EL-249 PROCEDURE 3 (Reclining encoder check) PROCEDURE 7 (Reclining motor check) EL-240 EL-247 9 Vehicle speed sensor PROCEDURE 12 (Vehicle speed sensor check) EL-252 PROCEDURE 4 [Lifting encoder (front) check] PROCEDURE 8 [Lifting motor (front) check] EL-242 EL-248 EL-232 AUTOMATIC DRIVE POSITIONER Trouble Diagnoses Trouble Diagnoses WORK FLOW NAEL0369 GI NAEL0369S01 MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS SEL599W *1 EL-231 *2 BT EL-232 HA SC IDX EL-233 AUTOMATIC DRIVE POSITIONER Trouble Diagnoses (Cont’d) PRELIMINARY CHECK NAEL0369S02 SEL600W *1: After reconnecting battery cable, perform initialization procedure A or B. If initialization has not been performed, automatic drive positioner will not operate. PROCEDURE A 1) Insert key in the ignition key cylinder. (Ignition switch is in “OFF” position.) 2) Open , close , open driver side door. (Do not perform with the door switch operation.) 3) End PROCEDURE B 1) Drive the vehicle at more than 30 km/h (19 MPH). EL-234 AUTOMATIC DRIVE POSITIONER Trouble Diagnoses (Cont’d) 2) End After performing preliminary check, go to symptom chart below. Before starting trouble diagnoses below, perform preliminary check, EL-234. Symptom numbers in the symptom chart correspond with those of preliminary check. SYMPTOM CHART 1 No seat system functions operate. 2 Some of the seat system functions do not operate during automatic/ manual operation. 3 240 242 244 246 247 DIAGNOSTIC PROCEDURE 5 [Lifting encoder (rear) check] DIAGNOSTIC PROCEDURE 6 (Sliding motor check) DIAGNOSTIC PROCEDURE 7 (Reclining motor check) MA EM LC EC FE CL MT AT X Sliding X Reclining TF X Lifting (Front) PD Lifting (Rear) AX No functions operate during automatic operation, and some/all functions do not during manual operation. Sliding 4 238 DIAGNOSTIC PROCEDURE 4 [Lifting encoder (front) check] SYMPTOM 237 DIAGNOSTIC PROCEDURE 3 (Reclining encoder check) ) DIAGNOSTIC PROCEDURE 2 (Sliding encoder check) REFERENCE PAGE (EL- Diagnostic procedure DIAGNOSTIC PROCEDURE 1 (Power supply and ground circuit for Driver’s seat control unit) PROCEDURE NAEL0369S03 GI Some of the seat system functions Reclining do not operate during automatic Lifting (Front) operation. Lifting (Rear) 5 No automatic operation functions operate. 6 Drive position cannot be retained in the memory. 7 Sliding Does not operate during manual Reclining operation. (Operates during auto- Lifting (Front) matic operation.) Lifting (Rear) 8 Automatic operation cannot be canceled. 9 Memory indicator does not light up. SU X BR X X X ST RS BT HA SC X : Applicable IDX EL-235 AUTOMATIC DRIVE POSITIONER Trouble Diagnoses (Cont’d) 1 No seat system functions operate. 2 Some of the seat system functions do not operate during automatic/ manual operation. 252 255 255 DIAGNOSTIC PROCEDURE 14 (Memory indicator check) 251 DIAGNOSTIC PROCEDURE 13 (Seat memory switch check) 250 DIAGNOSTIC PROCEDURE 12 (Key, park position, door switch and vehicle speed sensor check) 249 DIAGNOSTIC PROCEDURE 11 (Cancel switch check) SYMPTOM 248 DIAGNOSTIC PROCEDURE 10 (Power seat switch check) ) DIAGNOSTIC PROCEDURE 9 [Lifting motor (rear) check] REFERENCE PAGE (EL- Diagnostic procedure DIAGNOSTIC PROCEDURE 8 [Lifting motor (front) check] PROCEDURE Sliding Reclining Lifting (Front) Lifting (Rear) 3 No functions operate during automatic operation, and some/all functions do not during manual operation. 4 Sliding Some of the seat system functions Reclining do not operate during automatic Lifting (Front) operation. Lifting (Rear) 5 No automatic operation functions operate. 6 Drive position cannot be retained in the memory. 7 Sliding Does not operate during manual Reclining operation. (Operates during auto- Lifting (Front) matic operation.) Lifting (Rear) 8 Automatic operation cannot be canceled. 9 Memory indicator does not light up. X X X (ACC, ON START signal) X X X X (IGN ON signal) X X X X X X X X : Applicable EL-236 AUTOMATIC DRIVE POSITIONER Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 1 =NAEL0369S04 GI (Power supply and ground circuit for driver’s seat control unit) Power Supply Circuit Check NAEL0369S0401 Check voltage between seat control unit LH terminal 1 and ground. Ignition switch position EM Terminals OFF 1 - Ground SEL601W ACC ON MA START Battery voltage LC If NG, check the following. 쐌 40A fusible link (letter f, located in the fuse and fusible link box) 쐌 Circuit breaker 쐌 Harness for open or short between circuit breaker and seat control unit LH EC FE CL MT AT Ground Circuit Check NAEL0369S0402 Check continuity between seat control unit LH terminal 33 and ground. Terminals Continuity 33 - Ground Yes TF PD AX SU SEL602W BR ST RS BT HA SC IDX EL-237 AUTOMATIC DRIVE POSITIONER Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 2 =NAEL0369S05 (Sliding encoder check) 1 CHECK SLIDING ENCODER OUTPUT SIGNAL Measure voltage between seat control unit LH terminal 18 and ground with CONSULT-II or oscilloscope when power seat slide is operated. SEL603W OK or NG OK 䊳 Sliding encoder is OK. NG 䊳 GO TO 2. 2 CHECK SLIDING ENCODER INPUT SIGNAL Check voltage between seat control unit LH terminal 17 and ground. SEL604W OK or NG OK 䊳 GO TO 3. NG 䊳 Replace seat control unit LH. EL-238 AUTOMATIC DRIVE POSITIONER Trouble Diagnoses (Cont’d) 3 GI CHECK SLIDING ENCODER OPEN CIRCUIT 1. Disconnect seat control unit LH connector and sliding device LH connector. 2. Check harness continuity between seat control unit LH connector and sliding device LH connector. MA EM LC EC SEL605WA FE OK or NG OK 䊳 GO TO 4. NG 䊳 Repair harness. 4 CL MT CHECK SLIDING ENCODER SHORT CIRCUIT Check harness continuity between seat control unit LH connector and ground. AT TF PD AX SEL606W OK or NG OK 䊳 Replace sliding encoder. NG 䊳 Repair harness. SU BR ST RS BT HA SC IDX EL-239 AUTOMATIC DRIVE POSITIONER Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 3 =NAEL0369S06 (Reclining encoder check) 1 CHECK RECLINING ENCODER OUTPUT SIGNAL Measure voltage between seat control unit LH terminal 29 and ground with CONSULT-II or oscilloscope when power seat reclining is operated. SEL607W OK or NG OK 䊳 Reclining encoder is OK. NG 䊳 GO TO 2. 2 CHECK RECLINING ENCODER INPUT SIGNAL Check voltage between seat control unit LH terminal 17 and ground. SEL608W OK or NG OK 䊳 GO TO 3. NG 䊳 Replace seat control unit LH. EL-240 AUTOMATIC DRIVE POSITIONER Trouble Diagnoses (Cont’d) 3 GI CHECK RECLINING ENCODER OPEN CIRCUIT 1. Disconnect seat control unit LH connector and reclining device LH connector. 2. Check harness continuity between seat control unit LH connector and reclining LH connector. MA EM LC EC SEL609WA FE OK or NG OK 䊳 GO TO 4. NG 䊳 Repair harness. 4 CL MT CHECK RECLINING ENCODER SHORT CIRCUIT Check harness continuity between seat control unit LH connector and ground. AT TF PD AX SEL610W OK or NG OK 䊳 Replace reclining encoder. NG 䊳 Repair harness. SU BR ST RS BT HA SC IDX EL-241 AUTOMATIC DRIVE POSITIONER Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 4 =NAEL0369S07 [Lifting encoder (front) check] 1 CHECK LIFTING ENCODER (FRONT) OUTPUT SIGNAL Measure voltage between seat control unit LH terminal 19 and ground with CONSULT-II or oscilloscope when power seat lifting (front) is operated. SEL611W OK or NG OK 䊳 Lifting encoder (front) is OK. NG 䊳 GO TO 2. 2 CHECK LIFTING ENCODER (FRONT) INPUT SIGNAL Check voltage between seat control unit LH terminal 17 and ground. SEL612W OK or NG OK 䊳 GO TO 3. NG 䊳 Replace seat control unit LH. EL-242 AUTOMATIC DRIVE POSITIONER Trouble Diagnoses (Cont’d) 3 GI CHECK LIFTING ENCODER (FRONT) OPEN CIRCUIT 1. Disconnect seat control unit LH connector and front lifting device LH connector. 2. Check harness continuity between seat control unit LH connector and front lifting device LH connector. MA EM LC EC SEL613WA FE OK or NG OK 䊳 GO TO 4. NG 䊳 Repair harness. 4 CL MT CHECK LIFTING ENCODER (FRONT) SHORT CIRCUIT Check harness continuity between seat control unit LH connector and ground. AT TF PD AX SEL614W OK or NG OK 䊳 Replace lifting encoder (front). NG 䊳 Repair harness. SU BR ST RS BT HA SC IDX EL-243 AUTOMATIC DRIVE POSITIONER Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 5 =NAEL0369S08 [Lifting encoder (rear) check] 1 CHECK LIFTING ENCODER (REAR) OUTPUT SIGNAL Measure voltage between seat control unit LH terminal 30 and ground with CONSULT-II or oscilloscope when power seat lifting (rear) is operated. SEL615W OK or NG OK 䊳 Lifting encoder (rear) is OK. NG 䊳 GO TO 2. 2 CHECK LIFTING ENCODER (REAR) INPUT SIGNAL Check voltage between seat control unit LH terminal 17 and ground. SEL616W OK or NG OK 䊳 GO TO 3. NG 䊳 Replace seat control unit LH. EL-244 AUTOMATIC DRIVE POSITIONER Trouble Diagnoses (Cont’d) 3 GI CHECK LIFTING ENCODER (REAR) OPEN CIRCUIT 1. Disconnect seat control unit LH connector and rear lifting device LH connector. 2. Check harness continuity between seat control unit LH connector and rear lifting device LH connector. MA EM LC EC SEL617WA FE OK or NG OK 䊳 GO TO 4. NG 䊳 Repair harness. 4 CL MT CHECK LIFTING ENCODER (REAR) SHORT CIRCUIT Check harness continuity between seat control unit LH connector and ground. AT TF PD AX SEL618W OK or NG OK 䊳 Replace lifting encoder (rear). NG 䊳 Repair harness. SU BR ST RS BT HA SC IDX EL-245 AUTOMATIC DRIVE POSITIONER Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 6 =NAEL0369S09 (Sliding motor check) 1 CHECK OUTPUT SIGNAL TO SLIDING MOTOR Check voltage between seat control unit LH terminals 3 or 10 and ground. SEL619W OK or NG OK 䊳 GO TO 2. NG 䊳 Replace seat control unit LH. 2 CHECK SLIDING MOTOR 1. Disconnect sliding device LH connector. 2. Apply 12V DC direct current to motor and check operation. SEL620WA OK or NG OK 䊳 Check harness for operation between seat control unit LH and sliding motor. NG 䊳 Replace sliding motor. EL-246 AUTOMATIC DRIVE POSITIONER Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 7 =NAEL0369S10 GI (Reclining motor check) 1 CHECK OUTPUT SIGNAL TO RECLINING MOTOR MA Check voltage between seat control unit LH terminals 4 or 12 and ground. EM LC EC FE SEL621W OK or NG OK 䊳 GO TO 2. NG 䊳 Replace seat control unit LH. 2 CL MT CHECK RECLINING MOTOR AT 1. Disconnect reclining device LH connector. 2. Apply 12V DC direct current to motor and check operation. TF PD AX SU SEL622WA OK or NG OK 䊳 Check harness for operation between seat control unit LH and reclining motor. NG 䊳 Replace reclining motor. BR ST RS BT HA SC IDX EL-247 AUTOMATIC DRIVE POSITIONER Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 8 =NAEL0369S11 [Lifting motor (front) check] 1 CHECK OUTPUT SIGNAL TO LIFTING MOTOR (FRONT) Check voltage between seat control unit LH terminals 5 or 13 and ground. SEL623W OK or NG OK 䊳 GO TO 2. NG 䊳 Replace seat control unit LH. 2 CHECK LIFTING MOTOR (FRONT) 1. Disconnect front lifting device LH connector. 2. Apply 12V DC direct current to motor and check operation. SEL624WA OK or NG OK 䊳 Check harness for operation between seat control unit LH and lifting motor (front). NG 䊳 Replace lifting motor (front). EL-248 AUTOMATIC DRIVE POSITIONER Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 9 =NAEL0369S12 GI [Lifting motor (rear) check] 1 CHECK OUTPUT SIGNAL TO LIFTING MOTOR (REAR) MA Check voltage between seat control unit LH terminals 6 or 7 and ground. EM LC EC FE SEL625W OK or NG OK 䊳 GO TO 2. NG 䊳 Replace seat control unit LH. 2 CL MT CHECK LIFTING MOTOR (REAR) AT 1. Disconnect rear lifting device LH connector. 2. Apply 12V DC direct current to motor and check operation. TF PD AX SU SEL626WA OK or NG OK 䊳 Check harness for operation between seat control unit LH and lifting motor (rear). NG 䊳 Replace lifting motor (rear). BR ST RS BT HA SC IDX EL-249 AUTOMATIC DRIVE POSITIONER Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 10 =NAEL0369S13 (Power seat switch check) 1 CHECK POWER SEAT SWITCH 1. Disconnect power seat switch LH connector. 2. Check continuity between power seat switch terminals. SEL569X OK or NG OK 䊳 Check the following. 쐌 Ground circuit for power seat switch 쐌 Harness for open or short between seat control unit LH and power seat switch NG 䊳 Replace power seat switch. EL-250 AUTOMATIC DRIVE POSITIONER Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 11 =NAEL0369S14 GI (Cancel switch check) 1 CHECK CANCEL SWITCH MA 1. Disconnect cancel switch connector. 2. Check continuity between cancel switch terminals. EM LC EC FE SEL628WA OK or NG OK NG 䊳 䊳 Check the following. 쐌 Ground circuit for cancel switch 쐌 Harness for open or short between seat control unit LH and cancel switch Replace cancel switch. CL MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-251 AUTOMATIC DRIVE POSITIONER Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 12 =NAEL0369S15 (Key, detention, door switch and vehicle speed signal check) 1 CHECK KEY SWITCH INPUT SIGNAL Check voltage between seat control unit LH terminal 2 and ground. SEL629W OK or NG OK 䊳 GO TO 2. NG 䊳 Check the following. 쐌 7.5A fuse [No. 24, located in fuse block (J/B)] 쐌 Key switch 쐌 Harness for open or short between key switch and fuse 쐌 Harness for open or short between seat control unit LH and key switch 2 CHECK IGNITION SWITCH INPUT SIGNAL (ON AND START) Check voltage between seat control unit LH terminals and ground. SEL630W OK or NG OK 䊳 GO TO 3. NG 䊳 Check the following. 쐌 7.5A fuse [No. 11, located in fuse block (J/B)] 쐌 7.5A fuse [No. 26, located in fuse block (J/B)] 쐌 Harness for open or short between seat control unit LH and fuse EL-252 AUTOMATIC DRIVE POSITIONER Trouble Diagnoses (Cont’d) 3 GI CHECK PARK POSITION SWITCH INPUT SIGNAL Check voltage between seat control unit LH terminal 21 and ground. MA EM LC EC SEL631W FE OK or NG OK 䊳 GO TO 4. NG 䊳 Check the following. 쐌 Park position switch 쐌 Park position switch ground circuit 쐌 Harness for open or short between seat control unit LH and park position switch 4 CHECK DRIVER DOOR SWITCH INPUT SIGNAL CL MT AT Check voltage between seat control unit LH terminal 9 and ground. TF PD AX SU SEL632W OK or NG OK 䊳 GO TO 5. NG 䊳 Check the following. 쐌 Driver door switch 쐌 Driver door switch ground circuit 쐌 Harness for open or short between seat control unit LH and driver door switch 5 CHECK VEHICLE SPEED SIGNAL BR ST RS BT Does speedometer operate normally? Yes or No OK 䊳 GO TO 6. NG 䊳 Check speedometer and ABS actuator and electric unit circuit. Refer to EL-132. HA SC IDX EL-253 AUTOMATIC DRIVE POSITIONER Trouble Diagnoses (Cont’d) 6 CHECK VEHICLE SPEED SIGNAL PULL UP VOLTAGE 1. Turn ignition switch “ON”. 2. Check voltage between seat control unit LH terminal 32 and ground. SEL633W OK or NG OK 䊳 Harness for open or short between seat control unit LH and combination meter. NG 䊳 Repair harness. EL-254 AUTOMATIC DRIVE POSITIONER Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 13 =NAEL0369S16 GI (Seat memory switch check) 1 CHECK SEAT MEMORY SWITCH MA 1. Disconnect seat memory switch connector. 2. Check continuity between seat memory switch terminals. EM LC EC FE SEL634WA CL OK or NG OK NG 䊳 䊳 Check the following. 쐌 Ground circuit for seat memory switch 쐌 Harness for open or short between seat control unit LH and seat memory switch Replace seat memory switch. DIAGNOSTIC PROCEDURE 14 AT NAEL0369S17 (Memory indicator check) 1 MT TF CHECK INDICATOR LAMP Check indicator lamp illumination. PD OK or NG OK 䊳 GO TO 2. NG 䊳 Replace seat memory switch (indicator lamp). 2 AX SU CHECK POWER SUPPLY CIRCUIT FOR INDICATOR LAMP 1. Disconnect seat memory switch connector. 2. Check voltage between seat memory switch terminal and ground. BR ST RS BT SEL635WA HA OK or NG OK 䊳 Check harness for open or short between seat control unit LH and seat memory switch NG 䊳 Check the following. 쐌 7.5A fuse [No. 24 located in the fuse block (J/B)] 쐌 Harness for open or short between fuse and indicator lamp SC IDX EL-255 AUTOMATIC SPEED CONTROL DEVICE (ASCD) System Description System Description NAEL0461 Refer to EC-81, “Automatic Speed Control Device (ASCD) System” in “ENGINE AND EMISSION BASIC DESCRIPTION CONTROL SYSTEM”. EL-256 POWER WINDOW System Description System Description NAEL0378 Power is supplied at all times 쐌 from 40A fusible link (letter f, located in the fuse and fusible link box) 쐌 to circuit breaker terminal 1 쐌 through circuit breaker terminal 2 쐌 to power window relay terminal 3, 쐌 to power window main switch terminal 19, and 쐌 to front power window switch RH terminal 10. With ignition switch in ON or START position, power is supplied 쐌 through 7.5A fuse [No. 11, located in the fuse block (J/B)] 쐌 to smart entrance control unit terminal 27 쐌 to smart entrance control unit terminal 46 and 쐌 to power window relay terminal 2. Ground is supplied to power window relay terminal 1 쐌 through body grounds M4, M66, M111, M147 and M157. The power window relay is energized and power is supplied 쐌 through power window relay terminal 5 쐌 to power window main switch terminal 10, 쐌 to front power window switch RH terminal 14 and 쐌 to rear power window switch LH and RH terminals 4. MANUAL OPERATION Front Door LH GI MA EM LC EC FE CL MT AT NAEL0378S01 NAEL0378S0101 Ground is supplied 쐌 to power window main switch terminal 17 쐌 through body grounds M4, M66, M111, M147 and M157. WINDOW UP When the front LH switch in the power window main switch is pressed in the up position, power is supplied 쐌 to front power window regulator LH terminal 1 쐌 through power window main switch terminal 8. Ground is supplied 쐌 to front power window regulator LH terminal 3 쐌 through power window main switch terminal 11. Then, the motor raises the window until the switch is released. WINDOW DOWN When the LH switch in the power window main switch is pressed in the down position, power is supplied 쐌 to front power window regulator LH terminal 3 쐌 through power window main switch terminal 11. Ground is supplied 쐌 to front power window regulator LH terminal 1 쐌 through power window main switch terminal 8. Then, the motor lowers the window until the switch is released. Front Door RH NAEL0378S0102 Ground is supplied 쐌 to power window main switch terminal 17 쐌 through body grounds M4, M66, M111, M147 and M157. NOTE: Numbers in parentheses are terminal numbers, when power window switch is pressed in the UP and DOWN positions respectively. TF PD AX SU BR ST RS BT HA SC IDX EL-257 POWER WINDOW System Description (Cont’d) POWER WINDOW MAIN SWITCH OPERATION When front RH switch in the power window main switch is pressed UP or DOWN, power window main switch sends window up or down signal to front power window switch RH with power window serial link communication line. Refer to “POWER WINDOW SERIAL LINK” (EL-259). Signals are supplied 쐌 through power window main switch terminal 14 쐌 to front power window switch RH terminal 16. The subsequent operation is the same as the front power window switch RH operation. FRONT POWER WINDOW SWITCH RH OPERATION Power is supplied 쐌 through front power window switch RH (8, 9) 쐌 to front power window regulator RH (1, 3). Ground is supplied 쐌 to front power window regulator RH (3, 1) 쐌 through front power window switch RH (9, 8) 쐌 to front power window RH terminal 11 쐌 through body grounds M4, M66, M111, M147 and M157. Then, the motor raises or lowers the window until the switch is released. Rear Door LH NAEL0378S0103 Ground is supplied 쐌 to power window main switch terminal 17 쐌 through body grounds the M4, M66, M111, M147 and M157. NOTE: Numbers in parentheses are terminal numbers, when the power window switch is pressed in the UP and DOWN positions. POWER WINDOW MAIN SWITCH OPERATION Power is supplied 쐌 through power window main switch terminal (1, 3) 쐌 to rear power window switch LH terminal (5, 2) The subsequent operation is the same as the rear power window switch LH operation. REAR POWER WINDOW SWITCH LH Power is supplied 쐌 through rear power window switch LH (1, 3) 쐌 to rear power window regulator LH (1, 2) Ground is supplied 쐌 to rear power window regulator LH (2, 1) 쐌 through rear power window switch LH (3, 1) 쐌 to rear power window switch LH terminal (2, 5) 쐌 through power window main switch terminal (3, 1) Then, the motor raises or lowers the window until the switch is released. Rear Door RH NAEL0378S0104 Rear door RH windows will rise and lower in the same manner as the rear door LH window. AUTO OPERATION NAEL0378S02 The power window AUTO feature enables the driver or front passenger to open or close the driver’s and front passenger’s window without holding the window switch in the up or down position. The AUTO feature only operates on the driver’s and front passenger’s window upward and downward movement. POWER WINDOW LOCK NAEL0378S03 The power window lock is designed to lock operation of all windows except for driver’s door window. When the lock switch is pressed to lock position, the ground of the front and rear power window switches, in the power window main switch, is disconnected. This prevents the power window motors from operating. EL-258 POWER WINDOW System Description (Cont’d) RETAINED POWER OPERATION NAEL0378S04 When the ignition switch is turned to OFF position from ON or START position, power is supplied for 45 seconds 쐌 to power window relay terminal 2 쐌 from smart entrance control unit terminal 46. Ground is always supplied 쐌 to power window relay terminal 1 쐌 through body grounds M4, M66, M111, M147 and M157. When power and ground are supplied, the power window relay continues to be energized, and the power window can be operated. The retained power operation is canceled when the driver or passenger side door is opened. RAP signal’s period can be changed by CONSULT-II. (EL-267) INTERRUPTION DETECTION FUNCTION NAEL0378S05 Power window main switch and front power window switch RH monitor the power window regulator motor operation and the power window position (full closed or other) for driver’s and passenger’s power window by the signals from encoder and limit switch in front power window regulator LH or RH. When power window main switch or front power window switch RH detects interruption during the following close operation in the driver’s or front passenger’s side door, 쐌 automatic close operation when ignition switch is in the “ON” position 쐌 automatic close operation during retained power operation Power window main switch or front power window switch RH controls driver’s or front passenger’s power window regulator motor for open and the power window will be lowered about 150 mm (5.91 in). POWER WINDOW OPENED/CLOSED OPERATION WITH KEY CYLINDER NAEL0378S06 When ignition key switch is OFF, front power window can be opened or closed by turning the front door key cylinder LH to UNLOCK/LOCK position. 쐌 Power window can be opened as the door key cylinder is kept fully turning to the UNLOCK position. 쐌 Power window can be closed as the door key cylinder is kept fully turning to the LOCK position. The power window opening stops when the following operations are carried out: 쐌 While performing open/close the window, power window is stopped at the position as the door key cylinder is placed on Neutral. 쐌 When the ignition switch is turned ON while the power window opening is operated. POWER WINDOW SERIAL LINK GI MA EM LC EC FE CL MT AT TF PD AX SU NAEL0378S07 Power window main switch, front power window switch RH and smart entrance control unit transmit and receive the signal by power window serial link. The under-mentioned signal is transmitted from smart entrance control unit to power window main switch or front power window switch RH. 쐌 Door lock or unlock signal (remote keyless entry system) 쐌 Power window down signal (remote keyless entry system) The under-mentioned signal is transmitted from power window main switch to front power window switch RH. 쐌 Door lock or unlock signal (remote keyless entry system) 쐌 Power window open/closed operation signal by key cylinder 쐌 Power window lock signal BR ST RS BT HA SC IDX EL-259 POWER WINDOW Schematic Schematic NAEL0379 MEL020Q EL-260 POWER WINDOW Wiring Diagram — WINDOW — Wiring Diagram — WINDOW — NAEL0380 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL021Q EL-261 IDX POWER WINDOW Wiring Diagram — WINDOW — (Cont’d) MEL022Q EL-262 POWER WINDOW Wiring Diagram — WINDOW — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL023Q IDX EL-263 POWER WINDOW Wiring Diagram — WINDOW — (Cont’d) MEL024Q EL-264 POWER WINDOW Wiring Diagram — WINDOW — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL025Q IDX EL-265 POWER WINDOW CONSULT-II Inspection Procedure CONSULT-II Inspection Procedure “RETAINED PWR” NAEL0381 NAEL0381S01 1. 2. Turn ignition switch “OFF”. Connect “CONSULT-II” and “CONSULT-II CONVERTER” to the data link connector. 3. 4. Turn ignition switch “ON”. Touch “START (NISSAN BASED VHCL)”. 5. Touch “SMART ENTRANCE”. If “SMART ENTRANCE” is not indicated, go to GI-41, “CONSULT-II Data Link Connector (DLC) Circuit”. 6. Touch “RETAINED PWR”. 7. Select diagnosis mode. “DATA MONITOR”, “ACTIVE TEST” and “WORK SUPPORT” are available. SEL670Y SKIA3098E SEL669Y SEL751Y SEL400Y EL-266 POWER WINDOW CONSULT-II Application Items CONSULT-II Application Items “RETAINED PWR” Data Monitor GI NAEL0382S01 NAEL0382S0101 Monitored Item MA Description IGN ON SW Indicates [ON/OFF] condition of ignition switch. DOOR SW-DR Indicates [ON/OFF] condition of front door switch LH. DOOR SW-AS Indicates [ON/OFF] condition of front door switch RH. EM LC Active Test NAEL0382S0102 Test Item RETAINED PWR NAEL0382 EC Description This test is able to supply RAP signal (power) from smart entrance control unit to power window system, power sunroof system and headlamp battery saver control unit. Those systems can be operated when turning on “RETAINED PWR” on CONSULT-II screen even if the ignition switch is tuned OFF. NOTE: During this test, CONSULT-II can be operated with ignition switch in “OFF” position. “RETAINED PWR” should be turned “ON” or “OFF” on CONSULT-II screen when ignition switch is ON. Then turn ignition switch OFF to check retained power operation. CONSULT-II might be stuck if “RETAINED PWR” is turned “ON” or “OFF” on CONSULT-II screen when ignition switch is OFF. FE CL MT AT Work Support NAEL0382S0103 Work Item RETAINED PWR SET TF Description Rap signal’s power supply period can be changed by mode setting. Selects rap signal’s power supply period between three steps. 쐌 MODE 1 (45 sec.)/MODE 2 (OFF)/MODE 3 (2 min.) PD AX SU Trouble Diagnoses Symptom None of the power windows can be operated using any switch. Possible cause 1. 2. 3. 4. 5. 6. 7. 7.5A fuse, 40A fusible link M145 circuit breaker Power window relay M145 circuit breaker circuit Power window relay circuit Ground circuit Power window main switch NAEL0383 Repair order 1. Check 7.5A fuse [No. 11, located in fuse block (J/B)], 40A fusible link (letter f, located in fuse and fusible link box). 2. Check M145 circuit breaker. 3. Check power window relay. 4. Check the following. a. Harness between M145 circuit breaker and 40A fusible link b. Harness between M145 circuit breaker and power window main switch 5. Check the following. a. Harness between 7.5A fuse and power window relay b. Harness between M145 circuit breaker and power window relay 6. Check the following. a. Ground circuit of power window main switch terminal 17 b. Power window relay ground circuit 7. Check power window main switch. BR ST RS BT HA SC IDX EL-267 POWER WINDOW Trouble Diagnoses (Cont’d) Symptom Driver side power window cannot be operated but other windows can be operated. Possible cause 1. Front power window regulator LH circuit 2. Front power window regulator LH 3. Power window main switch Repair order 1. Check harness between power window main switch and front power window regulator LH for open or short circuit. 2. Check front power window regulator LH. 3. Check power window main switch. Passenger side power window can- 1. Power supply for front power not be operated but other window window switch RH can be operated. 2. Front power window switch RH ground circuit 3. Front power window switch RH circuit 4. Front power window regulator RH circuit 5. Front power window regulator RH 6. Power window main switch 7. Front power window switch RH 1. Check power supply for front power window switch RH terminals 10 and 14. 2. Check front power window switch RH ground circuit. 3. Check harness between front power window switch RH and power window main switch. 4. Check harness between front power window switch RH and front power window regulator RH for open or short circuit. 5. Check front power window regulator RH. 6. Check power window main switch. 7. Check front power window switch RH. One or more rear power windows except front window cannot be operated. 1. 2. 3. 4. a. 1. 2. 3. 4. Rear power window switches Rear power window regulators Power window main switch Rear power window circuit Check rear power window switches. Check rear power window regulator. Check power window main switch. Check the following. Harness between the rear power window switches (LH and RH) terminal 5 and power window relay terminal 4 b. Harnesses between power window main switch and rear power window switches for open/short circuit c. Harnesses between rear power window switches and rear power window regulator for open/short circuit Power windows except driver’s side 1. Power window main switch window cannot be operated using power window main switch but can be operated by power window switches. 1. Check power window main switch. Driver side power window automatic operation does not function properly. 1. Power window main switch 2. Encoder and limit switch 1. Check power window main switch. 2. Check encoder and limit switch. (EL-270) Front passenger side power window automatic operation does not function properly. 1. Front power window switch RH 2. Encoder and limit switch 1. Check front power window switch RH. 2. Check encoder and limit switch. (EL-270) EL-268 POWER WINDOW Trouble Diagnoses (Cont’d) Symptom Retained power operation does not operate properly. Possible cause 1. RAP signal circuit 2. Driver or passenger side door switch circuit 3. Smart entrance control unit Repair order 1. Check RAP signal. a. (With CONSULT-II) 쐌 Check RAP signal with CONSULT-II. Use “WORK SUPPORT” mode, “RETAINED PWR” in “SMART ENTRANCE”. (Refer to EL-267.) 쐌 Check RAP signal with CONSULT-II. Use “ACTIVE TEST” mode, “RETAINED PWR” in “SMART ENTRANCE”. (Refer to EL-266.) If NG, go to the step b. below. b. Verify 12 positive voltage from smart entrance control unit terminal 46 is present at terminal 2 of power window relay: 쐌 Within 45 seconds after ignition switch turns off.*1 쐌 When front door LH and RH is closed. 2. Check the following. a. Harness between smart entrance control unit and driver or passenger side door switch for short circuit b. Driver or passenger side door switch ground circuit c. Driver or passenger side door switch 3. Check smart entrance control unit. (EL-368) Passenger side power window can- 1. Power window main switch not be operated using power win2. Power window main switch cirdow main switch but can be opercuit ated by passenger side power window switch. 1. Check power window main switch. (EL-272) 2. Check harness for open or short circuit between power window main switch terminal 14 and front power window switch RH terminal 16. Rear LH power window cannot be operated using power window main switch but can be operated by rear LH power window switch. 1. Power window main switch 1. Check power window main switch. (EL-272) Rear RH power window cannot be operated using power window main switch but can be operated by rear RH power window switch. 1. Power window main switch GI MA EM LC EC FE CL MT AT TF PD 1. Check power window main switch. (EL-272) AX SU Power window open/close operation 1. Front door key cylinder switch with key cylinder does not operate LH properly. 2. Front door key cylinder switch LH circuit 3. Power window main switch *1: RAP signal’s period can be changed by CONSULT-II. (EL-267) 1. Check front door key cylinder switch LH. 2. Check harness for open or short circuit between front door key cylinder switch LH and power window main switch. 3. Check power window main switch. BR ST RS BT HA SC IDX EL-269 POWER WINDOW Trouble Diagnoses (Cont’d) ENCODER AND LIMIT SWITCH CHECK 1 =NAEL0383S01 CHECK DOOR WINDOW SLIDE MECHANISM Check the following. 쐌 Obstacles in window, glass molding, etc. 쐌 Worn or deformed glass molding 쐌 Door sash tilted too far inward or outward 쐌 Door window regulator OK or NG OK 䊳 GO TO 2. NG 䊳 Remove obstacles or repair door window slide mechanism. 2 CHECK POWER SUPPLY TO LIMIT SWITCH 1. Disconnect front power window regulator LH or RH harness connector. 2. Check voltage between power window main switch harness connector D6 terminal 9 (G/W) or front power window switch RH harness connector D44 terminal 15 (G/W) and ground. SEL686Y OK or NG OK 䊳 GO TO 3. NG 䊳 Replace power window main switch or front power window switch RH. 3 CHECK LIMIT SWITCH OPERATION 1. Connect front power window regulator LH or RH harness connector. 2. Check voltage between power window main switch harness connector D6 terminal 9 (G/W) or front power window switch RH harness connector D44 terminal 15 (G/W) and ground during power window closing operation. SEL687Y OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 4. EL-270 POWER WINDOW Trouble Diagnoses (Cont’d) 4 GI RESET LIMIT SWITCH Reset limit switch. Refer to BT-20, “Front Door Glass Limit Switch Reset”. Then check voltage between power window main switch harness connector D6 terminal 9 (G/W) or front power window switch RH harness connector D44 terminal 15 (G/W) and ground during power window closing operation at least ten times. MA EM LC EC SEL687Y FE OK or NG CL OK 䊳 GO TO 5. NG 䊳 Replace power window regulator motor. MT 5 CHECK ENCODER Measure voltage between power window main switch harness connector D6 terminal 13 (G/Y) or front power window switch RH harness connector D44 terminal 12 (G/Y) and ground with oscilloscope when power window is in automatic closing operation. AT TF PD AX SU SEL688Y OK or NG OK 䊳 Replace power window main switch. NG 䊳 Replace power window regulator motor. BR ST RS BT HA SC IDX EL-271 POWER WINDOW Trouble Diagnoses (Cont’d) MAIN SWITCH OPERATION CHECK Passenger Side Operation 1 NAEL0383S02 NAEL0383S0201 CHECK POWER WINDOW MAIN SWITCH OUTPUT SIGNAL With CONSULT-II 1. Turn ignition switch to ON position. 2. Turn power window main switch to ON (UP or DOWN). 3. Check signal between power window main switch harness connector D6 terminal 14 (BR) and ground when power window is in open or close operation. (Use “SIMPLE OSCILLOSCOPE” in “SUB MODE” with CONSULT-II.) SEL689Y Without CONSULT-II 1. Turn ignition switch to ON position. 2. Turn power window main switch to ON (UP or DOWN). 3. Check signal between power window main switch harness connector D6 terminal 14 (BR) and ground when power window is in open or close operation. SEL690Y OK or NG OK 䊳 GO TO 2. NG 䊳 Replace power window main switch. EL-272 POWER WINDOW Trouble Diagnoses (Cont’d) 2 GI CHECK SIGNAL CIRCUIT 1. Check continuity between power window switch harness connector D6 terminal 14 (BR) and front power window switch RH harness connector D44 terminal 16 (Y). MA EM LC EC SEL691Y FE Yes or No Yes 䊳 INSPECTION END No 䊳 Repair harness or connectors. CL MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-273 POWER WINDOW Trouble Diagnoses (Cont’d) Rear LH Side Window Operation 1 =NAEL0383S0202 CHECK POWER WINDOW MAIN SWITCH OUTPUT SIGNAL 1. Turn ignition switch to ON position. 2. Check voltage between power window main switch harness connector D6 terminal 1 (R/B) or 3 (G/W) and ground when rear power window LH side is in open or close operation. SEL692Y OK or NG OK 䊳 GO TO 2. NG 䊳 Replace power window main switch. 2 CHECK SIGNAL CIRCUIT 1. Turn ignition switch to OFF position. 2. Disconnect power window main switch connector and rear power window switch LH connector. 3. Check continuity between power window main switch harness connector D6 terminal 3 (G/W) and rear power window switch LH harness connector D52 terminal 2 (B/W). 4. Check continuity between power window main switch harness connector D6 terminal 1 (R/B) and rear power window switch LH harness connector D52 terminal 5 (W/B). SEL796Y Yes or No Yes 䊳 INSPECTION END No 䊳 Repair harness or connectors. EL-274 POWER WINDOW Trouble Diagnoses (Cont’d) Rear RH Side Window Operation 1 =NAEL0383S0203 GI CHECK POWER WINDOW MAIN SWITCH OUTPUT 1. Turn ignition switch to ON position. 2. Check voltage between power window main switch harness connector D6 terminal 5 (B/W) or 7 (W/B) and ground when rear power window RH side is in open or close operation. MA EM LC EC FE SEL694Y CL OK or NG OK 䊳 GO TO 2. NG 䊳 Replace power window main switch. 2 MT CHECK SIGNAL CIRCUIT AT 1. Turn ignition switch to OFF position. 2. Disconnect power window main switch connector and rear power window switch RH connector. 3. Check continuity between power window main switch harness connector D6 terminal 7 (W/B) and rear power window switch RH harness connector D72 terminal 5 (W/B). 4. Check continuity between power window main switch harness connector D6 terminal 5 (B/W) and rear power window switch RH harness connector D72 terminal 2 (B/W). TF PD AX SU BR SEL795Y ST Yes or No Yes 䊳 INSPECTION END No 䊳 Repair harness or connectors. RS BT HA SC IDX EL-275 POWER DOOR LOCK Component Parts and Harness Connector Location Component Parts and Harness Connector Location NAEL0384 SEL675Y System Description OPERATION 쐌 쐌 쐌 NAEL0385 NAEL0385S01 The lock/unlock switch (LH and RH) on door trim can lock and unlock all doors. With the door key inserted in the key cylinder on front LH or back door, turning it to “LOCK”, will lock all doors; turning it to “UNLOCK” once unlocks the corresponding door; turning it to “UNLOCK” again within 5 seconds after the first unlock operation unlocks all of the other doors. (Signals from door key cylinder switch) If the ignition key is in the ignition key cylinder and one or more of doors are open, setting the lock/unlock switch to “LOCK” locks the doors once but then immediately unlock them. (Combination signals from key switch and door switches) - (KEY REMINDER DOOR SYSTEM) EL-276 POWER DOOR LOCK Schematic Schematic NAEL0386 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL431P EL-277 IDX POWER DOOR LOCK Wiring Diagram — D/LOCK — Wiring Diagram — D/LOCK — FIG. 1 NAEL0387 NAEL0387S01 MEL026Q EL-278 POWER DOOR LOCK Wiring Diagram — D/LOCK — (Cont’d) FIG. 2 NAEL0387S02 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL027Q EL-279 IDX POWER DOOR LOCK Wiring Diagram — D/LOCK — (Cont’d) FIG. 3 NAEL0387S03 MEL028Q EL-280 POWER DOOR LOCK Wiring Diagram — D/LOCK — (Cont’d) FIG. 4 NAEL0387S04 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL434P EL-281 IDX POWER DOOR LOCK Wiring Diagram — D/LOCK — (Cont’d) FIG. 5 NAEL0387S05 MEL852L EL-282 POWER DOOR LOCK Wiring Diagram — D/LOCK — (Cont’d) FIG. 6 NAEL0387S06 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL029Q EL-283 IDX POWER DOOR LOCK CONSULT-II Inspection Procedure CONSULT-II Inspection Procedure “DOOR LOCK” =NAEL0388 NAEL0388S01 1. 2. Turn ignition switch “OFF”. Connect “CONSULT-II” and “CONSULT-II CONVERTER” to the data link connector. 3. 4. Turn ignition switch “ON”. Turn “START (NISSAN BASED VHCL)”. 5. Touch “SMART ENTRANCE”. If “SMART ENTRANCE” is not indicated, go to GI-41, “CONSULT-II Data Link Connector (DLC) Circuit”. 6. Touch “DOOR LOCK”. 7. Select diagnosis mode. “DATA MONITOR”, “ACTIVE TEST” and “WORK SUPPORT” are available. SEL670Y SKIA3098E SEL669Y SEL023X SEL274W EL-284 POWER DOOR LOCK CONSULT-II Application Items CONSULT-II Application Items “DOOR LOCK” Data Monitor Monitored Item NAEL0389 GI NAEL0389S01 NAEL0389S0101 MA Description KEY ON SW Indicates [ON/OFF] condition of key switch. LOCK SW DR/AS Indicates [ON/OFF] condition of lock signal from lock/unlock switch LH and RH. DOOR SW-RR Indicates [ON/OFF] condition of door switch (Rear). UNLK SW DR/AS Indicates [ON/OFF] condition of unlock signal from lock/unlock switch LH and RH. KEY CYL LK-SW Indicates [ON/OFF] condition of lock signal from key cylinder. KEY CYL UN-SW Indicates [ON/OFF] condition of unlock signal from key cylinder. LK BUTTON/SIG Indicates [ON/OFF] condition of lock signal from keyfob. UN BUTTON/SIG Indicates [ON/OFF] condition of unlock signal from keyfob. IGN ON SW Indicates [ON/OFF] condition of ignition switch. DOOR SW-DR Indicates [ON/OFF] condition of front door switch LH. DOOR SW-AS Indicates [ON/OFF] condition of front door switch RH. Active Test Test Item EM LC EC FE CL MT NAEL0389S0102 AT Description TF ALL D/LK MTR This test is able to check all door lock actuators lock operation. These actuators lock when “ON” on CONSULT-II screen is touched. DR D/UN MTR This test is able to check front door lock actuator LH unlock operation. The actuator unlocks when “ON” on CONSULT-II screen is touched. PD NON DR D/UN This test is able to check door lock actuators (except front door lock actuator LH) unlock operation. These actuators unlock when “ON” on CONSULT-II screen is touched. AX Work Support Work Item NAEL0389S0103 SU Description DOOR LOCK-UNLOCK SET Select unlock mode can be changed in this mode. Selects ON-OFF of select unlock mode. 쐌 MODE 1 (ON)/MODE 2 (OFF) BR ANTI-LOCK OUT SET Key reminder door mode can be changed in this mode. Selects ON-OFF of key reminder door mode. 쐌 MODE 1 (ON)/MODE 2 (OFF) ST RS BT HA SC IDX EL-285 POWER DOOR LOCK Trouble Diagnoses Trouble Diagnoses NAEL0390 SYMPTOM CHART 287 288 290 291 292 294 296 SYMPTOM MAIN POWER SUPPLY AND GROUND CIRCUIT CHECK DOOR SWITCH CHECK KEY SWITCH (INSERT) CHECK DOOR LOCK/UNLOCK SWITCH CHECK FRONT DOOR KEY CYLINDER SWITCH CHECK BACK DOOR KEY CYLINDER SWITCH CHECK DOOR LOCK ACTUATOR CHECK REFERENCE PAGE (EL- ) NAEL0390S01 Key reminder door system does not operate properly. X X X Specific door lock actuator does not operate. X Power door lock does not operate with door lock and unlock switch (LH and RH) on door trim. X Power door lock does not operate with front door key cylinder operation. X Power door lock does not operate with back door key cylinder operation. X X X X X X EL-286 POWER DOOR LOCK Trouble Diagnoses (Cont’d) MAIN POWER SUPPLY AND GROUND CIRCUIT CHECK GI =NAEL0390S02 Main Power Supply Circuit Check NAEL0390S0201 Terminals MA Ignition switch (+) Connector (–) OFF ACC ON EM Ground Battery voltage Battery voltage Battery voltage LC Terminal (Wire color) 49 (G/R) M123 51 (W/R) SEL007YA EC Ground Circuit Check NAEL0390S0202 Terminals FE (+) Continuity Connector Terminal (Wire color) M122 43 (B) M123 64 (B) (–) CL Ground SEL008Y Yes MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-287 POWER DOOR LOCK Trouble Diagnoses (Cont’d) DOOR SWITCH CHECK 1 =NAEL0390S03 CHECK DOOR SWITCH INPUT SIGNAL With CONSULT-II Check door switches (“DOOR SW-DR”, “DOOR SW-AS”, “DOOR SW-RR”) in “DATA MONITOR” mode with CONSULT-II. SEL009Y Without CONSULT-II Check voltage between smart entrance control unit harness connector M121 terminals 1 (G/OR), 2 (Y) or 3 (R/L) and ground. SEL010Y Refer to wiring diagram in EL-278. OK or NG OK 䊳 Door switch is OK. NG 䊳 GO TO 2. EL-288 POWER DOOR LOCK Trouble Diagnoses (Cont’d) 2 GI CHECK DOOR SWITCH 1. Disconnect door switch connector. 2. Check the following. 쐌 Continuity between front door switch harness connector B9 (LH) or B68 (RH) terminals 1 and 2 쐌 Continuity between front door switch harness connector B9 (LH) or B68 (RH) terminal 3 and ground 쐌 Continuity between back door switch harness connector D208 terminals 1 and 2 쐌 Continuity between rear door switch harness connector B18 (LH) or B71 (RH) terminal 1 and ground MA EM LC EC FE CL MT AT TF SEL287Y OK or NG OK NG 䊳 䊳 Check the following. 쐌 Door switches ground circuit (Front or back door) or rear door switches ground condition 쐌 Harness for open or short between smart entrance control unit and door switch PD AX Replace door switch. SU BR ST RS BT HA SC IDX EL-289 POWER DOOR LOCK Trouble Diagnoses (Cont’d) KEY SWITCH (INSERT) CHECK 1 =NAEL0390S04 CHECK KEY SWITCH INPUT SIGNAL With CONSULT-II Check key switch (“KEY ON SW”) in “DATA MONITOR” mode with CONSULT-II. SEL315W Without CONSULT-II Check voltage between smart entrance control unit harness connector M122 terminal 25 (W/R) and ground. SEL011Y Refer to wiring diagram in EL-279. OK or NG OK 䊳 Key switch is OK. NG 䊳 GO TO 2. 2 CHECK KEY SWITCH (INSERT) Check continuity between terminals 1 and 2. SEL308X OK or NG OK 䊳 Check the following. 쐌 7.5A fuse [No. 24, located in fuse block (J/B)] 쐌 Harness for open or short between key switch and fuse 쐌 Harness for open or short between smart entrance control unit and key switch NG 䊳 Replace key switch. EL-290 POWER DOOR LOCK Trouble Diagnoses (Cont’d) DOOR LOCK/UNLOCK SWITCH CHECK 1 =NAEL0390S05 GI CHECK DOOR LOCK/UNLOCK SWITCH INPUT SIGNAL With CONSULT-II Check door lock/unlock switch (“LOCK SW DR/AS”/“UNLK SW DR/AS”) in “DATA MONITOR” mode with CONSULT-II. MA EM LC EC FE SEL341W Without CONSULT-II 1. Remove key from ignition key cylinder. 2. Check the signal between smart entrance control unit harness connector M122 terminal 33 (BR) and ground with oscilloscope when door lock/unlock switch is turned “LOCK” or “UNLOCK”. 3. Make sure signals which are shown in the figure below can be detected during 10 sec. just after door lock/unlock switch is turned “LOCK” or “UNLOCK”. CL MT AT TF PD AX SEL699Y Refer to wiring diagram in EL-283. OK or NG OK 䊳 Door lock/unlock switch is OK. NG 䊳 Check the following. 쐌 Ground circuit for each front power window switch 쐌 Harness for open or short between each front power window switch and smart entrance control unit connector If above systems are normal, replace the front power window switch. SU BR ST RS BT HA SC IDX EL-291 POWER DOOR LOCK Trouble Diagnoses (Cont’d) FRONT DOOR KEY CYLINDER SWITCH CHECK 1 =NAEL0390S06 CHECK FRONT DOOR KEY CYLINDER SWITCH INPUT SIGNAL (LOCK/UNLOCK SIGNAL) With CONSULT-II Check front door key cylinder switch (“KEY CYL LK-SW”/“KEY CYL UN-SW”) in “DATA MONITOR” mode with CONSULTII. SEL342WF Without CONSULT-II 1. Check the signal between smart entrance control unit harness connector M122 terminal 33 (BR) and ground with oscilloscope when key inserted in front door key cylinder is turned “LOCK” or “UNLOCK”. 2. Make sure signals which are shown in the figure below can be detected during 10 sec. just after key is turned “LOCK” or “UNLOCK”. SEL700Y Refer to wiring diagram in EL-283. OK or NG OK 䊳 Front door key cylinder switch LH is OK. NG 䊳 GO TO 2. EL-292 POWER DOOR LOCK Trouble Diagnoses (Cont’d) CHECK FRONT DOOR KEY CYLINDER SWITCH GI 1. Disconnect front door key cylinder switch connector. 2. Check continuity between front door key cylinder switch terminals. MA 2 EM LC EC SEL313XB FE OK or NG OK NG 䊳 䊳 Check the following. 쐌 Front door key cylinder switch LH ground circuit 쐌 Harness for open or short between smart entrance control unit and power window main switch 쐌 Harness for open or short between power window main switch and front door key cylinder switch LH Replace front door key cylinder switch LH. CL MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-293 POWER DOOR LOCK Trouble Diagnoses (Cont’d) BACK DOOR KEY CYLINDER SWITCH CHECK 1 =NAEL0390S07 CHECK BACK DOOR KEY CYLINDER SWITCH INPUT SIGNAL (LOCK/UNLOCK SIGNAL) With CONSULT-II Check back door key cylinder switch (“KEY CYL LK-SW”/“KEY CYL UN-SW”) in “DATA MONITOR” mode with CONSULTII. SEL342WG Without CONSULT-II Check voltage between smart entrance control unit harness connector M121 terminals 10 (LG) or 11 (Y) and ground. SEL286Y Refer to wiring diagram in EL-280. OK or NG OK 䊳 Back door key cylinder switch is OK. NG 䊳 GO TO 2. EL-294 POWER DOOR LOCK Trouble Diagnoses (Cont’d) 2 GI CHECK BACK DOOR KEY CYLINDER SWITCH 1. Disconnect back door key cylinder switch connector. 2. Check continuity between back door key cylinder switch terminals. MA EM LC EC SEL315X FE OK or NG OK 䊳 Check the following. 쐌 Back door key cylinder switch ground circuit 쐌 Harness for open or short between smart entrance control unit and back door key cylinder switch NG 䊳 Replace back door key cylinder switch. CL MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-295 POWER DOOR LOCK Trouble Diagnoses (Cont’d) DOOR LOCK ACTUATOR CHECK 1 CHECK DOOR LOCK ACTUATOR OPERATION 1. 2. 3. 4. With CONSULT-II Select “ACTIVE TEST” in “DOOR LOCK” with CONSULT-II. Select “ALL D/LK MTR” and touch “ON”. Then, select “DR D/UN MTR” and touch “ON”. Select “NON DR D/UN” and touch “ON”. =NAEL0390S08 SEL343W NOTE: If CONSULT-II is not available, skip this procedure and go to the next step. OK or NG OK 䊳 Door lock actuator is OK. NG 䊳 GO TO 2. EL-296 POWER DOOR LOCK Trouble Diagnoses (Cont’d) 2 GI CHECK DOOR LOCK ACTUATOR CIRCUIT 쐌 Door lock actuator front LH Check voltage between smart entrance control unit harness connector M123 terminal 54 (L), 55 (W/PU) and ground. MA EM LC EC SEL014Y 쐌 Door lock actuator front RH and rear Chcek voltage between smart entrance control unit harness connector M123 terminal 54 (L), 56 (Y/B) and ground. FE CL MT AT TF SEL015Y Refer to wiring diagram in EL-281. OK or NG OK 䊳 GO TO 2. NG 䊳 Replace smart entrance control unit. (Before replacing smart entrance control unit, perform “DOOR LOCK/UNLOCK SWITCH CHECK”.) PD AX SU BR ST RS BT HA SC IDX EL-297 POWER DOOR LOCK Trouble Diagnoses (Cont’d) 3 CHECK DOOR LOCK ACTUATOR 1. Disconnect door lock actuator connector. 2. Apply 12V direct current to door lock actuator and check operation. SEL318X SEL319X OK or NG OK 䊳 Check harness for open or short between smart entrance control unit connector and door lock actuator. NG 䊳 Replace door lock actuator. EL-298 REMOTE KEYLESS ENTRY SYSTEM Component Parts and Harness Connector Location Component Parts and Harness Connector Location GI NAEL0391 MA EM LC EC FE CL MT AT TF PD SEL676Y AX SU System Description INPUTS NAEL0392 NAEL0392S01 Power is supplied at all times 쐌 to smart entrance control unit terminal 49 and 쐌 to key switch terminal 2 쐌 through 7.5A fuse [No. 24, located in the fuse block (J/B)], and 쐌 to smart entrance control unit terminal 51 쐌 through circuit breaker terminals 2 and 1 and 쐌 through 40A fusible link (letter f, located in fuse and fusible link box). When the key switch is ON (ignition key is inserted in key cylinder), power is supplied 쐌 through key switch terminal 1 쐌 to smart entrance control unit terminal 25. When the front door switch LH is ON (door is OPEN), ground is supplied 쐌 to smart entrance control unit terminal 1 쐌 through front door switch LH terminal 1 쐌 to front door switch LH terminal 2 쐌 through body grounds B11, B22 and D210. When the front door switch RH is ON (door is OPEN), ground is supplied 쐌 to smart entrance control unit terminal 2 쐌 through front door switch RH terminal 1 EL-299 BR ST RS BT HA SC IDX REMOTE KEYLESS ENTRY SYSTEM System Description (Cont’d) 쐌 to front door switch RH terminal 2 쐌 through body grounds B55 and B75. When the all doors switches are ON (door is OPEN), ground is supplied 쐌 to smart entrance control unit terminal 3 쐌 through front door switches terminal 3 쐌 to front door switches case grounds, and 쐌 through rear door switches terminal 1 쐌 to rear door switches case grounds, and 쐌 through back door switch terminal 2 쐌 to back door switch terminal 1 쐌 through body grounds B11, B22 and D210. When lock/unlock switch LH is LOCK/UNLOCK, ground is supplied 쐌 to power window main switch terminal 17 쐌 through body grounds M4, M66, M111, M147 and M157. Door lock or unlock operation signal is supplied 쐌 through power window main switch terminal 14 쐌 to smart entrance control unit terminal 33. When lock/unlock switch RH is LOCK/UNLOCK, ground is supplied 쐌 to front power window switch RH terminal 11 쐌 through body grounds M4, M66, M111, M147 and M157. Door lock or unlock operation signal is supplied 쐌 through power window main switch terminal 14 쐌 to smart entrance control unit terminal 33. Remote controller signal is inputted to smart entrance control unit (The antenna of the system is combined with smart entrance control unit). Smart entrance control unit is connected to power window main switch (door lock and unlock switch) and front power window switch RH (door lock and unlock switch) as serial link communication line. Refer to “POWER WINDOW SERIAL LINK” (EL-259). OPERATION NAEL0392S02 The remote keyless entry system controls operation of the 쐌 power door lock 쐌 auto door lock 쐌 interior lamp 쐌 panic alarm 쐌 hazard and horn reminder 쐌 power window opener OPERATED PROCEDURE Power Door Lock Operation NAEL0392S03 NAEL0392S0301 Smart entrance control unit receives a LOCK signal from keyfob. Smart entrance control unit locks all doors with input of LOCK signal from keyfob. When an UNLOCK signal is sent from keyfob once, driver’s door will be unlocked. Then, if an UNLOCK signal is sent from keyfob again within 5 seconds, all other door will be unlocked. Select unlock mode can be changed by CONSULT-II (EL-309). Auto Door Lock Operation NAEL0392S0308 Auto lock function signal is sent for operation when any of the following signals are not sent within 5 minutes after the unlock signal is sent from the keyfob: 쐌 when door switch is turned ON for open. 쐌 when the ignition switch is turned ON. 쐌 when the lock signal is sent from the keyfob. Auto door lock mode can be changed by CONSULT-II (EL-309). EL-300 REMOTE KEYLESS ENTRY SYSTEM System Description (Cont’d) Hazard and Horn Reminder NAEL0392S0302 Power is supplied at all times 쐌 to horn relay terminals 1 and 3 쐌 through 7.5A fuse (No. 52, located in the fusible link and fuse box), and 쐌 to horn relay terminal 6 쐌 through 10A fuse (No. 54, located in the fusible link and fuse box) When smart entrance control unit receives LOCK or UNLOCK signal from keyfob with all doors closed, ground is supplied 쐌 to horn relay terminal 2 쐌 through smart entrance control unit terminal 42, and 쐌 to smart entrance control unit terminals 47 and 48 from hazard warning lamp system. Horn relay are now energized, and hazard warning lamp flashes and horn sounds as a reminder. The hazard and horn reminder has C mode (horn chirp mode) and S mode (non-horn chirp mode). Operating function of hazard and horn reminder Lock GI MA EM LC EC FE Unlock CL Hazard warning lamp flash Horn sound Hazard warning lamp flash Horn sound C MODE Twice Once Once — S MODE Twice — — — MODE 3 — — — — MODE 4 Twice — Once — MODE 5 Twice Once — — MODE 6 — Once Once — MT AT TF PD How to change hazard and horn reminder mode With CONSULT-II Hazard and horn reminder can be changed by CONSULT-II (EL-309). Without CONSULT-II When LOCK and UNLOCK signals are sent from the keyfob for more than 2 seconds at the same time, the hazard and horn reminder mode is changed and hazard warning lamp flashes and horn sounds as follows: AX SU BR ST RS SEL153WA BT NOTE: Reminder mode setting cannot be changed without CONSULT-II for MODES 3, 4, 5, and 6. However, C and S MODES can be changed without CONSULT-II. HA Interior Lamp Operation SC NAEL0392S0303 When the following input signals are both supplied: 쐌 door switch CLOSED (when all the doors are closed); 쐌 driver’s door LOCKED; IDX EL-301 REMOTE KEYLESS ENTRY SYSTEM System Description (Cont’d) remote keyless entry system turns on interior lamp and (for 30 seconds) with input of UNLOCK signal from keyfob. For detailed description, refer to “INTERIOR, STEP, SPOT, VANITY MIRROR AND TRUNK ROOM LAMPS” (EL-97). Panic Alarm Operation NAEL0392S0304 When key switch is OFF (when ignition key is not inserted in key cylinder), remote keyless entry system turns horn and headlamp on and off intermittently with input of PANIC ALARM signal from keyfob. The alarm automatically turns off after 25 seconds or when smart entrance control unit receives any signal from keyfob. For detailed description, refer to “VEHICLE SECURITY SYSTEM” (EL-332). The panic alarm button’s pressing time on keyfob can be changed with CONSULT-II (EL-309). Power Window Opener Operation NAEL0392S0307 The front power windows open when the unlock button on keyfob is activated and kept pressed for more than 3 seconds with the ignition key OFF. The windows keep opening if the unlock button is continuously pressed. The power window opening stops when the following operations are carried out: 쐌 When the unlock button is kept pressed more than 15 seconds. 쐌 When the ignition switch is turned ON while the power window opening is operated. 쐌 When the unlock button is released. The unlock button’s pressing time can be changed with CONSULT-II (EL-309). Door Lock/Unlock and front power window down signal is sent from smart entrance control unit to power window main switch with power window serial link communication link. Refer to “POWER WINDOW SERIAL LINK” (EL-259). Signals are supplied 쐌 through smart entrance control unit terminal 33 쐌 to power window main switch terminal 14 and 쐌 to front power window switch RH terminal 16. EL-302 REMOTE KEYLESS ENTRY SYSTEM Schematic Schematic NAEL0393 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL433O EL-303 IDX REMOTE KEYLESS ENTRY SYSTEM Wiring Diagram — KEYLESS — Wiring Diagram — KEYLESS — FIG. 1 NAEL0394 NAEL0394S01 MEL030Q EL-304 REMOTE KEYLESS ENTRY SYSTEM Wiring Diagram — KEYLESS — (Cont’d) FIG. 2 NAEL0394S02 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL031Q EL-305 IDX REMOTE KEYLESS ENTRY SYSTEM Wiring Diagram — KEYLESS — (Cont’d) FIG. 3 NAEL0394S03 MEL413O EL-306 REMOTE KEYLESS ENTRY SYSTEM Wiring Diagram — KEYLESS — (Cont’d) FIG. 4 NAEL0394S05 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL032Q EL-307 IDX REMOTE KEYLESS ENTRY SYSTEM CONSULT-II Inspection Procedure CONSULT-II Inspection Procedure “MULTI REMOTE ENT” NAEL0395 NAEL0395S01 1. 2. Turn ignition switch “OFF”. Connect “CONSULT-II” and “CONSULT-II CONVERTER” to the data link connector. 3. 4. Turn ignition switch “ON”. Touch “START (NISSAN BASED VHCL)”. 5. Touch “SMART ENTRANCE”. If “SMART ENTRANCE” is not indicated, go to GI-41, “CONSULT-II Data Link Connector (DLC) Circuit”. 6. Touch “MULTI REMOTE ENT”. 7. Select diagnosis mode. “DATA MONITOR”, “ACTIVE TEST” and “WORK SUPPORT” are available. SEL670Y SKIA3098E SEL669Y SEL751Y SEL274W EL-308 REMOTE KEYLESS ENTRY SYSTEM CONSULT-II Application Items CONSULT-II Application Items “MULTI REMOTE ENT” Data Monitor NAEL0457 GI NAEL0457S01 NAEL0457S0101 Monitored Item MA Description IGN ON SW Indicates [ON/OFF] condition of ignition switch in ON position. ACC ON SW Indicates [ON/OFF] condition of ignition switch in ACC position. DOOR SW-RR Indicates [ON/OFF] condition of rear door switch. KEY ON SW Indicates [ON/OFF] condition of key switch. DOOR SW-DR Indicates [ON/OFF] condition of front door switch LH. DOOR SW-AS Indicates [ON/OFF] condition of door switch RH. LOCK SW DR/AS Indicates [ON/OFF] condition of lock signal from lock/unlock switch LH and RH. UNLK SW DR/AS Indicates [ON/OFF] condition of unlock signal from lock/unlock switch LH and RH. KEY CYL LK-SW Indicates [ON/OFF] condition of lock signal from key cylinder switch. LK BUTTON/SIG Indicates [ON/OFF] condition of lock signal from keyfob. UN BUTTON/SIG Indicates [ON/OFF] condition of unlock signal from keyfob. TRUNK BTN/SIG Indicates [ON/OFF] condition of trunk open signal from keyfob. PANIC BTN Indicates [ON/OFF] condition of panic signal from keyfob. UN BUTTON ON Indicates [ON/OFF] condition of unlock switch form keyfob. LK/UN BTN ON Indicates [ON/OFF] condition of lock/unlock signal at the same time from keyfob. EM LC EC FE CL MT AT TF NOTE: Even though TRUNK BTN/SIG is actually displayed on the CONSULT-II screen, it is not equipped, therefore, they cannot be activated. Active Test NAEL0457S0102 Test Item PD AX Description INT/IGN ILLUM This test is able to check interior lamp and ignition key hole illumination operation. The interior lamp and ignition key hole illumination are turned on when “ON” on CONSULT-II screen is touched. SU HAZARD This test is able to check hazard reminder operation. The hazard lamp turns on when “ON” on CONSULT-II screen is touched. BR TRUNK OUTPUT This test is able to check trunk lid opener actuator operation. The trunk is unlocked when “ON” on CONSULT-II screen is touched. ST HORN This test is able to check panic alarm and horn reminder operations. The alarm activate for 0.5 seconds after “ON” on CONSULT-II screen is touched. RS HEAD LAMP This test is able to check headlamps panic alarm operation. The headlamp illuminates for 0.5 seconds after “ON” on CONSULT-II screen is touched. PW REMOTE DOWN SET This test is able to check power window open operation. The front power windows activate for 10 seconds after “ON” on CONSULT-II screen is touched. NOTE: Even though TRUNK OUTPUT is actually displayed on the CONSULT-II screen, it is not equipped, therefore, they cannot be activated. Work Support NAEL0457S0103 Test Item BT HA SC Description REMO CONT ID CONFIR It can be checked whether keyfob ID code is registered or not in this mode. REMO CONT ID REGIST Keyfob ID code can be registered. REMO CONT ID ERASUR Keyfob ID code can be erased. EL-309 IDX REMOTE KEYLESS ENTRY SYSTEM CONSULT-II Application Items (Cont’d) Test Item Description MULTI ANSWER BACK SET Hazard and horn reminder mode can be changed with this mode. Selects hazard and horn reminder mode among six steps (EL-301). AUTO LOCK SET Auto door lock mode can be selected among the following periods: 쐌 MODE 1 (5 min.)/MODE 2 (OFF-Mode)/MODE 3 (1 min.) PANIC ALARM SET The panic alarm button’s pressing time on keyfob can be selected among the following periods: 쐌 MODE 1 (0.5 sec.)/MODE 2 (OFF-Mode)/MODE 3 (1.5 sec.) TRUNK OPENER The trunk lid opener button’s pressing time on keyfob can be selected among the following periods: 쐌 MODE 1 (0.5 sec.)/MODE 2 (OFF-Mode)/MODE 3 (1.5 sec.) PW DOWN SET The unlock button’s pressing time on keyfob can be selected among the following periods: 쐌 MODE 1 (3 sec.)/MODE 2 (OFF-Mode)/MODE 3 (5 sec.) NOTE: Even though TRUNK OPENER is actually displayed on the CONSULT-II screen, it is not equipped, therefore, they cannot be activated. Trouble Diagnoses NAEL0397 SYMPTOM CHART NAEL0397S01 NOTE: 쐌 Always check keyfob battery before replacing keyfob. 쐌 The panic alarm operation of remote keyless entry system does not activate with the ignition key inserted in the ignition key cylinder. Symptom All functions of remote keyless entry system do not operate. Diagnoses/service procedure Reference page (EL- ) 1. Keyfob battery and function check 312 2. Power supply and ground circuit for smart entrance control unit check 313 3. Replace keyfob. Refer to ID Code Entry Procedure. 325 NOTE: If the result of keyfob function check with CONSULT-II is OK, keyfob is not malfunctioning. The new ID of keyfob cannot be entered. 1. Keyfob battery and function check 312 2. Key switch (insert) check 317 3. Door switch check 315 4. Door lock/unlock switch LH check 318 5. Power supply and ground circuit for smart entrance control unit check 313 6. Replace keyfob. Refer to ID Code Entry Procedure. 325 NOTE: If the result of keyfob function check with CONSULT-II is OK, keyfob is not malfunctioning. Door lock or unlock does not function. (If the power door lock system does not operate manually, check power door lock system. Refer to EL-286) 1. Keyfob battery and function check 312 2. Replace keyfob. Refer to ID Code Entry Procedure. 325 NOTE: If the result of keyfob function check with CONSULT-II is OK, keyfob is not malfunctioning. EL-310 REMOTE KEYLESS ENTRY SYSTEM Trouble Diagnoses (Cont’d) Symptom Hazard and horn reminder does not activate properly when pressing lock or unlock button of keyfob. Diagnoses/service procedure Reference page (EL- ) 1. Keyfob battery and function check 312 2. Hazard reminder check 319 3. Horn reminder check* 320 *: Horn chirp can be activated or deactivated. First check the horn chirp setting. Refer to “System Description”, EL-301. 4. Door switch check 315 5. Replace keyfob. Refer to ID Code Entry Procedure. 325 NOTE: If the result of keyfob function check with CONSULT-II is OK, keyfob is not malfunctioning. GI MA EM LC EC FE Interior room lamp operation do not activate properly. 1. Interior room lamp operation check 322 2. Door switch check 315 Panic alarm (horn and headlamp) does not activate when panic alarm button is continuously pressed. 1. Keyfob battery and function check 312 2. Theft warning operation check. Refer to “PRELIMINARY CHECK” in “VEHICLE SECURITY SYSTEM”. 344 MT 3. Key switch (insert) check 317 AT 4. Replace keyfob. Refer to ID Code Entry Procedure. 325 NOTE: If the result of keyfob function check with CONSULT-II is OK, keyfob is not malfunctioning. CL TF PD AX SU BR ST RS BT HA SC IDX EL-311 REMOTE KEYLESS ENTRY SYSTEM Trouble Diagnoses (Cont’d) REMOTE CONTROLLER BATTERY AND FUNCTION CHECK =NAEL0397S02 1 CHECK REMOTE CONTROLLER BATTERY Remove battery (refer to EL-327) and measure voltage across battery positive and negative terminals, (+) and (−). Voltage [V]: 2.5 - 3.0 NOTE: Keyfob does not function if battery is not set correctly. SEL237W OK or NG OK 䊳 GO TO 2. NG 䊳 Replace battery. 2 CHECK REMOTE CONTROLLER FUNCTION With CONSULT-II Check keyfob function (“LK BUTTON/SIG”, “UN BUTTON/SIG”, “PANIC BTN”, “UN BUTTON ON” and “LK/UN BTN ON”) in “DATA MONITOR” mode with CONSULT-II. SEL423Y NOTE: Even though TRUNK BTN/SIG is actually displayed on the CONSULT-II screen, it is not equipped, therefore, they cannot be activated. OK or NG OK 䊳 Keyfob is OK. Further inspection is necessary. Refer to “SYMPTOM CHART”, EL-310. NG 䊳 Replace keyfob. Refer to ID Code Entry Procedure. EL-312 REMOTE KEYLESS ENTRY SYSTEM Trouble Diagnoses (Cont’d) POWER SUPPLY AND GROUND CIRCUIT CHECK =NAEL0397S03 GI 1 CHECK MAIN POWER SUPPLY CIRCUIT FOR SMART ENTRANCE CONTROL UNIT 1. Disconnect smart entrance control unit harness connector. 2. Check voltage between smart entrance control unit harness connector M123 terminal 49 (G/R) or 51 (W/R) and ground. MA EM LC EC FE SEL018Y Refer to wiring diagram in EL-304. CL OK or NG OK 䊳 GO TO 2. NG 䊳 Check the following. 쐌 40A fusible link (letter f, located in fuse and fusible link box) 쐌 7.5A fuse [No. 24, located in fuse block (J/B)] 쐌 M145 circuit breaker 쐌 Harness for open or short between smart entrance control unit and fuse 2 MT AT TF CHECK IGNITION SWITCH “ACC” CIRCUIT 1. Disconnect smart entrance control unit harness connector. 2. Check voltage between smart entrance control unit harness connector M122 terminal 26 (G/W) and ground while ignition switch is “ACC”. PD AX SU BR ST SEL019Y Refer to wiring diagram in EL-304. OK or NG OK 䊳 GO TO 3. NG 䊳 Check the following. 쐌 10A fuse [No. 10, located in fuse block (J/B)] 쐌 Harness for open or short between smart entrance control unit and fuse RS BT HA SC IDX EL-313 REMOTE KEYLESS ENTRY SYSTEM Trouble Diagnoses (Cont’d) 3 CHECK GROUND CIRCUIT FOR SMART ENTRANCE CONTROL UNIT Check continuity between smart entrance control unit harness connector M122 terminal 43 (B) or M123 terminal 64 (B) and ground. SEL020Y Refer to wiring diagram in EL-304. OK or NG OK 䊳 Power supply and ground circuits are OK. NG 䊳 Check ground harness. EL-314 REMOTE KEYLESS ENTRY SYSTEM Trouble Diagnoses (Cont’d) DOOR SWITCH CHECK 1 =NAEL0397S04 GI CHECK DOOR SWITCH INPUT SIGNAL With CONSULT-II Check door switches (“DOOR SW-RR”, “DOOR SW-DR” and “DOOR SW-AS”) in “DATA MONITOR” mode with CONSULT-II. MA EM LC EC FE SEL024Y Without CONSULT-II Check voltage between smart entrance control unit harness connector M121 terminals 1 (G/OR), 2 (Y) or 3 (R/L) and ground. CL MT AT TF PD SEL021YD Refer to wiring diagram in EL-305. AX OK or NG OK 䊳 Door switch is OK. NG 䊳 GO TO 2. SU BR ST RS BT HA SC IDX EL-315 REMOTE KEYLESS ENTRY SYSTEM Trouble Diagnoses (Cont’d) 2 CHECK DOOR SWITCH 1. Disconnect door switch harness connector. 2. Check the following. 쐌 Continuity between front door switch harness connector B9 (LH) or B68 (RH) terminals 1 and 2 쐌 Continuity between front door switch harness connector B9 (LH) or B68 (RH) terminal 3 and ground 쐌 Continuity between back door switch harness connector D208 terminals 1 and 2 쐌 Continuity between rear door switch harness connector B18 (LH) or B71 (RH) terminal 1 and ground SEL287Y OK or NG OK 䊳 Check the following. 쐌 Door switch ground circuit (Front or back door) or door switch ground condition (Rear door) 쐌 Harness for open or short between smart entrance control unit and door switch NG 䊳 Replace door switch. EL-316 REMOTE KEYLESS ENTRY SYSTEM Trouble Diagnoses (Cont’d) KEY SWITCH (INSERT) CHECK 1 =NAEL0397S05 GI CHECK KEY SWITCH INPUT SIGNAL MA With CONSULT-II Check key switch (“KEY ON SW”) in “DATA MONITOR” mode with CONSULT-II. EM LC EC FE SEL315W Without CONSULT-II Check voltage between control unit harness connector M122 terminal 25 (W/R) and ground. CL MT AT TF SEL022Y PD Refer to wiring diagram in EL-304. OK or NG OK 䊳 Key switch is OK. NG 䊳 GO TO 2. 2 AX SU CHECK KEY SWITCH (INSERT) BR Check continuity between key switch terminals 1 and 2. ST RS BT SEL308X HA OK or NG OK 䊳 Check the following. 쐌 7.5A fuse [No. 24, located in fuse block (J/B)] 쐌 Harness for open or short between key switch and fuse 쐌 Harness for open or short between smart entrance control unit and key switch NG 䊳 Replace key switch. SC IDX EL-317 REMOTE KEYLESS ENTRY SYSTEM Trouble Diagnoses (Cont’d) DOOR LOCK/UNLOCK SWITCH LH CHECK 1 =NAEL0397S06 CHECK DOOR LOCK/UNLOCK SWITCH INPUT SIGNAL With CONSULT-II Check door lock/unlock switch (“LOCK SW DR/AS”/“UNLK SW DR/AS”) in “DATA MONITOR” mode with CONSULT-II. SEL341W Without CONSULT-II 1. Remove key from ignition key cylinder. 2. Check the signal between smart entrance control unit harness connector M122 terminal 33 (BR) and ground with an oscilloscope when door lock/unlock switch is turned “LOCK” or “UNLOCK”. 3. Make sure signals shown in the figure below can be detected during the first 10 sec. just after door lock/unlock switch is turned to “LOCK” or “UNLOCK”. SEL699Y Refer to wiring diagram in EL-304. OK or NG OK 䊳 Door lock/unlock switch is OK. NG 䊳 Check the following. 쐌 Ground circuit for each front power window switch 쐌 Harness for open or short between each front power window switch and smart entrance control unit connector If above systems are normal, replace the front power window switch. EL-318 REMOTE KEYLESS ENTRY SYSTEM Trouble Diagnoses (Cont’d) HAZARD REMINDER CHECK 1 =NAEL0397S07 GI CHECK HAZARD INDICATOR MA Check if hazard indicator flashes with hazard switch. Does hazard indicator operate? Yes 䊳 GO TO 2. No 䊳 Check “hazard indicator” circuit. EM LC 2 CHECK HAZARD REMINDER OPERATION WITH CONSULT-II With CONSULT-II 1. Select “ACTIVE TEST” in “MULTI REMOTE ENT” with CONSULT-II. 2. Select “HAZARD” and touch “ON”. EC FE CL MT AT SEL347W NOTE: If CONSULT-II is not available, skip this procedure and go to the next step. TF OK or NG OK 䊳 Hazard reminder operation is OK. NG 䊳 Replace smart entrance control unit. 3 PD AX CHECK HAZARD REMINDER OPERATION WITHOUT CONSULT-II Without CONSULT-II Apply ground to smart entrance control unit harness connector M122 terminal 47 (GY/L) and 48 (GY/R). SU BR ST RS SEL027Y Refer to wiring diagram in EL-306. OK or NG OK 䊳 System is OK. NG 䊳 Replace smart entrance control unit. BT HA SC IDX EL-319 REMOTE KEYLESS ENTRY SYSTEM Trouble Diagnoses (Cont’d) HORN REMINDER CHECK 1 =NAEL0397S08 CHECK HORN Check if horn sounds with horn switch. Does horn operate? Yes 䊳 GO TO 2. No 䊳 Check horn circuit. 2 CHECK HORN REMINDER OPERATION WITH CONSULT-II With CONSULT-II 1. Select “ACTIVE TEST” in “MULTI REMOTE ENT” with CONSULT-II. 2. Select “HORN” and touch “ON”. SEL451Y NOTE: If CONSULT-II is not available, skip this procedure and go to the next step. OK or NG OK 䊳 Horn reminder operation is OK. NG 䊳 GO TO 4. 3 CHECK HORN REMINDER OPERATION WITHOUT CONSULT-II Without CONSULT-II 1. Disconnect smart entrance control unit harness connector. 2. Apply ground to smart entrance control unit harness connector M122 terminal 42 (LG/B). SEL028Y Refer to wiring diagram in EL-306. Does horn sound? Yes 䊳 Replace smart entrance control unit. No 䊳 GO TO 4. EL-320 REMOTE KEYLESS ENTRY SYSTEM Trouble Diagnoses (Cont’d) 4 GI CHECK HORN RELAY Check horn relay. MA OK or NG OK 䊳 GO TO 5. NG 䊳 Replace horn relay. 5 EM CHECK POWER SUPPLY FOR HORN RELAY LC 1. Disconnect horn relay harness connector. 2. Check voltage between horn relay harness connector E118 terminal 1 (G/B) and ground. EC FE CL MT SEL326XA AT OK or NG OK 䊳 GO TO 6. NG 䊳 Check the following. 쐌 7.5A fuse [No. 52, located in fuse block (J/B)] 쐌 Harness for open or short between horn relay and fuse 6 TF PD CHECK HORN RELAY CIRCUIT AX 1. Disconnect horn relay harness connector. 2. Check voltage between horn relay harness connector E118 terminals 3 (G/B) and 5 (R). 3. Check voltage between horn relay harness connector E118 terminals 6 (LG) and 7 (G). SU BR ST RS SEL327XA OK or NG OK 䊳 Check harness for open or short between smart entrance control unit and horn relay. NG 䊳 Check the following. 쐌 Harness for open or short between horn relay and fuse 쐌 Harness for open or short between horn relay and horns BT HA SC IDX EL-321 REMOTE KEYLESS ENTRY SYSTEM Trouble Diagnoses (Cont’d) INTERIOR ROOM LAMP OPERATION CHECK 1 =NAEL0397S09 CHECK ROOM INTERIOR LAMP Check if the interior room lamp switch is in the “ON” position and the lamp illuminates. Does interior room lamp illuminate? Yes 䊳 GO TO 2. No 䊳 Check the following. 쐌 Harness for open or short between smart entrance control unit and interior room lamp 쐌 Interior room lamp 2 CHECK INTERIOR ROOM LAMP OPERATION With CONSULT-II 1. Select “ACTIVE TEST” in “MULTI REMOTE ENT” with CONSULT-II. 2. Select “INT/IGN ILLUM” and touch “ON”. SEL312Y Without CONSULT-II Push unlock button of keyfob with all doors closed and driver’s door locked, and check voltage between smart entrance control unit harness connector M122 terminal 31 (R/B) and ground. SEL029Y Refer to wiring diagram in EL-304. OK or NG OK 䊳 System is OK. NG 䊳 Check harness for open or short between smart entrance control unit and interior room lamp. EL-322 REMOTE KEYLESS ENTRY SYSTEM ID Code Entry Procedure ID Code Entry Procedure KEYFOB ID SET UP WITH CONSULT-II =NAEL0398 GI NAEL0398S01 NOTE: If a keyfob is lost, the ID code of the lost keyfob must be erased to prevent unauthorized use. When the ID code of a lost keyfob is not known, all keyfob ID codes should be erased. After all ID codes are erased, the ID codes of all remaining and/or new keyfob must be re-registered. MA EM LC 1. 2. Turn ignition switch “OFF”. Connect “CONSULT-II” and “CONSULT-II CONVERTER” to the data link connector. EC FE CL MT SEL670Y 3. 4. Turn ignition switch “ON”. Touch “START (NISSAN BASED VHCL)”. AT TF PD AX SU SKIA3098E 5. Touch “SMART ENTRANCE”. If “SMART ENTRANCE” is not indicated, go to GI-41, “CONSULT-II Data Link Connector (DLC) Circuit”. BR ST RS BT SEL669Y 6. Touch “MULTI REMOTE ENT”. HA SC IDX SEL401Y EL-323 REMOTE KEYLESS ENTRY SYSTEM ID Code Entry Procedure (Cont’d) 7. Touch “WORK SUPPORT”. SEL274W 8. 쐌 SEL424Y The items are shown on the figure at left can be set up. “REMO CONT ID CONFIR” Use this mode to confirm if a keyfob ID code is registered or not. 쐌 “REMO CONT ID REGIST” Use this mode to register a keyfob ID code. NOTE: Register the ID code when keyfob or smart entrance control unit is replaced, or when additional keyfob is required. 쐌 “REMO CONT ID ERASUR” Use this mode to erase a keyfob ID code. Refer to the EL-309, “WORK SUPPORT” in “CONSULT-II Application Items” for the following items. 쐌 “MULTI ANSWER BACK SET” 쐌 “AUTO LOCK SET” 쐌 “PANIC ALARM SET” 쐌 “TRUNK OPENER” 쐌 “PW DOWN SET” NOTE: Even though TRUNK OPENER is actually displayed on the CONSULT-II screen, it is not equipped, therefore, they cannot be activated. EL-324 REMOTE KEYLESS ENTRY SYSTEM ID Code Entry Procedure (Cont’d) KEYFOB ID SET UP WITHOUT CONSULT-II NAEL0398S02 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC SEL170YA EL-325 IDX REMOTE KEYLESS ENTRY SYSTEM ID Code Entry Procedure (Cont’d) NOTE: 쐌 If a keyfob is lost, the ID code of the lost keyfob must be erased to prevent unauthorized use. A specific ID code can be erased with CONSULT-II. However, when the ID code of a lost keyfob is not known, all keyfob ID codes should be erased. After all ID codes are erased, the ID codes of all remaining and/or new keyfob must be re-registered. To erase all ID codes in memory, register one ID code (keyfob) four times. After all ID codes are erased, the ID codes of all remaining and/or new keyfob must be re-registered. 쐌 When registering an additional keyfob, the existing ID codes in memory may or may not be erased. If four ID codes are stored in memory, when an additional code is registered, only the oldest code is erased. If less than four ID codes are stored in memory, when an additional ID code is registered, the new ID code is added and no ID codes are erased. 쐌 If you need to activate more than two additional new keyfob, repeat the procedure “Additional ID code entry” for each new keyfob. 쐌 Entry of maximum four ID codes is allowed. When more than four ID codes are entered, the oldest ID code will be erased. 쐌 Even if the same ID code that is already in the memory is input, the same ID code can be entered. The code is counted as an additional code. EL-326 REMOTE KEYLESS ENTRY SYSTEM Keyfob Battery Replacement Keyfob Battery Replacement NAEL0399 GI MA EM LC EC FE CL MT AT TF SEL485Y PD AX SU BR ST RS BT HA SC IDX EL-327 VEHICLE SECURITY (THEFT WARNING) SYSTEM Component Parts and Harness Connector Location Component Parts and Harness Connector Location NAEL0400 SEL677Y EL-328 VEHICLE SECURITY (THEFT WARNING) SYSTEM System Description System Description DESCRIPTION 1. Operation Flow NAEL0401 GI NAEL0401S01 NAEL0401S0101 MA EM LC EC FE CL MT 2. Setting The Vehicle Security System SEL334W AT NAEL0401S0102 TF Initial condition 1) Ignition switch is in OFF position. Disarmed phase When the vehicle security system is in the disarmed phase, the security indicator lamp blinks every 2.6 seconds. Pre-armed phase and armed phase When the following operation 1) or 2) is performed, the vehicle security system turns into the “pre-armed” phase. (The security indicator lamp illuminates.) 1) Smart entrance control unit receives LOCK signal from key cylinder switch or keyfob after hood, glass hatch and all doors are closed. 2) Hood, glass hatch and all doors are closed after front doors are locked by key, lock/unlock switch or multiremote controller. After about 30 seconds, the system automatically shifts into the “armed” phase (the system is set). (The security indicator lamp blinks every 2.6 seconds.) 3. Canceling The Set Vehicle Security System SU BR ST RS BT NAEL0401S0104 Make sure the system is in the armed phase. (The security indicator lamp blinks every 2.6 seconds.) When the following operation 1) or 2) is performed, the system sounds the horns and flashes the headlamps for about 50 seconds. 1) Engine hood, glass hatch or any door is opened during armed phase. 2) Disconnecting and connecting the battery connector before canceling armed phase. POWER SUPPLY AND GROUND AX NAEL0401S0103 When the following 1) or 2) operation is performed, the armed phase is canceled. 1) Unlock the doors with the key or keyfob. 2) Open the glass hatch with the key or keyfob. 4. Activating The Alarm Operation of The Vehicle Security System PD HA SC NAEL0401S02 Power is supplied at all times 쐌 through 7.5A fuse [No. 24, located in the fuse block (J/B)] 쐌 to security indicator lamp terminal 1, and 쐌 to smart entrance control unit terminal 49. EL-329 IDX VEHICLE SECURITY (THEFT WARNING) SYSTEM System Description (Cont’d) With the ignition switch in the ON or START position, power is supplied 쐌 through 7.5A fuse [No. 11, located in the fuse block (J/B)] 쐌 to smart entrance control unit terminal 27. With the ignition switch in the ACC or ON position, power is supplied 쐌 through 10A fuse [No. 10, located in the fuse block (J/B)] 쐌 to smart entrance control unit terminal 26. Ground is supplied 쐌 to smart entrance control unit terminals 43 and 64 쐌 through body grounds M4, M66, M111, M147 and M157. INITIAL CONDITION TO ACTIVATE THE SYSTEM NAEL0401S03 The operation of the vehicle security system is controlled by the doors, hood and glass hatch. Pattern A NAEL0401S0301 To activate the vehicle security system, the smart entrance control unit must receive signals indicating the doors, hood and glass hatch are closed. When a door is open, smart entrance control unit terminal 1, 2 or 3 receives a ground signal from each door switch. When the hood is open, smart entrance control unit terminal 6 receives a ground signal 쐌 from terminal 1 of the hood switch 쐌 through body grounds E13 and E41. When the glass hatch is open, smart entrance control unit terminal 13 receives a ground signal 쐌 from terminal 1 of the glass hatch switch 쐌 through body grounds B11, B22 and D210. When smart entrance control unit receives LOCK signal from key cylinder switch or keyfob and none of the described conditions exist, the vehicle security system will automatically shift to armed mode. Pattern B NAEL0401S0302 To activate the vehicle security system, the smart entrance control unit must receive signal indicating any door (including hood and glass hatch) is opened. When the front doors are locked with key, lock/unlock switch or keyfob and then all doors are closed, the vehicle security system will automatically shift to armed mode. VEHICLE SECURITY SYSTEM ACTIVATION Pattern A NAEL0401S04 NAEL0401S0401 With all doors (including hood and glass hatch) closed, if the key is used to lock doors, smart entrance control unit terminal 33 receives a signal from power window main switch terminal 14. When key cylinder switch is in LOCK position, ground is supplied 쐌 to power window main switch terminal 6 쐌 from terminal 3 of the front door key cylinder switch LH 쐌 through terminal 2 of front door key cylinder switch LH 쐌 through body grounds M4, M66, M111, M147 and M157 or smart entrance control unit terminal 11 receives a ground signal 쐌 from terminal 1 of the back door key cylinder switch 쐌 through body grounds B11, B22 and D210. If this signal, or lock signal from keyfob is received by the smart entrance control unit, the vehicle security system will activate automatically. NOTE: Vehicle security system can be set even though all doors are not locked. Pattern B NAEL0401S0402 With any door (including hood and glass hatch) open, if lock/unlock switch is used to lock doors, smart entrance control unit terminal 33 receives a LOCK signal 쐌 from terminal 14 of lock/unlock switch LH or 쐌 from terminal 16 of lock/unlock switch RH, or EL-330 VEHICLE SECURITY (THEFT WARNING) SYSTEM System Description (Cont’d) With any door (including hood and glass hatch) open if the key is used to lock doors, smart entrance control unit terminal 33 receives a LOCK signal from power window main front switch terminal 14. Refer to power window serial link (EL-259). When key cylinder switch LOCK signal ground is supplied 쐌 to power window main switch terminal 4 쐌 from terminal 3 of the front door key cylinder switch LH 쐌 through terminal 2 of front door key cylinder switch LH 쐌 through body grounds M4, M66, M111, M147 and M157, or smart entrance control unit terminal 11 receives a ground signal 쐌 from terminal 1 of the back door key cylinder switch 쐌 through body grounds B11, B22 and D210. If these signals and lock signal from keyfob are received by the smart entrance control unit, ground signals of terminals 1, 2 and 3 are interrupted and all doors are closed, the vehicle security system will activate automatically. NOTE: Vehicle security system can be set even though the rear door is not locked. Once the vehicle security system has been activated, smart entrance control unit terminal 38 supplies ground to terminal 2 of the security indicator lamp. The security lamp will illuminate for approximately 30 seconds and then blinks every 2.6 seconds. Now the vehicle security system is in armed phase. VEHICLE SECURITY SYSTEM ALARM OPERATION NAEL0401S05 The vehicle security system is triggered by 쐌 opening a door 쐌 opening the hood or the glass hatch 쐌 detection of battery disconnect and connect. Once the vehicle security system is in armed phase, if the smart entrance control unit receives a ground signal at terminal 1, 2, 3 (door switch), 13 (glass hatch switch) or 6 (hood switch), the vehicle security system will be triggered. The headlamps flash and the horn sounds intermittently. Power is supplied at all times 쐌 through 7.5A fuse (No. 52, located in fuse and fusible link box) 쐌 to horn relay terminals 1 and 3. 쐌 through 10A fuse (No. 54, located in fuse and fusible link box) 쐌 to horn relay terminal 6. 쐌 through 15A fuse (No. 60, located in fuse and fusible link box) 쐌 to headlamp LH relay terminals 1 and 3, 쐌 through 15A fuse (No. 59, located in fuse and fusible link box) 쐌 to headlamp RH relay terminals 1 and 3. When the vehicle security system is triggered, ground is supplied intermittently 쐌 to headlamp (LH and RH) relay terminal 2 from smart entrance control unit terminals 21 and 59 쐌 through smart entrance control unit terminals 43 and 64. When headlamp relays (LH and RH) are energized and then power is supplied to headlamps (LH and RH). The headlamps flash intermittently. When the vehicle security system is triggered, ground is supplied intermittently 쐌 from smart entrance control unit terminal 42 쐌 to horn relay terminal 2. When horn relay are energized, then power is supplied to horn. The horn sounds intermittently. The alarm automatically turns off after 50 seconds but will reactivate if the vehicle is tampered with again. VEHICLE SECURITY SYSTEM DEACTIVATION MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC NAEL0401S06 To deactivate the vehicle security system, a door or glass hatch must be unlocked with the key or keyfob. When the key is used to unlock the door, smart entrance control unit terminal 33 receives an UNLOCK signal from power window main switch terminal 14. Refer to “POWER WINDOW SERIAL LINK” (EL-259). When key cylinder switch is in UNLOCK position, the ground is supplied EL-331 GI IDX VEHICLE SECURITY (THEFT WARNING) SYSTEM System Description (Cont’d) 쐌 to power window main switch terminal 6 쐌 from the front door key cylinder switch LH terminal 1 쐌 through front door key cylinder switch terminal 2, 쐌 through body grounds M4, M66, M111, M147 and M157. When the key is used to open the glass hatch, smart entrance control unit terminal 12 receives a ground signal from terminal 3 of the back door key cylinder switch. When the smart entrance control unit receives either one of these signals or unlock signal from keyfob, the vehicle security system is deactivated. (Disarmed phase) PANIC ALARM OPERATION NAEL0401S07 Remote keyless entry system may or may not operate vehicle security system (horn and headlamps) as required. When the remote keyless entry system (panic alarm) is triggered, ground is supplied intermittently 쐌 from smart entrance control unit terminals 21 and 59 쐌 to headlamp (LH and RH) relay terminal 2, and 쐌 from smart entrance control unit terminal 42 쐌 to horn relay terminal 2. The headlamp flashes and the horn sounds intermittently. The alarm automatically turns off after 25 seconds or when smart entrance control unit receives any signal from keyfob. EL-332 VEHICLE SECURITY (THEFT WARNING) SYSTEM System Description (Cont’d) NOTE: GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-333 VEHICLE SECURITY (THEFT WARNING) SYSTEM Schematic Schematic NAEL0402 MEL873N EL-334 VEHICLE SECURITY (THEFT WARNING) SYSTEM Schematic (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL437P IDX EL-335 VEHICLE SECURITY (THEFT WARNING) SYSTEM Wiring Diagram — VEHSEC — Wiring Diagram — VEHSEC — FIG. 1 NAEL0403 NAEL0403S01 MEL033Q EL-336 VEHICLE SECURITY (THEFT WARNING) SYSTEM Wiring Diagram — VEHSEC — (Cont’d) FIG. 2 NAEL0403S02 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL034Q EL-337 IDX VEHICLE SECURITY (THEFT WARNING) SYSTEM Wiring Diagram — VEHSEC — (Cont’d) FIG. 3 NAEL0403S03 MEL035Q EL-338 VEHICLE SECURITY (THEFT WARNING) SYSTEM Wiring Diagram — VEHSEC — (Cont’d) FIG. 4 NAEL0403S04 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL036Q EL-339 IDX VEHICLE SECURITY (THEFT WARNING) SYSTEM Wiring Diagram — VEHSEC — (Cont’d) FIG. 5 NAEL0403S05 MEL037Q EL-340 VEHICLE SECURITY (THEFT WARNING) SYSTEM Wiring Diagram — VEHSEC — (Cont’d) FIG. 6 NAEL0403S06 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL038Q EL-341 IDX VEHICLE SECURITY (THEFT WARNING) SYSTEM CONSULT-II Inspection Procedure CONSULT-II Inspection Procedure “THEFT WAR ALM” =NAEL0404 NAEL0404S01 1. 2. Turn ignition switch “OFF”. Connect “CONSULT-II” and “CONSULT-II CONVERTER” to the data link connector. 3. 4. Turn ignition switch “ON”. Touch “START (NISSAN BASED VHCL)”. 5. Touch “SMART ENTRANCE”. If “SMART ENTRANCE” is not indicated, go to GI-41, “CONSULT-II Data Link Connector (DLC) Circuit”. 6. Touch “THEFT WAR ALM”. 7. Select diagnosis mode. “DATA MONITOR”, “ACTIVE TEST” and “WORK SUPPORT” are available. SEL670Y SKIA3098E SEL669Y SEL751Y SEL274W EL-342 VEHICLE SECURITY (THEFT WARNING) SYSTEM CONSULT-II Application Item CONSULT-II Application Item “THEFT WAR ALM” Data Monitor NAEL0405 GI NAEL0405S01 NAEL0405S0101 Monitored Item MA Description IGN ON SW Indicates [ON/OFF] condition of ignition switch. ACC ON SW Indicates [ON/OFF] condition of ignition switch in ACC position. DOOR SW-RR Indicates [ON/OFF] condition of rear door switch. TRNK OPNR SW Indicates [ON/OFF] condition of back door switch. KEY CYL LK SW Indicates [ON/OFF] condition of lock signal from key cylinder switch. KEY CYL UN SW Indicates [ON/OFF] condition of unlock signal from key cylinder switch. DOOR SW-DR Indicates [ON/OFF] condition of front door switch LH. DOOR SW-AS Indicates [ON/OFF] condition of front door switch RH. TRNK OPN MNTR Indicates [ON/OFF] condition of back door switch. TRUNK KEY SW Indicates [ON/OFF] condition of back door key cylinder switch. HOOD SWITCH Indicates [ON/OFF] condition of hood switch. LOCK SW DR/AS Indicates [ON/OFF] condition of lock signal from door lock/unlock switch LH and RH. UNLK SW DR/AS Indicates [ON/OFF] condition of unlock signal from door lock/unlock LH and RH. LK BUTTON/SIG Indicates [ON/OFF] condition of lock signal from keyfob. UN BUTTON/SIG Indicates [ON/OFF] condition of unlock signal from keyfob. TRUNK BTN/SIG Indicates [ON/OFF] condition of trunk open signal from keyfob. EM LC EC FE CL MT AT TF PD NOTE: Even though TRUNK BTN/SIG is actually displayed on the CONSULT-II screen, it is not equipped, therefore, they cannot be activated. AX Active Test NAEL0405S0102 Test Item Description SU THEFT IND This test is able to check security indicator lamp operation. The lamp will be turned on when “ON” on CONSULT-II screen is touched. HORN This test is able to check vehicle security alarm operation. The alarm will be activated for 0.5 seconds after “ON” on CONSULT-II screen is touched. HEAD LAMP This test is able to check vehicle security alarm headlamp operation. The headlamp illuminates for 0.5 seconds after “ON” on CONSULT-II screen is touched. Work Support NAEL0405S0103 Test Item BR ST RS Description THEFT ALM TRG The switch which triggered theft warning alarm is recorded. This mode is able to confirm and erase the record of theft waning alarm. The trigger data can be erased by touching “CLEAR” on CONSULT-II screen. SECURITY ALARM SET Theft warning alarm mode can be changed in this mode. Selects ON-OFF of theft warning alarm mode. 쐌 MODE 1 (ON)/MODE 2 (OFF) BT HA SC IDX EL-343 VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses Trouble Diagnoses PRELIMINARY CHECK =NAEL0406 NAEL0406S01 The system operation is canceled by turning ignition switch to “ACC” at any step between START and ARMED in the following flow chart. SEL733W After performing preliminary check, go to symptom chart below. EL-344 VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d) SYMPTOM CHART 361 310 X X Door outside key X Back door key X Multi-remote control X Any door is opened. X Any door is unlocked without using key or multi-remote controller X All function X Horn alarm X Headlamp alarm X Door outside key X Back door key X Multi-remote control X Check “MULTI-REMOTE CONTROL” system. X VEHICLE SECURITY HEADLAMP ALARM CHECK All items Vehicle security system cannot be set by .... 359 VEHICLE SECURITY HORN ALARM CHECK X *1 Vehicle security system does not alarm when ... 356 BACK DOOR KEY CYLINDER SWITCH CHECK SECURITY INDICATOR LAMP CHECK X DOOR KEY CYLINDER SWITCH CHECK DOOR, HOOD AND GLASS HATCH SWITCH CHECK 4 354 GI MA POWER SUPPLY AND GROUND CIRCUIT CHECK 3 352 X Vehicle security indicator does not illuminate for 30 seconds. 2 347 X SYMPTOM 1 346 PRELIMINARY CHECK 344 Vehicle security alarm does not activate. ) Vehicle security system cannot be canceled by .... REFERENCE PAGE (EL- NAEL0406S02 EM LC EC FE CL MT AT TF X X X X PD AX SU BR X X ST X RS X BT X X X : Applicable *1: Make sure the system is in the armed phase. Before starting trouble diagnoses above, perform preliminary check, EL-344. Symptom numbers in the symptom chart correspond with those of preliminary check. HA SC IDX EL-345 VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d) POWER SUPPLY AND GROUND CIRCUIT CHECK NAEL0406S03 Power Supply Circuit Check NAEL0406S0301 Terminals Ignition switch position (+) Terminal (Wire color) (−) OFF ACC ON Connector M123 49 (G/R) Ground Battery voltage Battery voltage Battery voltage M122 26 (G/W) Ground 0V Battery voltage Battery voltage M122 27 (W/B) Ground 0V 0V Battery voltage If NG, check the following. 쐌 7.5A fuse [No. 24, located in fuse block (J/B)] 쐌 7.5A fuse [No. 11, located in fuse block (J/B)] 쐌 10A fuse [No. 10, located in fuse block (J/B)] 쐌 Harness for open or short between smart entrance control unit and fuse. SEL281Y Ground Circuit Check NAEL0406S0302 Terminals (+) Continuity Connector Terminal (Wire color) M122 43 (B) M123 64 (B) (−) Ground SEL282Y EL-346 Yes VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d) DOOR, HOOD AND GLASS HATCH SWITCH CHECK GI =NAEL0406S04 Door Switch Check NAEL0406S0401 1 MA PRELIMINARY CHECK 1. Turn ignition switch OFF and remove key from ignition key cylinder. “SECURITY” indicator lamp should blink every 2.6 seconds. 2. Close all doors, hood and glass hatch. 3. Lock doors with multi-remote controller from inside the vehicle. “SECURITY” indicator lamp should turn on for 30 seconds. 4. Unlock any door with the door lock knob and open the door within 30 seconds after door is locked. “SECURITY” indicator lamp should turn off. EM LC OK or NG OK 䊳 Door switch is OK, and go to hood switch check. NG 䊳 GO TO 2. 2 EC FE CHECK DOOR SWITCH INPUT SIGNAL With CONSULT-II Check door switches (“DOOR SW-RR”, “DOOR SW-DR” and “DOOR SW-AS”) in “DATA MONITOR” mode with CONSULT-II. CL MT AT TF PD SEL024Y Without CONSULT-II Check voltage between smart entrance control unit harness connector M121 terminals 1 (G/OR), 2 (Y) or 3 (R/L) and ground. AX SU BR ST RS SEL021YA Refer to wiring diagram in EL-337. OK or NG OK 䊳 Door switch is OK, and go to hood switch check. NG 䊳 GO TO 3. BT HA SC IDX EL-347 VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d) 3 CHECK DOOR SWITCH 1. Disconnect door switch connector. 2. Check the following. 쐌 Continuity between front door switch harness connector B9 (LH) or B68 (RH) terminals 1 and 2 쐌 Continuity between front door switch harness connector B9 (LH) or B68 (RH) terminals 3 and ground 쐌 Continuity between back door switch harness connector D208 terminals 1 and 2 쐌 Continuity between rear door switch harness connector B18 (LH) or B71 (RH) terminal 1 and ground SEL287Y OK or NG OK 䊳 Check the following. 쐌 Door switch ground circuit (Front or back) or door switch ground condition 쐌 Harness for open or short between smart entrance control unit and door switch NG 䊳 Replace door switch. EL-348 VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d) Hood Switch Check 1 =NAEL0406S0402 GI PRELIMINARY CHECK MA 1. Turn ignition switch OFF and remove key from ignition key cylinder. “SECURITY” indicator lamp should blink every 2.6 seconds. 2. Close all doors, hood and trunk lid. 3. Lock doors with multi-remote controller from inside the vehicle. “SECURITY” indicator lamp should turn on for 30 seconds. 4. Unlock hood with hood opener within 30 seconds after door is locked. “SECURITY” indicator lamp should turn off. EM LC OK or NG OK 䊳 Hood switch is OK, and go to trunk room lamp switch check. NG 䊳 GO TO 2. EC FE 2 CHECK HOOD SWITCH FITTING CONDITION CL OK or NG OK 䊳 GO TO 3. NG 䊳 Adjust installation of hood switch or hood. 3 MT CHECK HOOD SWITCH INPUT SIGNAL AT With CONSULT-II Check hood switch (“HOOD SWITCH”) in “DATA MONITOR” mode with CONSULT-II. TF PD AX SU SEL354W BR Without CONSULT-II Check voltage between smart entrance control unit harness connector M121 terminal 6 (Y/B) and ground. ST RS BT HA SEL035Y Refer to wiring diagram in EL-336. OK or NG OK 䊳 Hood switch is OK, and go to glass hatch switch check. NG 䊳 GO TO 4. SC IDX EL-349 VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d) 4 CHECK HOOD SWITCH 1. Disconnect hood switch connector. 2. Check continuity between hood switch terminals 1 and 2. SEL338X OK or NG OK 䊳 Check the following. 쐌 Hood switch ground circuit 쐌 Harness for open or short between smart entrance control unit and hood switch NG 䊳 Replace hood switch. EL-350 VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d) Glass Hatch Switch Check 1 =NAEL0406S0403 GI CHECK GLASS HATCH SWITCH INPUT SIGNAL MA Check voltage between smart entrance control unit harness connector M121 terminal 13 (L/W) and ground. EM LC EC SEL326YA Refer to wiring diagram in EL-336. OK or NG OK 䊳 Glass hatch switch is OK. NG 䊳 GO TO 2. 2 FE CL MT CHECK GLASS HATCH SWITCH AT 1. Disconnect glass hatch switch connector. 2. Check continuity between glass hatch switch terminals 1 and 2. TF PD AX SU SEL340X OK or NG OK NG 䊳 䊳 Check the following. 쐌 Glass hatch switch ground circuit 쐌 Harness for open or short between smart entrance control unit and glass hatch switch BR ST Replace glass hatch switch. RS BT HA SC IDX EL-351 VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d) SECURITY INDICATOR LAMP CHECK 1 =NAEL0406S05 CHECK INDICATOR LAMP OPERATION With CONSULT-II 1. Select “ACTIVE TEST” in “THEFT WAR ALM” with CONSULT-II. 2. Select “THEFT IND” and touch “ON”. SEL356W Without CONSULT-II 1. Disconnect smart entrance control unit harness connector. 2. Check voltage between smart entrance control unit harness connector M122 terminal 38 (BR/Y) and ground. SEL037Y Refer to wiring diagram in EL-336. OK or NG OK 䊳 Security indicator lamp is OK. NG 䊳 GO TO 2. 2 CHECK SECURITY INDICATOR LAMP 1. Disconnect security indicator lamp connector. 2. Apply 12V direct current to security indicator lamp harness connector M20 terminals 1 and 2. SEL696Y OK or NG OK 䊳 GO TO 3. NG 䊳 Replace security indicator lamp. EL-352 VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d) 3 GI CHECK POWER SUPPLY CIRCUIT FOR SECURITY INDICATOR LAMP 1. Disconnect security indicator lamp connector. 2. Check voltage between security indicator lamp harness connector M20 terminal 1 (R/G) and ground. MA EM LC EC SEL697Y FE OK or NG OK 䊳 Check harness for open or short between security indicator lamp and smart entrance control unit. CL NG 䊳 Check the following. 쐌 7.5A fuse [No. 24, located in fuse block (J/B)] 쐌 Harness for open or short between security indicator lamp and fuse MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-353 VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d) FRONT DOOR KEY CYLINDER SWITCH CHECK 1 =NAEL0406S06 CHECK FRONT DOOR KEY CYLINDER SWITCH INPUT SIGNAL (LOCK/UNLOCK SIGNAL) With CONSULT-II Check front door key cylinder switch (“KEY CYL LK-SW”/“KEY CYL UN-SW”) in “DATA MONITOR” mode with CONSULTII. SEL342WF Without CONSULT-II 1. Check the signal between smart entrance control unit harness connector M122 terminal 33 (BR) and ground with oscilloscope when key inserted in front key cylinder is turned “LOCK” or “UNLOCK”. 2. Make sure signals which are shown in the figure below can be detected during 10 sec. just after key is turned “LOCK” or “UNLOCK”. SEL700Y Refer to wiring diagram in EL-338. OK or NG OK 䊳 Front door key cylinder switch LH is OK. NG 䊳 GO TO 2. EL-354 VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d) 2 GI CHECK FRONT DOOR KEY CYLINDER SWITCH 1. Disconnect front door key cylinder switch LH connector. 2. Check continuity between front door key cylinder switch LH terminals. MA EM LC EC SEL313XB FE OK or NG OK 䊳 Check the following. 쐌 Front door key cylinder switch LH ground circuit 쐌 Harness for open or short between power window main switch and front door key cylinder switch LH NG 䊳 Replace front door key cylinder switch LH. CL MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-355 VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d) BACK DOOR KEY CYLINDER SWITCH CHECK 1 =NAEL0406S07 CHECK BACK DOOR KEY CYLINDER SWITCH INPUT SIGNAL (LOCK/UNLOCK SIGNAL) With CONSULT-II Check back door key cylinder switch (“KEY CYL LK-SW”/“KEY CYL UN-SW”) in “DATA MONITOR” mode with CONSULTII. SEL342WG Without CONSULT-II Check voltage between smart entrance control unit terminals 10 (LG), 11 (Y) or 12 (W/PU) and ground. SEL698Y Refer to wiring diagram in EL-339. OK or NG OK 䊳 Back door key cylinder switch is OK. NG 䊳 GO TO 2. EL-356 VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d) 2 GI CHECK BACK DOOR KEY CYLINDER SWITCH 1. Disconnect back door key cylinder switch connector. 2. Check continuity between back door key cylinder switch terminals. MA EM LC EC SEL345X FE OK or NG OK 䊳 Check the following. 쐌 Back door key cylinder switch ground circuit 쐌 Harness for open or short between smart entrance control unit and back door key cylinder switch NG 䊳 Replace back door key cylinder switch. CL MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-357 VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d) DOOR LOCK/UNLOCK SWITCH CHECK 1 =NAEL0406S08 CHECK DOOR LOCK/UNLOCK SWITCH INPUT SIGNAL With CONSULT-II Check door lock/unlock switch (“LOCK SW DR/AS”/“UNLK SW DR/AS”) in “DATA MONITOR” mode with CONSULT-II. SEL341W Without CONSULT-II 1. Remove key from ignition key cylinder. 2. Check the signal between smart entrance control unit harness connector M122 terminal 33 (BR) and ground with oscilloscope when door lock/unlock switch is turned “LOCK” or “UNLOCK”. 3. Make sure signals which are shown in the figure below can be detected during 10 sec. just after door lock/unlock switch is turned “LOCK” or “UNLOCK”. SEL699Y Refer to wiring diagram in EL-338. OK or NG OK 䊳 Door lock/unlock switch is OK. NG 䊳 Check the following. 쐌 Ground circuit for each front power window switch 쐌 Harness for open or short between each front power window switch and smart entrance control unit connector If above systems are normal, replace the front power window switch. EL-358 VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d) VEHICLE SECURITY HORN ALARM CHECK 1 =NAEL0406S09 GI CHECK VEHICLE SECURITY HORN MA With CONSULT-II 1. Select “ACTIVE TEST” in “THEFT WAR ALM” with CONSULT-II. 2. Select “HORN” and touch “ON”. EM LC EC FE SEL041Y CL Without CONSULT-II 1. Disconnect smart entrance control unit harness connector. 2. Apply ground to smart entrance control unit harness connector M122 terminal 42 (LG/B). MT AT TF PD SEL043YC AX Refer to wiring diagram in EL-339. OK or NG OK 䊳 Horn alarm is OK. NG 䊳 GO TO 2. 2 SU BR CHECK HORN RELAY ST Check horn relay. OK or NG OK 䊳 GO TO 3. NG 䊳 Replace horn relay. RS BT HA SC IDX EL-359 VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d) 3 CHECK POWER SUPPLY FOR HORN RELAY 1. Disconnect horn relay connector. 2. Check voltage between horn relay connector E118 terminal 1 (G/B) and ground. SEL326XA OK or NG OK 䊳 GO TO 4. NG 䊳 Check the following. 쐌 7.5A fuse (No. 52, located in the fuse and fusible link box) 쐌 Harness for open or short between horn relay and fuse 4 CHECK HORN RELAY CIRCUIT 1. Disconnect horn relay connector. 2. Check voltage between terminals 3 and 5. 3. Check voltage between terminals 6 and 7. SEL348X OK or NG OK 䊳 Check harness for open or short between horn relay and smart entrance control unit. NG 䊳 Check the following. 쐌 Harness for open or short between horn relay and fuse 쐌 7.5A fuse (No. 52, located in the fuse and fusible link box) 쐌 10A fuse (No. 54, located in the fuse and fusible link box) EL-360 VEHICLE SECURITY (THEFT WARNING) SYSTEM Trouble Diagnoses (Cont’d) VEHICLE SECURITY HEADLAMP ALARM CHECK =NAEL0406S10 GI 1 CHECK VEHICLE SECURITY HEADLAMP ALARM OPERATION MA With CONSULT-II 1. Select “ACTIVE TEST” in “THEFT WAR ALM” with CONSULT-II. 2. Select “HEADLAMP” and touch “ON”. EM LC EC FE SEL042Y CL Without CONSULT-II 1. Disconnect smart entrance control unit connector. 2. Apply ground to smart entrance control unit harness connector M121, M123 terminals 21 (PU/R) and 59 (PU/W). MT AT TF PD SEL198Y AX Refer to wiring diagram in EL-340. OK or NG OK 䊳 Headlamp is OK. NG 䊳 GO TO 2. 2 SU BR CHECK HEADLAMP OPERATION ST Does headlamp come on when turning lighting switch “ON”? Yes 䊳 Check harness for open or short between headlamp relay and smart entrance control unit. No 䊳 Check headlamp system. Refer to “HEADLAMP”. RS BT HA SC IDX EL-361 SMART ENTRANCE CONTROL UNIT Description Description OUTLINE NAEL0407 NAEL0407S01 The smart entrance control unit totally controls the following body electrical system operations. 쐌 Headlamp auto light control system 쐌 Warning chime 쐌 Rear defogger and door mirror defogger timer 쐌 Power door lock 쐌 Remote keyless entry system 쐌 Vehicle security system 쐌 Interior lamp In addition, the following timer operations are controlled by the smart entrance control unit. 쐌 Battery saver control 쐌 Retained power control BATTERY SAVER CONTROL NAEL0407S02 Headlamps/Parking Lamps/License Lamps/Tail Lamps/Fog Lamps/Illumination LampsNAEL0407S0201 While the headlamps (including parking, license, tail, fog and illumination lamps) are turned ON by “1ST” or “2ND” of lighting switch, the exterior lamp battery saver control is activated when the ignition switch signal changes from ON (or ACC) to OFF, and either one of LH or RH front door switch ON signal is received. The headlamps (including parking, license, tail, fog and illumination lamps) are turned off after 5 minutes. While the headlamps are turned ON by “AUTO” operation, the exterior lamp battery saver control is activated when the ignition switch is turned from ON (or ACC) to OFF, and either LH or RH front door switch ON signal is input. The smart entrance control unit controls timer activation as follows: 쐌 When the door switch signal changes from ON to OFF while the exterior lamp battery saver is activated, the operation is discontinued, restarts and lasts for 45 seconds, then the headlamps (including parking, license, tail, fog and illumination lamps) will be turned off. 쐌 When the door switch signal changes from OFF to ON while the exterior lamp battery saver is activated, the operation is discontinued, restarts and lasts for 45 seconds, then the headlamps will be turned off. 쐌 When the one of four door switch signals changes from OFF to ON while the exterior lamp battery saver is activated, the operation is discontinued, restarts and lasts for 5 minutes, then the headlamps (including parking, license, tail, fog and illumination lamps) will be turned off. 쐌 When all the door switch ON signals are input while the exterior lamp battery saver is activated, the operation is discontinued, restarts and lasts for 45 seconds, then the headlamps (including parking, license, tail, fog and illumination lamps) will be turned off. The “45” second timer’s duration can be changed with the function setting mode of CONSULT-II. Interior Lamp/Luggage Room Lamp/Spot Lamp/Vanity Mirror Illumination NAEL0407S0202 The lamps turn off automatically when the interior lamp, spot lamp or/and vanity mirror illumination are illuminated with the ignition key in the OFF position, if the lamp remains lit by the door switch open signal or if the lamp switch is in the ON position for more than 30 minutes. After lamps are turned off by the battery saver system, the lamps illuminate again when: 쐌 Door is locked or unlocked with keyfob or door lock/unlock switch or door key cylinder. 쐌 Ignition switch ON. 쐌 Door is opened or closed, 쐌 Key is inserted or removed into ignition key cylinder. Rear Window Defogger/Door Mirror Defogger NAEL0407S0203 Rear window defogger and door mirror defogger are turned off in approximately 15 minutes after the rear window defogger switch is turned on. RETAINED POWER CONTROL NAEL0407S03 When the ignition switch is turned to OFF (or ACC) position from ON or START position, the following systems can be operated for 45 seconds by the RAP signal from the smart entrance control unit terminal 46. 쐌 Electric sunroof 쐌 Power window The retained power operation is canceled when the driver or passenger side door is opened. EL-362 SMART ENTRANCE CONTROL UNIT Description (Cont’d) INPUT/OUTPUT NAEL0407S04 System Input GI Output MA Door lock and unlock switch LH and RH Key switch (Insert) Door switches Door key cylinder switches Door lock actuator Key switch (Insert) Ignition switch (ACC) Door switches Keyfob signal Door lock/unlock switch LH Horn relay Headlamp relay (LH and RH) Hazard warning lamp Interior lamp Power window main switch Door lock actuator Opener actuator Key switch (Insert) Ignition switch (ON) Lighting switch (1st) Seat belt switch (driver’s seat) Front door switch LH Warning chime (located in smart entrance control unit) Rear window defogger and door mirror defogger Ignition switch (ON) Rear window defogger switch Rear window defogger relay Vehicle security Ignition switch (ACC, ON) Door switches Hood switch Back door switch Glass hatch switch Door lock/unlock switches Door key cylinder switches (lock/unlock) Horn relay Headlamp relay Security indicator Door switches Keyfob signal (lock/unlock) Door lock/unlock switches (lock/unlock) Door key cylinder switch (lock/unlock) Ignition switch (ON) Key switch (Insert) Interior lamp Step lamp Door indicator Battery saver control for headlamps/parking lamps/ licence lamps/tail lamps/fog lamps/illumination lamps Ignition switch (ON) Lighting switches Headlamps Parking lamps Licence lamps Tail lamps Fog lamps Illumination lamps Battery saver control for interior lamp/spot lamp/vanity mirror illumination Ignition switch (ON) Front door switches Lamp switches Interior lamp Step lamp Spot lamp Vanity mirror illumination Battery saver control for rear window defogger and door mirror defogger Ignition switch (ON) Rear window defogger switch Rear window defogger relay BT Retained power control for electric sunroof Ignition switch (ON) Front door switches Sunroof motor HA Retained power control for power window Ignition switch (ON) Front door switches Power window relay Headlamp auto light control Auto light sensor Lighting switches Headlamp relay Tail lamp relay Power door lock Remote keyless entry Warning chime Interior lamp EM LC EC FE CL MT AT TF PD AX SU BR ST RS SC IDX EL-363 SMART ENTRANCE CONTROL UNIT CONSULT-II CONSULT-II NAEL0408 DIAGNOSTIC ITEMS APPLICATION Item (CONSULT-II screen terms) Diagnosed system NAEL0408S01 DATA MONITOR ACTIVE TEST WORK SUPPORT X DOOR LOCK Power door lock X X REAR DEFOGGER Rear window defogger X X KEY WARN ALM Warning chime X X LIGHT WARN ALM Warning chime X X SEAT BELT ALM Warning chime X X INT LAMP Interior lamps X X X BATTERY SAVER Battery saver control for interior lamp X X X THEFT WAR ALM Vehicle security system X X X RETAINED PWR Retained power control X X X MULTI REMOTE ENT Remote keyless entry system X X X HEAD LAMP Headlamp X X X X: Applicable For diagnostic item in each control system, refer to the relevant pages for each system. DIAGNOSTIC ITEM DESCRIPTION NAEL0408S02 MODE Description DATA MONITOR Input/output data in the smart entrance control unit can be read. ACTIVE TEST Diagnostic Test Mode in which CONSULT-II drives some systems apart from the smart entrance control unit. WORK SUPPORT for DOOR LOCK 쐌 Select unlock mode ON-OFF setting can be changed. 쐌 Key reminder door mode ON-OFF setting can be changed. WORK SUPPORT for INT LAMP Interior lamp timer mode ON-OFF setting can be changed. WORK SUPPORT for BATTERY SAVER Interior lamp battery saver period can be changed. WORK SUPPORT for THEFT WAR ALM 쐌 The recorded trigger signal when vehicle security system was activated can be checked. 쐌 Security alarm ON-OFF setting can be changed. WORK SUPPORT for RETAINED PWR SET RAP signal’s power supply period can be changed. WORK SUPPORT for MULTI REMOTE ENT 쐌 ID code of keyfob can be registered and erased. 쐌 Keyless answer back mode can be changed. 쐌 Pressing time of panic alarm, trunk lid opener and door unlock (for power window down operation) buttons on keyfob can be changed. 쐌 Auto lock operation starting time can be changed. WORK SUPPORT for HEADLAMP 쐌 Auto light sensitivity can be changed. 쐌 Exterior lamp battery saver control ON-OFF setting can be changed. 쐌 Auto light delay off time can be changed. EL-364 SMART ENTRANCE CONTROL UNIT CONSULT-II (Cont’d) CONSULT-II INSPECTION PROCEDURE 1. 2. NAEL0408S03 Turn the ignition switch “OFF”. Connect “CONSULT-II” and “CONSULT-II CONVERTER” to the data link connector. GI MA EM LC SEL670Y 3. 4. Turn ignition switch “ON”. Touch “START (NISSAN BASED VHCL)”. EC FE CL MT SKIA3098E 5. Touch “SMART ENTRANCE”. If “SMART ENTRANCE” is not indicated, go to GI-41, “CONSULT-II Data Link Connector (DLC) Circuit”. AT TF PD AX SU SEL669Y 6. Perform each diagnostic item according to “DIAGNOSTIC ITEMS APPLICATION”. Refer to EL-364. BR ST RS BT SEL751Y HA SC IDX EL-365 SMART ENTRANCE CONTROL UNIT Schematic Schematic NAEL0409 MEL086Q EL-366 SMART ENTRANCE CONTROL UNIT Schematic (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL039Q IDX EL-367 SMART ENTRANCE CONTROL UNIT Smart Entrance Control Unit Inspection Table Smart Entrance Control Unit Inspection Table NAEL0410 Terminal No. Wire color 1 G/OR 2 Y 3 6 7 Connections Voltage (Approximate values) Operated condition Driver door switch OFF (Closed) , ON (Open) 12V , 0V Passenger door switch OFF (Closed) , ON (Open) 5V , 0V R/L Rear door switch OFF (Closed) , ON (Open) 5V , 0V Y/B Hood switch ON (Open) , OFF (Closed) 0V , 12V Auto light sensor (Signal) Light is applied to auto light senIgnition switch ON sor. position Light is not applied to auto light sensor. W/G Less than 1V 8 L/R Auto light sensor (GND) 9 GY Auto light sensor (Power) Ignition switch (OFF , ON) 0V , 5V 10 LG Back door key cylinder unlock switch OFF (Neutral) , ON (Unlocked) 5V , 0V 11 Y Back door key cylinder lock switch OFF (Neutral) , ON (Locked) 5V , 0V 12 W/PU Back door key cylinder switch OFF (Neutral) , ON (Unlock) 5V , 0V 13 L/W Glass hatch switch 5V , 0V 14 OR Rear window defogger switch OFF , ON (Only when pushed) 19 R/G Tail lamp relay (Output) — 1 to 5V — ON (Open) , OFF (Closed) Ignition switch (with lighting switch 1ST or 2ND) ON or START , OFF position 5V , 0V More than 5 minutes after ignition switch is turned to OFF position 12V Within 5 minutes after ignition switch is turned to OFF position 0V ON or START position 20 21 G PU/R Tail lamp switch Headlamp LH relay 0V Headlamps illuminate by auto light control. (Operate , Not operate) Less than 1V , 12V Light switch (OFF or AUTO , 1ST or 2ND position) 12V , 0V Ignition switch (with lighting switch 2ND) ON or START , OFF position More than 5 minutes after ignition switch is turned to OFF position 12V Within 5 minutes after ignition switch is turned to OFF position 0V ON or START position Headlamps illuminate by auto light control. (Operate , Not operate) EL-368 0V Less than 1V , 12V SMART ENTRANCE CONTROL UNIT Smart Entrance Control Unit Inspection Table (Cont’d) Terminal No. Wire color Connections Operated condition Voltage (Approximate values) Except PASS or 2ND position 12V PASS or 2ND position 0V GI MA Lighting switch 22 SB Headlamp switch Headlamps illuminate by auto light control. (Operate , Not operate) 10V , 12V LC 23 L/Y Headlamp switch Ignition switch “ON” position Lighting switch (Except AUTO , AUTO position) 12V , 0V 25 W/R Ignition key switch (Insert) Key inserted , Key removed from IGN key cylinder 12V , 0V 26 G/W Ignition switch (ACC) “ACC” position 12V 27 W/B Ignition switch (ON) Ignition key is in “ON” position 12V 28 B/Y Seat belt buckle switch Unfastened , Fastened (Ignition key is in “ON” position) 0V , 12V Interior lamp When doors are locked using keyfob (Lamp switch in “DOOR” position) 0V , 12V 31 R/B BR Communication interface G/B 38 FE CL Refer to EL-370. AT TF Front door key cylinder switch LH (Neutral ,Lock/ unlock) 37 EC MT Door lock and unlock switches (Neutral ,Lock/ unlock) 33 EM Rear window defogger relay OFF , ON (Ignition key is in “ON” position) 12V , 0V BR/Y Security indicator Goes off , Illuminates 12V , 0V 42 LG/B Horn relay When panic alarm is operated using keyfob (ON , OFF) 12V , 0V 43 B 46 R/Y Power window relay Retained power operation is operated (ON , OFF) 12V , 0V 47 GY/L LH turn signal lamp When door lock or unlock is operated using keyfob (ON , OFF) 12V , 0V SU 48 GY/R RH turn signal lamp When door lock or unlock is operated using keyfob (ON , OFF) 12V , 0V BR 49 G/R Power source (Fuse) 50 R/W Battery saver (Interior lamp) 51 W/R Power source (PTC) 54 L Door lock actuators Door lock & unlock switch (Free , Lock) 0V , 12V 55 W/PU Driver door lock actuator Door lock & unlock switch (Free , Unlock) 0V , 12V 56 Y/B Passenger, rear and back doors lock actuator Door lock & unlock switch (Free , Unlock) 0V , 12V Ground — — Battery saver operates , Does not operate (ON ,OFF) — — PD AX 12V 12V , 0V 12V ST RS BT HA SC IDX EL-369 SMART ENTRANCE CONTROL UNIT Smart Entrance Control Unit Inspection Table (Cont’d) Terminal No. 57 Wire color R Connections Ignition switch (with lighting switch 1ST or 2ND) Tail lamp relay Voltage (Approximate values) Operated condition ON or START , OFF position More than 5 minutes after ignition switch is turned to OFF position 12V Within 5 minutes after ignition switch is turned to OFF position 0V ON or START position Headlamps illuminate by auto light control. (Operate , Not operate) 58 59 G/W PU/W Tail lamp switch Lighting switch OFF or AUTO , 1ST or 2ND Headlamp RH relay Ignition switch (with lighting switch OFF or 1ST) ON or START , OFF position 0V Less than 1V, 12V 12V , 0V More than 5 minutes after ignition switch is turned to OFF position 12V Within 5 minutes after ignition switch is turned to OFF position 0V ON or START position Headlamps illuminate by auto light control. (Operate , Not operate) 0V Less than 1V , 12V Except PASS or 2ND position 12V PASS or 2ND position 0V Lighting switch 60 L Headlamp switch Headlamps illuminate by auto light control. (Operate , Not operate) 64 B Ground — COMMUNICATION INTERFACE SIGNAL 10V , 12V — NAEL0410S02 Voltage: 12 V → 9V (10 sec.) measurement by analog circuit tester. SEL739Y EL-370 HOMELINK UNIVERSAL TRANSCEIVER Wiring Diagram — TRNSCV — Wiring Diagram — TRNSCV — NAEL0411 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL040Q EL-371 IDX HOMELINK UNIVERSAL TRANSCEIVER Trouble Diagnoses Trouble Diagnoses DIAGNOSTIC PROCEDURE NAEL0412 NAEL0412S01 SYMPTOM: Homelink universal transceiver does not activate receiver. Before conducting the procedure given below, make sure that system receiver (garage door opener, etc.) operates with original, hand-held transmitter. If NG, receiver or hand-held transmitter is at fault, not vehicle related. 1 PRELIMINARY CHECK 1. Turn ignition switch “OFF”. 2. Does red light (LED) of homelink universal transceiver illuminate when any button is pressed? SEL442UA Yes or No Yes 䊳 GO TO 2. No 䊳 GO TO 3. 2 CHECK HOMELINK UNIVERSAL TRANSCEIVER FUNCTION Check homelink universal transceiver with Tool. For details, refer to Technical Service Bulletin. OK or NG OK 䊳 Receiver or handheld transmitter fault, not vehicle related. NG 䊳 Replace homelink universal transceiver with sun visor assembly. 3 CHECK POWER SUPPLY 1. Disconnect homelink universal transceiver connector. 2. Turn ignition switch “OFF”. 3. Check voltage between homelink universal transceiver harness connector R5 terminal 1 (R/G) and ground. SEL358X OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 5. EL-372 HOMELINK UNIVERSAL TRANSCEIVER Trouble Diagnoses (Cont’d) 4 GI CHECK GROUND CIRCUIT Check continuity between homelink universal transceiver harness connector R5 terminal 2 (B) and ground. MA EM LC EC SEL359X FE OK or NG OK 䊳 Replace homelink universal transceiver with sun visor assembly. NG 䊳 Repair harness. 5 CL CHECK MAIN POWER SUPPLY FOR SMART ENTRANCE CONTROL UNIT MT 1. Disconnect smart entrance control unit. 2. Check voltage between smart entrance control unit harness connector M123 terminal 49 (G/R) and ground. AT TF PD AX SEL284Y OK or NG OK 䊳 GO TO 6. NG 䊳 Check the following. 쐌 7.5A fuse No. 24, located in fuse block (J/B) SU BR ST RS BT HA SC IDX EL-373 HOMELINK UNIVERSAL TRANSCEIVER Trouble Diagnoses (Cont’d) 6 CHECK GROUND CIRCUIT FOR SMART ENTRANCE CONTROL UNIT Check continuity between smart entrance control unit harness connector M122 terminal 43 (B) or M123 terminal 64 (B) and ground. SEL285Y OK or NG OK 䊳 Power supply and ground circuits are OK. NG 䊳 Check ground harness. EL-374 NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS) Component Parts and Harness Connetor Location Component Parts and Harness Connetor Location GI NAEL0413 MA EM LC EC FE CL SEL678Y NOTE: If customer reports a “No Start” condition, request ALL KEYS to be brought to the Dealer in case of an NVIS (NATS) malfunction. MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-375 NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS) System Description System Description =NAEL0414 NATS (Nissan Anti-Theft System) has the following immobilizer functions: 쐌 Since only NVIS (NATS) ignition keys, whose ID nos. have been registered into the ECM and IMMU of NVIS (NATS), allow the engine to run, operation of a stolen vehicle without an NVIS (NATS) registered key is prevented by NVIS (NATS). That is to say, NVIS (NATS) will immobilise the engine if someone tries to start it without the registered key of NVIS (NATS). 쐌 All of the originally supplied ignition key IDs (except for card plate key) have been NVIS (NATS) registered. If requested by the vehicle owner, a maximum of five key IDs can be registered into the NVIS (NATS) components. 쐌 The security indicator blinks when the ignition switch is in “OFF” or “ACC” position. Therefore, NVIS (NATS) warns outsiders that the vehicle is equipped with the anti-theft system. 쐌 When NVIS (NATS) detects trouble, the security indicator lamp lights up while ignition key is in the “ON” position. 쐌 NVIS (NATS) trouble diagnoses, system initialization and additional registration of other NVIS (NATS) ignition key IDs must be carried out using CONSULT-II hardware and CONSULT-II NVIS (NATS) software. When NVIS (NATS) initialization has been completed, the ID of the inserted ignition key is automatically NVIS (NATS) registered. Then, if necessary, additional registration of other NVIS (NATS) ignition key IDs can be carried out. Regarding the procedures of NVIS (NATS) initialization and NVIS (NATS) ignition key ID registration, refer to CONSULT-II operation manual, IVIS/NVIS. 쐌 When servicing a malfunction of the NVIS (NATS) (indicated by lighting up of Security Indicator Lamp) or registering another NVIS (NATS) ignition key ID no., it is necessary to re-register original key identification. Therefore, be sure to receive ALL KEYS from vehicle owner. System Composition NAEL0415 The immobiliser function of the NVIS (NATS) consists of the following: 쐌 NVIS (NATS) ignition key 쐌 NVIS (NATS) immobilizer control unit (IMMU) located in the ignition key cylinder 쐌 Engine control module (ECM) 쐌 Security indicator SEL085WF EL-376 NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS) Wiring Diagram — NATS — Wiring Diagram — NATS — NAEL0416 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL041Q EL-377 IDX NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS) CONSULT-II CONSULT-II NAEL0417 CONSULT-II INSPECTION PROCEDURE NAEL0417S01 1. Turn ignition switch OFF. 2. Insert NVIS (NATS) program card into CONSULT-II. Program card NATS (AEN02C) 3. Connect “CONSULT-II” and “CONSULT-II CONVERTER” to data link connector. SEL670Y 4. 5. Turn ignition switch ON. Touch “START”. 6. Select “NATS V.5.0”. PBR455D SEL851W 7. Perform each diagnostic test mode according to each service procedure. For further information, see the CONSULT-II Operation Manual, IVIS/NVIS. SEL363X CONSULT-II DIAGNOSTIC TEST MODE FUNCTION NAEL0417S02 CONSULT-II DIAGNOSTIC TEST MODE Description C/U INITIALIZATION When replacing any of the following three components, C/U initialization and re-registration of all NVIS (NATS) ignition keys are necessary. [NVIS (NATS) ignition key/IMMU/ECM] SELF-DIAG RESULTS Detected items (screen terms) are as shown in the chart EL-379. EL-378 NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS) CONSULT-II (Cont’d) NOTE: 쐌 When any initialization is performed, all ID previously registered will be erased and all NVIS (NATS) ignition keys must be registered again. 쐌 The engine cannot be started with an unregistered key. In this case, the system will show “DIFFERENCE OF KEY” or “LOCK MODE” as a self-diagnostic result on the CONSULT-II screen. 쐌 In rare case, “CHAIN OF ECM-IMMU” might be stored as a self-diagnostic result during key registration procedure, even if the system is not malfunctioning. HOW TO READ SELF-DIAGNOSTIC RESULTS NAEL0417S03 GI MA EM LC EC FE CL MT AT TF PD SEL364X NVIS (NATS) SELF-DIAGNOSTIC RESULTS ITEM CHART P No. Code Malfunction is detected when ..... (Self-diagDetected items (NATS program card nostic screen terms) result of “ENGINE” NAEL0417S04 Reference page SU BR ST ECM INT CIRC-IMMU NATS MAL- The malfunction of ECM internal circuit of IMMU comFUNCTION munication line is detected. P1613 EL-383 CHAIN OF ECM-IMMU Communication impossible between ECM and IMMU NATS MAL(In rare case, “CHAIN OF ECM-IMMU” might be stored FUNCTION during key registration procedure, even if the system is P1612 not malfunctioning.) EL-384 DIFFERENCE OF KEY NATS MAL- IMMU can receive the key ID signal but the result of ID FUNCTION verification between key ID and IMMU is NG. P1615 EL-388 CHAIN OF IMMU-KEY NATS MAL- IMMU cannot receive the key ID signal. FUNCTION P1614 EL-389 ID DISCORD, IMM-ECM NATS MAL- The result of ID verification between IMMU and ECM is FUNCTION NG. System initialization is required. P1611 EL-390 EL-379 AX RS BT HA SC IDX NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS) CONSULT-II (Cont’d) P No. Code Malfunction is detected when ..... (Self-diagDetected items (NATS program card nostic screen terms) result of “ENGINE” LOCK MODE DON’T ERASE BEFORE CHECKING ENG DIAG When the starting operation is carried out five or more times consecutively under the following conditions, NATS MALNVIS (NATS) will shift the mode to one which prevents FUNCTION the engine from being started. P1610 쐌 Unregistered ignition key is used. 쐌 IMMU or ECM’s malfunctioning. — All engine trouble codes except NVIS (NATS) trouble code has been detected in ECM. EL-380 Reference page EL-393 EL-381 NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS) Trouble Diagnoses Trouble Diagnoses WORK FLOW NAEL0418 GI NAEL0418S01 MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC SEL004XA EL-381 IDX NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS) Trouble Diagnoses (Cont’d) SYMPTOM MATRIX CHART 1 NAEL0418S02 (Self-diagnosis related item) SYMPTOM Displayed “SELF-DIAG RESULTS” on CONSULT-II screen. ECM INT CIRC-IMMU CHAIN OF ECM-IMMU DIAGNOSTIC PROCEDURE (Reference page) PROCEDURE 1 (EL-383) PROCEDURE 2 (EL-384) 쐌 Security indicator lighting up* 쐌 Engine cannot be started. DIFFERENCE OF KEY CHAIN OF IMMU-KEY ID DISCORD, IMMECM LOCK MODE 쐌 MIL staying ON 쐌 Security indicator lighting up* DON’T ERASE BEFORE CHECKING ENG DIAG PROCEDURE 3 (EL-388) PROCEDURE 4 (EL-389) PROCEDURE 5 (EL-390) PROCEDURE 7 (EL-393) WORK FLOW (EL-381) SYSTEM (Malfunctioning part or mode) REFERENCE PART NO. OF ILLUSTRATION ON NEXT PAGE ECM B In rare case, “CHAIN OF ECM-IMMU” might be stored during key registration procedure, even if the system is not malfunctioning. — Open circuit in battery voltage line of IMMU circuit C1 Open circuit in ignition line of IMMU circuit C2 Open circuit in ground line of IMMU circuit C3 Open circuit in communication line between IMMU and ECM C4 Short circuit between IMMU and ECM communication line and battery voltage line C4 Short circuit between IMMU and ECM communication line and ground line C4 ECM B IMMU A Unregistered key D IMMU A Malfunction of key ID chip E IMMU A System initialization has not yet been completed. F ECM F LOCK MODE D Engine trouble data and NVIS (NATS) trouble data have been detected in ECM — *: When NVIS (NATS) detects trouble, the security indicator lights up while ignition key is in the “ON” position. EL-382 NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS) Trouble Diagnoses (Cont’d) SYMPTOM MATRIX CHART 2 NAEL0418S03 GI (Non self-diagnosis related item) DIAGNOSTIC PROCEDURE (Reference page) SYMPTOM SYSTEM (Malfunctioning part or mode) Security ind. PROCEDURE 6 (EL-391) Security ind. does not light up. MA EM Open circuit between Fuse and IMMU Continuation of initialization mode LC IMMU DIAGNOSTIC SYSTEM DIAGRAM NAEL0418S04 EC FE CL MT AT TF PD SEL761Y AX SU DIAGNOSTIC PROCEDURE 1 NAEL0418S05 Self-diagnostic results: “ECM INT CIRC-IMMU” displayed on CONSULT-II screen 1. Confirm SELF-DIAGNOSTIC RESULTS “ECM INT CIRCIMMU” displayed on CONSULT-II screen. Ref. part No. B. 2. Replace ECM. 3. Perform initialization with CONSULT-II. For initialization, refer to “CONSULT-II operation manual IVIS/NVIS”. BR ST RS BT SEL365X HA SC IDX EL-383 NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS) Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 2 =NAEL0418S06 Self-diagnostic results: “CHAIN OF ECM-IMMU” displayed on CONSULT-II screen 1 CONFIRM SELF-DIAGNOSTIC RESULTS Confirm SELF-DIAGNOSTIC RESULTS “CHAIN OF ECM-IMMU” displayed on CONSULT-II screen. NOTE: In rare case, “CHAIN OF ECM-IMMU” might be stored during key registration procedure, even if the system is not malfunctioning. SEL366X Is CONSULT-II screen displayed as above? Yes 䊳 GO TO 2. No 䊳 GO TO SYMPTOM MATRIX CHART 1. 2 CHECK POWER SUPPLY CIRCUIT FOR IMMU 1. Disconnect IMMU connector. 2. Check voltage between terminal 8 of IMMU and ground with CONSULT-II or tester. SEL302WD OK or NG OK 䊳 GO TO 3. NG 䊳 Check the following 쐌 7.5A fuse (No. 62, located in the fuse and fusible link box) 쐌 Harness for open or short between fuse and IMMU connector Ref. Part No. C1 EL-384 NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS) Trouble Diagnoses (Cont’d) 3 GI CHECK IGN SW. ON SIGNAL 1. Turn ignition switch ON. 2. Check voltage between terminal 7 of IMMU and ground with CONSULT-II or tester. MA EM LC EC SEL303WF FE OK or NG OK 䊳 GO TO 4. NG 䊳 Check the following 쐌 10A fuse [No. 16, located in the fuse block (J/B)] 쐌 Harness for open or short between fuse and IMMU connector Ref. part No. C2 4 CL MT AT CHECK GROUND CIRCUIT FOR IMMU 1. Turn ignition OFF. 2. Check harness continuity between IMMU connector E113 terminal 4 (B) and ECM connector F203 terminal 67 (B/P). TF PD AX SU SEL762Y BR OK or NG OK 䊳 GO TO 5. NG 䊳 Repair harness. Ref. part No. C3 ST RS BT HA SC IDX EL-385 NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS) Trouble Diagnoses (Cont’d) 5 CHECK COMMUNICATION LINE OPEN CIRCUIT 1. Disconnect ECM connector. 2. Check harness continuity between ECM terminal 88 and IMMU terminal 1. SEL740Y OK or NG OK 䊳 GO TO 6. NG 䊳 Repair harness or connector. Ref. part No. C4 6 CHECK COMMUNICATION LINE BATTERY SHORT CIRCUIT 1. Turn ignition ON. 2. Check voltage between ECM terminal 88 or IMMU terminal 1 and ground. SEL741Y OK or NG OK 䊳 GO TO 7. NG 䊳 Communication line is short-circuited with battery voltage line or ignition switch ON line. Repair harness or connectors. Ref. part No. C4 EL-386 NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS) Trouble Diagnoses (Cont’d) 7 GI CHECK COMMUNICATION LINE GROUND SHORT CIRCUIT 1. Turn ignition switch OFF. 2. Check continuity between ECM terminal 88 or IMMU terminal 1 and ground. MA EM LC EC SEL742Y FE OK or NG OK 䊳 GO TO 8. NG 䊳 Communication line is short-circuited with ground line. Repair harness or connectors. Ref. part No. C4 8 CL MT SIGNAL FROM ECM TO IMMU CHECK AT 1. Check the signal between ECM harness connector F203 terminal 88 (G) and ground with CONSULT-II or oscilloscope when ignition switch is turned “ON”. 2. Make sure signals which are shown in the figure below can be detected during 750 msec. just after ignition switch is turned “ON”. TF PD AX SU BR SEL730W OK or NG OK NG 䊳 䊳 IMMU is malfunctioning. Replace IMMU. Ref. part No. A Perform initialization with CONSULT-II. For the operation of initialization, refer to “CONSULT-II Operation Manual IVIS/NVIS”. ECM is malfunctioning. Replace ECM. Ref. part No. B Perform initialization with CONSULT-II. For the operation of initialization, refer to “CONSULT-II Operation Manual IVIS/NVIS”. ST RS BT HA SC IDX EL-387 NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS) Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 3 =NAEL0418S07 Self-diagnostic results: “DIFFERENCE OF KEY” displayed on CONSULT-II screen 1 CONFIRM SELF-DIAGNOSTIC RESULTS Confirm SELF-DIAGNOSTIC RESULTS “DIFFERENCE OF KEY” displayed on CONSULT-II screen. SEL367X Is CONSULT-II screen displayed as above? Yes 䊳 GO TO 2. No 䊳 GO TO SYMPTOM MATRIX CHART 1. 2 PERFORM INITIALIZATION WITH CONSULT-II Perform initialization with CONSULT-II. Re-register all NVIS (NATS) ignition key IDs. For initialization and registration of NVIS (NATS) ignition key IDs, refer to “CONSULT-II operation manual NVIS/NVIS”. SEL297W NOTE: If the initialization is not completed or fails, CONSULT-II shows above message on the screen. Can the system be initialized and can the engine be started with re-registered NVIS (NATS) ignition key? Yes 䊳 Ignition key ID was unregistered. Ref. part No. D No 䊳 IMMU is malfunctioning. Replace IMMU. Ref. part No. A Perform initialization with CONSULT-II. For initialization, refer to “CONSULT-II operation manual IVIS/NVIS”. EL-388 NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS) Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 4 =NAEL0418S08 Self-diagnostic results: “CHAIN OF IMMU-KEY” displayed on CONSULT-II screen 1 CONFIRM SELF-DIAGNOSTIC RESULTS GI MA Confirm SELF-DIAGNOSTIC RESULTS “CHAIN OF IMMU-KEY” displayed on CONSULT-II screen. EM LC EC FE SEL368X Is CONSULT-II screen displayed as above? Yes 䊳 GO TO 2. No 䊳 GO TO SYMPTOM MATRIX CHART 1. 2 CHECK NVIS (NATS) IGNITION KEY ID CHIP CL MT AT Start engine with another registered NVIS (NATS) ignition key. Does the engine start? Yes No 3 䊳 䊳 Ignition key ID chip is malfunctioning. Replace the ignition key. Ref. part No. E Perform initialization with CONSULT-II. For initialization, refer to “CONSULT-II Operation Manual IVIS/NVIS”. GO TO 3. TF PD AX SU CHECK IMMU INSTALLATION Check IMMU installation. Refer to “How to Replace IMMU” in EL-394. BR OK or NG OK 䊳 IMMU is malfunctioning. Replace IMMU. Ref. part No. A Perform initialization with CONSULT-II. For initialization, refer to “CONSULT-II Operation Manual IVIS/NVIS”. NG 䊳 Reinstall IMMU correctly. ST RS BT HA SC IDX EL-389 NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS) Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 5 =NAEL0418S09 Self-diagnostic results: “ID DISCORD, IMM-ECM” displayed on CONSULT-II screen 1 CONFIRM SELF-DIAGNOSTIC RESULTS Confirm SELF-DIAGNOSTIC RESULTS “ID DISCORD, IMM-ECM” displayed on CONSULT-II screen. SEL369X NOTE: “ID DISCORD IMMU-ECM”: Registered ID of IMMU is in discord with that of ECM. Is CONSULT-II screen displayed as above? Yes 䊳 GO TO 2. No 䊳 GO TO SYMPTOM MATRIX CHART 1. 2 PERFORM INITIALIZATION WITH CONSULT-II Perform initialization with CONSULT-II. Re-register all NVIS (NATS) ignition key IDs. For initialization, refer to “CONSULT-II operation manual IVIS/NVIS”. SEL297W NOTE: If the initialization is not completed or fails, CONSULT-II shows above message on the screen. Can the system be initialized? Yes 䊳 Start engine. (END) (System initialization had not been completed. Ref. part No. F) No 䊳 ECM is malfunctioning. Replace ECM. Ref. part No. F Perform initialization with CONSULT-II. For initialization, refer to “CONSULT-II operation manual IVIS/NVIS”. EL-390 NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS) Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 6 =NAEL0418S10 GI “SECURITY INDICATOR LAMP DOES NOT LIGHT UP” 1 CHECK FUSE MA Check 10A fuse [No. 12, located in the fuse block (J/B)]. Is 10A fuse OK? Yes 䊳 GO TO 2. No 䊳 Replace fuse. 2 EM LC CHECK SECURITY INDICATOR LAMP EC 1. Install 10A fuse. 2. Perform initialization with CONSULT-II. For initialization, refer to “CONSULT-II Operation Manual IVIS/NVIS”. 3. Turn ignition switch OFF. 4. Start engine and turn ignition switch OFF. 5. Check the security indicator lamp lighting. Security indicator lamp should be blinking. FE CL OK or NG OK 䊳 INSPECTION END NG 䊳 GO TO 3. MT AT 3 CHECK SECURITY INDICATOR LAMP POWER SUPPLY CIRCUIT TF 1. Disconnect security indicator lamp connector. 2. Check voltage between security indicator lamp connector terminal 1 and ground. PD AX SU SEL370XA OK or NG OK 䊳 GO TO 4. NG 䊳 Check harness for open or short between fuse and security indicator lamp. BR ST RS BT HA SC IDX EL-391 NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS) Trouble Diagnoses (Cont’d) 4 CHECK SECURITY INDICATOR LAMP 1. Disconnect security indicator lamp connector. 2. Apply 12V direct current to security indicator lamp harness connector M20 terminals 1 and 2. SEL696Y OK or NG OK 䊳 GO TO 5. NG 䊳 Replace security indicator lamp. 5 CHECK IMMU FUNCTION 1. Connect IMMU connector. 2. Disconnect security indicator lamp connector. 3. Check continuity between IMMU terminal 5 and ground. SEL300WC OK or NG OK 䊳 Check harness for open or short between security indicator lamp and IMMU. NG 䊳 IMMU is malfunctioning. Replace IMMU. Perform initialization with CONSULT-II. For initialization, refer to “CONSULT-II operation manual IVIS/NVIS”. EL-392 NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS) Trouble Diagnoses (Cont’d) DIAGNOSTIC PROCEDURE 7 =NAEL0418S11 Self-diagnostic results: “LOCK MODE” displayed on CONSULT-II screen 1 GI MA CONFIRM SELF-DIAGNOSTIC RESULTS Confirm SELF-DIAGNOSTIC RESULTS “LOCK MODE” is displayed on CONSULT-II screen. EM LC EC FE SEL371X Is CONSULT-II screen displayed as above? Yes 䊳 GO TO 2. No 䊳 GO TO SYMPTOM MATRIX CHART 1. 2 1. 2. 3. 4. 5. CL MT AT ESCAPE FROM LOCK MODE Turn ignition switch OFF. Turn ignition switch ON with registered key. (Do not start engine.) Wait 5 seconds. Return the key to OFF position. Repeat steps 2 and 3 twice (total of three cycles). Start the engine. TF PD Does engine start? Yes 䊳 System is OK. (Now system is escaped from “LOCK MODE”.) No 䊳 GO TO 3. AX SU 3 CHECK IMMU ILLUSTRATION Check IMMU installation. Refer to “How to Replace IMMU” in EL-394. BR OK or NG OK 䊳 GO TO 4. NG 䊳 Reinstall IMMU correctly. ST RS BT HA SC IDX EL-393 NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS) Trouble Diagnoses (Cont’d) 4 PERFORM INITIALIZATION WITH CONSULT-II Perform initialization with CONSULT-II. For initialization, refer to “CONSULT-II operation manual IVIS/NVIS”. SEL297W NOTE: If the initialization is not completed or fails, CONSULT-II shows the above message on the screen. Can the system be initialized? Yes 䊳 System is OK. No 䊳 GO TO DIAGNOSTIC PROCEDURE 4 to check “CHAIN OF IMMU-KEY”, refer to EL-389. How to Replace NVIS (NATS) IMMU NAEL0419 NOTE: 쐌 If NVIS (NATS) IMMU is not installed correctly, NVIS (NATS) system will not operate properly and SELF-DIAG RESULTS on CONSULT-II screen will show “LOCK MODE”. SEL096WA EL-394 NAVIGATION SYSTEM Component Parts Location Component Parts Location NAEL0420 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SEL508X SC IDX EL-395 NAVIGATION SYSTEM System Description System Description =NAEL0421 OUTLINE SEL683V NAEL0421S01 The Navigation System (Multi-AV System) relies upon three sensing devices in order to determine vehicle location at regular time intervals. 1. Vehicle speed sensor: Determines the distance the vehicle has traveled. 2. Gyro (Angular velocity sensor): Determines vehicle steering angle and directional change. 3. GPS antenna (GPS data): Determines vehicle forward movement and direction. The data provided by the three sensing functions together with a comparison of the mapping information read from the CD-ROM drive permit accurate determination of the vehicle’s current location and subsequent course (map matching). The information appears on a liquid crystal display. This comparison of GPS data (vehicle position sensing) and map matching permits precise determination of vehicle location. Position Sensor Operating Principles SEL684V NAEL0421S0101 The sensor determines current vehicle location by calculating the previously sensed position, the distance traveled from this position, and the directional changes occurring during this travel. 1. Distance traveled The distance traveled is calculated using signals received from the vehicle speed sensor. The sensor automatically compensates for the slightly reduced wheel and tire diameter resulting from tire wear. 2. Forward movement (Direction) Changes in the direction of forward movement are calculated by the gyro (angular velocity sensor) and the GPS antenna (GPS data). Each of these functions has its advantage and disadvantages. Depending upon conditions, one function takes precedence over the other to accurately determine the direction of forward movement. Function type Advantage Gyro (Angular velocity sensor) 쐌 Able to accurately detect minute changes in steering angle and direction. GPS antenna (GPS data) 쐌 Able to sense vehicle travel 쐌 Unable to detect direction in four general directions of vehicle travel at low (North, South, East, and vehicle speeds. West) EL-396 Disadvantage 쐌 Calculation errors may accumulate over a long period of continuous vehicle travel. NAVIGATION SYSTEM System Description (Cont’d) Map Matching NAEL0421S0102 Map matching allows the driver to compare the sensed vehicle location data with the road map contained in the CD-ROM drive. Vehicle position is marked on the CD-ROM map. This permits the driver to accurately determine his/her present position on the highway and to make appropriate course decisions. When GPS data reception is poor during travel, the vehicle position is not amended. At this time, manual manipulation of the CDROM map position marker is required. GI MA EM LC SEL685V Map matching permits the driver to make priority judgments about possible appropriate roads other than the one currently being traveled. If there is an error in the distance or direction of travel, there will also be an error in the relative position of other routes. When two routes are closely parallel to one another, the indicated position for both routes will be nearly the same priority. This is so that, slight changes in the steering direction may cause the marker to indicate both routes alternately. SEL686V Newly constructed roads may not appear on the CD-ROM map. In this case, map matching is not possible. Changes in the course of a road will also prevent accurate map matching. When driving on a road not shown on the CD-ROM map, the position marker used for map matching may indicate a different route. Even after returning to a route shown on the map, the position marker may jump to the position currently detected. EC FE CL MT AT TF PD AX SU SEL687V GPS (Global Positioning System) SEL526V NAEL0421S0103 GPS is the global positioning system developed and operated by the US Department of Defense. GPS satellites (NAVSTAR) transmit radio waves and orbit around the earth at an altitude of approximately 21,000 km (13,000 miles). GPS receiver calculates the three-dimensional position of the vehicle (latitude, longitude, and altitude from the sea level) by the time difference of the radio wave arriving from more than four GPS satellites (three-dimensional positioning). When the radio wave is received from only three GPS satellites, the two-dimensional position (latitude and longitude) is calculated, using the altitude from the sea level data calculated by using four GPS satellites (two-dimensional positioning). Positioning capability is degraded in the following cases. 쐌 In two-dimensional positioning, when the vehicle’s altitude from the sea level changes, the precision becomes lower. 쐌 The location detection performance can have an error of about 100 m (300 ft) even in three-dimensional positioning with high precision. Because the precision is influenced by the location of GPS satellites used for positioning, the location detection performance may drop depending on the location of GPS satellites. 쐌 When the radio wave from GPS satellites cannot be received, EL-397 BR ST RS BT HA SC IDX NAVIGATION SYSTEM System Description (Cont’d) for example, when the vehicle is in a tunnel, in a parking lot inside building, under an elevated superhighway or near strong power lines, the location may not be detected. Turbulent/ electric weather conditions may also affect positioning performance. If something is placed on the antenna, the radio wave from GPS satellites may not be received. COMPONENT DESCRIPTION Display & NAVI Control Unit 쐌 쐌 쐌 SEL688V 쐌 NAEL0421S02 NAEL0421S0201 The gyro (angular speed sensor) and the CD-ROM drive are built-in units that control the navigation functions. Signals are received from the gyro, the vehicle speed sensor, and the GPS antenna. Vehicle location is determined by combining this data with the data contained in the CD-ROM map. Locational information is shown on liquid crystal display panel. Finger-operated touch switches are positioned on the liquid crystal display panel for easy operation. The touch switches used to control the equipment are beneath a glass sheet and two resistance membranes at the top of the liquid crystal display panel. The switches are sensitive to resistance value where touched with your finger to detect operating status. CD-ROM Driver NAEL0421S0202 Maps, traffic control regulations, and other pertinent information can be easily red from the CD-ROM disc. NOTE: 쐌 When removing the CD-ROM, allow it to remain open until the liquid crystal display locks. 쐌 The liquid crystal display must be closed when the vehicle is running. 쐌 Do not place cups, cans or other containers containing liquids on top of the liquid crystal display. SEL689V Map CD-ROM 쐌 쐌 NAEL0421S0203 The map CD-ROM has maps, traffic control regulations, and other pertinent information. To improve CD-ROM map matching and route determination functions, the CD-ROM uses an exclusive Nissan format. Therefore, the use of a CD-ROM provided by other manufacturers cannot be used. EL-398 NAVIGATION SYSTEM System Description (Cont’d) Gyro (Angular Speed Sensor) 쐌 쐌 쐌 SEL690V NAEL0421S0204 The oscillator gyro sensor is used to detect changes in vehicle steering angle. The oscillator gyro periodically senses oscillatory variation at the oscillation terminals. This variation is caused by changes in the vehicle angular velocity. Voltage variations are sensed by ceramic voltage sensors at the left and right sides of the terminals. Vehicle angular velocity corresponds directly with these changes in voltage. The gyro is built into the display & navigation (NAVI) control unit. GI MA EM LC EC BIRDVIEW姞 姞 NAEL0421S0205 The BIRDVIEW provides a detailed and easily seen display of road conditions covering the vehicle’s immediate to distant area. FE CL MT MAP DISPLAY AT TF PD AX BIRDVIEW R SU SEL636X Description 쐌 쐌 쐌 쐌 NAEL0421S0206 Display area: Trapezoidal representation showing approximate distances (Wn, D, and Wd). Ten horizontal grid lines indicate display width while six vertical grid lines indicate display depth and direction. Drawing line area shows open space, depth, and immediate front area. Each area is to a scale of approximately 5:6:25. When the “ZM−” button is pushed, the view point height is increased. Pushing the “ZM+” button decreases the height. Pushing the “ZM−” button or the “ZM+” button during operation indicates the scale change and the view point height at the left-hand side of the screen. BR ST RS BT HA SC IDX SEL691V EL-399 NAVIGATION SYSTEM System Description (Cont’d) FUNCTION OF TOUCH SWITCH (SUMMARY) Display with Pushed “MAP” Switch =NAEL0421S03 NAEL0421S0301 SEL475Y The function of each touch switch is as follows: 1) Azimuth indication 2) Position marker The tip of the arrow shows the current position. The shaft of the arrow indicates the direction in which the vehicle is traveling. 3) GPS reception signal (indicates current reception conditions) 4) Distance display (shows the distance in a reduced scale) 5) Current location voice information (this information is available when the route guide is being activated and the designated route is being traveled.) 6) Switch display from map screen to BIRDVIEW姞 screen (change to map screen on display when the BIRDVIEW姞 is being used.) 7) The following items can be set. 쐌 Save Current Location 쐌 Edit Address Book 쐌 Guide Volume 쐌 System Setting 8) The route guide operation can be canceled. EL-400 NAVIGATION SYSTEM System Description (Cont’d) Display with Pushed “DEST” Switch =NAEL0421S0302 GI MA EM LC EC FE CL SEL581X The function of each touch switch is as follows: Icon MT AT Description Address Book Favorite place can be saved to memory. The destination can be selected from the memory. Address/Street The destination can be searched from the address. Point of Interest (POI) The destination of favorite facility can be searched. Previous Dest. The previous ten destinations stored in memory are displayed. Intersection The destination from the intersection name can be retrieved. City The destination can be searched from city name. Map The destination can be searched from the map. TF PD AX SU BR ST RS BT HA SC IDX EL-401 NAVIGATION SYSTEM System Description (Cont’d) Display with Toutch Screen NAEL0421S0303 SEL476Y The function of each touch switch is as follows: Icon Description Quick Stop The selected facility is set as the destination or waypoint. (Route guidance has been turned OFF or the destination has been reached.) Where am I? Next, current and previous street names can be displayed. Route Info.* The following items can be set. 쐌 Complete Route 쐌 Turn List 쐌 Route Simulation (Displayed only when the destination area has been set.) Detour* Based on the selected distance, an alternative route is searched. [Displayed only when the recommended route (not its reverse) is followed.] Edit Route* Change the destination or add the transit points of the route set in the route guide. (Displayed only when the automatic reroute function has been turned OFF and the recommended route is not followed.) Route Calc. Search for a recommended route between the vehicle’s current location and the destination area. (Displayed only when the destination area has been set.) *: When destinations have been entered, route guidance has been turned OFF or destination has been reached, “Route Info.”, “Detour” and “Edit Route” are not displayed. EL-402 NAVIGATION SYSTEM Schematic Schematic NAEL0422 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL042Q EL-403 IDX NAVIGATION SYSTEM Wiring Diagram — NAVI — Wiring Diagram — NAVI — NAEL0423 MEL043Q EL-404 NAVIGATION SYSTEM Wiring Diagram — NAVI — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL044Q IDX EL-405 NAVIGATION SYSTEM Wiring Diagram — NAVI — (Cont’d) MEL045Q EL-406 NAVIGATION SYSTEM Self-diagnosis Mode Self-diagnosis Mode APPLICATION ITEMS Mode Description NAEL0424 GI NAEL0424S01 Reference page MA Self-diagnosis for display & NAVI control unit, CD-ROM and GPS antenna connection. EL-408 EM Display Diagnosis Color and gray gradation of display can be checked in this mode. EL-416 LC Diagnostic Signals from the Car Several input signals to display & NAVI control unit, can be monitored in this mode. EL-414 Check the map CDROM version The version (parts number) of inserted CD-ROM can be checked in this mode. EL-415 History of errors Diagnosis results previously stored in the memory (before turning ignition switch ON) are displayed in this mode. Time and location when/where the errors occurred are also displayed. EL-410 Longitude & Latitude Display the map. Use the joystick to adjust position. Longitude and latitude will be displayed. EL-417 Adjust the angle Turning angle of the vehicle on the display can be adjusted in this mode. EL-418 Under ordinary conditions, the navigation system distance measuring function will automatically compensate for minute decreases in wheel and tire diameter caused by tire wear or low pressure. Speed calibration immediately restores system accuracy in cases such as when distance calibration is needed because of the use of tire chains in inclement weather. EL-419 This mode is for initializing the current location. Use when the vehicle is transported a long distance on a trailer, etc. EL-444 Self Diagnosis Confirmation/ adjustment Navigation Speed Calibration Initialize Location EC FE CL MT AT TF PD AX SU HOW TO PERFORM SELF-DIAGNOSIS MODE 1. 2. NAEL0424S02 Start the engine. Push both of “MAP” and “D/N” switches at the same time for more than 5 seconds. BR ST RS BT SEL583X 3. 쐌 Touch “Self Diagnosis” or “Confirmation/ adjustment”. For further procedure, refer to the following pages which describe each application item of the self-diagnosis mode. HA SC IDX SEL584X EL-407 NAVIGATION SYSTEM Self-diagnosis Mode (Cont’d) “Self Diagnosis” 1. 2. NAEL0424S0201 3. Start the engine. Push both “MAP” and “D/N” switches at the same time for more than 5 seconds. Touch “Self Diagnosis”. 4. Self-diagnosis will be performed. 5. Diagnosis results will be displayed. Diagnosis results are indicated by display color. For details refer to “SELF-DIAGNOSIS RESULTS”. SEL584X SEL585X SEL586X To obtain detailed diagnosis results on the screen, touch “Navigation” or “GPS Antenna”. SEL587X EL-408 NAVIGATION SYSTEM Self-diagnosis Mode (Cont’d) SELF-DIAGNOSIS RESULTS Diagnosed item Displayed color Green “GPS Antenna” (GPS antenna con- Yellow nection) Green Detailed result — Description GPS antenna is connected to display & NAVI control unit correctly. Connection to the following unit is abnormal. See GPS antenna connection error is the Service Manual for detected. further diagnosis. — No failure is detected. Display & NAVI control unit is malfunctioning. Red [*** is abnormal.] Gray Self-diagnosis for CDROM DRIVER of DISP & Any CD-ROM is not inserted or disNAVI was not conducted play & NAVI control unit is malfuncdue to no insertion of tioning. CD-ROM. “Navigation” (Display & NAVI control unit) Yellow CD-ROM or CD-ROM DRIVER of DISP & NAVI is abnormal. See the Service Manual for further diagnosis. Display & NAVI control unit judges that inserted CD-ROM is malfunctioning. Map CD-ROM or CD-ROM driver of the unit is malfunctioning. CD-ROM is abnormal. Please check the disc. Inserted map CD-ROM can not be read. Map CD-ROM or CD-ROM driver of the unit is malfunctioning. Connection to the following unit is abnormal. See GPS antenna connection error is the Service Manual for detected. further diagnosis. =NAEL0424S03 Diagnoses/service procedure Recheck system at each check or replacement (When malfunction is eliminated, further repair work is not required.) GI MA EM — 1. Check GPS antenna feeder cable connection at display & NAVI control unit. 2. Visually check GPS antenna feeder cable. If NG, replace GPS antenna assembly. 3. Replace GPS antenna. LC EC FE — Replace display & NAVI control unit. 1. Confirm that map CD-ROM is not inserted into display & NAVI control unit. 2. Replace display & NAVI control unit. 1. Confirm the disk is installed correctly (not up side down.) 2. Perform “CHECK THE MAP CDROM VERSION” in EL-415 to confirm whether correct CD-ROM is inserted or not. 3. Check the disk surface. Are there any scratches, abrasions or pits on the surface? 4. Replace the CD-ROM. 5. Replace display & NAVI control unit. 1. Check GPS antenna feeder cable connection at display & NAVI control unit. 2. Visually check GPS antenna feeder cable. If NG, replace GPS antenna assembly. 3. Replace GPS antenna. CL MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-409 NAVIGATION SYSTEM Confirmation/Adjustment Mode Confirmation/Adjustment Mode “HISTORY OF ERRORS” MODE Description =NAEL0425 NAEL0425S01 NAEL0425S0101 In this mode, historical errors of the system are displayed with the following data. 쐌 How many times the error was detected 쐌 The last time data when the error was detected 쐌 The last place where the error was detected NOTE: 쐌 The number of errors can be counted up to 50 times. More than 51 times will be indicated as 50 times. 쐌 Malfunction of the GPS board (inside the display & NAVI control unit) will result in the display of incorrect time data. 쐌 When an error occurs, an incorrect position marker appears on the display. The accuracy of the display data (position marker) will be affected. How to Perform 1. 2. NAEL0425S0102 3. Start the engine. Push both “MAP” and “D/N” switch at the same time for more than 5 seconds. Touch “Confirmation/ adjustment”. 4. Touch “Navigation”. 5. Touch “Error history”. SEL584X SEL588X SEL453Y EL-410 NAVIGATION SYSTEM Confirmation/Adjustment Mode (Cont’d) 6. SEL590X If trouble items are displayed with time count, repair/replace the system according to “HISTORY OF ERRORS” TABLE, EL-412. 7. If necessary, touch error item to display the time when the error was detected and the place where the error was detected. 8. After repairing the system, erase the diagnosis memory. NOTE: When the display & NAVI control unit must be replaced, do not erase the diagnosis memory for further inspection of malfunctions. a. Start the engine. b. Push both “Map” and “D/N” switches at the same time for more than 5 seconds. c. Touch “Confirmation/ adjustment”. d. Touch “Navigation”. e. Touch “Error history”. f. Touch “Delete”. g. Touch “Yes”. GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-411 NAVIGATION SYSTEM Confirmation/Adjustment Mode (Cont’d) “HISTORY OF ERRORS” TABLE Detected items Description Diagnosis/service procedure Reference page Perform self-diagnosis to confirm whether the display & NAVI control unit is malfunctioning or not. If no failure is detected, a momentary and/or temporary malfunction may have been caused by strong electromagnetic wave interference. EL-407 Gyro sensor disconnected Communications malfunction between display & NAVI control unit and internal gyro Connection problem of speed sensor Check vehicle speed sensor signal in “DIAGNOSTIC SIGNALS FROM THE Input malfunction of display & NAVI con- CAR” mode. If the input signal is not trol unit and speed sensor detected correctly, check harness for open or short between combination meter and display & NAVI control unit. GPS disconnected Communications malfunction between GPS transmission cable malfuncdisplay & NAVI control unit and GPS tion board GPS input line connection error GPS TCXO over GPS TCXO under GPS ROM malfunction GPS RAM malfunction GPS RTC malfunction GPS antenna disconnected Low voltage of GPS CD-ROM communication error The transmission circuit of the GPS board frequency synchronization oscillator (inside the display & NAVI control unit) is sending an oscillation frequency that is greater or less than the set value. Internal malfunction of GPS board RAM or ROM inside the display & NAVI control unit. Malfunction of GPS board clock IC inside the display & NAVI control unit. — Power supply voltage for GPS board inside the display & NAVI control unit is low. CD-ROM driver malfunction (inside the display & NAVI control unit) EL-412 =NAEL0425S02 EL-414 Perform self-diagnosis to confirm whether the display & NAVI control unit is malfunctioning or not. If no failure is detected, a momentary and/or temporary malfunction may have been caused by strong electromagnetic wave interference. EL-407 A location error occurs. Strong electromagnetic wave interference may have occurred. The GPS antenna may be in a very hot or very cold environment. This is usually a temporary malfunction. — Perform self-diagnosis to confirm whether the display & NAVI control unit is malfunctioning or not. If no failure is detected, a momentary and/or temporary malfunction may have been caused by strong electromagnetic wave interference. EL-407 Perform self-diagnosis to confirm GPS antenna connection. If no failure is detected, a momentary and/or temporary malfunction may have been caused by a strong impact. EL-415 1. Check power supply circuits for display & NAVI control unit. EL-428 2. Perform self-diagnosis to confirm GPS antenna connection. EL-407 3. If above diagnosis results are OK, a momentary and/or temporary malfunction may have been caused by a strong impact. — Perform self-diagnosis to confirm whether the display & NAVI control unit is malfunctioning or not. If no failure is detected, a momentary and/or temporary malfunction may have been caused by strong electromagnetic wave interference. EL-407 NAVIGATION SYSTEM Confirmation/Adjustment Mode (Cont’d) Detected items Loading mechanism malfunction Description Diagnosis/service procedure — Check that whether the disc can be inserted and ejected correctly. If the loading function does not operate correctly, replace NAVI & display control unit. CD-ROM reading error It is confirmed that the appropriate CDROM disc is positioned in the CD-ROM loader. However, no data can be read. Malfunctioning of error correction for CD-ROM Erroneous data is read from the CDROM. The errors cannot be corrected. CD-ROM focus error CD-ROM data reading beam is out of focus. CD-ROM malfunction — GI MA EM LC Perform self-diagnosis to confirm whether the inserted disc is malfunctioning or not. Rough road driving might create CD skipping like music CD audio unit. Perform self-diagnosis to confirm whether the inserted disc is malfunctioning or not. — Reference page EL-407 — EL-407 EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-413 NAVIGATION SYSTEM Confirmation/Adjustment Mode (Cont’d) “DIAGNOSTIC SIGNALS FROM THE CAR” MODE =NAEL0425S03 Description NAEL0425S0301 In “Diagnostic Signals From the Car” mode, following input signals to the display & NAVI control unit can be checked on the display. Item Vehicle Speed* Indication Vehicle condition ON Vehicle speed is greater than 0 km/h (0 MPH). OFF Vehicle speed is 0 km/h (0 MPH). ON Lighting switch is in 1st or 2nd position. OFF Lighting switch is in “OFF” position. ON Ignition switch is in “ON” position. OFF Ignition switch is in “ACC” position. ON Selector/shift lever is in “Reverse” position. OFF Selector/shift lever is in other than “Reverse” position. Light IGN REVERSE* *: When ignition switch is in “ACC” position, indication will be changed to “-”. How to Perform 1. 2. NAEL0425S0302 3. Start the engine. Push both “MAP” and “D/N” switches at the same time for more than 5 seconds. Touch “Confirmation/ adjustment”. 4. Touch “Diagnostic Signals from the Car”. 5. Then “Diagnostic Signals from the Car” mode is performed. SEL584X SEL588X SEL591X EL-414 NAVIGATION SYSTEM Confirmation/Adjustment Mode (Cont’d) “CHECK THE MAP CD-ROM VERSION” MODE How to Perform 1. 2. 3. =NAEL0425S04 GI NAEL0425S0401 Start the engine. Push both “MAP” and “D/N” switches at the same time for more than 5 seconds. Touch “Confirmation/ adjustment”. MA EM LC SEL584X 4. Touch “Navigation”. EC FE CL MT SEL588X 5. Touch “Check the map CD-ROM version”. AT TF PD AX SU SEL589X 6. The version (parts number) of CD-ROM loaded to the display and NAVI control unit will be displayed. BR ST RS BT SEL592X HA SC IDX EL-415 NAVIGATION SYSTEM Confirmation/Adjustment Mode (Cont’d) “DISPLAY DIAGNOSIS” MODE Description =NAEL0425S05 NAEL0425S0501 Use the “Diagnosis Display” mode to check the display color brightness and shading. The display & NAVI control unit must be replaced if the color brightness and shading are abnormal. How to Perform 1. 2. NAEL0425S0502 3. Start the engine. Push both “MAP” and “D/N” switches at the same time for more than 5 seconds. Touch “Confirmation/ adjustment”. 4. Touch “Display Diagnosis”. 5. 6. Touch “Display color spectrum bar” or “Display gradation bar”. Then color bar/gray scale will be displayed. SEL584X SEL588X SEL454Y SEL455Y EL-416 NAVIGATION SYSTEM Confirmation/Adjustment Mode (Cont’d) “LONGITUDE & LATITUDE” MODE Description NAEL0425S06 GI NAEL0425S0601 The “Longitude & Latitude” is used to confirm the longitude and latitude of some optional area point. MA EM LC How to Perform 1. 2. 3. EC NAEL0425S0602 Start the engine. Push both “MAP” and “D/N” switches at the same time for more than 5 seconds. Touch “Confirmation/ adjustment”. FE CL MT SEL584X 4. Touch “Navigation”. AT TF PD AX SU SEL588X 5. Touch “Longitude & Latitude”. BR ST RS BT SEL589X 6. 7. Adjust the pointer with using the joystick and touch “Set”. The longitude and latitude are displayed. HA SC IDX SEL595X EL-417 NAVIGATION SYSTEM Confirmation/Adjustment Mode (Cont’d) “ADJUST THE ANGLE” MODE Description =NAEL0425S07 NAEL0425S0701 If the display indicates a larger or smaller turning angle than the actual turning angle, the gyro (angular speed sensor) sensing values must be checked. In case that the vehicle on the display makes larger angle turn than reality, touch “−”. In case that the vehicle on the display makes smaller angle turn than reality, touch “+”. How to Perform 1. 2. NAEL0425S0702 3. Start the engine. Push both “MAP” and “D/N” switches at the same time for more than 5 seconds. Touch “Confirmation/ adjustment”. 4. Touch “Navigation”. 5. Touch “Adjust the angle”. 6. Touch “Left Turn” to adjust the angle to the left. Touch “Right Turn” to adjust the angle to the right. Touch “+” to increase the angle change coefficient or “−” to reduce the angle change coefficient. Touch “Set” to save the changed values in memory. Then the vehicle turning angle on the display has adjusted. SEL584X SEL588X SEL453Y 7. 8. 9. SEL456Y EL-418 NAVIGATION SYSTEM Confirmation/Adjustment Mode (Cont’d) SPEED CALIBRATION 1. 2. 3. 4. =NAEL0425S08 Start the engine. Push both “MAP” and “D/N” switches at the same time for more than 5 seconds. Touch “Confirmation/ adjustment”. Touch “Navigation”. GI MA EM LC SEL584X 5. Touch “Speed Calibration”. EC FE CL MT SEL453Y 6. 쐌 쐌 7. Touch “+” or “−” to adjust the distance change coefficient. To make the distance change coefficient smaller, touch “−”. To make the distance change coefficient larger, touch “+”. Touch “Set”. AT TF PD AX SU SEL457Y BR ST RS BT HA SC IDX EL-419 NAVIGATION SYSTEM Setting Mode Setting Mode =NAEL0426 APPLICATION ITEMS Mode GPS Information Description NAEL0426S01 Reference page The GPS includes longtitude, latitude and altitude (distance above sea level) of the present vehicle position, and current date and time for the area in which the vehicle is being driven. Also indicated are the GPS reception conditions and the GPS satellite position. EL-420 Quick Stop Customer One facility of your selection can be added to your Quick Stop. Setting EL-423 Route Priorities Priorities of search request and automatic re-searching can be set for route search. EL-424 Tracking Tracking to the present vehicle position can be displayed. EL-425 Display Setting The following display settings can be customized. 쐌 Display color (Day mode or Night mode) 쐌 Brightness of display EL-422 Heading Heading of the map display can be customized for either north heading or the actual driving direction of the vehicle. EL-425 Nearby Display Icons Icons of facilities can be displayed. Facilities to be displayed can be selected from the variety of selections. EL-426 Adjust Current Location Current location of position marker can be adjusted. Direction of position marker also can be calibrated when heading direction of the vehicle on the display is not matched with the actual direction. EL-421 Avoid Area Setting Particular area can be avoided when routing. Beep On/Off Beep sounds which correspond to the system operation can be activated/deactivated. EL-422 Clear Memory Address book, Previous destination or Avoid area can be deleted. EL-426 HOW TO PERFORM CONTROL PANEL MODE 1. 2. 쐌 — NAEL0426S02 Start the engine. Push “MAP” switch. For further procedures, refer to the following pages which describe each application item of the control panel mode. SEL597X “GPS INFORMATION” SETTING 1. 2. 3. Start the engine. Push “MAP” switch. Touch “Setting”. SEL598X EL-420 NAEL0426S03 NAVIGATION SYSTEM Setting Mode (Cont’d) 4. Touch “System Setting”. GI MA EM LC SEL461Y 5. EC Touch “GPS Information”. FE CL MT SEL462Y 6. AT Then GPS information will be displayed. TF PD AX SU SEL146W “ADJUST CURRENT LOCATION” SETTING 1. 2. 3. 4. Start the engine. Push “MAP” switch. Touch “Setting”. Touch “System Setting”. NAEL0426S04 BR ST RS BT SEL460Y 5. Touch “Adjust Current Location”. HA SC IDX SEL463Y EL-421 NAVIGATION SYSTEM Setting Mode (Cont’d) 6. 7. 8. Touch “ ” or “ ” to calibrate the heading direction. (Arrow marks will rotate corresponding to the calibration key.) Touch “Set”. Then the vehicle mark will be matched to the arrow mark. Display will show “Heading direction has been calibrated” and then go back to the current location map. SEL602X BEEP ON/OFF SETTING NAEL0426S05 1. 2. 3. 4. Start the engine. Push “MAP” switch. Touch “Setting”. Touch “System Setting”. 5. Touch “Beep on/off”. 6. 쐌 쐌 7. Touch “On” or “Off” icon. If you want the beep sound, select “ON”. If you do not want the beep sound, select “OFF”. Push “MAP” switch, then the display will go back to the current location map. SEL460Y SEL463Y SEL464Y DISPLAY SETTING Description NAEL0426S06 NAEL0426S0601 The following display setting can be changed in this mode. 쐌 Dimmer operation (when lighting switch is turned on.) 쐌 Display color (Day mode or Night mode) 쐌 Brightness of display EL-422 NAVIGATION SYSTEM Setting Mode (Cont’d) DISPLAY COLOR SETTING NAEL0426S07 1. 2. 3. 4. 5. SEL465Y Start the engine. Push “MAP” switch. Touch “Setting”. Touch “System Setting”. Touch “Color”. Display color will change to Day mode/Night mode. 6. Touch “Previous”. NOTE: 쐌 Display color can be changed independently when lighting switch is turned on and off. 쐌 Initial setting of the color is as follows: When lighting switch is turned off: Day mode When lighting switch is turned on: Night mode Day mode: White background Night mode: Black background GI MA EM LC EC FE CL MT BRIGHTNESS SETTING SEL465Y AT NAEL0426S08 1. Start the engine. 2. Push “MAP” switch. 3. Touch “Setting”. 4. Touch “System Setting”. 5. Touch “Display Setting”. 6. Touch “Bright” or “Dark” to adjust the brightness of display. 7. Touch “Previous”. NOTE: Display brightness can be adjusted independently when lighting switch is turned on and off. TF PD AX SU BR ST RS BT “QUICK STOP CUSTOMER SETTING” MODE 1. 2. 3. 4. Start the engine. Push the “MAP” switch. Touch “Setting”. Touch “System Setting”. NAEL0426S09 HA SC IDX SEL460Y EL-423 NAVIGATION SYSTEM Setting Mode (Cont’d) 5. Touch “Quick Stop Customer Setting”. 6. Select from the itemized list. SEL462Y SEL466Y “ROUTE PRIORITIES” MODE 1. 2. 3. 4. Start the engine. Push the “MAP” switch. Touch “Setting”. Touch “System Setting”. 5. Touch “Route Priorities”. 6. Select from the itemized list. SEL460Y SEL467Y SEL468Y EL-424 NAEL0426S10 NAVIGATION SYSTEM Setting Mode (Cont’d) “TRACKING” MODE 1. 2. 3. 4. NAEL0426S11 Start the engine. Push the “MAP” switch. Touch “Setting”. Touch “System Setting”. GI MA EM LC SEL460Y 5. EC Touch “Tracking”. FE CL MT SEL467Y 6. 쐌 쐌 7. Touch the “On” or “Off” icon. If you don’t need a trail on the map, select “Off”. If you need a trail on the map, select “On”. Push the “MAP” switch to return the display to the current location map. NOTE: When a trail display is turned OFF, trail data is erased from the memory. AT TF PD AX SU SEL470Y “HEADING” MODE 1. 2. 3. 4. Start the engine. Push the “MAP” switch. Touch “Setting”. Touch “System Setting”. NAEL0426S12 BR ST RS BT SEL460Y 5. Touch “Heading”. HA SC IDX SEL467Y EL-425 NAVIGATION SYSTEM Setting Mode (Cont’d) 6. 쐌 쐌 7. Touch the “Heading up” or “North up” icon. To display North up, select “North up”. To display the car heading up, select “Heading up”. Push the “MAP” switch, then the display will go back to the current location map. SEL470Y “NEARBY DISPLAY ICONS” MODE NAEL0426S13 1. 2. 3. 4. Start the engine. Push the “MAP” switch. Touch “Setting”. Touch “System Setting”. 5. Touch “Nearby Display Icons”. 6. 7. Select and touch the itemized list. Push the “MAP” switch to return the display to the current location map. SEL460Y SEL463Y SEL471Y “CLEAR MEMORY” MODE 1. 2. 3. 4. Start the engine. Push the “MAP” switch. Touch “Setting”. Touch “System Setting”. SEL460Y EL-426 NAEL0426S14 NAVIGATION SYSTEM Setting Mode (Cont’d) 5. Touch “Clear Memory”. GI MA EM LC SEL462Y 6. To delete all the stored places in the “Address Book”, “Avoid Area” and “Previous Dest.”, select “Yes”. EC FE CL MT SEL472Y “MAP & A/C” MODE 1. 2. 3. 4. AT NAEL0426S15 Start the engine. Push “MAP” switch. Touch “Setting”. Touch “System Setting”. TF PD AX SU SEL460Y 5. Touch “MAP & A/C”. BR ST RS BT SEL462Y 6. 쐌 SEL474Y Touch “Map & A/C” or “Map” icon. To set the split display with both the map and the air conditioner information as the initial setting of the NAVI system, select “MAP & A/C”. 쐌 To set the map only display as the initial setting of the NAVI system, select “MAP”. 7. Push “MAP” switch, then the display will go back to the current location map. NOTE: When the enlarged view is displayed, the air conditioner control screen will not be displayed. EL-427 HA SC IDX NAVIGATION SYSTEM Trouble diagnoses Trouble diagnoses SYMPTOM CHART Symptom Any function of the system does not operate. Diagnoses/service procedure NAEL0427 NAEL0427S01 Reference page Check power supply and ground circuit for display & NAVI control unit. EL-431 Strange screen color or unusual screen brightness. 1. Check “DISPLAY SETTING”. EL-422 The display is not dimmed when turning lighting switch to ON. 1. Check “DISPLAY SETTING”. EL-422 2. Check lighting switch signal input to display & NAVI control unit correctly in “DIAGNOSTIC SIGNAL FROM THE CAR” MODE. EL-414 No navigation guide voice are heard from both front speakers. 1. Check “Voice Guidance Setting”. 2. Check display in “Diagnosis of Display” MODE. — — 2. Check voice guide operation. EL-432 Beep does not sound when the system guides route. Check “BEEP ON/OFF SETTING”. EL-422 Position marker does not trace along the route being traveled. Go to “WORK FLOW FOR NAVIGATION INSPECTION”. EL-429 Position marker does not Check reverse signal input to display & NAVI control unit correctly by “DIAGNOSindicate forward or backward TIC SIGNAL FROM THE CAR” MODE. movement. Radio wave of GPS cannot be received. (GPS marker on the display does not become green color.) Heading direction of position marker does not match vehicle direction. 1. Is there anything obstructing the GPS antenna on the rear parcel finisher? (GPS antenna located under the rear parcel finisher.) — 2. Check GPS radio wave receive condition in “GPS INFORMATION SETTING”. EL-420 3. Check GPS antenna in “Self Diagnosis”. EL-407 1. Perform “ADJUST CURRENT LOCATION” SETTING. EL-421 2. Go to “WORK FLOW FOR NAVIGATION INSPECTION”. EL-429 Stored location in the address book and other Stored location in the address book and other memory functions may be lost if the memory functions are lost battery is disconnected or becomes discharged. If this should occur, charge or when battery is disconnected replace the battery as necessary and re-enter the information. or becomes discharged. Map appears grey and cannot be scrolled. EL-414 The current location in the memory is out of the map data area. Perform “Initialize Location”. EL-428 — EL-444 NAVIGATION SYSTEM Trouble diagnoses (Cont’d) WORK FLOW FOR NAVIGATION INSPECTION NAEL0427S02 GI MA EM LC EC FE CL MT AT TF PD AX SU BR SEL629XA ST *1: EL-434 *2: EL-407 *3: EL-410 *4: EL-414 *5: EL-430 *6: EL-409 *7: EL-412 RS BT HA SC IDX EL-429 NAVIGATION SYSTEM Trouble diagnoses (Cont’d) DRIVING TEST =NAEL0427S03 During the driving test, diagnose the system by checking the difference of symptoms with each sensor ON or OFF. Test pattern 1 Test method in which current position adjustment is not made according to GPS data. 쐌 Remove the GPS antenna connector from the display & NAVI control unit. Drive the vehicle. Before driving the vehicle, perform “ADJUST CURRENT LOCATION” (EL-421). Test pattern 2 Test procedure in which map matching is not used. 쐌 Before driving the vehicle, perform “ADJUST CURRENT LOCATION” (EL-421). With the ignition switch OFF and the map CD-ROM removed from the display & NAVI control unit, drive the vehicle. After driving the vehicle, reinstall the map CD-ROM. Compare the saved driving tracks for the vehicle’s current location with roads on the map. Example , Perform test pattern 1. , Perform test patterns 1 and 2. 쐌 Compare the map and the saved driving tracks. The precision of the saved driving tracks is within several hundred meters. , Perform test patterns 1 and 2. 쐌 Make adjustments by driving the vehicle over a known course (highway or other road where distances are clearly marked). Calibrate the distance against the known distance. Use the formula below. Calibration value = Screen display distance/Actual distance EL-430 NAVIGATION SYSTEM Trouble diagnoses (Cont’d) POWER SUPPLY AND GROUND CIRCUIT CHECK FOR GI DISPLAY & NAVI CONTROL UNIT =NAEL0427S04 Power Supply Circuit Check NAEL0427S0401 MA Terminal SEL693VD Ignition switch (+) (−) OFF ACC ON 1 Ground Battery voltage Battery voltage Battery voltage 2 Ground Battery voltage Battery voltage Battery voltage 5 Ground 0V 0V Battery voltage 6 Ground 0V Battery voltage Battery voltage If NG, check the following. 쐌 7.5A fuse [No. 11, located in the fuse block (J/B)] 쐌 10A fuse [No. 10, located in the fuse block (J/B)] 쐌 15A fuse [No. 4, located in the fuse block (J/B)] 쐌 Harness for open or short between fuse and display & NAVI control unit EM LC EC FE CL MT AT Ground Circuit Check NAEL0427S0402 Terminals Continuity 3 - Ground Yes 4 - Ground Yes TF PD AX SU SEL694VD BR ST RS BT HA SC IDX EL-431 NAVIGATION SYSTEM Trouble diagnoses (Cont’d) VOICE GUIDE OPERATION CHECK 1 =NAEL0427S05 PRELIMINARY CHECK 1. Turn ignition switch to ACC position. 2. Insert the music CD into the radio and CD player. 3. Try to play the music CD. Is the sound emitted from all speakers? Yes or No Yes 䊳 GO TO 2. No 䊳 Repair or replace audio system. Refer to “AUDIO”, EL-173. 2 CHECK NAVI OPERATION ON SIGNAL 1. Disconnect audio unit connector. 2. Push “VOICE” button. 3. Check voltage between terminal 28 and ground. SEL645XA OK or NG OK 䊳 GO TO 3. NG 䊳 Repair or replace harness or NAVI control unit. 3 CHECK VOICE SIGNAL CIRCUIT 1. Push “VOICE” button. 2. Check voltage between display and NAVI control unit harness connector M118 terminal 30 (G/Y) or 31 (OR/L) and ground. SEL797Y OK or NG OK 䊳 GO TO 4. NG 䊳 Repair or replace NAVI control unit. EL-432 NAVIGATION SYSTEM Trouble diagnoses (Cont’d) 4 GI CHECK VOICE SIGNAL CIRCUIT 1. Turn ignition switch OFF. 2. Disconnect display and NAVI control unit connector and AUDIO unit connector. 3. Check continuity between display and NAVI control unit harness connector M118 terminal 30 (G/Y) and AUDIO unit harness connector M139 terminal 36 (G/Y). 4. Check continuity between display and NAVI control unit harness connector M118 terminal 31 (OR/L) and AUDIO unit harness connector M139 terminal 34 (OR/L). MA EM LC EC FE SEL798Y CL Yes or No Yes 䊳 Repair or replace audio system. Refer to “AUDIO”, EL-173. No 䊳 Repair or replace harness or connector. MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-433 NAVIGATION SYSTEM This Condition is Not Abnormal This Condition is Not Abnormal EXAMPLE OF BASIC OPERATIONAL ERRORS Symptom No image is displayed. Possible cause Repair order Monitor brightness control is set to full dark. Map does not appear Map CD is not inserted or inserted upside down. on display. Map mode is turned OFF. No guide tone is heard. =NAEL0428 NAEL0428S01 Readjust monitor brightness. Insert the map CD with the label facing up. Press the “MAP” button. Voice guide adjustment OFF/Volume is set to the lowest or highest level. Adjust the voice guide level. Dark display/Slow image movement Low vehicle interior temperature Wait until vehicle interior temperature rises to appropriate level. Small black or white dots appear on the screen. Unique liquid crystal display phenomena No problem “Unable to read CD” message appears only during specified operation. Map CD surface is tainted/CD surface is partially scratched. Voice guide volume is too high or too low. Check map CD surface. If dirty, wipe clean with a soft cloth. If map CD surface is damaged, replace the CD. Area place names are not displayed. If area place names do not appear on the map display, these names may not be available. Use the BIRDVIEW姞 flat surface map display function. Display output may differ. Note the items related to BIRDVIEW姞 below. 쐌 Priority is given to the display of place names in the direction of vehicle travel. 쐌 Extended display of vehicle travel distance for both surfaces and steering angle (flat directional changes). This phenomenon disappears after the display image has been replaced by another one. 쐌 The names of route and area might vary between the immediate front area and distance front area. 쐌 Alphanumeric display characters are limited to maintain display simplicity and clarity. Display details may differ with time and place. 쐌 Identical place and road names may appear on the display at more than one location. EL-434 NAVIGATION SYSTEM This Condition is Not Abnormal (Cont’d) EXAMPLE OF CURRENT VEHICLE POSITION MARKER ERROR =NAEL0428S02 The navigation system reads the vehicle distance and steering angle data. Because the vehicle is moving, there will be an error in the current position indication. After the error appears, drive the vehicle for a short distance. Stop the vehicle. If the position marker does not return to its original position, perform “ADJUST CURRENT LOCATION” (EL-421). GI MA EM LC EC FE CL MT AT TF PD SEL698V AX SU BR ST RS BT HA SC IDX EL-435 NAVIGATION SYSTEM This Condition is Not Abnormal (Cont’d) Possible cause Drive condition Slippery road surface On wet, icy, or gravel road where frequent wheel slippage occurs, distance calculations may be erroneous. The position marker may show the vehicle to be in inaccurate position. Slanted area Hilly areas where the road has banked curves. When the vehicle enters these banked curves, there may be an error in steering angle measurement. The position marker may show the vehicle to be in inaccurate position. Area Map data When the vehicle is driven on a newly constructed road that does Map display for a given road does not appear. not appear on the existing map. Map marking and calibration are not possible. The position marker may indicate inaccurate position in close proximity to the actual position. Subsequently, when the vehicle is driven on a road which is available as map data, the position marker SEL699V may still indicate an inaccurate position. Service procedure If the position marker does not move to the correct position even after the vehicle has been driven approximately 10 km (6 miles), perform “ADJUST CURRENT LOCATION” (EL-421). If necessary, perform “SPEED CALIBRATION” (EL-419). The vehicle is driven on a road whose course has been altered (usually to improve the road or When the map data shown on the to eliminate some hazard). display and the actual conditions are different. Map matching will not be possible. The position marker may indicate inaccurate position in close proximity to the actual position. If the vehicle is driven on the indicated road, further errors may occur. SEL700V Vehicle Use of tire chains (Stormy weather) Tire chains will affect distance sensing. The position marker may indicate inaccurate position. EL-436 If the position marker does not move to the correct position even after the vehicle has been driven approximately 10 km (6 miles), perform “SPEED CALIBRATION” (EL-419). After removing the tire chains, sensing accuracy may recover by itself. NAVIGATION SYSTEM This Condition is Not Abnormal (Cont’d) Possible cause Drive condition Driving immediately after starting engine. Operation The gyro (angular velocity sensor) needs about 15 seconds after the engine is started to precisely sense the angular velocity. Directional sensing errors will occur if the vehicle is moved immediately after starting the engine. The position marker may indicate inaccurate position. When the vehicle is driven continuously without stopping over a long Continuous driving for long distances (non-stop) distance, errors in directional sensing may occur. The position marker may indicate inaccurate position. Service procedure MA Wait a few moments between starting the engine and actually driving the vehicle. EM LC Stop the vehicle. Perform “SPEED CALIBRATION” (EL419). EC FE If the position marker does not Wheel spinning (peeling out) or simimove to the correct position lar rough driving techniques can even after the vehicle has been adversely affect sensing accuracy. driven approximately 10 km (6 The position marker may indicate miles), perform “ADJUST CURinaccurate position. RENT LOCATION” (EL-421). Rough or violent driving GI CL MT Positional calibration precision Positional calibration pro- Position calibration direction cedures If current vehicle location is roughly set, the system may be unable to locate the road that the vehicle is traveling on. (This is especially true in an area where there are many roads.) Perform “ADJUST CURRENT LOCATION” (EL-421) within a precision standard of 1 mm (0.04 in) on the display. Note: During calibration, use the most detailed map possible. AT TF PD SEL701V When calibrating the position, check the vehicle direction. If the vehicle direction is not correct, subsequent precision of current location will be affected. SEL702V AX Perform “ADJUST CURRENT LOCATION”, refer to EL-421. SU BR ST RS BT HA SC IDX EL-437 NAVIGATION SYSTEM This Condition is Not Abnormal (Cont’d) Possible cause: —: Vehicle running ---: Indication Drive condition Service procedure Y-intersection In Y-intersections with a very gradual change in course, a directional sensing may be inaccurate. This may result in the position marker giving the wrong road indication. SEL703V Spiral road On loop bridges and similar structures which result in a large and continuous turn, turning angle may be sensed inaccurately. As a result, the position marker may separate from the route on the map. SEL704V Straight road Road shapes Winding road In long distance driving on a straight road or road with very gradual curves, map marking inaccuracies may occur. In such cases, the position marker may stray from the route being traveled during subsequent If the position marker does not turns due to inaccurate distance cal- move to the correct position culation. even after the vehicle has been SEL705V driven approximately 10 km (6 miles), perform “Store place”. If required, also perform Directional sensing precision errors “ADJUST CURRENT LOCAmay occur when traveling on windTION” (EL-421). ing roads. During map matching, the position marker may stray to an adjacent road having a similar shape. Subsequent position marker error may occur. SEL706V Grid-like road shape Directional sensing and distance sensing, precision errors may occur because of many roads having a similar shape in the immediate area. During map matching, the position marker may stray to an adjacent road having a similar shape. Subsequent position marker error may SEL707V occur. Parallel roads When driving on a parallel road, map matching errors may occur. Subsequent position marker error may also occur. SEL708V EL-438 NAVIGATION SYSTEM This Condition is Not Abnormal (Cont’d) GI Possible cause: —: Vehicle running ---: Indication Parking lot or similar area Location Turntable Drive condition Service procedure When the vehicle is driven in a parking lot or similar area, such as in an area not normally marked as a road on map, during map matching, the system may select nearby roads. This error may continue after the vehicle exits the parking area and begins to run on ordinary roads. Vehicle operation in a parking area may involve frequent turns and up and/or down operation. Directional SEL709V sensing errors may occur leading to subsequent route and position mistakes. When the ignition switch is OFF (the usual situation when the vehicle is on a turntable), the navigation system receives no data from the gyro (angular velocity sensor). When the turntable rotates, no directional change is sensed. During subsequent vehicle operation, directional SEL710V and route errors may occur. Position marker displays a completely different location In circumstances such as those described below, GPS signal reception conditions may result in an erroneous position of the position marker. Perform “ADJUST CURRENT LOCATION” (EL-421). NOTE: 쐌 When GPS satellite signal reception conditions are poor, the position of position marker may be erroneous. If correction is not made immediately, the position marker error will be compounded and a completely different location will be indicated. In an area where GPS satellite signal reception conditions are good, the system can be returned to normal operation. 쐌 The vehicle is driven aboard a car ferry or is towed for some distance with the ignition switch OFF. Vehicle movement is not sensed. Current location calculations do not occur and current location data does not appear on the display screen. Use GPS to accurately determine actual vehicle position. The system can be returned to normal operation when the GPS satellite signal reception conditions are good. Position marker jumps In circumstances such as those described below, the position marker may jump as a result of automatic current location corrections made by the system. During map matching 쐌 During map matching, the position marker may jump from one spot to another. In this case, it may be corrected to a wrong road or to an area where no road exist. GPS location correcting 쐌 Vehicle current location is sensed using the GPS data. Positional calibration is performed. The position marker continues to be in the wrong position. It may jump about from one area of the screen to another. In this case, it may be corrected to a wrong road or to an area where no road exist. Position marker indicates that the vehicle is in the middle of an ocean or large river The navigation system does not distinguish between land and water surfaces. In some cases, a position marker error may cause the display to show the vehicle above a water surface. Position of position marker varies when the vehicle is repeatedly operated on the same road Driving lane and steering wheel movement results in a variety of different positions of the position mark when traveling on the same road based on sensing results by the GPS antenna and gyro (angular velocity sensor). Slow locational correction using map matching 쐌 The map matching function requires verification of local data. To make the map matching function, some distance needs to be driven. 쐌 The map matching function may not provide accurate performance in an area where there are numerous parallel roads. Until the system judges the road characteristics, an incorrect position may be shown. EL-439 MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC IDX NAVIGATION SYSTEM This Condition is Not Abnormal (Cont’d) GPS signal reception conditions are good. However, the position mark does not return to its proper position. 쐌 he system senses the vehicle location with an error of approximately 100 m (328 ft). Due to the limitation of precision, the position marker may be inaccurate even if the GPS signal reception condition is good. 쐌 The navigation system uses GPS data to determine vehicle location. GPS data is compared with other locational sensing data during the map matching process. The system decides which data is more precise and uses that data. 쐌 When the vehicle is stationary, GPS data cannot be used to make system corrections. Area designations on the map display and the BIRDVIEW姞 display differ. To prevent the display from becoming congested, alphanumeric information is abridged. [No problem] Correct position of your vehicle is not displayed. Vehicle position changed after ignition key was turned to the OFF position (Vehicle is transported on car ferry, car train, or by some other means). [Operate vehicle for short time under GPS receiving conditions.] The display does not change to night-time mode even though the light switch has been turned ON. Lights have been turned on. In “DISPLAY CHANGE” mode, night-time mode on display has been switched to day-time mode and still is. [Turn lights on again. Set the display to night-time mode. Refer to EL-422.] Map does not scroll even though the position of your vehicle is changed. Present area does not appear on the display. [Press the “MAP” switch.] Vehicle position marker does not appear. Present area does not appear on the display. [Press the “MAP” switch.] The map surface precision display (GPS satellite marker) still remains gray. Vehicle is parked inside a building or in the shadow of a large building. This intercepts the GPS signal. [Move the vehicle to a more open position.] GPS signal is not received because objects are placed on the rear parcel shelf. [Remove objects from the rear parcel shelf.] GPS satellite position is bad. [Wait until GPS satellite position improves.] Vehicle position precision is bad. The map surface precision display (GPS satellite marker) still remains gray. [Refer to “The map surface precision display (GPS satellite marker) still remains gray” item (Symptoms)] Vehicle speed and elapsed distance is calculated from the vehicle speed pulse. This pulse is dependent upon tire size. If tire chains are used on the vehicle, accuracy will be affected (pulse rate will be too fast or too slow). The same is true if the system installed to your vehicle is removed and installed on another vehicle. [Drive the vehicle at a speed higher than 30 km/h (19 MPH) for approximately 30 minutes. Automatic readjustment should occur. If it does not (remains too fast or too slow), distance calibration is required. Or, drive the vehicle for a short distance. Perform “SPEED CALIBRATION” (EL-419). After removing the tire chains, sensing accuracy may recover by itself.] Bad map data or system defect (same error consistently occurs in the same area) ROUTE SEARCH/ROUTE GUIDE 쐌 쐌 쐌 쐌 쐌 쐌 쐌 NAEL0428S03 If the present location or the destination location is displayed in the avoid area, it is not possible to search routes. If the avoid area is set to wide range area, it may not be possible to find appropriate routes or search for alternate routes. The automatic re-route calculates a return to the original route. Because of this, it may not be possible to search appropriate new routes. If you deviate from the original route and wish to select an appropriate new route, touch “Route Calculation”. The automatic re-route function may sometimes require considerable time. Displayed route number and directional information at a highway junction may differ from the information posted on the actual road signs. Displayed street name information at a highway exit may differ from the information posted on the actual road signs. Street name information displayed on the enlarged intersection map may differ from the information posted on the actual road signs. EL-440 NAVIGATION SYSTEM This Condition is Not Abnormal (Cont’d) 쐌 쐌 쐌 The enlarged intersection map may display an “Unknown Street” message at some street intersections. Because of road configuration, etc. the guide may finish early. If this occurs, follow the marker to reach your destination. Destination area side information (left side and right side) may differ from actual conditions because of data error. Unable to Set Destination, Way Point, and/or Menu Items Symptom NAEL0428S0301 GI MA EM Possible cause Repair order A way point already crossed or determined to have been crossed. If you desire to pass through a way point for a second time, reperform route edit. Route search does not occur. Set designation areas and perform route search. EC Car marker does not appear on recommended route. Drive on the recommended route. FE Route guide is canceled. Turn the route guide ON. (Push “VOICE” switch.) CL Automatic search does not function. Vehicle is not running on search object route (road indicated by orange, brown or red line). Drive the vehicle on the search object route or perform a manual route search. Note that all routes will be re-searched at this time. MT Unable to select detour route. Vehicle is not running on recommended route. Use the “RE-ROUTE” mode to search again or return to the recommended route. Detour route search results are identical to previous search. All possible conditions were considered, but results are the same. This is not abnormal. Unable to set a way point. More than five way points have been previously set (and not cleared). More than five way points cannot be specified at the same time. Break down into smaller segments and perform search. Unable to select starting point during route edit. Starting point will normally be your present location during route edit. This is not abnormal. Unable to search way points in re-search mode Turn list is not displayed. Cannot select certain menu items. While vehicle is running. Park the vehicle in a safe area and perform operation. Voice guide does not function. Possible cause Repair order PD AX BR Voice guide is only available at certain intersections (marked with ). In some cases, the guide is not available even when the vehicle makes a turn. This is not abnormal. ST Vehicle is not running on recommended route. Return to recommended route or reperform route search. RS Voice guide is OFF. Set voice guide to the ON position. Route guide is canceled. Turn the route guide ON. (Push “VOICE” switch.) Operate vehicle following the traffic rules and regulation. Route Search Information Proceeding in desired direction. However, route search in desired direction does not function. TF NAEL0428S0302 The guide content does not corre- The content of the voice guide may vary spond to actual conditions. depending on the type of junction. Symptom AT SU Voice Guide Information Symptom LC NAEL0428S0303 Possible cause BT HA SC Repair order Unable to find appropriate route in the desired This is not abnormal. direction. IDX EL-441 NAVIGATION SYSTEM This Condition is Not Abnormal (Cont’d) Symptom Possible cause Repair order No object route is searched near destination area. Adjust position to wide road (brown) near destination area. In an area where traffic direction is displayed separately, pay close attention to the direction of travel. Set the destination area and the way point over the road. Starting point and destination areas are very near. Move destination areas away from starting point on the screen. No route is displayed. Recommended route which has been passed disappears from the display. The recommended route is divided into individual control segments. When way point 1 is This is not abnormal. passed, the data from the starting point to the way point 1 is erased. Search recommends roundabout route. There may be special conditions for roads Slightly change starting point and destination near the starting point and destination area (one-way traffic, etc.). A roundabout route may area settings. be displayed. Landmark display does not show actual conditions. Mistaken or missing map data may result in erroneous display. Change map CD. Recommended route drawn slightly away from starting point, way points, and destination area. Course search data may not exist for closely positioned starting point, way points, and destination area shown on the map. Route guide starting point, way point, and destination point may be separated. Set the destination area to the general route (indicated by a thick brown line). However, even if the selected route is a major one, appropriate route search data may not be available. LOCATION OF CAR MARKER 쐌 쐌 NAEL0428S04 If the vehicle has been parked in a multi-level parking facility or underground parking facility, the car marker position may be inaccurate immediately after exiting the parking facility. The GPS accuracy is within ±100 m (300 ft). Even when receiving conditions are excellent, further positional correction may not occur. STREET INDICATION 쐌 쐌 NAEL0428S05 Street names displayed on the map may differ from the actual street names. An “Unknown Street” message may appear on the map in place of street name information. RESEARCH 쐌 쐌 쐌 NAEL0428S06 Position may be searched by house number. However, the displayed position and street may differ from the actual position and street. When position is searched using POI, the displayed position may differ from the actual position. Some data may not be available for new buildings and other structures in a map. GPS ANTENNA 쐌 쐌 NAEL0428S07 Do not place metal objects above the GPS antenna mounted on the rear parcel shelf. This will cause interference with signal reception. Do not place mobile telephones or vehicle radio transceivers in close proximity to the GPS antenna mounted on the rear parcel shelf. This may cause interference with signal reception. EL-442 NAVIGATION SYSTEM Program Loading Program Loading NAEL0429 GI MA Power supply ON Insert CD-ROM with designated program. EM LC EC FE CL Push for changing version. MT AT No TF PD Yes AX SU * Program loading progress is shown on the bar graph at the center of the screen. BR ST RS BT Map CD-ROM insertion HA Position marker screen display SC Note: Load the program only after the engine has been started. EL-443 SEL612X IDX NAVIGATION SYSTEM Initialization Initialization NAEL0430 This procedure is for initializing the current location. Perform “Initialize Location” when the vehicle is transported a long distance by trailer, etc. Map with grey background appears and the vehicle location cannot be adjusted by scrolling the display when the vehicle location in the memory is out of the area of the inserted map data. Perform “Initialize Location” when this occurs. NOTE: 쐌 Only initialize the system when the display & NAVI control unit is replaced. If the system is initialized in other cases, it may cause inaccurate positioning of the position marker for a while. 쐌 Initialize the system outside for receiving the radio wave from the GPS satellite. HOW TO PERFORM NAEL0430S01 1. Switch the navigation system mode to self-diagnosis by pushing both “MAP” and “D/N” switches at the same time for more than 5 seconds. 2. Touch “Confirmation/ adjustment”. 3. Touch “Initialize Location”. Then the previous screen is displayed. SEL583X SEL584X SEL588X EL-444 NAVIGATION SYSTEM Initialization (Cont’d) 4. Push “Previous” switch. GI MA EM LC SEL584X 5. 6. Push the “MAP” switch. Touch “Setting”. EC FE CL MT SEL598X 7. Touch “System Setting”. AT TF PD AX SU SEL599X 8. Touch “GPS Information”. BR ST RS BT SEL600X 9. More than one GPS satellite icon turns green. (It may take 1 to 15 minutes.) NOTE: Drive the vehicle for a while* in order to change the receiving condition of the radio wave from the GPS satellite if the GPS icon does not turn green. * The driving distance which is necessary depends on the receiving condition of the radio wave from the GPS satellite. HA SC IDX SEL146W EL-445 NAVIGATION SYSTEM Initialization (Cont’d) 10. 쐌 쐌 쐌 Push “MAP” switch and check the following. Confirm that the GPS icon on the map turns green. Then the position marker should show the current location. Position marker rotates corresponding to the movement of the vehicle. 11. Initialization is completed. SEL613X EL-446 CAN COMMUNICATION System Description System Description NAEL0462 CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. CAN Communication Unit NAEL0463 Go to CAN system, when selecting your CAN system type from the following table. Body type A/T Brake control CAN system trouble diagnosis EM LC EC VQ35DE Transmission CAN system type MA Wide/Wagon Engine Axle GI M/T VDC 4WD (All-mode) ABS 4WD (Part time) 2WD 4WD (All-mode) 4WD (Part time) 2WD 4WD (Part time) 1 2 3 4 (EL-452) (EL-476) (EL-498) (EL-511) TYPE 1 System Diagram NAEL0463S01 FE CL MT AT NAEL0463S0101 TF PD AX SEL683Y SU BR ST RS BT HA SC IDX EL-447 CAN COMMUNICATION CAN Communication Unit (Cont’d) Input/Output Signal Chart =NAEL0463S0102 T: Transmit R: Receive Signals ECM TCM Transfer control unit ABS actuaSteering tor and elec- Combination angle sensor tric unit (conmeter trol unit) Engine speed signal T R R Accelerator pedal position signal T R R Closed throttle position signal T R Wide open throttle position signal T R VDC operation signal R R T TCS operation signal R R T ABS operation signal R R T Output shaft revolution signal R ETC fail signal T During shifting signal R T R R T R Steering wheel angle sensor signal R T Wheel speed sensor signal R Stop lamp switch signal R R T R T MIL signal T R Engine coolant temperature signal T R Fuel consumption signal T R T R Vehicle speed signal R T Lock-up prohibition signal T R Lock-up signal R T Neutral range switch signal R T Parking range switch signal R T Overdrive control switch signal R T A/C compressor feedback signal T R Fuel level sensor signal R T A/T position indicator signal T R O/D OFF indicator signal T R EL-448 CAN COMMUNICATION CAN Communication Unit (Cont’d) TYPE 2 System Diagram =NAEL0463S02 GI NAEL0463S0201 MA EM LC EC SEL682Y FE Input/Output Signal Chart NAEL0463S0202 T: Transmit R: Receive Signals ECM TCM Steering angle sensor Combination meter R Engine speed signal T R Accelerator pedal position signal T R Closed throttle position signal T R Wide open throttle position signal T R VDC operation signal R T TCS operation signal R T ABS operation signal R T Steering wheel angle sensor signal CL ABS actuator and electric unit (control unit) MT AT TF T PD AX R MIL signal T R Engine coolant temperature signal T R Fuel consumption signal T R T R SU BR Vehicle speed signal R T Stop lamp switch signal R Lock-up prohibition signal T R Lock-up signal R T T ST RS Neutral range switch signal R T Parking range switch signal R T Overdrive control switch signal R T A/C compressor feedback signal T R Fuel level sensor signal R T A/T position indicator signal T R O/D OFF indicator signal T R BT HA SC IDX EL-449 CAN COMMUNICATION CAN Communication Unit (Cont’d) TYPE 3 System Diagram =NAEL0463S03 NAEL0463S0301 SEL684Y Input/Output Signal Chart NAEL0463S0302 T: Transmit R: Receive Signals ECM TCM Engine speed signal T Closed throttle position signal T R Wide open throttle position signal T R Stop lamp switch signal Combination meter R R Lock-up prohibition signal T R Lock-up signal R T T Neutral range switch signal R T Parking range switch signal R T Overdrive control switch signal R T MIL signal T R Engine coolant temperature signal T R Fuel consumption signal T R Vehicle speed signal R T A/C compressor feedback signal T R Fuel level sensor signal R T A/T position indicator signal T R O/D OFF indicator signal T R EL-450 CAN COMMUNICATION CAN Communication Unit (Cont’d) TYPE 4 System Diagram =NAEL0463S04 GI NAEL0463S0401 MA EM LC EC SEL681Y FE Input/Output Signal Chart NAEL0463S0402 T: Transmit R: Receive Signals ECM Combination meter Engine speed signal T R MIL signal T R Engine coolant temperature signal T R Fuel consumption signal T R Vehicle speed signal R T A/C compressor feedback signal T R Fuel level sensor signal R T CL MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-451 CAN SYSTEM (TYPE 1) Component Parts and Harness Connector Location Component Parts and Harness Connector Location NAEL0464 SEL702Y System Description NAEL0465 CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. EL-452 CAN SYSTEM (TYPE 1) Wiring Diagram — CAN — Wiring Diagram — CAN — NAEL0466 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL578Q EL-453 IDX CAN SYSTEM (TYPE 1) Wiring Diagram — CAN — (Cont’d) MEL579Q EL-454 CAN SYSTEM (TYPE 1) Trouble Diagnoses Trouble Diagnoses WORK FLOW NAEL0467 GI NAEL0467S01 1. Print all the data of “SELF-DIAG RESULTS” for “ENGINE”, “A/T”, “ALL MODE AWD/4WD” and “ABS” displayed on CONSULT-II. MA EM LC EC PKIA8260E 2. Print all the data of “CAN DIAG SUPPORT MNTR” for “ENGINE”, “A/T”, “ALL MODE AWD/4WD” and “ABS” displayed on CONSULT-II. FE CL MT AT TF PKIA8343E 3. Attach the printed sheet of “SELF-DIAG RESULTS” and “CAN DIAG SUPPORT MNTR” onto the check sheet. Refer to “CHECK SHEET” (EL-456). 4. Based on the “CAN DIAG SUPPORT MNTR” results, put “v” marks onto the items with “UNKWN” or “NG” in the check sheet table. Refer to “CHECK SHEET” (EL-456). NOTE: If “NG” is displayed on “INITIAL DIAG (Initial diagnosis)” as “CAN DIAG SUPPORT MNTR” for the diagnosed control unit, replace the control unit. 5. According to the check sheet results (example), start inspection. Refer to “CHECK SHEET RESULTS (EXAMPLE)” (EL-457). PD AX SU BR ST RS BT HA SC IDX EL-455 CAN SYSTEM (TYPE 1) Trouble Diagnoses (Cont’d) CHECK SHEET =NAEL0467S02 NOTE: If “NG” is displayed on “INITIAL DIAG (Initial diagnosis)” as “CAN DIAG SUPPORT MNTR” for the diagnosed control unit, replace the control unit. PKIA8707E EL-456 CAN SYSTEM (TYPE 1) Trouble Diagnoses (Cont’d) CHECK SHEET RESULTS (EXAMPLE) =NAEL0467S03 NOTE: If “NG” is displayed on “INITIAL DIAG (Initial diagnosis)” as “CAN DIAG SUPPORT MNTR” for the diagnosed control unit, replace the control unit. Case 1 NAEL0467S0301 Check harness between TCM and transfer control unit. Refer to “CIRCUIT CHECK BETWEEN TCM AND TRANSFER CONTROL UNIT” (EL-462). GI MA EM LC EC FE CL PKIA8711E MT AT TF PD PKIA8734E AX Case 2 NAEL0467S0302 Check harness between transfer control unit and steering angle sensor. Refer to “CIRCUIT CHECK BETWEEN TRANSFER CONTROL UNIT AND STEERING ANGLE SENSOR” (EL-463). SU BR ST RS PKIA8712E BT HA SC IDX PKIA8735E EL-457 CAN SYSTEM (TYPE 1) Trouble Diagnoses (Cont’d) Case 3 NAEL0467S0303 Check harness between steering angle sensor and ABS actuator and electric unit (control unit). Refer to “CIRCUIT CHECK BETWEEN STEERING ANGLE SENSOR AND ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)” (EL-464). PKIA8713E PKIA8736E Case 4 NAEL0467S0304 Check ECM circuit. Refer to “ECM CIRCUIT CHECK” (EL-465). PKIA8714E PKIA8737E EL-458 CAN SYSTEM (TYPE 1) Trouble Diagnoses (Cont’d) Case 5 =NAEL0467S0305 GI Check TCM circuit. Refer to “TCM CIRCUIT CHECK” (EL-466). MA EM LC EC PKIA8715E FE CL MT AT PKIA8738E TF Case 6 NAEL0467S0306 Check transfer control unit circuit. Refer to “TRANSFER CONTROL UNIT CIRCUIT CHECK” (EL-467). PD AX SU BR PKIA8716E ST RS BT HA PKIA8739E SC IDX EL-459 CAN SYSTEM (TYPE 1) Trouble Diagnoses (Cont’d) Case 7 =NAEL0467S0307 Check steering angle sensor circuit. Refer to “STEERING ANGLE SENSOR CIRCUIT CHECK” (EL-468). PKIA8717E PKIA8740E Case 8 NAEL0467S0308 Check ABS actuator and electric unit (control unit) circuit. Refer to “ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) CIRCUIT CHECK” (EL-469). PKIA8718E PKIA8741E EL-460 CAN SYSTEM (TYPE 1) Trouble Diagnoses (Cont’d) Case 9 =NAEL0467S0309 GI Check combination meter circuit. Refer to “COMBINATION METER CIRCUIT CHECK” (EL-470). MA EM LC EC PKIA8719E FE CL MT AT PKIA8742E TF Case 10 NAEL0467S0310 Check CAN communication circuit. Refer to “CAN COMMUNICATION CIRCUIT CHECK” (EL-471). PD AX SU BR PKIA8720E ST RS BT HA SC IDX EL-461 CAN SYSTEM (TYPE 1) Trouble Diagnoses (Cont’d) CIRCUIT CHECK BETWEEN TCM AND TRANSFER CONTROL UNIT 1 NAEL0467S05 CHECK HARNESS FOR OPEN CIRCUIT 1. Disconnect TCM connector, transfer control unit connector and combination meter connector. 2. Check continuity between TCM harness connector M119 terminals 5 (L), 6 (R) and transfer control unit harness connector M142 terminals 7 (L), 8 (R). SEL707Y OK or NG OK 䊳 Connect all the connectors and diagnose again. Refer to “Work Flow” (EL-455). NG 䊳 Repair harness. EL-462 CAN SYSTEM (TYPE 1) Trouble Diagnoses (Cont’d) CIRCUIT CHECK BETWEEN TRANSFER CONTROL UNIT AND STEERING ANGLE SENSOR GI =NAEL0467S06 1 CHECK CONNECTOR 1. Turn ignition switch OFF. 2. Check following terminals and connector for damage, bend and loose connection (connector-side and harness-side). 쐌 Harness connector M1 쐌 Harness connector E1 MA EM OK or NG OK 䊳 GO TO 2. NG 䊳 Repair terminal or connector. LC EC 2 CHECK HARNESS FOR OPEN CIRCUIT 1. Disconnect transfer control unit connector and harness connector M1. 2. Check continuity between transfer control unit harness connector M142 terminals 7 (L), 8 (R) and harness connector M1 terminals 4m (L), 11r (R). FE CL MT AT TF SEL708Y PD OK or NG OK 䊳 GO TO 3. NG 䊳 Repair harness. 3 AX CHECK HARNESS FOR OPEN CIRCUIT SU 1. Disconnect steering angle sensor connector. 2. Check continuity between harness connector E1 terminals 4m (L), 11r (R) and steering angle sensor harness connector E136 terminals 3 (L), 4 (R). BR ST RS BT SEL709Y HA OK or NG OK 䊳 Connect all the connectors and diagnose again. Refer to “Work Flow” (EL-455). NG 䊳 Repair harness. SC IDX EL-463 CAN SYSTEM (TYPE 1) Trouble Diagnoses (Cont’d) CIRCUIT CHECK BETWEEN STEERING ANGLE SENSOR AND ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) 1 =NAEL0467S07 CHECK HARNESS FOR OPEN CIRCUIT 1. Disconnect steering angle sensor connector, ABS actuator and electric unit (control unit) connector and combination meter connector. 2. Check continuity between steering angle sensor harness connector E136 terminals 3 (L), 4 (R) and ABS actuator and electric unit (control unit) harness connector E142 terminals 11 (L), 15 (R). SEL710Y OK or NG OK 䊳 Connect all the connectors and diagnose again. Refer to “Work Flow” (EL-455). NG 䊳 Repair harness. EL-464 CAN SYSTEM (TYPE 1) Trouble Diagnoses (Cont’d) ECM CIRCUIT CHECK 1 =NAEL0467S08 CHECK CONNECTOR 1. Turn ignition switch OFF. 2. Check following terminals and connector for damage, bend and loose connection (control module-side and harnessside). 쐌 ECM 쐌 Harness connector F23 쐌 Harness connector M32 OK 䊳 GO TO 2. NG 䊳 Repair terminal or connector. MA EM LC OK or NG 2 GI EC FE CHECK HARNESS FOR OPEN CIRCUIT 1. Disconnect ECM connector. 2. Check resistance between ECM harness connector F203 terminals 94 (L) and 86 (R). CL MT AT TF SEL711Y PD OK or NG OK 䊳 Replace ECM. NG 䊳 Repair harness between ECM and TCM. AX SU BR ST RS BT HA SC IDX EL-465 CAN SYSTEM (TYPE 1) Trouble Diagnoses (Cont’d) TCM CIRCUIT CHECK 1 =NAEL0467S09 CHECK CONNECTOR 1. Turn ignition switch OFF. 2. Check the terminals and connector of TCM for damage, bend and loose connection (control module-side and harnessside). OK or NG OK 䊳 GO TO 2. NG 䊳 Repair terminal or connector. 2 CHECK HARNESS FOR OPEN CIRCUIT 1. Disconnect TCM connector. 2. Check resistance between TCM harness connector M119 terminals 5 (L) and 6 (R). SEL712Y OK or NG OK 䊳 Replace ECM. NG 䊳 Repair harness between TCM and transfer control unit. EL-466 CAN SYSTEM (TYPE 1) Trouble Diagnoses (Cont’d) TRANSFER CONTROL UNIT CIRCUIT CHECK 1 =NAEL0467S10 CHECK CONNECTOR 1. Turn ignition switch OFF. 2. Check the terminals and connector of transfer control unit for damage, bend and loose connection (control unit-side and harness-side). OK 䊳 GO TO 2. NG 䊳 Repair terminal or connector. MA EM OK or NG 2 GI LC EC CHECK HARNESS FOR OPEN CIRCUIT 1. Disconnect transfer control unit connector. 2. Check resistance between transfer control unit harness connector M142 terminals 7 (L) and 8 (R). FE CL MT AT SEL713Y TF OK or NG OK 䊳 Replace transfer control unit. NG 䊳 Repair harness between transfer control unit and harness connector M1. PD AX SU BR ST RS BT HA SC IDX EL-467 CAN SYSTEM (TYPE 1) Trouble Diagnoses (Cont’d) STEERING ANGLE SENSOR CIRCUIT CHECK 1 =NAEL0467S11 CHECK CONNECTOR 1. Turn ignition switch OFF. 2. Check the terminals and connector of steering angle sensor for damage, bend and loose connection (sensor-side and harness-side). OK or NG OK 䊳 GO TO 2. NG 䊳 Repair terminal or connector. 2 CHECK HARNESS FOR OPEN CIRCUIT 1. Disconnect steering angle sensor connector. 2. Check resistance between steering angle sensor harness connector E136 terminals 3 (L) and 4 (R). SEL714Y OK or NG OK 䊳 Replace steering angle sensor. NG 䊳 Repair harness between steering angle sensor and ABS actuator and electric unit (control unit). EL-468 CAN SYSTEM (TYPE 1) Trouble Diagnoses (Cont’d) ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) CIRCUIT CHECK 1 =NAEL0467S12 CHECK CONNECTOR 1. Turn ignition switch OFF. 2. Check the terminals and connector of ABS actuator and electric unit (control unit) for damage, bend and loose connection (control unit-side and harness-side). OK 䊳 GO TO 2. NG 䊳 Repair terminal or connector. MA EM OK or NG 2 GI LC EC CHECK HARNESS FOR OPEN CIRCUIT 1. Disconnect ABS actuator and electric unit (control unit) connector. 2. Check resistance between ABS actuator and electric unit (control unit) harness connector E142 terminals 11 (L) and 15 (R). FE CL MT AT SEL715Y TF OK or NG OK 䊳 Replace ABS actuator and electric unit (control unit). PD NG 䊳 Repair harness between ABS actuator and electric unit (control unit) and harness connector E1. AX SU BR ST RS BT HA SC IDX EL-469 CAN SYSTEM (TYPE 1) Trouble Diagnoses (Cont’d) COMBINATION METER CIRCUIT CHECK 1 =NAEL0467S13 CHECK CONNECTOR 1. Turn ignition switch OFF. 2. Check following terminals and connector for damage, bend and loose connection (meter-side and harness-side). 쐌 Combination meter. 쐌 Harness connector M1. 쐌 Harness connector E1. OK or NG OK 䊳 GO TO 2. NG 䊳 Repair terminal or connector. 2 CHECK HARNESS FOR OPEN CIRCUIT 1. Disconnect combination meter connector. 2. Check resistance between combination meter harness connector M25 terminals 34 (Y) and 35 (L). SEL716Y OK or NG OK 䊳 Replace combination meter. NG 䊳 Repair harness between combination meter and ABS actuator and electric unit (control unit). EL-470 CAN SYSTEM (TYPE 1) Trouble Diagnoses (Cont’d) CAN COMMUNICATION CIRCUIT CHECK 1 =NAEL0467S14 GI CHECK CONNECTOR 1. Turn ignition switch OFF. 2. Check following terminals and connector for damage, bend and loose connection (meter-side, control unit-side, sensorside, control module-side and harness-side). 쐌 Combination meter 쐌 ABS actuator and electric unit (control unit) 쐌 Steering angle sensor 쐌 Transfer control unit 쐌 TCM 쐌 ECM 쐌 Between combination meter and ECM MA EM LC EC OK or NG OK 䊳 GO TO 2. NG 䊳 Repair terminal or connector. FE CL 2 CHECK HARNESS FOR SHORT CIRCUIT 1. Disconnect ECM connector and harness connector F23. 2. Check continuity between ECM harness connector F203 terminals 94 (L) and 86 (R). MT AT TF PD SEL717Y AX OK or NG SU OK 䊳 GO TO 3. NG 䊳 Repair harness between ECM and harness connector F23. BR 3 CHECK HARNESS FOR SHORT CIRCUIT Check continuity between ECM harness connector F203 terminals 94 (L), 86 (R) and ground. ST RS BT HA SEL718Y SC OK or NG OK 䊳 GO TO 4. NG 䊳 Repair harness between ECM and harness connector F23. IDX EL-471 CAN SYSTEM (TYPE 1) Trouble Diagnoses (Cont’d) 4 CHECK HARNESS FOR SHORT CIRCUIT 1. Disconnect TCM connector, transfer control unit connector and harness connector M1. 2. Check continuity between TCM harness connector M119 terminals 5 (L) and 6 (R). SEL440Y OK or NG OK 䊳 GO TO 5. NG 䊳 쐌 Repair harness between TCM and harness connector M1. 쐌 Repair harness between TCM and harness connector M32. 쐌 Repair harness between TCM and transfer control unit. 5 CHECK HARNESS FOR SHORT CIRCUIT Check continuity between TCM harness connector M119 terminals 5 (L), 6 (R) and ground. SEL441Y OK or NG OK 䊳 GO TO 6. NG 䊳 쐌 Repair harness between TCM and harness connector M1. 쐌 Repair harness between TCM and harness connector M32. 쐌 Repair harness between TCM and transfer control unit. EL-472 CAN SYSTEM (TYPE 1) Trouble Diagnoses (Cont’d) 6 GI CHECK HARNESS FOR SHORT CIRCUIT 1. Disconnect steering angle sensor connector and ABS actuator and electric unit (control unit) connector. 2. Check continuity between ABS actuator and electric unit (control unit) harness connector E142 terminals 11 (L) and 15 (R). MA EM LC EC SEL719Y OK or NG FE CL OK 䊳 GO TO 7. NG 䊳 쐌 Repair harness between ABS actuator and electric unit (control unit) and harness connector E1. 쐌 Repair harness between ABS actuator and electric unit (control unit) and steering angle sensor. MT AT 7 CHECK HARNESS FOR SHORT CIRCUIT Check continuity between ABS actuator and electric unit (control unit) harness connector E142 terminals 11 (L), 15 (R) and ground. TF PD AX SU BR SEL720Y OK or NG OK 䊳 GO TO 8. NG 䊳 쐌 Repair harness between ABS actuator and electric unit (control unit) and harness connector E1. 쐌 Repair harness between ABS actuator and electric unit (control unit) and steering angle sensor. ST RS BT HA SC IDX EL-473 CAN SYSTEM (TYPE 1) Trouble Diagnoses (Cont’d) 8 CHECK HARNESS FOR SHORT CIRCUIT 1. Disconnect combination meter connector. 2. Check continuity between combination meter harness connector M25 terminals 34 (Y) and 35 (L). SEL721Y OK or NG OK 䊳 GO TO 9. NG 䊳 Repair harness between combination meter and harness connector M1. 9 CHECK HARNESS FOR SHORT CIRCUIT Check continuity between combination meter harness connector M25 terminals 34 (Y), 35 (L) and ground. SEL722Y OK or NG OK 䊳 GO TO 10. NG 䊳 Repair harness between combination meter and harness connector M1. 10 ECM/COMBINATION METER INTERNAL CIRCUIT INSPECTION Check components inspection. Refer to “ECM/COMBINATION METER INTERNAL CIRCUIT INSPECTION” (EL-475). OK or NG OK 䊳 Connect all the connectors and diagnose again. Refer to “Work Flow” (EL-455). NG 䊳 Replace ECM and/or combination meter. EL-474 CAN SYSTEM (TYPE 1) Component Inspection Component Inspection NAEL0468 ECM/COMBINATION METER INTERNAL CIRCUIT INSPECTION 쐌 쐌 쐌 SEL723Y =NAEL0468S01 Remove ECM and combination meter from vehicle. Check resistance between ECM terminals 94 and 86. Check resistance between combination meter terminals 34 and 35. Unit Terminal ECM 94 - 86 Combination meter 34 - 35 Resistance value (Ω) GI MA EM LC Approx. 108 - 132 EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-475 CAN SYSTEM (TYPE 2) Component Parts and Harness Connector Location Component Parts and Harness Connector Location NAEL0469 SEL724Y System Description NAEL0470 CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electonic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. EL-476 CAN SYSTEM (TYPE 2) Wiring Diagram — CAN — Wiring Diagram — CAN — NAEL0471 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL576Q EL-477 IDX CAN SYSTEM (TYPE 2) Wiring Diagram — CAN — (Cont’d) MEL577Q EL-478 CAN SYSTEM (TYPE 2) Trouble Diagnoses Trouble Diagnoses WORK FLOW NAEL0472 GI NAEL0472S01 1. Print all the data of “SELF-DIAG RESULTS” for “ENGINE”, “A/T” and “ABS” displayed on CONSULT-II. MA EM LC EC PKIA8260E 2. Print all the data of “CAN DIAG SUPPORT MNTR” for “ENGINE”, “A/T” and “ABS” displayed on CONSULTII. FE CL MT AT TF PKIA8343E 3. Attach the printed sheet of “SELF-DIAG RESULTS” and “CAN DIAG SUPPORT MNTR” onto the check sheet. Refer to “CHECK SHEET” (EL-480). 4. Based on the “CAN DIAG SUPPORT MNTR” results, put “v” marks onto the items with “UNKWN” or “NG” in the check sheet table. Refer to “CHECK SHEET” (EL-480). NOTE: If “NG” is displayed on “INITIAL DIAG (Initial diagnosis)” as “CAN DIAG SUPPORT MNTR” for the diagnosed control unit, replace the control unit. 5. According to the check sheet results (example), start inspection. Refer to “CHECK SHEET RESULTS (EXAMPLE)” (EL-481). PD AX SU BR ST RS BT HA SC IDX EL-479 CAN SYSTEM (TYPE 2) Trouble Diagnoses (Cont’d) CHECK SHEET =NAEL0472S02 NOTE: If “NG” is displayed on “INITIAL DIAG (Initial diagnosis)” as “CAN DIAG SUPPORT MNTR” for the diagnosed control unit, replace the control unit. PKIA8708E EL-480 CAN SYSTEM (TYPE 2) Trouble Diagnoses (Cont’d) CHECK SHEET RESULTS (EXAMPLE) =NAEL0472S03 NOTE: If “NG” is displayed on “INITIAL DIAG (Initial diagnosis)” as “CAN DIAG SUPPORT MNTR” for the diagnosed control unit, replace the control unit. Case 1 NAEL0472S0301 Check harness between TCM and steering angle sensor. Refer to “CIRCUIT CHECK BETWEEN TCM AND STEERING ANGLE SENSOR” (EL-486). GI MA EM LC EC FE CL PKIA8721E MT AT TF PD PKIA8743E AX SU BR ST RS BT HA SC IDX EL-481 CAN SYSTEM (TYPE 2) Trouble Diagnoses (Cont’d) Case 2 =NAEL0472S0302 Check harness between steering angle sensor and ABS actuator and electric unit (control unit). Refer to “CIRCUIT CHECK BETWEEN STEERING ANGLE SENSOR AND ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)” (EL-487). PKIA8722E PKIA8744E Case 3 NAEL0472S0303 Check ECM circuit. Refer to “ECM CIRCUIT CHECK” (EL-488). PKIA8723E PKIA8745E EL-482 CAN SYSTEM (TYPE 2) Trouble Diagnoses (Cont’d) Case 4 =NAEL0472S0304 GI Check TCM circuit. Refer to “TCM CIRCUIT CHECK” (EL-489). MA EM LC EC PKIA8724E FE CL MT AT PKIA8746E TF Case 5 NAEL0472S0305 Check steering angle sensor circuit. Refer to “STEERING ANGLE SENSOR CIRCUIT CHECK” (EL-490). PD AX SU BR PKIA8725E ST RS BT HA PKIA8747E SC IDX EL-483 CAN SYSTEM (TYPE 2) Trouble Diagnoses (Cont’d) Case 6 =NAEL0472S0306 Check ABS actuator and electric unit (control unit) circuit. Refer to “ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) CIRCUIT CHECK” (EL-491). PKIA8726E PKIA8748E Case 7 NAEL0472S0307 Check combination meter circuit. Refer to “COMBINATION METER CIRCUIT CHECK” (EL-492). PKIA8727E PKIA8749E EL-484 CAN SYSTEM (TYPE 2) Trouble Diagnoses (Cont’d) Case 8 =NAEL0472S0308 GI Check CAN communication circuit. Refer to “CAN COMMUNICATION CIRCUIT CHECK” (EL-493). MA EM LC EC PKIA8728E FE CL MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-485 CAN SYSTEM (TYPE 2) Trouble Diagnoses (Cont’d) CIRCUIT CHECK BETWEEN TCM AND STEERING ANGLE SENSOR 1 =NAEL0472S06 CHECK CONNECTOR 1. Turn ignition switch OFF. 2. Check following terminals and connector for damage, bend and loose connection (connector-side and harness-side). 쐌 Harness connector M1 쐌 Harness connector E1 OK or NG OK 䊳 GO TO 2. NG 䊳 Repair terminal or connector. 2 CHECK HARNESS FOR OPEN CIRCUIT 1. Disconnect TCM connector and harness connector M1. 2. Check continuity between TCM harness connector M119 terminals 5 (L), 6 (R) and harness connector M1 terminals 4m (L), 11r (R). SEL728Y OK or NG OK 䊳 GO TO 3. NG 䊳 Repair harness. 3 CHECK HARNESS FOR OPEN CIRCUIT 1. Disconnect steering angle sensor connector. 2. Check continuity between harness connector E1 terminals 4m (L), 11r (R) and steering angle sensor harness connector E136 terminals 3 (L), 4 (R). SEL709Y OK or NG OK 䊳 Connect all the connectors and diagnose again. Refer to “Work Flow” (EL-479). NG 䊳 Repair harness. EL-486 CAN SYSTEM (TYPE 2) Trouble Diagnoses (Cont’d) CIRCUIT CHECK BETWEEN STEERING ANGLE SENSOR AND ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) 1 GI =NAEL0472S07 CHECK HARNESS FOR OPEN CIRCUIT MA 1. Disconnect steering angle sensor connector, ABS actuator and electric unit (control unit) connector and combination meter connector. 2. Check continuity between steering angle sensor harness connector E136 terminals 3 (L), 4 (R) and ABS actuator and electric unit (control unit) harness connector E142 terminals 11 (L), 15 (R). EM LC EC FE CL SEL710Y OK or NG OK 䊳 Connect all the connectors and diagnose again. Refer to “Work Flow” (EL-479). NG 䊳 Repair harness. MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-487 CAN SYSTEM (TYPE 2) Trouble Diagnoses (Cont’d) ECM CIRCUIT CHECK 1 =NAEL0472S08 CHECK CONNECTOR 1. Turn ignition switch OFF. 2. Check following terminals and connector for damage, bend and loose connection (control module-side and harnessside). 쐌 ECM 쐌 Harness connector F23 쐌 Harness connector M32 OK or NG OK 䊳 GO TO 2. NG 䊳 Repair terminal or connector. 2 CHECK HARNESS FOR OPEN CIRCUIT 1. Disconnect ECM connector. 2. Check resistance between ECM harness connector F203 terminals 94 (L) and 86 (R). SEL711Y OK or NG OK 䊳 Replace ECM. NG 䊳 Repair harness between ECM and TCM. EL-488 CAN SYSTEM (TYPE 2) Trouble Diagnoses (Cont’d) TCM CIRCUIT CHECK 1 =NAEL0472S09 CHECK CONNECTOR 1. Turn ignition switch OFF. 2. Check the terminals and connector of TCM for damage, bend and loose connection (control module-side and harnessside). OK 䊳 GO TO 2. NG 䊳 Repair terminal or connector. MA EM OK or NG 2 GI LC EC CHECK HARNESS FOR OPEN CIRCUIT 1. Disconnect TCM connector. 2. Check resistance between TCM harness connector M119 terminals 5 (L) and 6 (R). FE CL MT AT SEL712Y TF OK or NG OK 䊳 Replace TCM. NG 䊳 Repair harness between TCM and harness connector M1. PD AX SU BR ST RS BT HA SC IDX EL-489 CAN SYSTEM (TYPE 2) Trouble Diagnoses (Cont’d) STEERING ANGLE SENSOR CIRCUIT CHECK 1 =NAEL0472S11 CHECK CONNECTOR 1. Turn ignition switch OFF. 2. Check the terminals and connector of steering angle sensor for damage, bend and loose connection (sensor-side and harness-side). OK or NG OK 䊳 GO TO 2. NG 䊳 Repair terminal or connector. 2 CHECK HARNESS FOR OPEN CIRCUIT 1. Disconnect steering angle sensor connector. 2. Check resistance between steering angle sensor harness connector E136 terminals 3 (L) and 4 (R). SEL714Y OK or NG OK 䊳 Replace steering angle sensor. NG 䊳 Repair harness between steering angle sensor and ABS actuator and electric unit (control unit). EL-490 CAN SYSTEM (TYPE 2) Trouble Diagnoses (Cont’d) ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) CIRCUIT CHECK 1 =NAEL0472S12 CHECK CONNECTOR 1. Turn ignition switch OFF. 2. Check the terminals and connector of ABS actuator and electric unit (control unit) for damage, bend and loose connection (control unit-side and harness-side). OK 䊳 GO TO 2. NG 䊳 Repair terminal or connector. MA EM OK or NG 2 GI LC EC CHECK HARNESS FOR OPEN CIRCUIT 1. Disconnect ABS actuator and electric unit (control unit) connector. 2. Check resistance between ABS actuator and electric unit (control unit) harness connector E142 terminals 11 (L) and 15 (R). FE CL MT AT SEL715Y TF OK or NG OK 䊳 Replace ABS actuator and electric unit (control unit). PD NG 䊳 Repair harness between ABS actuator and electric unit (control unit) and harness connector E1. AX SU BR ST RS BT HA SC IDX EL-491 CAN SYSTEM (TYPE 2) Trouble Diagnoses (Cont’d) COMBINATION METER CIRCUIT CHECK 1 =NAEL0472S13 CHECK CONNECTOR 1. Turn ignition switch OFF. 2. Check following terminals and connector for damage, bend and loose connection (meter-side and harness-side). 쐌 Combination meter. 쐌 Harness connector M1. 쐌 Harness connector E1. OK or NG OK 䊳 GO TO 2. NG 䊳 Repair terminal or connector. 2 CHECK HARNESS FOR OPEN CIRCUIT 1. Disconnect combination meter connector. 2. Check resistance between combination meter harness connector M25 terminals 34 (Y) and 35 (L). SEL716Y OK or NG OK 䊳 Replace combination meter. NG 䊳 Repair harness between combination meter and ABS actuator and electric unit (control unit). EL-492 CAN SYSTEM (TYPE 2) Trouble Diagnoses (Cont’d) CAN COMMUNICATION CIRCUIT CHECK 1 =NAEL0472S14 CHECK CONNECTOR 1. Turn ignition switch OFF. 2. Check following terminals and connector for damage, bend and loose connection (meter-side, control unit-side, sensorside, control module-side and harness-side). 쐌 Combination meter 쐌 ABS actuator and electric unit (control unit) 쐌 Steering angle sensor 쐌 TCM 쐌 ECM 쐌 Between combination meter and ECM OK 䊳 GO TO 2. NG 䊳 Repair terminal or connector. MA EM LC EC OK or NG 2 GI FE CL CHECK HARNESS FOR SHORT CIRCUIT 1. Disconnect ECM connector and harness connector F23. 2. Check continuity between ECM harness connector F203 terminals 94 (L) and 86 (R). MT AT TF PD SEL717Y OK or NG OK 䊳 GO TO 3. NG 䊳 Repair harness between ECM and harness connector F23. 3 AX SU BR CHECK HARNESS FOR SHORT CIRCUIT Check continuity between ECM harness connector F203 terminals 94 (L), 86 (R) and ground. ST RS BT HA SEL718Y OK or NG OK 䊳 GO TO 4. NG 䊳 Repair harness between ECM and harness connector F23. SC IDX EL-493 CAN SYSTEM (TYPE 2) Trouble Diagnoses (Cont’d) 4 CHECK HARNESS FOR SHORT CIRCUIT 1. Disconnect TCM connector and harness connector M1. 2. Check continuity between TCM harness connector M119 terminals 5 (L) and 6 (R). SEL440Y OK or NG OK 䊳 GO TO 5. NG 䊳 쐌 Repair harness between TCM and harness connector M1. 쐌 Repair harness between TCM and harness connector M32. 5 CHECK HARNESS FOR SHORT CIRCUIT Check continuity between TCM harness connector M119 terminals 5 (L), 6 (R) and ground. SEL441Y OK or NG OK 䊳 GO TO 6. NG 䊳 쐌 Repair harness between TCM and harness connector M1. 쐌 Repair harness between TCM and harness connector M32. EL-494 CAN SYSTEM (TYPE 2) Trouble Diagnoses (Cont’d) 6 GI CHECK HARNESS FOR SHORT CIRCUIT 1. Disconnect steering angle sensor connector and ABS actuator and electric unit (control unit) connector. 2. Check continuity between ABS actuator and electric unit (control unit) harness connector E142 terminals 11 (L) and 15 (R). MA EM LC EC SEL719Y OK or NG FE CL OK 䊳 GO TO 7. NG 䊳 쐌 Repair harness between ABS actuator and electric unit (control unit) and harness connector E1. 쐌 Repair harness between ABS actuator and electric unit (control unit) and steering angle sensor. MT AT 7 CHECK HARNESS FOR SHORT CIRCUIT Check continuity between ABS actuator and electric unit (control unit) harness connector E142 terminals 11 (L), 15 (R) and ground. TF PD AX SU BR SEL720Y OK or NG OK 䊳 GO TO 8. NG 䊳 쐌 Repair harness between ABS actuator and electric unit (control unit) and harness connector E1. 쐌 Repair harness between ABS actuator and electric unit (control unit) and steering angle sensor. ST RS BT HA SC IDX EL-495 CAN SYSTEM (TYPE 2) Trouble Diagnoses (Cont’d) 8 CHECK HARNESS FOR SHORT CIRCUIT 1. Disconnect combination meter connector. 2. Check continuity between combination meter harness connector M25 terminals 34 (Y) and 35 (L). SEL721Y OK or NG OK 䊳 GO TO 9. NG 䊳 Repair harness between combination meter and harness connector M1. 9 CHECK HARNESS FOR SHORT CIRCUIT Check continuity between combination meter harness connector M25 terminals 34 (Y), 35 (L) and ground. SEL722Y OK or NG OK 䊳 GO TO 10. NG 䊳 Repair harness between combination meter and harness connector M1. 10 ECM/COMBINATION METER INTERNAL CIRCUIT INSPECTION Check components inspection. Refer to “ECM/COMBINATION METER INTERNAL CIRCUIT INSPECTION” (EL-497). OK or NG OK 䊳 Connect all the connectors and diagnose again. Refer to “Work Flow” (EL-479). NG 䊳 Replace ECM and/or combination meter. EL-496 CAN SYSTEM (TYPE 2) Component Inspection Component Inspection =NAEL0473 ECM/COMBINATION METER INTERNAL CIRCUIT INSPECTION 쐌 쐌 쐌 SEL723Y NAEL0473S01 Remove ECM and combination meter from vehicle. Check resistance between ECM terminals 94 and 86. Check resistance between combination meter terminals 34 and 35. Unit Terminal ECM 94 - 86 Combination meter 34 - 35 Resistance value (Ω) GI MA EM LC Approx. 108 - 132 EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-497 CAN SYSTEM (TYPE 3) Component Parts and Harness Connector Location Component Parts and Harness Connector Location NAEL0474 SEL729Y System Description NAEL0475 CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electonic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. EL-498 CAN SYSTEM (TYPE 3) Wiring Diagram — CAN — Wiring Diagram — CAN — NAEL0476 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL580Q EL-499 IDX CAN SYSTEM (TYPE 3) Trouble Diagnoses Trouble Diagnoses WORK FLOW NAEL0477 NAEL0477S01 1. Print all the data of “SELF-DIAG RESULTS” for “ENGINE” and “A/T” displayed on CONSULT-II. PKIA8260E 2. Print all the data of “CAN DIAG SUPPORT MNTR” for “ENGINE” and “A/T” displayed on CONSULT-II. PKIA8343E 3. Attach the printed sheet of “SELF-DIAG RESULTS” and “CAN DIAG SUPPORT MNTR” onto the check sheet. Refer to “CHECK SHEET” (EL-501). 4. Based on the “CAN DIAG SUPPORT MNTR” results, put “v” marks onto the items with “UNKWN” or “NG” in the check sheet table. Refer to “CHECK SHEET” (EL-501). NOTE: If “NG” is displayed on “INITIAL DIAG (Initial diagnosis)” as “CAN DIAG SUPPORT MNTR” for the diagnosed control unit, replace the control unit. 5. According to the check sheet results (example), start inspection. Refer to “CHECK SHEET RESULTS (EXAMPLE)” (EL-502). EL-500 CAN SYSTEM (TYPE 3) Trouble Diagnoses (Cont’d) CHECK SHEET =NAEL0477S02 NOTE: If “NG” is displayed on “INITIAL DIAG (Initial diagnosis)” as “CAN DIAG SUPPORT MNTR” for the diagnosed control unit, replace the control unit. GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT PKIA8709E HA SC IDX EL-501 CAN SYSTEM (TYPE 3) Trouble Diagnoses (Cont’d) CHECK SHEET RESULTS (EXAMPLE) =NAEL0477S03 NOTE: If “NG” is displayed on “INITIAL DIAG (Initial diagnosis)” as “CAN DIAG SUPPORT MNTR” for the diagnosed control unit, replace the control unit. Case 1 NAEL0477S0301 Check ECM circuit. Refer to “ECM CIRCUIT CHECK” (EL-504). PKIA8729E PKIA8750E Case 2 NAEL0477S0302 Check TCM circuit. Refer to “TCM CIRCUIT CHECK” (EL-505). PKIA8730E PKIA8751E EL-502 CAN SYSTEM (TYPE 3) Trouble Diagnoses (Cont’d) Case 3 NAEL0477S0303 GI Check combination meter circuit. Refer to “COMBINATION METER CIRCUIT CHECK” (EL-506). MA EM LC EC PKIA8731E FE CL MT AT PKIA8752E TF Case 4 NAEL0477S0304 Check CAN communication circuit. Refer to “CAN COMMUNICATION CIRCUIT CHECK” (EL-507). PD AX SU BR PKIA8732E ST RS BT HA SC IDX EL-503 CAN SYSTEM (TYPE 3) Trouble Diagnoses (Cont’d) ECM CIRCUIT CHECK 1 =NAEL0477S07 CHECK CONNECTOR 1. Turn ignition switch OFF. 2. Check following terminals and connector for damage, bend and loose connection (control module-side and harnessside). 쐌 ECM 쐌 Harness connector F23 쐌 Harness connector M32 OK or NG OK 䊳 GO TO 2. NG 䊳 Repair terminal or connector. 2 CHECK HARNESS FOR OPEN CIRCUIT 1. Disconnect ECM connector. 2. Check resistance between ECM harness connector F203 terminals 94 (L) and 86 (R). SEL711Y OK or NG OK 䊳 Replace ECM. NG 䊳 Repair harness between ECM and TCM. EL-504 CAN SYSTEM (TYPE 3) Trouble Diagnoses (Cont’d) TCM CIRCUIT CHECK 1 =NAEL0477S08 CHECK CONNECTOR 1. Turn ignition switch OFF. 2. Check the terminals and connector of TCM for damage, bend and loose connection (control module-side and harnessside). OK 䊳 GO TO 2. NG 䊳 Repair terminal or connector. MA EM OK or NG 2 GI LC EC CHECK HARNESS FOR OPEN CIRCUIT 1. Disconnect TCM connector. 2. Check resistance between TCM harness connector M119 terminals 5 (L) and 6 (R). FE CL MT AT SEL712Y TF OK or NG OK 䊳 Replace TCM. NG 䊳 Repair harness between TCM and harness connector M1. PD AX SU BR ST RS BT HA SC IDX EL-505 CAN SYSTEM (TYPE 3) Trouble Diagnoses (Cont’d) COMBINATION METER CIRCUIT CHECK 1 =NAEL0477S11 CHECK CONNECTOR 1. Turn ignition switch OFF. 2. Check following terminals and connector for damage, bend and loose connection (meter-side and harness-side). 쐌 Combination meter 쐌 Harness connector M1 쐌 Harness connector E1 OK or NG OK 䊳 GO TO 2. NG 䊳 Repair terminal or connector. 2 CHECK HARNESS FOR OPEN CIRCUIT 1. Disconnect combination meter connector. 2. Check resistance between combination meter harness connector M25 terminals 34 (Y) and 35 (L). SEL716Y OK or NG OK 䊳 Replace combination meter. NG 䊳 Repair harness between combination meter and TCM. EL-506 CAN SYSTEM (TYPE 3) Trouble Diagnoses (Cont’d) CAN COMMUNICATION CIRCUIT CHECK 1 =NAEL0477S12 GI CHECK CONNECTOR 1. Turn ignition switch OFF. 2. Check following terminals and connector for damage, bend and loose connection (meter-side, control module-side and harness-side). 쐌 Combination meter 쐌 TCM 쐌 ECM 쐌 Between combination meter and ECM MA EM LC OK or NG OK 䊳 GO TO 2. NG 䊳 Repair terminal or connector. EC FE 2 CHECK HARNESS FOR SHORT CIRCUIT 1. Disconnect ECM connector and harness connector F23. 2. Check continuity between ECM harness connector F203 terminals 94 (L) and 86 (R). CL MT AT TF SEL717Y PD OK or NG AX OK 䊳 GO TO 3. NG 䊳 Repair harness between ECM and harness connector F23. SU 3 CHECK HARNESS FOR SHORT CIRCUIT BR Check continuity between ECM harness connector F203 terminals 94 (L), 86 (R) and ground. ST RS BT SEL718Y HA OK or NG OK 䊳 GO TO 4. NG 䊳 Repair harness between ECM and harness connector F23. SC IDX EL-507 CAN SYSTEM (TYPE 3) Trouble Diagnoses (Cont’d) 4 CHECK HARNESS FOR SHORT CIRCUIT 1. Disconnect TCM connector and harness connector M1. 2. Check continuity between TCM harness connector M119 terminals 5 (L) and 6 (R). SEL440Y OK or NG OK 䊳 GO TO 5. NG 䊳 쐌 Repair harness between TCM and harness connector M1. 쐌 Repair harness between TCM and harness connector M32. 5 CHECK HARNESS FOR SHORT CIRCUIT Check continuity between TCM harness connector M119 terminals 5 (L), 6 (R) and ground. SEL441Y OK or NG OK 䊳 GO TO 6. NG 䊳 쐌 Repair harness between TCM and harness connector M1. 쐌 Repair harness between TCM and harness connector M32. EL-508 CAN SYSTEM (TYPE 3) Trouble Diagnoses (Cont’d) 6 GI CHECK HARNESS FOR SHORT CIRCUIT Check continuity between harness connector E1 terminals 6m (L) and 12m (R). MA EM LC EC SEL732Y FE OK or NG OK 䊳 GO TO 7. NG 䊳 Repair harness between harness connector E1 and harness connector E1. 7 CL CHECK HARNESS FOR SHORT CIRCUIT MT Check continuity between harness connector E1 terminals 6m (L), 12m (R) and ground. AT TF PD AX SEL733Y OK or NG OK 䊳 GO TO 8. NG 䊳 Repair harness between harness connector E1 and harness connector E1. 8 SU BR CHECK HARNESS FOR SHORT CIRCUIT ST 1. Disconnect combination meter connector. 2. Check continuity between combination meter harness connector M25 terminals 34 (Y) and 35 (L). RS BT HA SC SEL721Y OK or NG OK 䊳 GO TO 9. NG 䊳 Repair harness between combination meter and harness connector M1. EL-509 IDX CAN SYSTEM (TYPE 3) Trouble Diagnoses (Cont’d) 9 CHECK HARNESS FOR SHORT CIRCUIT Check continuity between combination meter harness connector M25 terminals 34 (Y), 35 (L) and ground. SEL722Y OK or NG OK 䊳 GO TO 10. NG 䊳 Repair harness between combination meter and harness connector M1. 10 ECM/COMBINATION METER INTERNAL CIRCUIT INSPECTION Check components inspection. Refer to “ECM/COMBINATION METER INTERNAL CIRCUIT INSPECTION” (EL-510). OK or NG OK 䊳 Connect all the connectors and diagnose again. Refer to “Work Flow” (EL-500). NG 䊳 Replace ECM and/or combination meter. Component Inspection NAEL0478 ECM/COMBINATION METER INTERNAL CIRCUIT INSPECTION 쐌 쐌 쐌 SEL723Y NAEL0478S01 Remove ECM and combination meter from vehicle. Check resistance between ECM terminals 94 and 86. Check resistance between combination meter terminals 34 and 35. Unit Terminal ECM 94 - 86 Combination meter 34 - 35 Resistance value (Ω) Approx. 108 - 132 EL-510 CAN SYSTEM (TYPE 4) Component Parts and Harness Connector Location Component Parts and Harness Connector Location GI NAEL0479 MA EM LC SEL734Y System Description EC NAEL0480 CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. FE CL MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-511 CAN SYSTEM (TYPE 4) Wiring Diagram — CAN — Wiring Diagram — CAN — NAEL0481 MEL581Q EL-512 CAN SYSTEM (TYPE 4) Trouble Diagnoses Trouble Diagnoses WORK FLOW NAEL0482 GI NAEL0482S01 1. Print all the data of “SELF-DIAG RESULTS” for “ENGINE” displayed on CONSULT-II. MA EM LC EC PKIA8260E FE 2. Print all the data of “CAN DIAG SUPPORT MNTR” for “ENGINE” displayed on CONSULT-II. CL MT AT TF PKIA8343E 3. Attach the printed sheet of “SELF-DIAG RESULTS” and “CAN DIAG SUPPORT MNTR” onto the check sheet. Refer to “CHECK SHEET” (EL-514). 4. Based on the “CAN DIAG SUPPORT MNTR” results, put “v” marks onto the items with “UNKWN” or “NG” in the check sheet table. Refer to “CHECK SHEET” (EL-514). NOTE: If “NG” is displayed on “INITIAL DIAG (Initial diagnosis)” as “CAN DIAG SUPPORT MNTR” for the diagnosed control unit, replace the control unit. 5. According to the check sheet results (example), start inspection. Refer to “CHECK SHEET RESULTS (EXAMPLE)” (EL-514). PD AX SU BR ST RS BT HA SC IDX EL-513 CAN SYSTEM (TYPE 4) Trouble Diagnoses (Cont’d) CHECK SHEET =NAEL0482S02 NOTE: If “NG” is displayed on “INITIAL DIAG (Initial diagnosis)” as “CAN DIAG SUPPORT MNTR” for the diagnosed control unit, replace the control unit. PKIA8710E CHECK SHEET RESULTS (EXAMPLE) NAEL0482S03 NOTE: If “NG” is displayed on “INITIAL DIAG (Initial diagnosis)” as “CAN DIAG SUPPORT MNTR” for the diagnosed control unit, replace the control unit. Case 1 NAEL0482S0301 Check CAN communication circuit. Refer to “CAN COMMUNICATION CIRCUIT CHECK” (EL-515). PKIA8733E EL-514 CAN SYSTEM (TYPE 4) Trouble Diagnoses (Cont’d) CAN COMMUNICATION CIRCUIT CHECK 1 NAEL0482S08 CHECK CONNECTOR 1. Turn ignition switch OFF. 2. Check following terminals and connector for damage, bend and loose connection (meter-side, control module-side and harness-side) 쐌 Combination meter 쐌 ECM 쐌 Between combination meter and ECM OK 䊳 GO TO 2. NG 䊳 Repair terminal or connector. MA EM LC OK or NG 2 GI EC FE CHECK HARNESS FOR SHORT CIRCUIT 1. Disconnect ECM connector and combination meter connector. 2. Check continuity between ECM harness connector F203 terminals 94 (L) and 86 (R). CL MT AT TF SEL717Y PD OK or NG OK 䊳 GO TO 3. NG 䊳 Repair harness between ECM and combination meter. 3 AX SU CHECK HARNESS FOR SHORT CIRCUIT Check continuity between ECM harness connector F203 terminals 94 (L), 86 (R) and ground. BR ST RS BT SEL718Y OK or NG OK 䊳 GO TO 4. NG 䊳 Repair harness between ECM and combination meter. HA SC IDX EL-515 CAN SYSTEM (TYPE 4) Trouble Diagnoses (Cont’d) 4 CHECK HARNESS FOR OPEN CIRCUIT Check continuity between ECM harness connector F203 terminals 94 (L), 86 (R) and combination meter harness connector M25 terminals 34 (Y), 35 (L). SEL737Y OK or NG OK 䊳 GO TO 5. NG 䊳 Repair harness. 5 ECM/COMBINATION METER INTERNAL CIRCUIT INSPECTION Check components inspection. Refer to “ECM/COMBINATION METER INTERNAL CIRCUIT INSPECTION” (EL-516). OK or NG OK 䊳 Connect all the connectors and diagnose again. Refer to “Work Flow” (EL-513). NG 䊳 Replace ECM and/or combination meter. Component Inspection NAEL0483 ECM/COMBINATION METER INTERNAL CIRCUIT INSPECTION 쐌 쐌 쐌 SEL723Y NAEL0483S01 Remove ECM and combination meter from vehicle. Check resistance between ECM terminals 94 and 86. Check resistance between combination meter terminals 34 and 35. Unit Terminal ECM 94 - 86 Combination meter 34 - 35 Resistance value (Ω) Approx. 108 - 132 EL-516 ELECTRICAL UNITS LOCATION Engine Compartment Engine Compartment NAEL0431 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL063Q EL-517 IDX ELECTRICAL UNITS LOCATION Passenger Compartment Passenger Compartment NAEL0432 MEL064Q EL-518 ELECTRICAL UNITS LOCATION Passenger Compartment (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL065Q IDX EL-519 HARNESS LAYOUT How to Read Harness Layout How to Read Harness Layout NAEL0433 SEL252V The following Harness Layouts use a map style grid to help locate connectors on the drawings: 쐌 Main Harness 쐌 Engine Room Harness (Engine Compartment) 쐌 Engine Control Harness TO USE THE GRID REFERENCE 1. 2. 3. 4. 5. NAEL0433S01 Find the desired connector number on the connector list. Find the grid reference. On the drawing, find the crossing of the grid reference letter column and number row. Find the connector number in the crossing zone. Follow the line (if used) to the connector. CONNECTOR SYMBOL NAEL0433S02 Main symbols of connector (in Harness Layout) are indicated in the below. Water proof type Standard type Connector type Male Female — — 쐌 Cavity: Less than 4 쐌 Relay connector 쐌 Cavity: From 5 to 8 쐌 Cavity: More than 9 쐌 Ground terminal etc. — EL-520 Male Female HARNESS LAYOUT Outline Outline NAEL0434 GI MA EM LC EC FE CL MT AT TF PD AX MEL072M SU BR ST RS BT HA SC IDX EL-521 HARNESS LAYOUT Main Harness Main Harness NAEL0435 MEL051Q EL-522 HARNESS LAYOUT Main Harness (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL052Q IDX EL-523 HARNESS LAYOUT Engine Room Harness Engine Room Harness NAEL0436 MEL053Q EL-524 HARNESS LAYOUT Engine Room Harness (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL054Q IDX EL-525 HARNESS LAYOUT Engine Control Harness Engine Control Harness NAEL0437 MEL413R EL-526 HARNESS LAYOUT Engine Control Harness (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL414R IDX EL-527 HARNESS LAYOUT Body Harness LH Body Harness LH NAEL0438 MEL057Q EL-528 HARNESS LAYOUT Body Harness RH Body Harness RH NAEL0439 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL058Q EL-529 IDX HARNESS LAYOUT Back Door Harness Back Door Harness NAEL0440 MEL059Q EL-530 HARNESS LAYOUT Engine and Transmission Harness Engine and Transmission Harness NAEL0441 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL060Q EL-531 IDX HARNESS LAYOUT Room Lamp Harness Room Lamp Harness NAEL0442 MEL061Q EL-532 HARNESS LAYOUT Air Bag Harness Air Bag Harness NAEL0443 GI MA EM LC EC FE CL MT AT TF PD AX MEL244M SU BR ST RS BT HA SC IDX EL-533 HARNESS LAYOUT Front Door Harness Front Door Harness NAEL0444 MEL062Q EL-534 HARNESS LAYOUT Rear Door Harness Rear Door Harness NAEL0445 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC MEL261M EL-535 IDX NAEL0446 BULB SPECIFICATIONS Headlamp Headlamp Item NAEL0446S01 Wattage W High/Low (Semi-sealed beam) 60/55 (HB2) Exterior Lamp Item NAEL0446S02 Wattage W Front fog lamp 55 Front turn signal lamp 21 Parking lamp 5 Turn signal lamp Rear combination lamp 27 Stop/Tail lamp 21/5 Back-up lamp 18 License plate lamp 5 High-mounted stop lamp 5 Interior Lamp Item NAEL0446S03 Wattage W Interior lamp 10 Vanity mirror lamp 1.4 Spot lamp 8 Luggage room lamp 10 EL-536 NAEL0447 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 DTRL Section Wiring Diagram Name EL Headlamp — With Daytime Light System — EC ECM Power supply (Back-up) ECTS EC Engine Coolant Temperature Sensor EM LC AT A/T 1ST Signal 2NDSIG AT A/T 2ND Signal ENGSS AT Engine Speed Signal 3RDSIG AT A/T 3RD Signal ETC1 EC Electric Throttle Control Function 4THSIG AT A/T 4TH Signal ETC2 EC Electric Throttle Control Motor Relay A/C, A HA Auto Air Conditioner ETC3 EC Electric Throttle Control Motor A/C, M HA Manual Air Conditioner F/FOG EL Front Fog Lamp F/PUMP EC Fuel Pump Control FTS AT A/T Fluid Temperature Sensor FTTS EC Fuel Tank Temperature Sensor FUELB1 EC Fuel Injection System Function (Bank 1) FUELB2 EC Fuel Injection System Function (Bank 2) H/LAMP EL Headlamp HEATER HA Heater HORN EL Horn HSEAT EL Heated Seat IATS EC Intake Air Temperature Sensor IGNSYS EC Ignition Signal ILL EL Illumination INJECT EC Injector INT/L EL Interior, Spot, Vanity Mirror, and Luggage Room Lamps IVCB1 EC Intake Valve Timing Control Solenoid Valve Bank 1 IVCB2 EC Intake Valve Timing Control Solenoid Valve Bank 2 KEYLES EL Remote Keyless Entry System KS EC Knock Sensor LOAD EC Electrical Load Signal LPSV AT Line Pressure Solenoid Valve MAFS EC Mass Air Flow Sensor MAIN AT Main Power Supply and Ground Circuit MAIN EC Main Power Supply and Ground Circuit BR Anti-lock Brake System APPS1 EC Accelerator Pedal Position Sensor 1 APPS2 APPS EC EC Accelerator Pedal Position Sensor 2 Accelerator Pedal Position Sensor ASC/BS EC Automatic Speed Control Device Brake Switch ASC/SW EC Automatic Speed Control Device Steering Switch ASCIND EC Automatic Speed Control Device Indicator ASCBOF EC Automatic Speed Control Device Brake Switch (Off) AUDIO EL Audio AUT/DP EL Automatic Drive Positioner BA/FTS AT A/T Fluid Temperature Sensor and TCM Power Supply BACK/L EL Back-up Lamp BRK/SW EC Brake Switch BYPS/V EC Vacuum Cut Valve Bypass Valve CAN AT CAN Communication Line CAN EC CAN Communication Line CAN EL CAN System CHARGE SC Charging System CHIME EL Warning Chime CIGAR EL Cigarette Lighter CLOCK EL Clock COMPAS EL Compass and Thermometer D/LOCK EL Power Door Lock DEF EL Rear Window Defogger MA ECM/PW 1STSIG ABS GI EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-537 WIRING DIAGRAM CODES (CELL CODES) Code Section Wiring Diagram Name METER EL Speedometer, Tachometer, Temp., Oil, and Fuel Gauges MIL/DL EC MIL and Data Link Connectors MIRROR EL Door Mirror NATS EL NVIS (NISSAN Vehicle Immobilizer System) NAVI EL NONDTC O2H1B1 Code Section Wiring Diagram Name SEAT EL Power Seat SEN/PW EC Sensor Power Supply SHIFT AT A/T Shift Lock System SROOF EL Sunroof SRS RS Supplemental Restraint System Navigation System SSV/A AT Shift Solenoid Valve A AT Non-detectable Items SSV/B AT Shift Solenoid Valve B EC Heated Oxygen Sensor 1 Heater (Bank 1) START SC Starting System STOP/L EL Stop lamp O2H1B2 EC Heated Oxygen Sensor 1 Heater (Bank 2) SWL/V EC Swirl Control Valve Control Solenoid Valve O2H2B1 EC Heated Oxygen Sensor 2 Heater (Bank 1) T&FILD EL Trunk Lid and Fuel Lid Opener O2H2B2 EC Heated Oxygen Sensor 2 Heater (Bank 2) T/F TF Transfer T/WARN SU Low Tire Pressure Warning TAIL/L EL Parking, License and Tail Lamps O2S1B1 EC Heated Oxygen Sensor 1 (Bank 1) TCCSIG AT A/T TCC Signal (Lock up) O2S1B2 EC Heated Oxygen Sensor 1 (Bank 2) TCV AT Torque Converter Clutch Solenoid Valve Heated Oxygen Sensor 2 (Bank 1) TPS AT Throttle Position Sensor O2S2B1 EC O2S2B2 EC Heated Oxygen Sensor 2 (Bank 2) TPS1 EC Electric Throttle Control Actuator (Throttle Position Sensor 1) OVRCSV AT Overrun Clutch Solenoid Valve TPS2 EC Electric Throttle Control Actuator (Throttle Position Sensor 2) P/ANT EL Power Antenna TPS3 EC PHSB1 EC Camshaft Position Sensor (PHASE) Bank 1 Electric Throttle Control Actuator (Throttle Position Sensor) TRNSCV EL Homelink Universal Transceiver PHSB2 EC Camshaft Position Sensor (PHASE) Bank 2 TRSA/T AT Turbine Revolution Sensor PGC/V EC EVAP Canister Purge Volume Control Solenoid Valve TURN EL Turn Signal and Hazard Warning Lamps PNP/SW EC Park/Neutral Position PNP Switch VDC BR Vehicle Dynamics control System PNP/SW AT Park/Neutral Position PNP Switch VEHSEC EL Vehicle Security System POS EC Crankshaft Position Sensor (CKPS) (POS) VENT/V EC EVAP Canister Vent Control Valve POWER EL Power Supply Routing VIAS/V EC Variable Induction Air Control System PRE/SE EC EVAP Control System Pressure Sensor VSS EC Vehicle Speed Sensor VSSA/T AT Vehicle Speed Sensor A/T (Revolution Sensor) VSSMTR AT Vehicle Speed Sensor MTR WARN EL Warning Lamps WINDOW EL Power Window WIP/R EL Rear Wiper and Washer PS/SEN EC Power Steering Pressure Sensor REMOTE EL Audio (Remote Control Switch) RP/SEN EC Refrigerant Pressure S/VCSW EC Swirl Control Valve Control Vacuum Check Switch EL-538 WIRING DIAGRAM CODES (CELL CODES) Code WIPER Section EL GI Wiring Diagram Name Front Wiper and Washer MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC IDX EL-539 NOTES FRONT & REAR AXLE SECTION AX GI MA EM LC EC FE CONTENTS FRONT AXLE ..................................................................2 Precautions ..................................................................2 PRECAUTIONS .........................................................2 Preparation ..................................................................2 SPECIAL SERVICE TOOLS ........................................2 COMMERCIAL SERVICE TOOLS ................................2 Noise, Vibration and Harshness (NVH) Troubleshooting ...........................................................3 NVH TROUBLESHOOTING CHART ............................3 On-vehicle Service.......................................................3 FRONT AXLE PARTS ................................................3 FRONT WHEEL BEARING .........................................4 DRIVE SHAFT (4WD).................................................5 Wheel Hub and Rotor Disc..........................................6 COMPONENTS .........................................................6 REMOVAL .................................................................7 INSTALLATION..........................................................9 DISASSEMBLY ..........................................................9 INSPECTION .............................................................9 ASSEMBLY .............................................................10 Knuckle Spindle .........................................................10 REMOVAL ...............................................................10 INSPECTION ...........................................................11 INSTALLATION........................................................11 Drive Shaft (4WD) .....................................................12 COMPONENTS .......................................................12 REMOVAL ...............................................................12 DISASSEMBLY ........................................................13 INSPECTION ...........................................................14 ASSEMBLY .............................................................14 INSTALLATION........................................................15 Service Data and Specifications (SDS).....................16 WHEEL BEARING (FRONT) .....................................16 DRIVE SHAFT (4WD)...............................................16 REAR AXLE...................................................................18 Precautions ................................................................18 PRECAUTIONS .......................................................18 Preparation ................................................................18 SPECIAL SERVICE TOOLS ......................................18 COMMERCIAL SERVICE TOOLS ..............................19 Noise, Vibration and Harshness (NVH) Troubleshooting .........................................................19 On-vehicle Service.....................................................19 REAR AXLE PARTS.................................................19 REAR WHEEL BEARING .........................................19 Components...............................................................20 Removal.....................................................................20 Inspection...................................................................22 AXLE SHAFT...........................................................22 BEARING CAGE ......................................................22 REAR AXLE HOUSING ............................................22 Installation..................................................................22 Service Data and Specifications (SDS).....................23 WHEEL BEARING (REAR) .......................................23 CL MT AT TF PD SU BR ST RS BT HA SC EL IDX FRONT AXLE Precautions Precautions PRECAUTIONS I I I SBR686C I NAAX0001 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. Use flare nut wrench when removing and installing brake tubes. After installing removed suspension parts, check wheel alignment and adjust if necessary. Always torque brake lines when installing. Preparation SPECIAL SERVICE TOOLS NAAX0002 The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name Description ST29020001 (J24319-01) Ball joint remover Removing tie-rod outer end and lower ball joint a: 34 mm (1.34 in) b: 6.5 mm (0.256 in) c: 61.5 mm (2.421 in) NT694 KV401021S0 ( — ) Bearing race drift Installing wheel bearing outer race NT153 KV40105400 (J36001) Wheel bearing lock nut wrench Removing and installing wheel bearing lock nut NT154 COMMERCIAL SERVICE TOOLS Tool name NAAX0003 Description 1 Flare nut crowfoot 2 Torque wrench Removing and installing each brake piping a: 10 mm (0.39 in) NT360 Hub cap drift Installing hub cap (2WD) a: 85 mm (3.35 in) dia. b: 72 mm (2.83 in) dia. Installing hub cap (4WD) a: 57 mm (2.24 in) dia. b: 46 mm (1.81 in) dia. NT115 AX-2 FRONT AXLE Noise, Vibration and Harshness (NVH) Troubleshooting Noise, Vibration and Harshness (NVH) Troubleshooting GI NAAX0034 NVH TROUBLESHOOTING CHART NAAX0034S01 Symptom AXLE ST-6 BR-7 SU-4 SU-4 SU-4 Refer to AXLE in this chart. Refer to DRIVE SHAFT in this chart. PD-4 PD-4 AX-4, 19 — LC EC SUSPENSION TIRES ROAD WHEEL BRAKES STEERING × AXLE AX-6, 20 — × × × × × × × × × × × × × × × × × × × × × × × DRIVE SHAFT × EM CL DIFFERENTIAL Shake Wheel bearing damage × Parts interference × MA FE PROPELLER SHAFT DRIVE SHAFT Improper installation, looseness Joint sliding resistance Noise, Vibration Possible cause and SUSPECTED PARTS Imbalance Excessive joint angle Reference page AX-14 — Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts. × Noise × × × Shake × × × × × × Vibration × × × × × × Shimmy × × × × × × × Judder × × × × × × Poor quality ride or handling × × × × × × × MT AT TF PD × SU BR ×: Applicable ST RS BT On-vehicle Service FRONT AXLE PARTS HA NAAX0004 Check front axle parts for excessive play, cracks, wear and other damage. 1. Shake each front wheel to check for excessive play. 2. Retighten all nuts and bolts to the specified torque. Tightening torque: Refer to “Wheel Hub and Rotor Disc”, AX-6. SC EL IDX SMA525A AX-3 FRONT AXLE On-vehicle Service (Cont’d) FRONT WHEEL BEARING 1. 2. 3. NAAX0005 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. SFA747B Preload Adjustment NAAX0005S01 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. 2. I I I I Apply multi-purpose grease sparingly to the following parts: Threaded portion of spindle Contact surface between wheel bearing lock washer (chamfered side) and outer wheel bearing Grease seal lip Wheel hub (as shown at left) — 4WD — SFA891 3. 4. 5. 6. Tighten wheel bearing lock nut with Tool. : 78 - 98 N·m (8 - 10 kg-m, 58 - 72 ft-lb) Turn wheel hub several times in both directions. Loosen wheel bearing lock nut so that torque becomes 0 N·m (0 kg-m, 0 ft-lb). 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) SFA748B 7. 8. 9. Turn wheel hub several times in both directions. 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) Measure wheel bearing axial end play. Axial end play: 0 mm (0 in) SFA747B AX-4 FRONT AXLE On-vehicle Service (Cont’d) 10. Measure starting force “A” at wheel hub bolt. GI MA EM LC SMA580A SFA830 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 procedure 10. 14. Wheel bearing preload “C” can be calculated as shown below. C=B−A Wheel bearing preload “C”: 7.06 - 20.99 N (0.72 - 2.14 kg, 1.59 - 4.72 lb) 15. If wheel bearing preload “C” is outside specifications, remove lock washer. Tighten or loosen lock nut within ±15 degrees (Refer to step 11 above). Install lock washer, then repeat steps 12, 13 and 14. 16. Repeat above procedures until correct axial end play and wheel bearing preload are obtained. 17. Install drive flange (4WD models) and wheel hub cap. EC FE CL MT AT TF PD SU DRIVE SHAFT (4WD) I NAAX0006 Check boot and drive shaft for cracks, wear, damage and grease leakage. BR ST RS BT SFA901 HA SC EL IDX AX-5 FRONT AXLE Wheel Hub and Rotor Disc Wheel Hub and Rotor Disc COMPONENTS 2WD Model NAAX0007 NAAX0007S01 SFA976B AX-6 FRONT AXLE Wheel Hub and Rotor Disc (Cont’d) 4WD Model NAAX0007S02 GI MA EM LC EC FE CL MT AT TF SFA908B PD SU REMOVAL SFA529A NAAX0008 CAUTION: Before removing the front axle assembly, disconnect the ABS wheel sensor from the assembly. Then move it away from the front axle assembly area. Failure to do so may result in damage to the sensor wires and the sensor becoming inoperative. 1. Remove brake caliper assembly. Brake hose need not be disconnected from brake caliper. In this case, suspend caliper assembly with wire so as not to stretch brake hose. Be careful not to depress brake pedal, or piston will pop out. Make sure brake hose is not twisted. BR ST RS BT HA SC EL IDX AX-7 FRONT AXLE Wheel Hub and Rotor Disc (Cont’d) 2. Remove hub cap with suitable tool. 3. 4. Remove snap ring with suitable tool. — 4WD — Remove drive flange. — 4WD — 5. Remove lock washer. 6. Remove wheel bearing lock nut. SFA752B SFA753B SFA364BA SFA754B AX-8 FRONT AXLE Wheel Hub and Rotor Disc (Cont’d) 7. Remove wheel hub and wheel bearing. Be careful not to drop outer bearing. INSTALLATION 1. GI NAAX0009 After installing wheel hub and wheel bearing, adjust wheel bearing preload. Refer to “Preload Adjustment”, “FRONT WHEEL BEARING”, “On-vehicle Service”, AX-4. MA EM LC SFA832 2. 3. Pack drive flange groove with grease, apply grease to O-ring (two places) and mating surface of drive flange, and install flange. — 4WD — Install snap ring. — 4WD — EC FE CL MT SFA755B 4. Install hub cap using a suitable tool. Do not reuse hub cap. When installing, replace it with a new one. AT TF PD SU SFA759B DISASSEMBLY I NAAX0010 Remove grease seal and bearing outer races with suitable brass bar. BR ST RS BT FA858 INSPECTION NAAX0011 Thoroughly clean wheel bearings and wheel hub. Wheel Bearing I Wheel Hub I NAAX0011S01 Make sure wheel bearing rolls freely and is free from noise, crack, pitting and wear. NAAX0011S02 Check wheel hub for crack by using a magnetic exploration or dyeing test. HA SC EL IDX AX-9 FRONT AXLE Wheel Hub and Rotor Disc (Cont’d) ASSEMBLY NAAX0012 1. Install bearing outer race with Tool until it seats in hub. 2. Pack multi-purpose grease into wheel hub. — 4WD — 3. 4. 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. SFA197-A SFA891 SFA459B Knuckle Spindle REMOVAL 1. NAAX0013 Remove drive shaft. — 4WD — Refer to “Drive Shaft”, AX-12. 2. Separate tie-rod end and lower ball joint from knuckle with Tool. Install stud nut conversely on stud bolt so as not to damage stud bolt. SFA756B AX-10 FRONT AXLE Knuckle Spindle (Cont’d) 3. Separate knuckle from strut. GI MA EM LC SFA758B INSPECTION Knuckle Spindle I NAAX0014S01 Check knuckle spindle for deformation, cracks and other damage by using a magnetic exploration or dyeing test. Needle Bearing — 4WD — I EC NAAX0014 NAAX0014S02 Check needle bearing for wear, scratches, pitting, flaking and burn marks. FE CL MT INSTALLATION AT NAAX0015 1. Install needle bearing into knuckle spindle. — 4WD — Make sure that needle bearing is facing in proper direction. Apply multi-purpose grease. 2. Install knuckle with wheel hub. 3. Install tie-rod end and lower ball joint. TF PD SU SFA962 4. 5. After installing knuckle spindle, adjust wheel bearing preload. Refer to “Preload Adjustment”, “FRONT WHEEL BEARING”, “On-vehicle Service”, AX-4. After installing drive shaft, check drive shaft axial end play. — 4WD — Do not reuse snap ring once it has been removed. Refer to “Drive Shaft”, AX-12. BR ST RS BT SFA369B HA SC EL IDX AX-11 FRONT AXLE Drive Shaft (4WD) Drive Shaft (4WD) COMPONENTS NAAX0016 SAX018 REMOVAL 1. NAAX0017 2. Remove hub cap and snap ring. Refer to “REMOVAL”, “Wheel Hub and Rotor Disc”, AX-7. Remove bolts fixing drive shaft to final drive. 3. Remove transverse link fixing nut and bolts. SFA236 SFA760B 4. Separate drive shaft from knuckle by lightly tapping it with a copper hammer. Cover boots with shop towel so as not to damage them when removing drive shaft. SFA761B AX-12 FRONT AXLE Drive Shaft (4WD) (Cont’d) DISASSEMBLY Final Drive Side (TS82F) 1. 2. NAAX0018 GI NAAX0018S01 Remove plug seal from slide joint housing by lightly tapping around slide joint housing. Remove boot bands. MA EM LC SFA880 3. Move boot and slide joint housing toward wheel side, and put matching marks. EC FE CL MT SFA963 4. AT Remove snap ring. TF PD SU SFA964 5. Detach spider assembly with press. BR ST RS BT SFA392 6. Draw out boot. Cover drive shaft serration with tape so as not to damage the boot. HA Wheel Side (ZF100) SC NAAX0018S02 CAUTION: The joint on the wheel side cannot be disassembled. ZF100 type joint assembly cannot be disassembled because a plastic boot and special boot band are used. Do not use other drive shaft boots. If the boot or joint is damaged, replace the drive shaft assembly. SFA799 AX-13 EL IDX FRONT AXLE Drive Shaft (4WD) (Cont’d) INSPECTION NAAX0019 Thoroughly clean all parts in cleaning solvent, and dry with compressed air. Check parts for evidence of deformation and other damage. Drive Shaft NAAX0019S01 Replace drive shaft assembly if it is twisted or cracked. Boot (Final drive side) NAAX0019S02 Check boot for fatigue, cracks, and wear. Replace boot with new boot bands. Joint Assembly (Final drive side) I I I NAAX0019S03 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 necessary. Joint Assembly (Wheel side) NAAX0019S04 Replace drive shaft assembly if joint is deformed or damaged. ASSEMBLY I I NAAX0020 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. Final Drive Side (TS82F) NAAX0020S01 1. Install new small boot band, boot and side joint housing to drive shaft. Cover drive shaft serration with tape so as not to damage boot during installation. SFA800 2. I 3. Install spider assembly securely, ensuring marks are properly aligned. Press-fit with spider assembly serration chamfer facing shaft. Install new snap ring. SFA397 AX-14 FRONT AXLE Drive Shaft (4WD) (Cont’d) 4. 5. Pack with grease. Specified amount of grease: 95 - 105 g (3.35 - 3.70 oz) Make sure that boot is properly installed on the drive shaft groove. Set boot so that it does not swell and deform when its length is “L1”. Length “L1”: 95 - 97 mm (3.74 - 3.82 in) GI MA EM LC SFA460BA 6. Lock new larger boot band securely with a suitable tool, then lock new smaller boot band. 7. Install new plug seal to slide joint housing by lightly tapping it. Apply sealant to mating surface of plug seal. Wheel Side (ZF100) SFA443B NAAX0020S02 CAUTION: The joint on the wheel side cannot be disassembled. ZF100 type joint assembly cannot be disassembled because a plastic boot and special boot band are used. Do not use other drive shaft boots. If the boot or joint is damaged, replace the drive shaft assembly. INSTALLATION 1. EC FE CL MT AT NAAX0021 Apply multi-purpose grease. TF PD SU SFA887 2. Install thrust washer onto drive shaft. Make sure that thrust washer is facing in proper direction, apply multi-purpose grease. BR ST RS BT SFA846-A 3. a. When installing drive shaft, adjust drive shaft axial end play by selecting a suitable snap ring. Temporarily install new snap ring on drive shaft in the same thickness as it was installed before removal. HA SC EL IDX SFA762B AX-15 FRONT AXLE Drive Shaft (4WD) (Cont’d) b. c. d. Set dial gauge on drive shaft end. Measure axial end play of drive shaft. Axial end play: 0.45 mm (0.0177 in) or less If axial end play is not within the specified limit, select another snap ring. 1.1 1.3 1.5 1.7 mm mm mm mm (0.043 (0.051 (0.059 (0.067 in) in) in) in) 1.9 mm (0.075 in) 2.1 mm (0.083 in) 2.3 mm (0.091 in) SFA847 Service Data and Specifications (SDS) WHEEL BEARING (FRONT) NAAX0022 Tightening torque 78 - 98 N·m (8 - 10 kg-m, 58 - 72 ft-lb) Retightening torque after loosening wheel bearing lock nut Axial end play Wheel bearing lock nut 0 mm (0 in) Starting force at wheel hub bolt N (kg, lb) Turning angle A 15° - 30° Starting force at wheel hub bolt N (kg, lb) Wheel bearing preload at wheel hub bolt 0.5 - 1.5 N·m (0.05 - 0.15 kg-m, 4.3 - 13.0 in-lb) B−A B 7.06 - 20.99 N (0.72 - 2.14 kg, 1.59 - 4.72 lb) DRIVE SHAFT (4WD) Drive shaft joint type NAAX0033 Final drive side TS82F Wheel side ZF100* Fixed joint axial end play limit Diameter 1 mm (0.04 in) Wheel side (D1) 29.0 mm (1.142 in) Quality Nissan genuine grease or equivalent Grease Specified amount of grease Final drive side Drive shaft axial end play Boot length 95 - 105 g (3.35 - 3.70 oz) 0.45 mm (0.0177 in) or less Final drive side (L1) 95 - 97 mm (3.74 - 3.82 in) SAX019 *: ZF100 type joint assembly cannot be disassembled because a plastic boot and special boot band are used. Do not use other drive shaft boots. If the boot or joint is damaged, replace the drive shaft assembly. AX-16 FRONT AXLE Service Data and Specifications (SDS) (Cont’d) Drive Shaft End Snap Ring Thickness mm (in) 1.1 1.3 1.5 1.7 (0.043) (0.051) (0.059) (0.067) =NAAX0033S01 Part No. Thickness mm (in) Part No. 39253-88G10 39253-88G11 39253-88G12 39253-88G13 1.9 (0.075) 2.1 (0.083) 2.3 (0.091) 39253-88G14 39253-88G15 39253-88G16 GI MA EM LC EC FE CL MT AT TF PD SU BR ST RS BT HA SC EL IDX AX-17 REAR AXLE Precautions Precautions PRECAUTIONS I I I SBR686C I NAAX0023 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. Use flare nut wrench when removing and installing brake tubes. After installing removed suspension parts, check wheel alignment and adjust if necessary. Always torque brake lines when installing. Preparation SPECIAL SERVICE TOOLS NAAX0024 The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name Description KV40101000 (J25604-01) Axle stand Removing rear axle shaft NT159 ST36230000 (J25840-A) Sliding hammer Removing rear axle shaft NT126 ST38020000 ( — ) Bearing lock nut wrench Removing wheel bearing lock nut NT160 HT72480000 or HT72210000 (J25852-B) Rear axle shaft bearing puller Removing wheel bearing NT161 ST37840000 ( — ) Rear axle shaft guide Installing rear axle shaft NT162 AX-18 REAR AXLE Preparation (Cont’d) COMMERCIAL SERVICE TOOLS Tool name NAAX0025 GI Description MA Removing and installing each brake piping a: 10 mm (0.39 in) 1 Flare nut crowfoot 2 Torque wrench EM LC NT360 Rear axle oil seal drift Installing oil seal a: 74 mm (2.91 in) dia. b: 68 mm (2.68 in) dia. c: 10 mm (0.39 in) EC FE NT163 CL MT Noise, Vibration and Harshness (NVH) Troubleshooting AT NAAX0035 Refer to “Noise, Vibration and Harshness (NVH) Troubleshooting”, “FRONT AXLE”, AX-3. TF PD SU On-vehicle Service REAR AXLE PARTS NAAX0026 Check rear axle parts for excessive play, wear and damage. 1. Shake each rear wheel to check for excessive play. 2. Retighten all nuts and bolts to the specified torque. Tightening torque: Refer to “Components”, AX-20. BR ST RS BT SMA525A REAR WHEEL BEARING 1. 2. Check that wheel bearings operate smoothly. Check axial end play. Axial end play: 0 mm (0 in) NAAX0027 HA SC EL IDX SRA755A AX-19 REAR AXLE Components Components NAAX0028 SRA756A Removal NAAX0029 CAUTION: I Before removing the rear axle, disconnect the ABS wheel sensor from the assembly. Then move it away from the axle. Failure to do so may result in damage to the sensor wires and the sensor becoming inoperative. I Wheel bearing does not require maintenance. I If growling noise is emitted from wheel bearing during operation, replace wheel bearing assembly. I If the wheel bearing assembly is removed, it must be renewed. The old assembly must not be re-used. 1. Disconnect parking brake cable and brake tube. 2. Remove nuts securing wheel bearing cage with baffle plate. SAX002 3. Draw out axle shaft with Tool. When drawing out axle shaft, be careful not to damage oil seal. SRA758A AX-20 REAR AXLE Removal (Cont’d) 4. Remove oil seal with a screwdriver. Do not reuse oil seal once it is removed. Always install new one. 5. Remove ABS sensor rotor. GI MA EM LC SRA759A 6. Unbend lock washer with a screwdriver. Do not reuse lock washer once removed. Always install new one. EC FE CL MT SRA104 7. Remove bearing lock nut with Tool. AT TF PD SU SRA728 8. Remove wheel bearing together with bearing cage and baffle plate from axle shaft. BR ST RS BT SRA729-B 9. Remove grease seal with a screwdriver. 10. Remove wheel bearing assembly with a brass drift. HA SC EL IDX SRA106 AX-21 REAR AXLE Inspection Inspection AXLE SHAFT NAAX0030 NAAX0030S01 Check axle shaft for straightness, cracks, damage, wear and distortion. Replace if necessary. BEARING CAGE NAAX0030S02 Check bearing cage for deformation and cracks. Replace if necessary. REAR AXLE HOUSING NAAX0030S03 Check rear axle housing for yield, deformation and cracks. Replace if necessary. Installation NAAX0031 1. Press new wheel bearing until it bottoms end face of bearing cage. Maximum load P: 39 kN (4 ton, 4.4 US ton, 3.9 Imp ton) Always press outer race of wheel bearing during installation. SRA288A 2. Press new grease seal until it bottoms end face of bearing cage. Maximum load P: 8,300 N (847 kg, 1,866 lb) After installing new grease seal, coat sealing lip with multipurpose grease. SRA289A 3. Press axle shaft into inner race of wheel bearing. Maximum load P: 47.1 kN (4.8 ton, 5.3 US ton, 4.72 Imp ton) Be careful not to damage and deform grease seal. SRA761A 4. 5. Install bearing washer and a new wheel bearing lock washer. Tighten wheel bearing lock nut to specified torque. : 245 - 314 N·m (25 - 32 kg-m, 181 - 231 ft-lb) Fit wheel bearing lock washer lip in wheel bearing lock nut groove correctly by tightening lock nut. Be sure to bend it up. SRA762A AX-22 REAR AXLE Installation (Cont’d) 6. a. b. Check wheel bearing preload. Turn bearing cage (with respect to axle shaft) two or three times. It must turn smoothly. Attach spring gauge to bearing cage bolt (as shown at left) and pull it at a speed of 10 rpm to measure preload. Spring gauge indication: 6.7 - 47 N (0.68 - 4.79 kg, 1.51 - 10.57 lb) GI MA EM LC SRA763A 7. Install new oil seal to rear axle housing using a suitable tool. After installing new oil seal, coat sealing lip with multi-purpose grease. EC FE CL MT SRA292A 8. Press ABS sensor rotor onto axle shaft until it contacts wheel bearing lock nut. 9. Position axle shafts in rear axle housing with Tool as a guide. Be careful not to damage oil seal. AT TF PD SU SRA012 10. Check axial end play. a. Check that wheel bearings operate smoothly. b. Check axial end play. Axial end play: 0 mm (0 in) BR ST RS BT SRA755A Service Data and Specifications (SDS) HA WHEEL BEARING (REAR) NAAX0032 Wheel bearing axial end play 0 mm (0 in) Wheel bearing lock nut tightening torque 245 - 314 N·m (25 - 32 kg-m, 181 - 231 ft-lb) Wheel bearing preload measured at bearing cage bolt 6.7 - 47 N (0.68 - 4.79 kg, 1.51 - 10.57 lb) SC EL IDX AX-23 NOTES TRANSFER SECTION TF GI MA EM LC EC FE CONTENTS PREPARATION ...............................................................4 Special Service Tools ..................................................4 Commercial Service Tools ...........................................9 TX10A NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ...................................................10 NVH Troubleshooting Chart.......................................10 TRANSFER .............................................................10 DESCRIPTION ...............................................................11 Cross-sectional View .................................................11 ON-VEHICLE SERVICE ................................................12 Replacing Oil Seal .....................................................12 CENTER CASE OIL SEAL ........................................12 SHIFT SHAFT OIL SEAL ..........................................13 REAR OIL SEAL ......................................................13 Position Switch Check ...............................................14 REMOVAL AND INSTALLATION .................................15 Removal.....................................................................15 Installation..................................................................15 M/T MODEL ............................................................15 A/T MODEL .............................................................15 OVERHAUL ...................................................................16 Transfer Gear Control................................................16 Case Components .....................................................17 Gear Components .....................................................18 Shift Control Components .........................................19 DISASSEMBLY..............................................................20 REPAIR FOR COMPONENT PARTS ...........................24 Mainshaft ...................................................................24 DISASSEMBLY ........................................................24 INSPECTION ...........................................................25 ASSEMBLY .............................................................25 Front Drive Shaft .......................................................26 DISASSEMBLY ........................................................26 INSPECTION ...........................................................26 ASSEMBLY .............................................................26 Counter Gear .............................................................26 DISASSEMBLY ........................................................26 CL INSPECTION ...........................................................27 ASSEMBLY .............................................................27 Main Gear ..................................................................27 DISASSEMBLY ........................................................27 INSPECTION ...........................................................28 ASSEMBLY .............................................................28 Front Case .................................................................28 REMOVAL ...............................................................28 INSTALLATION........................................................29 Front Case Cover ......................................................29 REMOVAL ...............................................................29 INSTALLATION........................................................29 Bearing Retainer........................................................29 REMOVAL ...............................................................29 INSTALLATION........................................................29 Center Case...............................................................30 REMOVAL ...............................................................30 INSTALLATION........................................................30 Rear Case..................................................................30 REMOVAL ...............................................................30 INSTALLATION........................................................30 Shift Control Components .........................................31 INSPECTION ...........................................................31 ASSEMBLY....................................................................32 SERVICE DATA AND SPECIFICATIONS (SDS) .........39 General Specifications...............................................39 Gear End Play ...........................................................39 Available Snap Ring ..................................................39 MAINSHAFT FRONT BEARING ................................39 MAINSHAFT REAR BEARING ..................................39 MAIN GEAR BEARING.............................................39 Available Shim ...........................................................40 COUNTER GEAR REAR BEARING ...........................40 ATX14A PRECAUTIONS .............................................................41 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″.............41 Precautions ................................................................41 Service Notice............................................................42 MT AT PD AX SU BR ST RS BT HA SC EL IDX CONTENTS Wiring Diagrams and Trouble Diagnosis...................42 ALL-MODE 4WD SYSTEM ...........................................43 Cross-sectional View .................................................43 Control System ..........................................................44 ALL-MODE 4WD TRANSFER BASIC CONTROL ........45 HYDRAULIC CONTROL CIRCUITS ...........................45 OUTLINE ................................................................45 CONTROL SYSTEM DIAGRAM ................................46 INDICATIONS OF 4WD WARNING LAMP..................46 CAN Communication (With VDC)..............................47 SYSTEM DESCRIPTION ..........................................47 INPUT/OUTPUT SIGNAL CHART..............................47 Location of Electrical Parts........................................49 Description of Electrical Parts ...................................50 TRANSFER MOTOR ................................................50 WAIT DETECTION SWITCH .....................................50 2-4WD SHIFT SOLENOID VALVE .............................51 LINE PRESSURE SWITCH .......................................51 Circuit Diagram for Quick Pinpoint Check.................52 Wiring Diagram - TF -................................................53 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ...............................................................62 Trouble Diagnosis without CONSULT-II ....................62 DESCRIPTION ........................................................62 SELF-DIAGNOSTIC PROCEDURE............................63 INDICATIONS OF 4WD WARNING LAMP..................64 Trouble Diagnosis with CONSULT-II .........................65 CONSULT-II FUNCTION ...........................................65 SELF-DIAGNOSIS ...................................................65 SELF-DIAGNOSTIC ITEMS ......................................67 DATA MONITOR......................................................68 DATA MONITOR ITEMS ...........................................70 REFERENCE VALUE IN DATA MONITOR MODE ......72 WORK SUPPORT ....................................................75 CLUTCH FORCE RELEASE LIMIT ADJUSTMENT .....76 TROUBLE DIAGNOSIS - INTRODUCTION..................77 Introduction ................................................................77 DESCRIPTION ........................................................77 DIAGNOSTIC WORKSHEET.....................................77 Work Flow..................................................................79 HOW TO PERFORM TROUBLE DIAGNOSES FOR QUICK AND ACCURATE REPAIR .............................79 TROUBLE DIAGNOSIS - BASIC INSPECTION ...........80 Listen to Customer Complaints .................................80 Transfer Fluid Check .................................................80 Road Test...................................................................80 PREPARATION FOR ROAD TEST ............................80 1. CHECK BEFORE ENGINE IS STARTED ...............81 2. CHECK AT IDLE ..................................................82 3. CRUISE TEST .....................................................86 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION ...............................................................89 Transfer Control Unit Terminals and Reference Value ..........................................................................89 (Cont’d) REMOVAL AND INSTALLATION OF TRANSFER CONTROL UNIT ......................................................89 INSPECTION OF TRANSFER CONTROL UNIT..........89 TRANSFER CONTROL UNIT INSPECTION TABLE ....90 DTC U1000 CAN COMMUNICATION LINE (WITH VDC)...............................................................................96 Description .................................................................96 On Board Diagnosis Logic.........................................96 Possible Cause..........................................................96 DTC Confirmation Procedure ....................................96 WITH CONSULT-II ..............................................96 WITH GST .........................................................96 Diagnostic Procedure ................................................97 VEHICLE SPEED SENSOR (FRONT REVOLUTION SENSOR) (WITHOUT VDC) .................98 Diagnostic Procedure ................................................98 4WD SOLENOID VALVE.............................................101 Diagnostic Procedure ..............................................101 2-4WD SHIFT SOLENOID VALVE AND 4WD SHIFT SWITCH............................................................103 Diagnostic Procedure ..............................................103 TRANSFER MOTOR AND TRANSFER MOTOR RELAY .........................................................................107 Diagnostic Procedure ..............................................107 TRANSFER FLUID TEMPERATURE SENSOR..........110 Diagnostic Procedure ..............................................110 ATP SWITCH, WAIT DETECTION SWITCH AND NEUTRAL-4LO SWITCH.............................................113 Diagnostic Procedure ..............................................113 CLUTCH PRESSURE SWITCH ..................................117 Diagnostic Procedure ..............................................117 LINE PRESSURE SWITCH .........................................120 Diagnostic Procedure ..............................................120 ABS OPERATION SIGNAL (WITHOUT VDC) ...........123 Diagnostic Procedure ..............................................123 DATA ERASE/DISPLAY .............................................125 Diagnostic Procedure ..............................................125 SHIFT ACTUATOR......................................................126 Diagnostic Procedure ..............................................126 SHIFT ACTUATOR POSITION SWITCH ....................129 Diagnostic Procedure ..............................................129 SHIFT ACTUATOR CIRCUIT ......................................131 Diagnostic Procedure ..............................................131 TROUBLE DIAGNOSES FOR SYMPTOMS ...............135 Symptom 1. 4WD Shift Indicator Lamp Does Not Turn ON ...................................................................135 Symptom 2. 4WD Warning Lamp Does Not Turn ON............................................................................137 Symptom 3. 4WD Shift Indicator Lamp Does Not Turn OFF .................................................................139 Symptom 4. ATP Warning Lamp Does Not Turn ON............................................................................139 TF-2 CONTENTS Symptom 5. 4LO Indicator Lamp Does Not Turn ON............................................................................141 Symptom 6. 4WD Shift Indicator Lamp Does Not Indicate ″4H″............................................................143 Symptom 7. 4WD Shift Indicator Lamp Repeats Flickering..................................................................144 Symptom 8. Tight Corner Braking Symptom...........145 Symptom 9. 4WD System Does Not Operate.........146 COMPONENT INSPECTION .......................................148 4WD Shift Switch.....................................................148 2-4WD Shift Solenoid Valve and Transfer Fluid Temperature Sensor ................................................148 4WD Solenoid Valve, Clutch Pressure Switch and Line Pressure Switch........................................148 Front Revolution Sensor..........................................149 Transfer Dropping Resistor......................................149 ATP Switch, Neutral-4LO Switch and Wait Detection Switch ......................................................149 Transfer Motor .........................................................150 Transfer Motor Relay ...............................................150 Transfer Sub-harness ..............................................150 FRONT REVOLUTION SENSOR SUB-HARNESS CONNECTOR ........................................................150 TRANSFER SWITCH ASSEMBLY SUB-HARNESS CONNECTOR ........................................................151 TRANSFER TERMINAL CORD ASSEMBLY SUBHARNESS CONNECTOR .......................................151 Transfer Shift Relay (High & low)............................151 Actuator & Actuator Position Switch........................152 ACTUATOR ...........................................................152 ACTUATOR POSITION SWITCH ............................152 ON-VEHICLE SERVICE ..............................................153 Replacing Oil Seal ...................................................153 FRONT CASE OIL SEAL ........................................153 SHIFT SHAFT OIL SEAL ........................................154 REAR OIL SEAL ....................................................154 Transfer Motor .........................................................155 REMOVAL .............................................................155 INSTALLATION......................................................155 Transfer Oil Filter .....................................................155 REMOVAL .............................................................155 INSTALLATION......................................................155 (Cont’d) REMOVAL AND INSTALLATION ...............................156 Removal...................................................................156 Installation................................................................156 OVERHAUL .................................................................157 Transfer Gear Control..............................................157 Transfer Components ..............................................158 DISASSEMBLY............................................................160 Rear Case................................................................160 DISASSEMBLY ......................................................160 Center Case.............................................................160 DISASSEMBLY ......................................................160 Front Case ...............................................................170 DISASSEMBLY ......................................................170 REPAIR FOR COMPONENT PARTS .........................174 Front Case ...............................................................174 INSPECTION .........................................................174 Center Case.............................................................175 INSPECTION .........................................................175 ASSEMBLY..................................................................178 Front Case ...............................................................178 ASSEMBLY ...........................................................178 Center Case.............................................................182 ASSEMBLY ...........................................................182 Final Assembly.........................................................190 SERVICE DATA AND SPECIFICATIONS (SDS) .......193 General Specifications.............................................193 Inner Gear and Outer Gear .....................................193 SUB-OIL PUMP .....................................................193 MAIN OIL PUMP ....................................................193 Control Valve ...........................................................193 VALVE ..................................................................193 SPRING ................................................................193 Clutch.......................................................................194 DRIVE PLATE .......................................................194 DRIVEN PLATE .....................................................194 RETURN SPRING..................................................194 RETAINING PLATE................................................194 Seal Ring (Mainshaft side) ......................................195 Bearing Race (Thrust needle bearing side) ............195 Snap Ring (Sun gear side)......................................195 GI MA EM LC EC FE CL MT AT PD AX SU BR ST RS BT HA SC EL IDX TF-3 PREPARATION Special Service Tools 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.) Tool name Description KV38108300 (J44195) Companion flange wrench Removing companion flange nut Installing companion flange nut NT771 ST30021000 (J22912-01) Puller Removing low gear Removing counter gear front bearing (Use with ST36710010) Removing L & H hub a: 110 mm (4.33 in) dia. b: 68 mm (2.68 in) dia. NT411 ST30031000 (J22912-01) Puller Removing counter gear rear bearing (Use with ST36710010) a: 90 mm (3.54 in) dia. b: 50 mm (1.97 in) dia. NT411 ST33290001 (J25810-A) Puller Removing center case oil seal Removing rear oil seal a: 250 mm (9.84 in) b: 160 mm (6.30 in) NT414 ST33051001 (J22888) Puller Removing companion flange a: 135 mm (5.31 in) b: 100 mm (3.94 in) c: 130 mm (5.12 in) NT657 ST30720000 1 (J25273) 2 (J25405) Drift 1 Installing center case oil seal 2 Installing rear oil seal a: 77 mm (3.03 in) dia. b: 55.5 mm (2.185 in) dia. NT658 TF-4 NATF0093 PREPARATION Special Service Tools (Cont’d) Tool number (Kent-Moore No.) Tool name ST36710010 ( — Drift GI Description Removing counter gear front bearing (Use with ST30021000) Removing counter gear rear bearing (Use with ST30031000) a: 34.5 mm (1.358 in) dia. ) NT063 ST33061000 (J8107-2) Drift Removing main gear bearing a: 28.5 mm (1.122 in) dia. b: 38 mm (1.50 in) dia. MA EM LC EC FE NT116 ST30613000 1 (J25742-3) 2 (J34339) Drift 1 Installing main gear bearing 2 Installing front case cover oil seal a: 72 mm (2.83 in) dia. b: 48 mm (1.89 in) dia. CL MT NT073 (J35864) Drift Installing shift shaft oil seal a: 26 mm (1.02 in) dia. b: 20 mm (0.79 in) dia. c: 150 mm (5.91 in) AT NT117 (J26092) Drift Seating counter gear assembly a: 44.5 mm (1.752 in) dia. b: 38.5 mm (1.516 in) dia. PD AX NT065 (J34291) Shim setting gauge set Selecting counter gear rear bearing shim SU BR NT101 (J34291-20) Plunger-shim setting gauge Selecting counter gear rear bearing shim ST RS NT118 BT KV40100621 (J26091) Drift Installing front drive shaft bearing a: 76 mm (2.99 in) dia. b: 69 mm (2.72 in) dia. HA SC NT086 EL IDX TF-5 PREPARATION Special Service Tools (Cont’d) Tool number (Kent-Moore No.) Tool name ST30032000 ( — Base Description Installing front drive shaft bearing a: 38 mm (1.50 in) dia. b: 80 mm (3.15 in) dia. ) NT660 ST33052000 ( — Adapter Removing front drive shaft bearing a: 28 mm (1.10 in) dia. b: 22 mm (0.87 in) dia. ) NT431 ST35271000 (J26091) Drift Installing rear oil seal Removing and installing press flange snap ring a: 72 mm (2.83 in) dia. b: 63 mm (2.48 in) dia. NT115 ST27863000 ( — Support ring Removing and installing press flange snap ring a: 74.5 mm (2.933 in) dia. b: 62.5 mm (2.461 in) dia. ) NT661 KV40104710 ( — Support ring Removing and installing press flange snap ring a: 76.3 mm (3.004 in) dia. b: 67.9 mm (2.673 in) dia. ) NT661 ST35291000 ( — Remover Removing mainshaft rear bearing a: 40 mm (1.57 in) dia. b: 29.5 mm (1.161 in) dia. c: 22.5 mm (0.886 in) dia. ) NT662 TF-6 PREPARATION Special Service Tools (Cont’d) Tool number (Kent-Moore No.) Tool name ST30090010 ( — Remover GI Description Removing mainshaft rear bearing a: 165 mm (6.50 in) b: 25 mm (0.98 in) dia. c: M16 x P2.0 ) MA EM LC EC NT663 KV38100500 ( — Drift Installing front drive shaft oil seal a: 80 mm (3.15 in) dia. b: 60 mm (2.36 in) dia. ) FE CL NT115 KV40100621 (J25273) Drift Installing mainshaft rear bearing a: 76 mm (2.99 in) dia. b: 69 mm (2.72 in) dia. MT AT NT104 KV32101100 ( — Pin punch Removing and installing L-H fork, 2-4 fork a: 6 mm (0.24 in) dia. ) PD AX NT410 ST3306S001 (J22888-D) Differential side bearing puller set 1: ST33051001 ( — ) Puller 2: ST33061000 (J8107-2) Adapter ST30911000 ( — Puller Installing mainshaft rear bearing Removing sun gear assembly a: 28.5 mm (1.122 in) dia. b: 38 mm (1.50 in) dia. SU BR ST NT072 Installing mainshaft and planetary carrier assembly a: 98 mm (3.86 in) dia. b: 40.5 mm (1.594 in) dia. ) RS BT HA NT664 SC EL IDX TF-7 PREPARATION Special Service Tools (Cont’d) Tool number (Kent-Moore No.) Tool name Description KV381054S0 ( — ) Outer race puller Removing rear oil seal NT665 KV40105230 ( — Adapter Installing planetary carrier assembly a: 92 mm (3.62 in) dia. b: 86 mm (3.39 in) dia. c: 12 mm (0.47 in) ) NT666 KV40105310 ( — Support ring Installing planetary carrier assembly a: 89.1 mm (3.508 in) dia. b: 80.7 mm (3.177 in) dia. ) NT661 KV40105500 ( — Support Installing planetary carrier assembly a: 69 mm (2.72 in) dia. b: 52 mm (2.05 in) dia. c: 120 mm (4.72 in) dia. ) NT667 KV38100200 ( — Drift Installing transfer cover oil seal a: 65 mm (2.56 in) dia. b: 49 mm (1.93 in) dia. ) NT673 KV31103300 ( — Drift Removing and installing press flange snap ring a: 76.3 mm (3.004 in) dia. b: 130 mm (5.12 in) ) NT668 TF-8 PREPARATION Special Service Tools (Cont’d) Tool number (Kent-Moore No.) Tool name GI Description KV31103400 ( — ) Clutch piston attachment 1 Shaft-drift 2 Guide-cylinder MA Installing clutch piston a: 88.5 mm (3.484 in) dia. b: 158 mm (6.22 in) dia. EM LC EC NT669 (J35864) Drift Installing oil seal FE CL MT NT671 Commercial Service Tools Tool name AT NATF0094 Description Puller Removing front drive shaft front bearing Removing front drive shaft rear bearing Removing main gear bearing PD AX NT077 Drift 1 Installing mainshaft rear bearing 2 Installing L & H hub 1 a: 50 mm (1.97 in) dia. b: 42 mm (1.65 in) dia. c: 180 mm (7.09 in) 2 a: 60 mm (2.36 in) dia. b: 50 mm (1.97 in) dia. c: 60 mm (2.36 in) NT117 SU BR ST RS BT HA SC EL IDX TF-9 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NATF0095 TX10A NVH Troubleshooting Chart NVH Troubleshooting Chart NATF0095S01 Use the chart below to help you find the cause of the symptom. The numbers indicate the order of inspection. If necessary, repair or replace these parts. TRANSFER Fluid leakage 3 1 Hard to shift or will not shift 1 1 2 TF-19 TF-18 TF-18 SHIFT FORK (Worn) GEAR (Worn or damaged) BEARING (Worn or damaged) TF-17, 19 CHECK SPRING AND CHECK BALL (Worn or damaged) TF-17 2 OIL SEAL (Worn or damaged) 1 FLUID (Level too high) FLUID (Wrong) Noise FLUID (Level low) SUSPECTED PARTS (Possible cause) TF-17 Reference page LIQUID GASKET (Damaged) Refer to MA-22, “Checking Transfer Fluid”. NATF0095S0101 3 3 2 Symptom Jumps out of gear 1 TF-10 2 2 DESCRIPTION TX10A Cross-sectional View Cross-sectional View NATF0096 GI MA EM LC EC FE CL MT AT PD AX SU BR ST RS BT HA SC EL SMT164E TF-11 IDX ON-VEHICLE SERVICE TX10A Replacing Oil Seal Replacing Oil Seal CENTER CASE OIL SEAL 1. NATF0097 NATF0097S01 3. Remove exhaust front tube and heat insulator. Refer to “Removal”, TF-15. Remove front propeller shaft. Refer to PD-8, “Removal and Installation”. Remove companion flange nut. 4. Remove companion flange. 5. Remove center case oil seal. 6. I 7. Install center case oil seal. Before installing, apply multi-purpose grease to seal lip. Install companion flange. 2. SMT844DB SMT802C SMT803C SMT183E 8. Tighten nut to the specified torque. 9. Install front propeller shaft. 10. Install exhaust front tube and heat insulator. SMT845DB TF-12 ON-VEHICLE SERVICE TX10A Replacing Oil Seal (Cont’d) SHIFT SHAFT OIL SEAL 1. 2. 3. NATF0097S02 Remove front propeller shaft. Refer to PD-8, “Removal and Installation”. Remove companion flange. Refer to center case oil seal, TF-12. Remove transfer control lever from transfer outer shift lever. Then remove outer shift lever. GI MA EM LC SMT863C 4. I EC Remove shift shaft oil seal. Be careful not to damage cross shaft. FE CL MT SMT491A 5. I 6. 7. 8. Install shift shaft oil seal. Before installing, apply multi-purpose grease to seal lip. Install outer shift lever. Then install transfer control lever to transfer outer shift lever. Install companion flange. Refer to center case oil seal, TF-12. Install front propeller shaft. AT PD AX SU SMT805C REAR OIL SEAL 1. 2. NATF0097S03 Remove rear propeller shaft. Refer to PD-8, “Removal and Installation”. Remove rear oil seal. BR ST RS BT SMT806C 3. I 4. Install rear oil seal. Before installing apply multi-purpose grease to seal lip. Install rear propeller shaft. HA SC EL IDX SMT807C TF-13 ON-VEHICLE SERVICE TX10A Position Switch Check Position Switch Check Switch NATF0098 Gear position Continuity 4WD Yes Except 4WD No Neutral No Except neutral Yes 4WD switch Neutral position switch SMT790CA TF-14 REMOVAL AND INSTALLATION TX10A Removal Removal NATF0099 1. 2. SMT800C Drain fluid from transfer and oil from transmission. Remove exhaust front and rear tubes. Refer to FE-9, “Removal and Installation”. 3. Remove front and rear propeller shaft. Refer to PD-8, “Removal and Installation”. 4. Insert plug into rear oil seal after removing propeller shaft. I Be careful not to damage spline, sleeve yoke and rear oil seal, when removing propeller shaft. 5. Disconnect neutral position and 4WD switch harness connectors. 6. Remove transfer control lever from transfer outer shift lever. 7. Remove transfer from transmission. WARNING: Support transfer while removing it. GI MA EM LC EC FE CL MT SMT863C AT Installation I NATF0100 Apply recommended sealant to mating surface to transmission. (M/T model only) Recommended sealant: Genuine Anaerobic Liquid Gasket or equivalent Refer to TF-17. PD AX SU SMT495A I Tighten bolts securing transfer. M/T MODEL NATF0100S01 Bolt No. Tightening torque N·m (kg-m, ft-lb) 1 32 - 42 (3.2 - 4.3, 24 - 31) 60 (2.36) 2 32 - 42 (3.2 - 4.3, 24 - 31) 45 (1.77)  A/T MODEL SMT496AB mm (in) NATF0100S02 Bolt No. Tightening torque N·m (kg-m, ft-lb) 1 32 - 42 (3.2 - 4.3, 24 - 31) 45 (1.77) 2 32 - 42 (3.2 - 4.3, 24 - 31) 45 (1.77)  BR ST RS BT mm (in) HA SC EL IDX TF-15 OVERHAUL TX10A Transfer Gear Control Transfer Gear Control NATF0101 SMT184E TF-16 OVERHAUL TX10A Case Components Case Components NATF0102 GI MA EM LC EC FE CL MT AT PD AX SU BR ST RS BT HA SC EL SMT165E TF-17 IDX OVERHAUL TX10A Gear Components Gear Components NATF0103 SMT185E TF-18 OVERHAUL TX10A Shift Control Components Shift Control Components NATF0104 GI MA EM LC EC FE CL MT AT PD AX SU BR ST RS BT HA SC EL SMT186E TF-19 IDX NATF0105 DISASSEMBLY TX10A 1. 2. Remove nut of companion flange. Remove companion flange. 3. 4. I Remove 4WD switch. Remove rear case. Be careful not to damage the mating surface. 5. 6. Remove oil cover and oil gutter. Remove snap ring and retainer ring from 2-4 shift rod. 7. I Remove bolts securing bearing retainer. This step is necessary to remove mainshaft from center case. 8. Remove bolts securing center case to front case and then separate center case and front case. SMT846DA SMT270A SMT435C SMT273A SMT274A TF-20 DISASSEMBLY 9. I TX10A Measure end play of low gear. Standard: 0.2 - 0.35 mm (0.0079 - 0.0138 in) If end play is beyond the maximum value, check low gear and L & H hub for wear. GI MA EM LC SMT342A 10. Disassemble center case assembly. a. Remove snap ring from mainshaft. EC FE CL MT SMT275A b. Pull out low gear with L & H hub. AT PD AX SU SMT757A c. Remove needle bearing of low gear. BR ST RS BT SMT758A d. Make sure of the direction of the drive chain before removing it. (It must be reinstalled in the same direction.) HA SC EL IDX SMT788C TF-21 DISASSEMBLY e. I TX10A Remove mainshaft, front drive and drive chain as a set by tapping front end of mainshaft and front drive shaft alternately. Be careful not to bend drive chain. SMT279A 11. Disassemble front case assembly. a. Remove neutral position switch, plugs, check springs and check balls. SMT822D b. Remove outer shift lever. c. Remove lock pin of inner shift lever and drive out cross shaft with plug. d. Remove 2-4 shift rod. SMT867C SMT282A SMT283A TF-22 DISASSEMBLY e. TX10A Remove L & H shift rod and fork assembly with coupling sleeve. GI MA EM LC SMT284A f. Remove needle bearing from main gear. EC FE CL MT SMT286A g. Remove bolts securing front case cover and then remove case. AT PD AX SU SMT287A h. Remove counter gear by tapping lightly. BR ST RS BT SMT759A i. Remove main gear by tapping lightly. HA SC EL IDX SMT288A TF-23 REPAIR FOR COMPONENT PARTS TX10A Mainshaft Mainshaft DISASSEMBLY 1. I NATF0106 Check end play of front drive sprocket. Standard: 0.2 - 0.35 mm (0.0079 - 0.0138 in) If end play is beyond the maximum value, check front drive sprocket and clutch gear for wear. SMT347A 2. I Remove retainer ring, speedometer drive gear and steel ball. Be careful not to lose the steel ball. 3. Remove snap ring and spacer. 4. 5. Press out front drive sprocket with mainshaft rear bearing and clutch gear together. Remove needle bearing. 6. Remove bearing retainer and then remove snap ring. SMT289A SMT290A SMT291A SMT292A TF-24 REPAIR FOR COMPONENT PARTS TX10A Mainshaft (Cont’d) 7. Press out mainshaft front bearing from mainshaft. GI MA EM LC SMT293A INSPECTION Gear and Shaft I I I EC NATF0107 NATF0107S01 Check gears for excessive wear, chips or cracks. Check shaft for cracks, wear or bending. Check coupling sleeve for wear or damage. FE CL MT SMT348A Bearing I AT NATF0107S02 Make sure bearings roll freely and are free from noise, crack, pitting or wear. PD AX SU SMT042E ASSEMBLY 1. I NATF0108 Press mainshaft front bearing onto mainshaft. Pay special attention to its direction. BR ST RS BT SMT294A 2. 3. Select snap ring with proper thickness and install it. Allowable clearance between snap ring and groove: 0 - 0.15 mm (0 - 0.0059 in) Available snap ring for mainshaft front bearing: Refer to SDS, TF-39. Regarding to further procedures, refer to “ASSEMBLY”, TF-32. HA SC EL IDX SMT295A TF-25 REPAIR FOR COMPONENT PARTS TX10A Front Drive Shaft Front Drive Shaft DISASSEMBLY I NATF0109 Front drive shaft front bearing and rear bearing SMT437C INSPECTION Sprocket and Shaft I I NATF0110S01 Check sprocket for excessive wear, chips or cracks. Check shaft for cracks or wear. Bearing I NATF0110 NATF0110S02 Make sure bearings roll freely and are free from noise, crack, pitting or wear. SMT357A ASSEMBLY I NATF0111 Press front drive shaft front bearing and rear bearing. SMT438C Counter Gear DISASSEMBLY NATF0112 1. Press out counter gear front bearing. 2. I Press out counter gear rear bearing. Remove rear sub-gear, spacer and dish plate (M/T model only). SMT300A SMT301A TF-26 REPAIR FOR COMPONENT PARTS TX10A Counter Gear (Cont’d) INSPECTION Gear and Shaft I I GI NATF0113S01 Check gears for excessive wear, chips or cracks. Check shaft for cracks or wear. Bearing I NATF0113 MA NATF0113S02 Make sure bearings roll freely and are free from noise, crack, pitting or wear. EM LC SMT358A ASSEMBLY 1. 2. I EC NATF0114 Press on counter gear front bearing. Install rear sub-gear, dish plate and spacer. Press on counter gear rear bearing (M/T model only). FE CL MT SMT439C AT Main Gear DISASSEMBLY Main Gear Bearing 1. NATF0115 NATF0115S01 Remove snap ring. PD AX SU SMT304A 2. Pull out main gear bearing. BR ST RS BT SMT305A Plug I NATF0115S02 Always replace it with new one whenever it is removed. HA SC EL IDX SMT187E TF-27 REPAIR FOR COMPONENT PARTS TX10A Main Gear (Cont’d) INSPECTION Gear and Shaft I I NATF0116S01 Check gears for excessive wear, chips or cracks. Check shaft for cracks or wear. Bearing I NATF0116 NATF0116S02 Make sure bearings roll freely and are free from noise, crack, pitting or wear. SMT359A ASSEMBLY Main Gear Bearing NATF0117 NATF0117S01 1. Press on main gear bearing. 2. Select snap ring with proper thickness and install it. 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-39. SMT307A SMT030D Plug I NATF0117S02 Apply sealant to plug and install it. Sealant: Refer to Gear Components, TF-18. SMT188E Front Case REMOVAL Shift Shaft Oil Seal I I I NATF0118 NATF0118S01 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 TF-28 REPAIR FOR COMPONENT PARTS TX10A Front Case (Cont’d) INSTALLATION Shift Shaft Oil Seal I I NATF0119 GI NATF0119S01 Install new shift shaft oil seal until flush with case. Before installing, apply multi-purpose grease to seal lip. MA EM LC SMT805C EC Front Case Cover REMOVAL Cover Oil Seal I I NATF0120 NATF0120S01 Drive out old seal from inside of front case cover. Be careful not to damage front case cover. FE CL MT SMT189E INSTALLATION Cover Oil Seal I I AT NATF0121 NATF0121S01 Install new front case cover oil seal until it stops. Before installing, apply multi-purpose grease to seal lip. PD AX SU SMT868C Bearing Retainer REMOVAL Oil Catcher I I NATF0122 BR NATF0122S01 Drive out oil catcher from inside of bearing retainer. Be careful not to damage bearing retainer. ST RS BT SMT190E INSTALLATION Oil Catcher I I I NATF0123 HA NATF0123S01 Install oil catcher until it stops. Be careful not to damage or distort oil catcher or bearing retainer. Before installing, apply multi-purpose grease to seal lip. SC EL IDX SMT191E TF-29 REPAIR FOR COMPONENT PARTS TX10A Center Case Center Case REMOVAL Center Case Oil Seal I NATF0124 NATF0124S01 Remove center case oil seal. SMT863D INSTALLATION Center Case Oil Seal I NATF0125 NATF0125S01 Install center case oil seal. SMT864D Rear Case REMOVAL Rear Oil Seal I NATF0126 NATF0126S01 Pull out rear oil seal. SMT316A INSTALLATION Rear Oil Seal I I NATF0127 NATF0127S01 Install new rear oil seal until it stops. Before installing, apply multi-purpose grease to seal lip. SMT317A Air Breather I Install as shown in illustration. SMT799A TF-30 NATF0127S02 REPAIR FOR COMPONENT PARTS TX10A Shift Control Components Shift Control Components INSPECTION I GI NATF0128 Check contact surface and sliding surface for wear, scratches, projections or other faulty conditions. MA EM LC SMT360A L & H Shift Rod & Fork I EC NATF0128S01 Assemble as shown in illustration. * Retaining pin is the same size as the one for 2-4 shift rod. Tool number: KV32101100 ( — ) FE CL MT SMT823D 2-4 Shift Rod & Fork I AT NATF0128S02 Assemble as shown in illustration. * Retaining pins are the same size. Tool number: KV32101100 ( — ) PD AX SU SMT320A I Pay special attention to the direction of fork guide collar. BR ST RS BT SMT031D HA SC EL IDX TF-31 NATF0129 ASSEMBLY TX10A 1. a. Assemble front case. Install main gear assembly by tapping lightly. b. Apply sealant to the mating surface of front case cover and install it on front case. These ten bolts should be coated with sealant. Tightening torque A: 20 - 23 N·m (2.0 - 2.4 kg-m, 15 - 17 ft-lb) B: 24 - 28 N·m (2.4 - 2.9 kg-m, 18 - 20 ft-lb) (Always replace after every disassembly.) Sealant: Refer to Case Components, TF-17. SMT323A I I SMT166E c. Apply gear oil to needle bearing and install it into main gear. d. Install counter gear assembly by tapping lightly. e. I Install cross shaft and inner shift lever. When replacing cross shaft, outer shift lever or lock pin of outer shift lever, replace them as a set. SMT326A SMT327A SMT032D TF-32 ASSEMBLY f. TX10A Apply sealant to plug and install it into front case. Sealant: Refer to Case Components, TF-17. GI MA EM LC SMT330A g. Insert interlock plunger into front case. EC FE CL MT SMT331A h. Install L & H shift rod and fork assembly with coupling sleeve. CAUTION: L & H coupling sleeve have directional property. (A/T vehicle only) AT PD AX SU SMT167E i. Install 2-4 shift rod. BR ST RS BT SMT333A j. I Install neutral position switch, check balls, check springs and plugs. Apply sealant to switches and plugs. Sealant: Refer to Case Components, TF-17. HA SC EL IDX SMT822D TF-33 ASSEMBLY TX10A 2. a. Select counter gear rear bearing shim. Seat counter gear assembly. b. Place J34291-1 (bridge), J34291-2 (legs) and J34291-5 (gauging cylinder) on machined surface of center case and allow gauging cylinder to rest on top outer portion of counter gear rear bearing. Lock gauging cylinder in place. c. Insert J34291-20 (gauging plunger) into J34291-5 (gauging cylinder). d. Place bridge, legs, gauging cylinder and gauging plunger onto machined surface of front case assembly, and allow gauging plunger to drop until it contacts counter gear rear bearing mating surface. SMT033D SMT591A SMT592A SMT034D TF-34 ASSEMBLY e. TX10A GI g. Lock gauging plunger in place and use feeler gauge to measure gap between gauging cylinder and gauging plunger. Use measured distance and following chart to select correct shim. Counter gear end play: 0 - 0.2 mm (0 - 0.008 in) Counter gear rear bearing shim: Refer to SDS, TF-40. Select counter gear rear bearing shim. 3. 4. Place suitable shim on counter gear rear bearing with grease. Apply ATF to each part in front case. EC f. MA EM LC SMT035D FE CL MT SMT036D 5. a. I Assemble center case assembly. Install mainshaft on center case by tapping lightly. Apply ATF to mainshaft front bearing. AT PD AX SU SMT406A b. Install bearing retainer. BR ST RS BT SMT407A HA SC EL IDX TF-35 ASSEMBLY TX10A c. Put drive chain onto the front drive sprocket and front drive shaft, and then put them in center case. d. I Install front drive shaft by tapping lightly. Make sure shafts are lined up in the case. e. Apply ATF to needle bearings and install them into front drive sprocket. These needle bearings can be installed more easily if front drive sprocket is rotated while installing them. SMT168E SMT409A SMT410A I SMT411A f. I Install 2-4 coupling sleeve with 2-4 shift fork. Pay special attention to direction of coupling sleeve. SMT412A TF-36 ASSEMBLY g. I TX10A Install clutch gear and mainshaft rear bearing. Place wooden block under mainshaft in order to protect mainshaft front bearing. GI MA EM LC SMT192E h. i. Install spacer. Select snap ring with proper thickness and install it. 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-39. EC FE CL MT SMT414A j. I Install steel ball, speedometer drive gear and retainer ring. Steel ball is the smallest of check balls for this unit. AT PD AX SU SMT415A k. I Install low gear and its bearing to mainshaft. Apply ATF to needle bearing. BR ST RS BT SMT340A l. I Install L & H hub and snap ring to mainshaft. Pay special attention to direction of L & H hub. HA SC EL IDX SMT193E TF-37 ASSEMBLY TX10A m. Measure end play of low gear. Standard: 0.2 - 0.35 mm (0.0079 - 0.0138 in) SMT342A 6. Apply sealant to mating surface and put center case assembly onto front case and tighten bolts. Sealant: Refer to Case Components, TF-17. 7. Install snap ring to 2-4 shift rod. 8. 9. Install oil gutter and oil cover. Apply ATF to each part in center case. SMT343A SMT272A SMT344A 10. Apply sealant to mating surface and install rear case on center case. 11. Install 4WD switch. I Apply sealant to thread of switch. Sealant: Refer to Case Components, TF-17. SMT037D TF-38 SERVICE DATA AND SPECIFICATIONS (SDS) TX10A General Specifications General Specifications NATF0130 Transfer model GI TX10A High 1.000 Low 2.020 MA Gear ratio Number of teeth Main gear 29 Low gear 37 High 38 Low 24 EM LC Counter gear Front drive sprocket 41 Front drive shaft 41 Fluid capacity  (US qt, Imp qt)* EC FE 2.2 (2-3/8, 2) *: Refer to MA-12, “Fluids and Lubricants”. CL Gear End Play NATF0131 Unit: mm (in) Front drive sprocket 0.2 - 0.35 (0.0079 - 0.0138) Low gear 0.2 - 0.35 (0.0079 - 0.0138) Counter gear MT AT 0 - 0.2 (0 - 0.008) Available Snap Ring NATF0132 MAINSHAFT FRONT BEARING NATF0132S01 Allowable clearance PD 0 - 0.15 mm (0 - 0.0059 in) Thickness mm (in) Part number* 3.10 (0.1220) 3.19 (0.1256) 3.28 (0.1291) 33138-73P10 33138-73P11 33138-73P12 AX SU *: Always check with the Parts Department for the latest parts information. MAINSHAFT REAR BEARING NATF0132S02 Allowable clearance BR 0 - 0.15 mm (0 - 0.0059 in) Thickness mm (in) 1.80 1.89 1.98 2.07 2.16 Part number* (0.0709) (0.0744) (0.0780) (0.0815) (0.0850) ST 33138-73P20 33138-73P21 33138-73P22 33138-73P23 33138-73P24 RS *: Always check with the Parts Department for the latest parts information. BT MAIN GEAR BEARING NATF0132S03 Allowable clearance 0 - 0.15 mm (0 - 0.0059 in) Thickness mm (in) Part number* 2.60 (0.1024) 2.69 (0.1059) 2.78 (0.1094) 33114-73P00 33114-73P01 33114-73P02 *: Always check with the Parts Department for the latest parts information. HA SC EL IDX TF-39 SERVICE DATA AND SPECIFICATIONS (SDS) TX10A Available Shim Available Shim NATF0133 COUNTER GEAR REAR BEARING NATF0133S01 Allowable clearance 0 - 0.2 mm (0 - 0.008 in) Thickness mm (in) 0.1 0.2 0.3 0.4 0.5 0.6 Part number* (0.004) (0.008) (0.012) (0.016) (0.020) (0.024) 33112-C6900 33112-C6901 33112-C6902 33112-C6903 33112-33G00 33112-33G01 *: Always check with the Parts Department for the latest parts information. TF-40 PRECAUTIONS ATX14A Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” GI NATF0001 The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS system composition which is available to NISSAN MODEL PATHFINDER is as follows: I For a frontal collision The Supplemental Restraint System consists of driver air bag module (located in the center of the steering wheel), front passenger air bag module (located on the instrument panel on passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. I For a side collision The Supplemental Restraint System consists of side air bag module (located in the outer side of front seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision). Information necessary to service the system safely is included in the RS section of this Service Manual. WARNING: I 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. I Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the RS section. I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified with yellow harness connector (and with yellow harness protector or yellow insulation tape before the harness connectors). MA EM LC EC FE CL MT AT PD AX SU Precautions I NATF0092 Before connecting or disconnecting the Transfer control unit harness connector, turn ignition switch OFF and disconnect negative battery terminal. Failure to do so may damage the Transfer control unit. Because battery voltage is applied to Transfer control unit even if ignition switch is turned off. BR ST RS BT SEF289H I When connecting or disconnecting pin connectors into or from Transfer control unit, take care not to damage pin terminals (bend or break). Make sure that there are not any bends or breaks on Transfer control unit pin terminal, when connecting pin connectors. HA SC EL IDX SEF291H TF-41 PRECAUTIONS ATX14A Precautions (Cont’d) I Before replacing Transfer control unit, perform Transfer control unit input/output signal inspection and make sure whether Transfer control unit functions properly or not. (See page TF-90.) MEF040DB Service Notice NATF0002 1) Before proceeding with disassembly, thoroughly clean the outside of the all-mode 4WD transfer. It is important to prevent the internal parts from becoming contaminated by dirt or other foreign matter. 2) Disassembly should be done in a clean work area. 3) Use lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could interfere with the operation of the all-mode 4WD transfer. 4) Place disassembled parts in order for easier and proper assembly. 5) All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or reassembly. 6) Gaskets, seals and O-rings should be replaced any time the all-mode 4WD transfer is disassembled. 7) It is very important to perform functional tests whenever they are indicated. 8) The valve body contains precision parts and requires extreme care when parts are removed and serviced. Place removed parts in a parts rack in order to replace them in correct positions and sequences. Care will also prevent springs and small parts from becoming scattered or lost. 9) Properly installed valves, sleeves, plugs, etc. will slide along bores in valve body under their own weight. 10) Before assembly, apply a coat of recommended ATF to all parts. Apply petroleum jelly to protect O-rings and seals, and to hold bearings and washers in place during assembly. Do not use grease. 11) Extreme care should be taken to avoid damage to O-rings, seals and gaskets when assembling. 12) After overhaul, refill the transfer with new ATF. 13) When the all-mode 4WD transfer drain plug is removed, only some of the fluid is drained. Old all-mode 4WD transfer fluid will remain in torque converter and ATF cooling system. Always follow the procedures, MA-24, “Changing All-mode 4WD Transfer Fluid”. Wiring Diagrams and Trouble Diagnosis When you read wiring diagrams, refer to the following: I GI-11, “HOW TO READ WIRING DIAGRAMS” I EL-11, “POWER SUPPLY ROUTING” When you perform trouble diagnosis, refer to the following: I GI-35, “HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSIS” I GI-24, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT” TF-42 NATF0003 ALL-MODE 4WD SYSTEM ATX14A Cross-sectional View Cross-sectional View NATF0006 GI MA EM LC EC FE CL MT AT PD AX SU BR ST RS BT HA SC EL SMT953CA TF-43 IDX ALL-MODE 4WD SYSTEM ATX14A Control System Control System NATF0007 SMT169E TF-44 ALL-MODE 4WD SYSTEM ATX14A Control System (Cont’d) ALL-MODE 4WD TRANSFER BASIC CONTROL NATF0007S01 GI MA EM LC EC FE CL SMT043D HYDRAULIC CONTROL CIRCUITS NATF0007S02 MT AT PD AX SU BR ST SMT040D OUTLINE NATF0007S03 All-mode 4WD transfer is controlled by the transfer control unit and sensors. If a malfunction occurs in the all-mode 4WD system, the 4WD warning lamp lights up to indicate the system malfunction. There are two ways to identify the cause of the malfunction. 1) Performing the self-diagnosis. (The 4WD warning lamp will indicate what kind of malfunction has occurred by flickering.) 2) Performing diagnosis using CONSULT-II. RS BT HA SC EL IDX TF-45 ALL-MODE 4WD SYSTEM ATX14A Control System (Cont’d) CONTROL SYSTEM DIAGRAM NATF0007S04 SMT170E INDICATIONS OF 4WD WARNING LAMP Condition Content NATF0007S05 4WD warning lamp During self-diagnosis Indicates the malfunction position by number of flickers. Flickers at malfunction mode. Lamp check* Checks the lamp by turning ON during engine starting. After engine starts, it turns OFF if there are no malfunctions. ON Malfunction in 4WD system* Turns ON to indicate malfunction. When ignition switch is turned to “OFF” or the malfunction is corrected, it turns OFF. ON When vehicle is driven with different Flickers once every 2 seconds. diameters of front and rear tires Turns OFF when ignition switch is “OFF”. Flickers once every 2 seconds. High fluid temperature in transfer unit When fluid temperature is high or fluid temperature sensor circuit is shorted, it flickers twice every second. It turns OFF when fluid temperature becomes normal. Flickers twice a second. Other than above (System is normal.) Lamp is OFF. OFF *: When 4WD warning lamp is ON, all the 4WD shift indicator lamps turn OFF. TF-46 ALL-MODE 4WD SYSTEM ATX14A CAN Communication (With VDC) CAN Communication (With VDC) =NATF0134 SYSTEM DESCRIPTION GI NATF0134S01 CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line). These allow a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. MA EM LC EC FE CL SKIA1526E MT INPUT/OUTPUT SIGNAL CHART NATF0134S02 T: Transmit R: Receive Signals ECM TCM ABS actuator Transfer con- Steering angle and electric trol unit sensor unit (control unit) Engine speed signal T R R Accelerator pedal position signal T R R Closed throttle position signal T R Shift pattern signal R T VDC operation signal R R T TCS operation signal R R T ABS operation signal R R T Output shaft revolution signal R ETC fail signal T During shifting signal R Combination meter R PD AX T SU BR R R T ST R Steering wheel angle sensor signal R T Wheel speed sensor signal R Brake switch signal AT RS R T R T MI signal T R Engine coolant temperature signal T R Fuel consumption signal T R T T Lock-up prohibition signal T R Lock-up signal R T HA SC R Vehicle speed signal R BT EL IDX TF-47 ALL-MODE 4WD SYSTEM ATX14A CAN Communication (With VDC) (Cont’d) Signals ECM TCM Transfer con- Steering angle trol unit sensor ABS actuator and electric unit (control unit) Combination meter Neutral range switch signal R T Parking range switch signal R T O/D off switch signal R T POWER mode signal R T A/C compressor feedback signal T R Fuel level sensor signal R T TF-48 ALL-MODE 4WD SYSTEM ATX14A Location of Electrical Parts Location of Electrical Parts NATF0008 GI MA EM LC EC FE CL MT AT PD AX SU BR ST RS BT HA SC EL SMT171E TF-49 IDX ALL-MODE 4WD SYSTEM ATX14A Description of Electrical Parts Description of Electrical Parts NATF0067 TRANSFER MOTOR NATF0067S01 1. The transfer motor drives the sub-oil pump to provide proper lubrication and oil pressure control when the vehicle is at standstill, during low-speed operations or is being driven in reverse. 2. The main oil pump is operated by the driving force of the mainshaft. In other words, sufficient oil pressure buildup does not occur when the vehicle is at standstill or during low-speed operations. While the vehicle is being driven in reverse, the main oil pump rotates in the reverse direction. Therefore the main oil pump does not discharge oil pressure. During any of the above vehicle operations, the transfer motor drives the sub-oil pump to compensate for insufficient oil pressure. 3. The transfer motor operates as follows: 1) The motor relay turns OFF in the 2WD mode. 2) The motor relay operates as described in the table below in modes other than the 2WD mode. Table 1 PNP switch “R” position VFF (Vehicle speed) A/T position Motor relay drive command ON — R ON 0 km/h Positions other than the “P” or “N” positions ON — “P” or “N” position (See Table 2.) — 0 < VFF % 30 km/h — ON 30 < VFF < 35 km/h — HOLD 35 km/h % VFF — OFF OFF Table 2 Throttle position A/T position N-4L SW 0 - 0.07/8 0.07/8 - 1/8 1/8 - MAX LOCK (4H) ON ON ON Positions other than the LOCK position (2WD or AUTO) See NOTE. HOLD ON ON — See NOTE. HOLD ON — — See NOTE. HOLD ON OFF N P 4WD mode NOTE: OFF (after 2.5 seconds have elapsed.) 4. 4WD shift switch, PNP switch, Neutral-4LO switch, vehicle speed sensor and throttle position sensor are used in conjunction with the transfer motor. WAIT DETECTION SWITCH NATF0067S02 1. The wait detection switch releases the “booming” torque produced in the propeller shaft. After the release of the “booming” torque, the wait detection switch helps provide the 4WD lock gear (clutch drum) shifts. A difference may occur between the operation (“4LO” to “4H” shift only) of the 4WD shift switch and actual drive mode. At this point, the wait detection switch senses an actual drive mode. 2. The wait detection switch operates as follows: 4WD lock gear (clutch drum) locked: ON 4WD lock gear (clutch drum) released: OFF 3. The wait detection switch senses an actual drive mode and the 4WD shift indicator lamp indicates the vehicle drive mode. TF-50 ALL-MODE 4WD SYSTEM ATX14A Description of Electrical Parts (Cont’d) 2-4WD SHIFT SOLENOID VALVE NATF0067S03 GI The 2-4WD shift solenoid valve operates to apply oil pressure to the wet, multiplate clutch, depending on the drive mode. The driving force is transmitted to the front wheels through the clutch so the vehicle is set in the 4WD mode. Setting the vehicle in the 2WD mode requires no pressure buildup. In other words, pressure force applied to the wet, multiplate clutch becomes zero. MA LINE PRESSURE SWITCH EM NATF0067S04 1. With the transfer system design, control of the oil pressure provides the transmission of drive torque to the front wheels. The main pressure to control the oil pressure is referred to as the line pressure. The line pressure switch determines whether or not adequate line pressure has built up under different operating conditions. 2. The line pressure switch turns ON when line pressure is produced. 3. The line pressure switch senses line pressure abnormalities and turns the 4WD warning lamp ON. LC EC FE CL MT AT PD AX SU BR ST RS BT HA SC EL IDX TF-51 ALL-MODE 4WD SYSTEM ATX14A Circuit Diagram for Quick Pinpoint Check Circuit Diagram for Quick Pinpoint Check NATF0009 MTF171A TF-52 ALL-MODE 4WD SYSTEM ATX14A Wiring Diagram — TF — Wiring Diagram — TF — NATF0010 GI MA EM LC EC FE CL MT AT PD AX SU BR ST RS BT HA SC EL MTF172A TF-53 IDX ALL-MODE 4WD SYSTEM ATX14A Wiring Diagram — TF — (Cont’d) MTF173A TF-54 ALL-MODE 4WD SYSTEM ATX14A Wiring Diagram — TF — (Cont’d) GI MA EM LC EC FE CL MT AT PD AX SU BR ST RS BT HA SC EL MTF174A IDX TF-55 ALL-MODE 4WD SYSTEM ATX14A Wiring Diagram — TF — (Cont’d) MTF175A TF-56 ALL-MODE 4WD SYSTEM ATX14A Wiring Diagram — TF — (Cont’d) GI MA EM LC EC FE CL MT AT PD AX SU BR ST RS BT HA SC EL MTF176A IDX TF-57 ALL-MODE 4WD SYSTEM ATX14A Wiring Diagram — TF — (Cont’d) MTF177A TF-58 ALL-MODE 4WD SYSTEM ATX14A Wiring Diagram — TF — (Cont’d) GI MA EM LC EC FE CL MT AT PD AX SU BR ST RS BT HA SC EL MTF178A IDX TF-59 ALL-MODE 4WD SYSTEM ATX14A Wiring Diagram — TF — (Cont’d) MTF179A TF-60 ALL-MODE 4WD SYSTEM ATX14A Wiring Diagram — TF — (Cont’d) GI MA EM LC EC FE CL MT AT PD AX SU BR ST RS BT HA SC EL MTF180A IDX TF-61 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A Trouble Diagnosis without CONSULT-II Trouble Diagnosis without CONSULT-II DESCRIPTION NATF0011 NATF0011S01 If the engine starts when there is something wrong with the allmode 4WD system, the 4WD warning lamp turns ON or flickers in the combination meter. When the system functions properly, the warning lamp turns ON when the ignition switch is turned to “ON”, and it turns OFF after engine starts. To locate the cause of a problem, start the self-diagnosis function. The 4WD warning lamp in the combination meter will indicate the problem area by flickering according to the self-diagnostic results. As for the details of the 4WD warning lamp flickering patterns, refer to TF-64. TF-62 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A Trouble Diagnosis without CONSULT-II (Cont’d) SELF-DIAGNOSTIC PROCEDURE NATF0011S02 GI MA EM LC EC FE CL MT AT PD AX SU BR ST RS BT HA SMT993D *1: TF-137 SC *2: TF-64 EL IDX TF-63 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A Trouble Diagnosis without CONSULT-II (Cont’d) INDICATIONS OF 4WD WARNING LAMP Flickering pattern or flickering condition Malfunction NATF0011S03 Check items 1 Front revolution sensor circuit is shorted or open. Revolution sensor (front) circuit, TF-98. 2 Rear revolution sensor circuit is shorted or open. Revolution sensor (rear) [Refer to AT-117, “DTC P0720 Vehicle Speed Sensor·A/T (Revolution sensor)”.] 3 4WD solenoid valve circuit is shorted or open. 4WD solenoid valve circuit, TF-101. 4 2-4WD shift solenoid valve circuit is shorted or 2WD switch of 4WD shift switch is shorted. 2-4WD shift solenoid valve circuit or 4WD shift switch circuit, TF-103. 5 Transfer motor relay circuit is shorted or open. Transfer motor relay circuit, TF-107. 6 If unexpected signal is detected because of ABS wheel sensor malfunction or communications error between the vehicles Refer to ABS wheel sensor signal circuit diagnosis. 7 When malfunction in CAN communication system is detected Refer to CAN communication system diagnosis. 8 Power supply voltage of throttle position sensor is improper. Or A/D converter of transfer control unit functions improperly. Throttle position sensor (Refer to AT-182, “DTC P1705 Throttle Position Sensor”.) 9 Transfer fluid temperature sensor circuit is open. Transfer fluid temperature sensor circuit, TF-110. 10 Neutral-4LO switch circuit is shorted or open. Neutral-4LO switch circuit, TF-113. 11 2-4WD shift solenoid valve circuit, 2WD switch of 4WD shift switch circuit or clutch pressure switch circuit is shorted or open. 2-4WD shift solenoid valve circuit, 4WD shift switch circuit or clutch pressure switch circuit, TF-103, 117. 12 Line pressure switch circuit is shorted or open. Line pressure switch circuit, TF-120. 13 Engine speed signal circuit is shorted or open. Engine speed signal (Refer to AT-122, “DTC P0725 Engine Speed Signal”.) 14 Throttle position sensor circuit is shorted or open. Throttle position sensor (Refer to AT-182, “DTC P1705 Throttle Position Sensor”.) 15 Malfunction in power supply circuit of transfer control unit. Power supply of transfer control unit 16 4WD shift switch circuit is shorted. 4WD shift switch circuit, TF-103. 17 ABS operation signal circuit is shorted. ABS operation signal circuit, TF-123. 18 ATP switch, wait detection switch or neutral-4LO switch circuit is ATP switch, wait detection switch or shorted or open. neutral-4LO switch circuit*, TF-113. 19 Transfer control device actuator motor is malfunctioning. (Malfunctions are detected when actuator motor fails to operate while shifting from “4H” to “4LO” or vice versa.) Actuator motor and motor circuit, TF-152, 126. 20 Transfer control device actuator motor arm position sensing switch is malfunctioning. Actuator motor arm position sensing switch and sensing switch circuit, TF-152, 129. 21 Transfer control device actuator circuit is shorted or open. (Malfunctions are detected when motor relay circuit is open/shorted or relay monitor circuit is open/shorted.) Actuator motor, actuator motor arm position sensing switch and their associated circuits, TF-151, 152 and 131. 22 If VDC operation signal is being input because of VDC malfuncRefer to VDC C/U diagnosis. tion or communication error between the vehicles TF-64 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A Trouble Diagnosis without CONSULT-II (Cont’d) GI Flickering pattern or flickering condition Malfunction 23 If TCS operation signal is being input because of TCS malfunction or communication error between the vehicles Refer to VDC C/U diagnosis. MA 24 If unexpected signal is input because of AT PNP switch circuit or communication error between the vehicles Refer to AT trouble diagnosis. EM Check items Repeats flickering every 2 to 5 sec. Circuits that the self-diagnosis covers have no malfunction. Repeats flickering every 0.25 sec. I Power supply failure of memory back-up. I Battery is disconnected for a long time. I Battery performance is poor. Data erase/display circuit, TF-125. PNP switch or 4WD shift switch circuit is shorted or open. PNP switch (Refer to AT-105, “DTC P0705 Park/Neutral Position Switch”.) or 4WD shift switch circuit, TF-103. No flickering — LC EC FE CL *: If revolution sensor malfunction is simultaneously detected, check revolution sensor first. MT AT Trouble Diagnosis with CONSULT-II CONSULT-II FUNCTION Diagnostic test mode NATF0012 NATF0012S10 Function Work support I This mode enables a technician to adjust some devices faster and more accurately by following the indications on the CONSULT-II unit. Self-diagnostic results I Self-diagnostic results can be read and erased quickly. Data monitor I Input/Output data in the AWD control unit can be read. CAN diagnostic support monitor I The results of transmit/receive diagnosis of CAN communication can be read. Active test I Diagnostic Test Mode in which CONSULT-II drives some actuators apart from the AWD control unit and also shifts some parameters in a specified range. ECU part number I AWD control unit part number can be read. PD AX SU BR ST RS BT SELF-DIAGNOSIS CONSULT-II Setting Procedure 1. NATF0012S01 HA NATF0012S0101 Turn ignition switch to “OFF” position. SC EL IDX SAT601J TF-65 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A Trouble Diagnosis with CONSULT-II (Cont’d) 2. Connect CONSULT-II and CONSULT-II CONVERTER to data link connector which is located in instrument lower panel on driver side. 3. 4. Start engine. On CONSULT-II screen, touch “START (NISSAN BASED VHCL)”. 5. Touch “ALL MODE AWD/4WD” on SELECT SYSTEM screen. 6. Touch “SELF-DIAG RESULTS” on SELECT DIAG MODE screen. 7. Self-diagnostic results are displayed. SMT962D SAIA0450E SDIA2216E SMT212E SMT966D TF-66 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A Trouble Diagnosis with CONSULT-II (Cont’d) SELF-DIAGNOSTIC ITEMS Detected items (Screen terms for CONSULT-II, “SELF-DIAG RESULT” mode) Malfunction is detected when... NATF0012S02 Check items GI MA Revolution sensor (front) (Note 3) (VHCL SPEED SEN·FR) I Front revolution sensor (installed on T/F) signal is not input due to open circuit. I Improper signal is input while driving. Revolution sensor (front) circuit, TF-98. EM Revolution sensor (rear) (VHCL SPEED SEN·RR) I Signal from vehicle speed sensor 1 (installed on A/T) is not input due to open circuit. I Improper signal is input while driving. Revolution sensor (rear) [Refer to AT-117, “DTC P0720 Vehicle Speed Sensor·A/T (Revolution sensor)”.] LC 4WD solenoid valve (DUTY SOLENOID) 2-4WD shift solenoid valve (2-4WD SOLENOID) I Proper voltage is not applied to solenoid valve due to open or short circuit. EC 4WD solenoid valve, TF-101. 2-4WD shift solenoid valve or 4WD shift switch circuit, TF-103. FE Transfer motor relay (MOTOR RELAY) I Motor does not operate properly due to open or short circuit in transfer motor or motor relay. Transfer motor relay circuit, TF-107. CL Transfer fluid temperature sensor (FLUID TEMP SENSOR) I Signal voltage from fluid temperature sensor is abnormally high (T/F fluid temperature is abnormally low) while driving. Transfer fluid temperature sensor circuit, TF-110. MT Neutral-4LO switch (N POSI SW TF) I Improper signal is input while driving. Neutral-4LO switch, TF-113. Clutch pressure (CLUTCH PRESSURE) I Improper signal is input due to open or short circuit. I Malfunction occurs in clutch pressure hydraulic circuit. Clutch pressure switch circuit (*1), TF-117. Line pressure (LINE PRESSURE) I Improper signal is input due to open or short circuit. I Malfunction occurs in line pressure hydraulic circuit. Line pressure switch circuit (*1), TF-120. PD Engine speed signal (Note 1) (ENGINE SPEED SIG) I Engine speed is abnormally low while driving. Engine speed signal (Refer to AT-122, “DTC P0725 Engine Speed Signal”.) AX Throttle position sensor (THRTL POSI SEN) I Signal voltage from throttle position sensor is abnormally high. I Signal voltage from throttle position sensor is abnormally low when closed throttle position switch is OFF. Throttle position sensor (Refer to AT-182, “DTC P1705 Throttle Position Sensor”.) Transfer control unit (ADC) C/U (ADC)/THRTL SEN I Power supply voltage for throttle position sensor is improper or A/D converter system of transfer control unit is malfunctioning. Throttle position sensor (Refer to AT-182, “DTC P1705 Throttle Position Sensor”.) Battery voltage (Note 1) (BATTERY VOLTAGE) I Power supply voltage for transfer control unit is abnormally low while driving. Power supply circuit (Refer to AT-102, “Wiring Diagram — AT — MAIN”.) 4WD shift switch (4WD MODE SW) I More than two switch inputs are simultaneously detected due to short circuit of 4WD shift switch. 4WD shift switch circuit, TF-103. ABS operation signal (Note 4) (ABS OPER SIGNAL) I When a malfunction signal due to disconnection or shorting is detected. I When a defect signal is entered from the ABS control unit. ABS operation signal circuit, TF-123. Wait detection switch (Note 2) (WAIT DETECT SWITCH) I Improper signal is input due to open or short circuit. ATP switch, wait detection switch and neutral-4LO switch circuits (*2), TF-113. Shift actuator abnormal (SHIFT ACT) Transfer control device actuator motor is malfunctioning. (Malfunctions are detected when actuator motor fails to operate while shifting from “4H” to “4LO” or vice versa.) Actuator motor and motor circuit, TF-152, 126. AT SU BR ST RS BT HA SC EL IDX TF-67 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A Trouble Diagnosis with CONSULT-II (Cont’d) Detected items (Screen terms for CONSULT-II, “SELF-DIAG RESULT” mode) Malfunction is detected when... Check items Shift actuator position switch abnormal (SHIFT ACT P/S) Actuator motor arm position Transfer control device actuator motor arm position senssensing switch and sensing ing switch is malfunctioning. switch circuit, TF-152, 129. Shift actuator circuit abnormal (SHIFT ACT CIR) Actuator motor, actuator motor Transfer control device actuator circuit is shorted or arm position sensing switch and open. (Malfunctions are detected when motor relay circuit their associated circuits, TF-151, is open/shorted or relay monitor circuit is open/shorted.) 152 and 131. Memory power supply stop I Due to removal of battery which cuts off power supply to transfer control unit, self-diagnosis memory function is suspended. Transfer control unit (RAM) [CONTROL UNIT (RAM)] I Malfunction is detected in the memory (RAM) system of transfer control unit. Transfer control unit (ROM) [CONTROL UNIT (ROM)] I Malfunction is detected in the memory (ROM) system of transfer control unit. Transfer control unit (EEPROM) [CONTROL UNIT (EEPROM)] I Malfunction is detected in the memory (EEPROM) system of transfer control unit. Longitudinal G-sensor Displayed, but do not use. ABS VHL SPD SEN I ABS vehicle speed sensor signal is not input due to an open circuit. Refer to ABS vehicle speed senI An unexpected signal is input when vehicle is being sor diagnosis. driven. STEERING ANGLE SENSOR Displayed, but do not use. VDC OPER SIG If VDC operation signal is being input because of VDC Refer to VDC C/U diagnosis. malfunction or communication error between the vehicles TCS OPER SIG If TCS operation signal is being input because of TCS Refer to VDC C/U diagnosis. malfunction or communication error between the vehicles CAN COMM Malfunction is detected in CAN communication. CAN communication circuit A/T POSITION SIGNAL When AT PNP switch circuit is malfunction or communication error between the vehicles Refer to AT PNP switch circuit diagnosis. Data erase/display circuit, TF-125. Note 1: When a malfunction occurs, it is only displayed and not stored in the memory. Note 2: When the wait detection switch has been properly fixed, malfunction information is erased from the memory. Note 3: If 4WD shift switch is left between 4H and 4LO for a while, this indication may be displayed. (*1): If the malfunction is detected only while driving in reverse, check the continuity of “R” position on A/T PNP switch. When there is nothing wrong with the electrical system, check the hydraulic system. (*2): If a revolution sensor malfunction is detected at the same time, check the revolution sensor circuit first. Note 4: When this malfunction is detected with the ABS warning lamp off, first check for disconnection or shorting in the harness between the transfer control unit and the ABS control unit. DATA MONITOR CONSULT-II Setting Procedure 1. 2. 3. 4. NATF0012S03 NATF0012S0301 Turn ignition switch to “OFF” position. Connect CONSULT-II and CONSULT-II CONVERTER to data link connector, which is located in instrument lower panel on driver side. Turn ignition switch to “ON” position. Touch “START”. SMT962D TF-68 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A Trouble Diagnosis with CONSULT-II (Cont’d) 5. Touch “ALL MODE AWD/4WD”. GI MA EM LC SDIA2216E 6. Touch “DATA MONITOR”. EC FE CL MT SMT212E 7. 8. 9. Touch “ECU INPUT SIGNALS” or “MAIN SIGNALS”. Select “Numerical Display”, “Bar Chart Display” or “Line Graph Display”. Touch “SETTING” to set record conditions. AT PD AX SU SAT972J 10. Touch “AUTO TRIG” or “MANU TRIG”. 11. Return to “SELECT MONITOR ITEM” on “DATA MONITOR” screen and touch “START”. BR ST RS BT SAT973J 12. Monitored data are displayed. HA SC EL IDX SMT963D TF-69 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A Trouble Diagnosis with CONSULT-II (Cont’d) DATA MONITOR ITEMS NATF0012S04 q: Standard H: Option Monitor item Item [Unit] ECU input signals Main signals Item menu selection Remarks Revolution sensor-front [km/h (MPH)] q H Revolution sensor installed on T/F Revolution sensor-rear [km/h (MPH)] q H Vehicle speed sensor·A/T Engine speed [rpm] q H Throttle position sensor [V] q H Transfer fluid temperature sensor [V] q H Battery voltage [V] q H 2WD switch [ON-OFF] q H 2WD switch of 4WD shift switch AUTO switch [ON-OFF] q H AUTO switch of 4WD shift switch Lock switch [ON-OFF] q H 4H switch of 4WD shift switch 4L switch [ON-OFF] q H 4LO switch of 4WD shift switch N position switch TF [ON-OFF] q H N position switch of transfer Line pressure switch [ON-OFF] q H Line pressure switch Clutch pressure switch [ON-OFF] q H Clutch pressure switch ATP switch [ON-OFF] q H N position switch [ON-OFF] q H “N” position on A/T PNP switch R position switch [ON-OFF] q H “R” position on A/T PNP switch P position switch [ON-OFF] q H “P” position on A/T PNP switch Closed throttle position switch [ON/OFF] q H Displayed, but do not use. ABS operation switch [ON-OFF] q H ABS operation switch Wait detection switch [ON-OFF] q H Throttle opening q H Throttle opening recognized by transfer control unit 4WD-mode q H 4WD-mode recognized by transfer control unit (2WD, AUTO, 4H & 4LO) Vehicle speed comp [km/h (MPH)] q H Vehicle speed recognized by transfer control unit *Control torque [N·m (kg-m, ft-lb)] q H Calculated torque recognized by transfer control unit Duty solenoid valve [%] (Transfer 4WD solenoid valve) q H 2-4WD shift solenoid valve [ON-OFF] q H Transfer motor relay [ON-OFF] q H Shift activating 1 [ON-OFF] q H Shift activating 2 [ON-OFF] q H TF-70 Control signal outputs of transfer control unit ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A Trouble Diagnosis with CONSULT-II (Cont’d) GI Monitor item Item [Unit] ECU input signals Main signals Item menu selection 2-4WD shift solenoid valve monitor [ON-OFF] H Transfer motor relay monitor [ON-OFF] H Shift activating monitor 1 [ON-OFF] H Shift activating monitor 2 [ON-OFF] H q 4WD fail lamp [ON-OFF] H Shift position switch 1 [ON-OFF] q H Shift position switch 2 [ON-OFF] q H Remarks MA Check signal (re-input signal) of transfer control unit control signal output is displayed. If circuit is shorted or open, ON/OFF state does not change. EM Transfer control unit control signal output for 4WD warning lamp (left) EC LC FE 2WD indicator lamp [ON-OFF] H Transfer control unit control signal output for 4WD shift indicator lamp (rear) CL AUTO indicator lamp [ON-OFF] H Transfer control unit control signal output for 4WD shift indicator lamp (front & rear) MT LOCK indicator lamp [ON-OFF] H Transfer control unit control signal output for 4WD shift indicator lamp (center) 4LO indicator lamp [ON-OFF] H Transfer control unit control signal output for 4WD shift indicator lamp (right) Offset at starting H Appears on monitor but does not function. Clutch limit [N·m (kg-m, ft-lb)] H Clutch force release limit value set in WORK SUPPORT Voltage [V] H Value measured by voltage probe is displayed. AX H Value measured by pulse probe is displayed. If measurement is impossible, “#” sign is displayed. “#” sign is also displayed at the final data value until the measurement result is obtained. Duty cycle value for measurement probe is displayed. BR Measured pulse width of measurement probe is displayed. ST Frequency [Hz] DUTY-HI H DUTY-LOW H PLS WIDTH-HI H PLS WIDTH-LOW H AT PD SU VHCL SPEED SEN-FR [km/h] q H Indicates average vehicle speed of ABS front left/right wheel. RS VHCL SPEED SEN-RR [km/h] q H Indicates average vehicle speed of ABS rear left/right wheel. BT LONGITUDINAL G-SENSOR [G] q H Displayed, but do not use. TF VHCL SPD-FR [km/h] q H Displayed, but do not use. AT VHCL SPD-RR q H Indicates A/T rear vehicle speed. A/T actual gear position q H Indicates A/T actual gear position. VDC OPER SIG [ON-OFF] q H Indicates VDC operation switch. TCS OPER SIG [ON-OFF] q H Indicates TCS operation switch. H Indicates C/U control signal output of ATP lamp. ATP LAMP [ON-OFF] TF-71 HA SC EL IDX ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A Trouble Diagnosis with CONSULT-II (Cont’d) Monitor item Item [Unit] ECU input signals Main signals Remarks Item menu selection CAN COMM Condition of CAN communication (ON/OFF) is displayed. CAN CIRC 1 Condition of CAN communication (ON/UNKWN) is displayed. CAN CIRC 2 Condition of CAN communication (ON/UNKWN) is displayed. CAN CIRC 3 Condition of CAN communication (ON/UNKWN) is displayed. CAN CIRC 4 Condition of CAN communication (ON/UNKWN) is displayed. CAN CIRC 5 Condition of CAN communication (ON/UNKWN) is displayed. *: This item is indicated as “COMP CL TORQ”. REFERENCE VALUE IN DATA MONITOR MODE Indicated items (Screen terms for CONSULT-II, “DATA MONITOR” mode) Display NATF0012S09 Conditions Throttle position sensor (THRTL POS SEN) Approx. 0.5 - 4.0V Throttle valve fully closed to fully open Transfer fluid temperature sensor (FLUID TEMP SE) Approx. 1.5 - 0.5V Transfer fluid temperature approx. 20 - 80°C (68 176°F) Closed throttle position switch (CLOSED THL/SW) (Without VDC) OFF Displayed, but do not use. ABS operation switch (ABS OPER SW) OFF ABS is not operating. ON ABS is operating. 2WD position (2WD SW) ON 4WD shift switch is in “2WD”. OFF Except the above condition ON 4WD shift switch is in “4H”. OFF Except the above condition Lock position (LOCK SWITCH) 4WD shift switch position Neutral-4LO switch (N POSI SW TF) ATP switch (ATP SWITCH) Wait detection switch (WAIT DETCT SW) ATP switch Neutral-4LO switch 2WD, AUTO, 4H (N) 4LO OFF ON OFF OFF ON OFF ON Wait detection switch See Note. Note: When shifting from “4LO” to “2WD”, “AUTO”, “4H”, it turns ON when “Wait” function is operating (and it turns OFF when “Wait” function is canceled). TF-72 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A Trouble Diagnosis with CONSULT-II (Cont’d) Indicated items (Screen terms for CONSULT-II, “DATA MONITOR” mode) GI Display Throttle valve Transfer motor relay (MOTOR RELAY) Fully closed Conditions MA 4WD shift switch A/T selector lever Motor relay 2WD — OFF AUTO, 4LO P, N OFF Others ON P OFF Others ON EM 4H ON for approx. 2 sec. after shifting to “P” LC EC The vehicle has been left at room temperature for 5 minutes and more with ignition switch in “OFF” position. FE ON Ignition switch in “ON”, and 4WD shift switch in “AUTO” or “4H” and A/T selector lever in “D”. CL OFF Ignition switch in “ON”, and 4WD shift switch in “2WD”. (“Wait” function is not operating.) MT ON Ignition switch in “ON”, and 4WD shift switch in “AUTO” or “4H” and A/T selector lever in “D”. (“Wait” function is not operating.) Clutch pressure switch (CL PRES SW) 0 kg-m In “2WD” position 39 - 1,079 N·m (4 - 110 kg-m, 29 - 796 ft-lb) In “AUTO” position 1,079 N·m (110 kg-m, 796 ft-lb) 4% 4WD solenoid (DUTY SOLENOID) ON for approx. 2 sec. after shifting to “P” and “N” OFF Line pressure switch (LINE PRES SW) Control torque (COMP CL TORQ) Remarks 4WD shift switch (“Wait” function is not oper- In “4H” or “4LO” position ating.) In “2WD” position 94 - 4% AT PD AX In “AUTO” position 4% In “4H” or “4LO” position OFF In “2WD” position SU BR ON (“Wait” function is not operating.) In “AUTO” position 2-4WD shift solenoid valve (2-4WD SOL) OFF (“Wait” function is operating.) ST 4WD shift switch ON (“Wait” function is not operating.) In “4H” position OFF (“Wait” function is operating.) ON RS BT In “4LO” position HA SC EL IDX TF-73 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A Trouble Diagnosis with CONSULT-II (Cont’d) Indicated items (Screen terms for CONSULT-II, “DATA MONITOR” mode) Battery voltage Display Conditions Approx. 12V Key switch “ON” and engine at rest Approx. 13 - 14V AUTO switch 4L switch N position switch R position swtich P position switch Throttle opening During idling OFF 4WD shift switch in other than “AUTO” position ON 4WD shift switch in “AUTO” position OFF 4WD shift switch in other than “4LO” position ON 4WD shift switch in “4LO” position OFF A/T selector lever in other than “N” position ON A/T selector lever in “N” position OFF A/T selector lever in other than “R” position ON A/T selector lever in “R” position OFF A/T selector lever in other than “P” position ON A/T selector lever in “P” position 0.0/8 - 8.0/8 Throttle fully closed (0.0/8) or throttle fully open (8.0/8) 2WD In “2WD” position AUTO In “AUTO” position 4WD-mode 4WD shift switch LOCK In “4H” position 4L In “4LO” position Front wheel speed 0 - 255 km/h (0 - 158 MPH) 0 km/h (vehicle at standstill) Rear wheel speed 0 - 255 km/h (0 - 158 MPH) 0 km/h (vehicle at standstill) Shift ACTR operating 1, Shift activating monitor 1 OFF During normal operation ON During shifts from “4H” to “4LO” position Shift ACTR operating 2, Shift activating monitor 2 OFF During normal operation ON During shifts from “4LO” to “4H” position 4WD fail lamp OFF During normal operation ON During 2-second period (after key switch turned to “ON”) or when system is out of order Shift ACTR position sensing switch 1 OFF 4WD shift switch is in a position other than “4LO”. ON 4WD shift switch in “4LO” position Shift ACTR position sensing switch 2 OFF 4WD shift switch in “4LO” position ON 4WD shift switch is in a position other than “4LO”. 2WD indicator lamp OFF Engine at rest or system out of order ON Except the above condition OFF Engine at rest during 2WD-mode operation or system out of order ON 4WD shift switch in “4LO” or “4H” or “AUTO” position OFF Engine at rest and 4WD shift switch in “AUTO” position during 2WD-mode operation or system out of order ON 4WD shift switch in “4H” or “4LO” position AUTO indicator lamp LOCK indicator lamp TF-74 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A Trouble Diagnosis with CONSULT-II (Cont’d) Indicated items (Screen terms for CONSULT-II, “DATA MONITOR” mode) 4LO indicator lamp GI Display Conditions OFF Engine at rest and 4WD shift switch in “AUTO” position during 2WD-mode operation or system out of order ON 4WD shift switch in “4LO” position VDC operation switch (VDC OPER SW) OFF VDC is not operating. ON VDC is operating. TCS operation switch (TCS OPER SW) OFF TCS is not operating. ON TCS is operating. WORK SUPPORT Purpose MA EM LC EC NATF0012S06 FE NATF0012S0601 When there is no problem with transfer and 4WD system, following symptoms in “AUTO” mode may be claimed by a customer. I Tight corner braking symptom after accelerator (throttle) opening (Note 1) I Vibration when accelerating on a low µ road (snow-covered or icy road) (Note 2) It is possible to deal with these symptoms by changing “CLUTCH FORCE RELEASE LIMIT VALUE”. However, be careful when changing the values because it may adversely affect driving performance. NOTE: 1) When the accelerator is slightly open (approx. 1/8) or fully closed after being opened. The tight corner braking symptom during idle creep driving with accelerator fully closed cannot be solved by this method. Refer to SYMPTOM 8, TF-145. 2) A slight shock is felt at a few hertz as if it were being pushed lightly from behind. CL MT AT PD AX SU CONSULT-II Setting Procedure 1. 2. 3. 4. 5. NATF0012S0602 Turn ignition switch to “OFF” position. Connect CONSULT-II and CONSULT-II CONVERTER to data link connector, which is located in instrument lower panel on driver side. Turn ignition switch to “ON” position. Touch “START”. Touch “ALL MODE 4WD”. BR ST RS BT SMT962D 6. Touch “WORK SUPPORT”. HA SC EL IDX SMT212E TF-75 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A Trouble Diagnosis with CONSULT-II (Cont’d) 7. Select WORK ITEM by touching “CLUTCH/F RLS LIM ADJ”. NOTE: “START TORQ OFFSET ADJ” is displayed, but the transfer does not have this function. SMT967D CLUTCH FORCE RELEASE LIMIT ADJUSTMENT NATF0012S07 1.2 kg-m: Tight corner braking symptom is alleviated. However, vibration may occur when accelerating on a low µ road (icy road, etc.). 0.3 kg-m: Initial set value 0.2 kg-m: Do not set to this value because the tight corner braking symptom will get worse. 1. 2. Current CLUTCH FORCE RELEASE LIMIT value “0.3 kg-m” appears under “CONDITION SETTING” on CONSULT-II display. Touch “1.2” on the display. 3. Display changes to “NOW ADJUSTING” in a short time. 4. When clutch force release limit value is set to “1.2 kg-m”, current value “0.3 kg-m” shown on display will be replaced by “1.2 kg-m” and “ADJUSTING COMPLETE” will appear at the same time. Clutch force release limit value setting is now complete. SMT968D SMT969D SMT970D TF-76 TROUBLE DIAGNOSIS — INTRODUCTION ATX14A Introduction Introduction DESCRIPTION NATF0013 GI NATF0013S01 When a malfunction (indicated by the 4WD warning lamp illumination) occurs, collect information first from the customer about how the malfunction occurs. Then, proceed with the diagnosis presuming it is the cause. Also inspect the electrical system, paying close attention to other possibilities such as fluid level and leaks. All-mode 4WD transfer is controlled by transfer control unit and sensors. If a malfunction occurs in the all-mode 4WD system, the 4WD warning lamp lights up to inform of the system malfunction. There are two ways to identify the cause of the malfunction. 1) Performing the self-diagnosis. (The 4WD warning lamp will indicate what kind of malfunction has occurred by flickering.) 2) Performing diagnosis using CONSULT-II. DIAGNOSTIC WORKSHEET Information from Customer MA EM LC EC NATF0013S02 NATF0013S0201 KEY POINTS WHAT ..... Vehicle model WHEN..... Date, Frequencies WHERE..... Road conditions HOW..... Operating conditions, Symptoms FE CL MT Information sheet from customer Customer name MR/MS Model & Year VIN Transfer model ATX14A Engine Mileage Incident Date Manuf. Date In Service Date Frequency l Continuous l Intermittent ( Symptoms l 4WD shift indicator lamp does not turn on. times a day) l 4WD warning lamp does not turn on. l 4WD shift indicator lamp does not turn off. l ATP warning lamp does not turn on. AT PD AX SU l 4LO indicator lamp does not turn on. l 4WD shift indicator lamp does not indicate “4H”. BR l 4WD shift indicator lamp repeats flicking. l Tight corner braking symptom occurs. ST l 4WD system does not operate. RS l Others. 4WD warning lamp l Continuously lit l Not lit BT HA SC EL IDX TF-77 TROUBLE DIAGNOSIS — INTRODUCTION ATX14A Introduction (Cont’d) Diagnostic Worksheet NATF0013S0202 1. l Listen to customer complaints. TF-80 2. l Check transfer fluid. TF-80 l Leakage l Fluid condition l Fluid level 3. l Road testing TF-80 l 1. Check before engine is started. l 2. Check at idle. l 3. Cruise test 4. l Perform self-diagnosis NG items (with CONSULT-II and without CONSULT-II). TF-65, TF-62 5. l Check component. Repair or replace the damaged parts. TF-148 6. l Perform final check. Perform road test (1 through 3). TF-80 TF-78 TROUBLE DIAGNOSIS — INTRODUCTION ATX14A Work Flow Work Flow =NATF0014 HOW TO PERFORM TROUBLE DIAGNOSES FOR QUICK AND ACCURATE REPAIR GI NATF0014S01 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. Make good use of the two sheets provided, “Information from Customer” (Refer to TF-77.) and “Diagnostic Worksheet” (Refer to TF-78.), to perform the best troubleshooting possible. MA EM LC EC FE CL MT AT PD AX SU BR ST RS BT HA MTF013A SC *1: TF-80 *2: TF-80 *3: TF-80 *4: TF-135 - TF-146 *5: TF-98 - TF-131 *6: TF-80 EL IDX TF-79 TROUBLE DIAGNOSIS — BASIC INSPECTION ATX14A Listen to Customer Complaints Listen to Customer Complaints I I Transfer Fluid Check I PREPARATION FOR ROAD TEST I I SMT089D 1. 2. 3. I NATF0016 Check fluid for leaks and fluid level. Refer to MA-24, “Checking All-mode 4WD Transfer Fluid”. Road Test I NATF0015 Each customer feels differently about a problem. It is important to fully understand the symptoms or conditions for a customer complaint. Listen to the customer about how and when the malfunction occurs, and make good use of it when performing the road test. NATF0017 NATF0017S01 The purpose of the test is to determine overall performance of transfer and analyze causes of problems. The road test consists of the following three parts: When a malfunction is found in any part of transfer, perform the road test to locate the malfunction area and repair the malfunction parts. Check before engine is started Check at idle Cruise test Perform road test and place checks for NG items on the diagnostic worksheet. Refer to TF-78. TF-80 TROUBLE DIAGNOSIS — BASIC INSPECTION ATX14A Road Test (Cont’d) 1. CHECK BEFORE ENGINE IS STARTED 1 1. 2. 3. 4. =NATF0017S02 GI CHECK 4WD SHIFT INDICATOR LAMP MA Park vehicle on flat surface. Turn ignition switch to “OFF” position. Move A/T selector lever to “P” position. Set 4WD shift switch to “4H” position. EM LC EC FE SMT849D 5. Set 4WD shift switch to “2WD” position. 6. Turn ignition switch to “ON” position. (Do not start engine.) 7. Does 4WD shift indicator lamp turn ON for approx. 1 second? CL MT AT PD SMT994D AX Yes or No Yes © GO TO 2. No © Go to Symptom 1. Refer to TF-135. SU BR 2 CHECK 4WD WARNING LAMP Is 4WD warning lamp turned ON? ST RS BT HA SMT994D Yes or No Yes © 1. Turn ignition switch to “OFF” position. 2. Perform self-diagnosis. Refer to “Trouble Diagnosis without CONSULT-II”, TF-62. 3. Go to “2. CHECK AT IDLE”. Refer to TF-82. No © Go to Symptom 2. Refer to TF-137. TF-81 SC EL IDX TROUBLE DIAGNOSIS — BASIC INSPECTION ATX14A Road Test (Cont’d) 2. CHECK AT IDLE 1 1. 2. 3. 4. 5. 6. 7. =NATF0017S03 CHECK 4WD SHIFT INDICATOR LAMP Park vehicle on flat surface. Turn ignition switch to “OFF” position. Move A/T selector lever to “P” or “N” position. Set 4WD shift switch to “4H” position. Set 4WD shift switch to “2WD” position. Start engine. Is 4WD shift indicator lamp turned OFF? SMT994D Yes or No Yes © Go to “ATP SWITCH, WAIT DETECTION SWITCH AND NEUTRAL-4LO SWITCH”. Refer to TF-113. No © GO TO 2. 2 CHECK 4WD WARNING LAMP Is 4WD warning lamp turned OFF? Yes or No Yes © GO TO 3. No © Perform self-diagnosis. Refer to “Trouble Diagnosis without CONSULT-II”, TF-62. TF-82 TROUBLE DIAGNOSIS — BASIC INSPECTION ATX14A Road Test (Cont’d) 3 GI CHECK 4WD SHIFT INDICATOR LAMP 1. Set 4WD shift switch to “2WD”, “AUTO”, “4H”, “4LO”, “4H” and “2WD” in order. (Stay at each switch position for at least 1 second.) 2. Does 4WD shift indicator lamp change properly and does buzzer sound? MA EM LC EC SMT851D FE CL MT AT PD AX SU SMT971D BR Yes or No ST Yes © GO TO 4. No © Go to “2-4WD SHIFT SOLENOID VALVE AND 4WD SHIFT SWITCH”. Refer to TF-103. RS 4 CHECK 4WD WARNING LAMP BT Is 4WD warning lamp turned ON? Yes or No Yes © Perform self-diagnosis. (Refer to “Trouble Diagnosis without CONSULT-II”, TF-62.) No © GO TO 5. HA SC EL IDX TF-83 TROUBLE DIAGNOSIS — BASIC INSPECTION ATX14A Road Test (Cont’d) 5 CHECK 4WD SHIFT INDICATOR LAMP 1. Move A/T selector lever to “P” position. 2. Set 4WD shift switch from “4H” to “4LO”. SMT849D 3. While shifting from “4H” to “4LO”, does 4WD shift indicator lamp turn OFF and ATP warning lamp turn ON? SMT994D Yes or No Yes © GO TO 6. No © Go to Symptoms 3 and 4. Refer to TF-139. TF-84 TROUBLE DIAGNOSIS — BASIC INSPECTION ATX14A Road Test (Cont’d) 6 GI CHECK 4WD SHIFT INDICATOR LAMP Does 4WD shift indicator lamp indicate 4LO indicator lamp turn ON when 4WD shift switch is set in “4LO”? MA EM LC EC SMT849D FE CL MT AT SMT770D Yes or No Yes © GO TO 7. No © Go to Symptom 5. Refer to TF-141. 7 PD AX CHECK 4WD SHIFT INDICATOR LAMP (*1) 1. Set 4WD shift switch from “4LO” to “4H”. 2. Does 4LO indicator lamp flicker? (*1) *1: While “Wait” function is operating, 4LO indicator lamp flashes. Yes or No Yes © Go to Symptoms 6 and 7. Refer to TF-143 and TF-144. No © Go to “3. CRUISE TEST”. Refer to TF-86. SU BR ST RS BT HA SC EL IDX TF-85 TROUBLE DIAGNOSIS — BASIC INSPECTION ATX14A Road Test (Cont’d) 3. CRUISE TEST 1 =NATF0017S04 INSPECTION START SMT849D SMT994D WITH CONSULT-II © GO TO 2. WITHOUT CONSULT-II © GO TO 3. TF-86 TROUBLE DIAGNOSIS — BASIC INSPECTION ATX14A Road Test (Cont’d) 2 GI CHECK INPUT SIGNAL With CONSULT-II Warm up engine to normal operating temperature. Park vehicle on flat surface. Move A/T selector lever to “P” position. Set 4WD shift switch to “4H” position. Set 4WD shift switch to “AUTO” position. Start engine. Drive for at least 30 seconds at a speed higher than 20 km/h (12 MPH). (Drive vehicle until “FLUID TEMP SE” exceeds 0.9V.) 8. Park vehicle on flat surface. 9. Move A/T selector lever to “P” position. 10. Set 4WD shift switch to “2WD” position. 11. Leave vehicle for at least 80 seconds with “FLUID TEMP SE” at 0.9V or less. 1. 2. 3. 4. 5. 6. 7. MA EM LC EC FE CL MT AT SMT972D 12. Is 4WD warning lamp turned ON? Yes or No Yes © Perform self-diagnosis. Refer to “Trouble Diagnosis with CONSULT-II”, TF-65. No © GO TO 4. 3 AX CHECK INPUT SIGNAL Without CONSULT-II 1. Warm up engine to normal operating temperature. 2. Park vehicle on flat surface. 3. Move A/T selector lever to “P” position. 4. Set 4WD shift switch to “4H” position. 5. Set 4WD shift switch to “AUTO” position. 6. Start engine. 7. Drive vehicle for at least 30 seconds at a speed higher than 20 km/h (12 MPH). 8. Park vehicle on flat surface. 9. Move A/T selector lever to “P” position. 10. Set 4WD shift switch to “2WD” position. 11. Is 4WD warning lamp turned ON? Yes or No Yes © Perform self-diagnosis. Refer to “Trouble Diagnosis without CONSULT-II”, TF-62. No © GO TO 4. 4 PD SU BR ST RS BT HA (1) CHECK TIGHT CORNER BRAKING SYMPTOM 1. Set 4WD shift switch to “AUTO” position. 2. Drive vehicle at speed lower than 20 km/h (12 MPH) with steering wheel fully turned. 3. Does tight corner braking symptom occur? Yes or No Yes © GO TO 5. No © GO TO 6. SC EL IDX TF-87 TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d) 5 CONFIRM SYMPTOM AGAIN Confirm symptom and self-diagnosis again. Refer to “Trouble Diagnosis without CONSULT-II”, TF-62 and “Trouble Diagnosis with CONSULT-II”, TF-65. OK or NG OK © GO TO 6. NG © Go to Symptoms 8 and 9. Refer to TF-145, 146. 6 (2) CHECK TIGHT CORNER BRAKING SYMPTOM 1. Set 4WD shift switch to “4H” position. 2. Drive vehicle at speed lower than 20 km/h (12 MPH) with steering wheel fully turned. 3. Does tight corner braking symptom occur? Yes or No Yes © INSPECTION END No © GO TO 7. 7 CONFIRM SYMPTOM AGAIN Confirm symptom and self-diagnosis again. Refer to “Trouble Diagnosis without CONSULT-II”, TF-62 and “Trouble Diagnosis with CONSULT-II”, TF-65. OK or NG OK © INSPECTION END NG © Go to Symptoms 8 and 9. Refer to TF-145, 146. TF-88 ATX14A TROUBLE DIAGNOSIS — GENERAL DESCRIPTION ATX14A Transfer Control Unit Terminals and Reference Value Transfer Control Unit Terminals and Reference Value GI REMOVAL AND INSTALLATION OF TRANSFER CONTROL UNIT Removal MA NATF0018 1. SMT862D 2. 3. 4. 5. 6. 7. 8. 9. I NATF0018S03 NATF0018S0301 Turn ignition switch OFF and disconnect negative battery terminal. Remove console box. Remove cluster lid C. Remove audio assembly and A/C control unit. Remove instrument lower panel on driver side. Remove glove box. Remove instrument lower panel on passenger side. Remove instrument lower center panel. Remove transfer control unit. For steps 2 through 8 above, refer to BT-22, “Instrument Panel Assembly”. Installation NATF0018S0302 I Installation is in the reverse order of removal. When installing transfer control unit, tighten transfer control unit lock nut. Tightening torque: : 4.3 - 5.8 N·m (0.44 - 0.59 kg-m, 38 - 51 in-lb) EM LC EC FE CL MT AT PD AX SU INSPECTION OF TRANSFER CONTROL UNIT I NATF0018S01 Measure voltage between each terminal and terminal 6 or 45 by following “TRANSFER CONTROL UNIT INSPECTION TABLE”, TF-90. BR ST RS BT SMT771D I Pin connector terminal layout HA SC EL IDX TF-89 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION ATX14A Transfer Control Unit Terminals and Reference Value (Cont’d) SMT772D TRANSFER CONTROL UNIT INSPECTION TABLE NATF0018S02 (Data are reference values.) Terminal No. 1 2 Item 2-4WD shift solenoid valve Condition Ground 4 Transfer shift relay (High) Less than 1V 4WD shift switch is set to any position other than “2WD”. Battery voltage Lamp lights while system is operating properly. Less than 1V 2WD indicator lamp does not come on. Battery voltage — & 5 4WD shift switch is set to “2WD” position. & 4WD shift indicator lamp (2WD) 3 Judgement standard 4WD warning lamp While actuator is operating (4H , 4LO) Battery voltage Actuator does not operate. Less than 1V Lamp comes ON. (when engine is stopped.) (Fail-safe condition appears on display, engine is stopped, actuator Less than 1V position detection switch is inoperative, oil temperature is too high and/or tires of different size are installed.) Except above 6 — Battery voltage Ground — — — 7 CAN H (With VDC) — — — 7 (Without VDC) PNP switch (R position) 8 CAN L (With VDC) 8 (Without VDC) — A/T selector lever is set to “reverse” position. Battery voltage A/T selector lever is set to any position other than “reverse”. Less than 1V & — — — — — — TF-90 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION ATX14A Transfer Control Unit Terminals and Reference Value (Cont’d) GI Terminal No. 9 Item Condition Judgement standard 4WD shift switch is set to “2WD” position. Battery voltage MA 4WD shift switch is set to any position other than “2WD”. Less than 1V EM 4WD shift switch is set to “AUTO” position. Approx. 4 - 14V 4WD shift switch is set to any position other than “2WD”. Less than 1V “4H” indicator lamp comes ON. Less than 1V 4WD shift switch is set to any position other than “4H”. Battery voltage “4LO” indicator lamp comes ON. Approx. 0V 4WD shift switch is set to any position other than “4LO”. Battery voltage While actuator is operating (4LO , 4H) Battery voltage Actuator does not operate. Approx. 0V Transfer motor relay is ON. Battery voltage Transfer motor relay is OFF. Less than 1V AT selector lever is set to “P” position. Battery voltage AT selector lever is set to any position other than “P”. Approx. 0V A/T selector lever is set to “N” position. Battery voltage A/T selector lever is set to any position other than “N” position. Less than 1V Ignition key is set to “ON” position. Battery voltage Ignition key is set to “OFF” position. Approx. 0V 4WD shift switch (2WD) & 10 11 12 13 14 Transfer dropping resistor 4WD shift indicator lamp (4H) 4WD shift indicator lamp (4LO) Transfer shift relay (Low) 16 & 18 19 20 FE CL MT AT PD AX PNP switch (N position) Power supply — 17 (With VDC) 17 (Without VDC) EC Transfer motor relay 15 ATP lamp (With VDC) 15 (Without VDC) LC BR ST Do not use. A/T selector lever is set to “P” position. Battery voltage A/T selector lever is set to any position other than “P”. Less than 1V 4WD shift switch is set to “4H” position. Battery voltage 4WD shift switch is set to any position other than “4H”. Less than 1V 4WD shift switch is set to “AUTO” position. Approx. 1.5 - 3V SC 4WD shift switch is set to any position other than “2WD”. Less than 1V EL PNP switch (P position) 4WD shift switch (4H) SU RS BT & HA 4WD solenoid valve — — — — IDX TF-91 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION ATX14A Transfer Control Unit Terminals and Reference Value (Cont’d) Terminal No. Item 21 4WD shift indicator lamp (AUTO) 22 23 24 Power supply Condition 27 28 4WD shift switch is set to any position other than “AUTO”. Battery voltage Ignition key is set to “ON” position. Battery voltage Ignition key is set to “OFF” position. Approx. 0V 4WD shift switch is set to “4LO” position. Battery voltage 4WD shift switch is set to any position other than “4LO”. Less than 1V 4WD shift switch is set to “AUTO” position. Battery voltage 4WD shift switch is set to any position other than “AUTO”. Less than 1V Transfer is set to “4LO” position. Approx. 0V Transfer is set to any position other than “4LO”. Power supply 4WD shift switch is set to “4H” position. Less than 1V 4WD shift switch is set to any position other than “4H”. Battery voltage 4WD shift switch (AUTO) Neutral-4LO switch Transfer 4H actuator switch Throttle valve is closed. Throttle position sensor (Ground) TCM signal (Vehicle speed signal) 30 Throttle position sensor (Power supply for throttle position sensor) 32 (With VDC) Approx. 0V 4WD shift switch (4LO) 29 31 “AUTO” indicator lamp comes ON. — & 25 Judgement standard Transfer fluid temperature sensor Less than 1V Throttle valve is fully open. & When moving at 20 km/h (12 MPH), use the CONSULT-II pulse frequency measuring function.*1 CAUTION: Connect the diagnosis data link Approximately 225 Hz cable to the vehicle diagnosis connector. *1: A circuit tester cannot be used to test this item. Ignition key is set to “ON” position. Approx. 4.5 - 5.5V Ignition key is set to “OFF” position. Approx. 0V At 20°C (68°F) Approx. 1.5V At 80°C (176°F) Approx. 0.5V & & Do not use. TF-92 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION ATX14A Transfer Control Unit Terminals and Reference Value (Cont’d) Terminal No. 32 (Without VDC) 33 GI Item ABS signal Condition & Transfer shift relay (High) Judgement standard When moving, use the CONSULT-II pulse frequency measuirng function.*2 CAUTION: Refer to the illustration Connect the diagnosis data link (SMT973D) at the end of cable to the vehicle diagnosis this section. connector. *2: A circuit tester cannot be used to test this item. MA While actuator is operating from “4H” to “4LO” Battery voltage EC Actuator does not operate. Approx. 0V 35 Clutch pressure switch & Line pressure switch 4WD shift switch is set to “2WD”, “AUTO” or “4H”, then A/T selector lever is set to “D” position. (wait detection system: ON) Approx. 0V 4WD shift switch is set to “2WD”, “AUTO” or “4H”, then A/T selector lever is set to “D” position. Battery voltage — 36 CONSULT-II (RX) 37 (With VDC) 37 (Without VDC) 39 (With VDC) — CL MT AT Approx. 0V — PD Do not use. AX Tachometer 38 Front revolution sensor (With VDC) 38 (Without VDC) — LC FE 4WD shift switch is set to “AUTO” or “4H”, then A/T selector lever is set to Battery voltage “D” position. (wait detection system: OFF) 34 EM Front revolution sensor — Refer to EC-149, “ECM Inspection Table”. Sensor is installed, but do not use. (Wheel speed is sent from VDC C/U via CAN communication.) 4WD shift switch is set to “4H” position. A/T selector lever is set to “D” position. Do not use. Approx. 1V [30 km/h (19 MPH)] Voltage rises in response to vehicle speed. SU BR ST RS BT HA SC EL IDX TF-93 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION ATX14A Transfer Control Unit Terminals and Reference Value (Cont’d) Terminal No. 39 (Without VDC) 40 41 42 43 44 45 46 Item Condition ECM (Throttle position sensor) Judgement standard Throttle valve is fully open. Approx. 0.5V Throttle valve is closed. Approx. 4.2V A/T selector lever is set to “P” position. Battery voltage A/T selector lever is set to any position other than “P”. Less than 1V Transfer motor relay is ON. Battery voltage Transfer motor relay is OFF. Less than 1V While actuator is operating from “4LO” to “4H” position Battery voltage Actuator does not operate. Approx. 0V 4WD shift switch is set to any position other than “4LO”. Battery voltage 4WD shift switch is set to “4LO” position.*3 Less than 1V 4WD shift switch is set to any position other than “4LO”. (Actuator: High position) Battery voltage 4WD shift switch is set to “4LO” position. (Actuator: Low position) Less than 1V ATP switch Transfer motor relay monitor Transfer shift relay (LOW) & Wait detection switch Transfer 4LO actuator switch Ground — — — — — — — 47 Power supply (memory back up) & — 48 CONSULT-II (TX) — — *3: While wait detection system is operating, terminal 43 exists battery voltage. TF-94 Battery voltage — TROUBLE DIAGNOSIS — GENERAL DESCRIPTION ATX14A Transfer Control Unit Terminals and Reference Value (Cont’d) GI MA EM LC EC FE CL SMT172E MT AT PD AX SU BR ST RS BT HA SC EL IDX TF-95 DTC U1000 CAN COMMUNICATION LINE (WITH VDC) ATX14A Description Description NATF0135 CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. On Board Diagnosis Logic I I NATF0136 This is an OBD-II self-diagnostic item. Diagnostic trouble code “CAN COMM CIRCUIT” with CONSULT-II or U1000 without CONSULT-II is detected when TCM cannot communicate to other control unit. Possible Cause NATF0137 Harness or connectors (CAN communication line is open or shorted.) DTC Confirmation Procedure NATF0138 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. WITH CONSULT-II 1. 2. 3. 4. NATF0138S01 Turn ignition switch to “ON” position. (Do not start engine.) Select “DATA MONITOR” mode for “ALL MODE AWD/4WD” with CONSULT-II. Start engine and wait for at least 6 seconds. If DTC is detected, go to TF-97, “Diagnostic Procedure”. SDIA2216E WITH GST Follow the procedure “WITH CONSULT-II”. TF-96 NATF0138S02 DTC U1000 CAN COMMUNICATION LINE (WITH VDC) ATX14A Diagnostic Procedure Diagnostic Procedure 1 NATF0139 GI CHECK CAN COMMUNICATION CIRCUIT MA With CONSULT-II 1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Select “DATA MONITOR” mode for “ALL MODE 4WD” with CONSULT-II. 3. The “CAN COMM CIRCUIT” is detected. EM LC EC FE PCIA0061E CL Yes or No Yes © Go to EL-447, “CAN Communication Unit”. No © INSPECTION END MT AT PD AX SU BR ST RS BT HA SC EL IDX TF-97 VEHICLE SPEED SENSOR (FRONT REVOLUTION SENSOR) (WITHOUT VDC) ATX14A Diagnostic Procedure Diagnostic Procedure 1 FRONT REVOLUTION SENSOR Refer to “Front Revolution Sensor”, “COMPONENT INSPECTION”, TF-149. OK or NG OK © GO TO 3. NG © GO TO 2. 2 CHECK CONTINUITY Check the following. I Continuity of transfer sub-harness Refer to “Transfer Sub-harness”, “COMPONENT INSPECTION”, TF-150. OK or NG OK © Repair or replace front revolution sensor. NG © Repair or replace front revolution sensor and transfer sub-harness. 3 CHECK INPUT SIGNAL WITH CONSULT-II © GO TO 4. WITHOUT CONSULT-II © GO TO 5. TF-98 NATF0019 VEHICLE SPEED SENSOR (FRONT REVOLUTION SENSOR) (WITHOUT VDC) ATX14A Diagnostic Procedure (Cont’d) 4 GI CHECK INPUT SIGNAL With CONSULT-II 1. Start engine. 2. Select “ECU INPUT SIGNALS” in Data Monitor. 3. Read out the value of “VEHICLE SPEED SENSOR (FRONT)” while driving. MA EM LC EC FE SMT773D CL MT AT PD AX SU BR SMT974D 4. Check if the value changes according to accelerating and decelerating the vehicle. ST OK or NG OK © GO TO 6. NG © GO TO 7. RS BT HA SC EL IDX TF-99 VEHICLE SPEED SENSOR (FRONT REVOLUTION SENSOR) (WITHOUT VDC) ATX14A Diagnostic Procedure (Cont’d) 5 CHECK INPUT SIGNAL Without CONSULT-II 1. Start engine. 2. Check voltage between transfer control unit harness connector terminals 38 and 28. (Measure it in AC range.) Voltage: 0 km/h (0 MPH): 0V 30 km/h (19 MPH): More than 1V (Voltage rises gradually in response to vehicle speed.) SMT774D OK or NG OK © GO TO 6. NG © GO TO 7. 6 PERFORM SELF-DIAGNOSIS AGAIN After driving for a while, perform self-diagnosis again. Refer to “Trouble Diagnosis without CONSULT-II”, TF-62. OK or NG OK © INSPECTION END NG © 1. Perform transfer control unit input/output signal inspection. Refer to “TRANSFER CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL DESCRIPTION”, TF-90. 2. If NG, recheck transfer control unit pin terminals for damage or loose connection with harness connector. 7 CHECK HARNESS CONTINUITY BETWEEN TRANSFER CONTROL UNIT AND FRONT REVOLUTION SENSOR SUB-HARNESS CONNECTOR OK or NG OK © GO TO 6. NG © Repair or replace sub-harness connector between transfer control unit and front revolution sensor. TF-100 4WD SOLENOID VALVE ATX14A Diagnostic Procedure Diagnostic Procedure 1 NATF0020 GI CHECK 4WD SOLENOID VALVE MA EM LC EC SMT775D Refer to “4WD Solenoid Valve, Clutch Pressure Switch and Line Pressure Switch”, “COMPONENT INSPECTION”, TF-148. FE OK or NG CL OK © GO TO 2. NG © Check the following. If OK, repair or replace 4WD solenoid valve. I Continuity of transfer sub-harness Refer to “TRANSFER TERMINAL CORD ASSEMBLY SUB-HARNESS CONNECTOR”, “COMPONENT INSPECTION”, TF-151. MT AT 2 CHECK POWER SOURCE CIRCUIT 1. Turn ignition switch to “OFF” position. 2. Disconnect transfer control unit harness connector. 3. Check resistance between transfer terminal cord assembly sub-harness connector terminal 6 and transfer control unit harness connector terminal 10. Resistance: 11.2 - 12.8Ω PD AX SU BR ST SMT150E OK or NG OK © GO TO 3. NG © Check the following. I Transfer dropping resistor Refer to “Transfer Dropping Resistor”, “COMPONENT INSPECTION”, TF-149. I Continuity between transfer terminal cord assembly sub-harness connector terminal 6 and transfer control unit harness connector terminal 10. RS BT HA SC EL IDX TF-101 4WD SOLENOID VALVE ATX14A Diagnostic Procedure (Cont’d) 3 CHECK POWER SOURCE CIRCUIT 1. Turn ignition switch to “OFF” position. 2. Check continuity between transfer terminal cord assembly sub-harness connector terminal 6 and transfer control unit harness connector terminal 19. Continuity should exist. SMT777D OK or NG OK © GO TO 4. NG © Repair or replace harness between transfer terminal cord assembly sub-harness connector terminal 6 and transfer control unit harness connector terminal 19. 4 PERFORM SELF-DIAGNOSIS After driving for a while, perform self-diagnosis. Refer to “Trouble Diagnosis without CONSULT-II”, TF-62 and “Trouble Diagnosis with CONSULT-II”, TF-65. OK or NG OK © INSPECTION END NG © 1. Perform transfer control unit input/output signal inspection. Refer to “TRANSFER CONTROL UNIT INSPECTION TABLE”, TF-90. 2. If NG, recheck transfer control unit pin terminals for damage or loose connection with harness connector. TF-102 2-4WD SHIFT SOLENOID VALVE AND 4WD SHIFT SWITCH ATX14A Diagnostic Procedure Diagnostic Procedure 1 NATF0021 GI CHECK 2-4WD SHIFT SOLENOID VALVE AND 4WD SHIFT SWITCH Refer to “2-4WD Shift Solenoid Valve and Transfer Fluid Temperature Sensor”, “COMPONENT INSPECTION”, TF-148. MA EM LC EC SMT778D FE OK or NG CL OK © GO TO 2. NG © Check the following. If OK, repair or replace 2-4WD shift solenoid valve and 4WD shift switch. I Continuity of transfer sub-harness Refer to “TRANSFER TERMINAL CORD ASSEMBLY SUB-HARNESS CONNECTOR”, “COMPONENT INSPECTION”, TF-151. MT AT PD AX SU BR ST RS BT HA SC EL IDX TF-103 2-4WD SHIFT SOLENOID VALVE AND 4WD SHIFT SWITCH ATX14A Diagnostic Procedure (Cont’d) 2 CHECK INPUT SIGNAL With CONSULT-II 1. Select “ECU INPUT SIGNALS” in Data Monitor. 2. Read out ON/OFF status of “2WD SW” and “LOCK SWITCH”. SMT974D OK or NG OK © 1. Perform transfer control unit input/output signal inspection. Refer to “TRANSFER CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL DESCRIPTION”, TF-90. 2. If NG, recheck transfer control unit pin terminals for damage or loose connection with harness connector. NG © GO TO 3. TF-104 2-4WD SHIFT SOLENOID VALVE AND 4WD SHIFT SWITCH ATX14A Diagnostic Procedure (Cont’d) 3 GI CHECK 4WD SHIFT SWITCH POWER SOURCE 1. Disconnect 4WD shift switch harness connector. 2. Turn ignition switch to “ON” position. 3. Check voltage between 4WD shift switch harness connector terminal 1 and body ground. Voltage: Battery voltage MA EM LC EC FE SMT852D OK or NG OK © GO TO 4. NG © Check the following. I No. 18 fuse (10A) I Continuity between ignition switch and 4WD shift switch CL MT AT PD AX SU BR ST RS BT HA SC EL IDX TF-105 2-4WD SHIFT SOLENOID VALVE AND 4WD SHIFT SWITCH ATX14A Diagnostic Procedure (Cont’d) 4 CHECK HARNESS CONTINUITY 1. Turn ignition switch to “OFF” position. 2. Check continuity between the following terminals: I Transfer control unit 9 and 4WD shift switch 2 (2WD) I Transfer control unit 18 and 4WD shift switch 5 (4H) I Transfer control unit 24 and 4WD shift switch 3 (AUTO) I Transfer control unit 23 and 4WD shift switch 6 (4LO) I Transfer control unit 1 and Transfer terminal cord assembly sub-harness connector 4 I 4WD shift switch 4 and Transfer terminal cord assembly sub-harness connector 5 Continuity should exist. SMT853D OK or NG OK © GO TO 5. NG © Repair harness or connector. 5 PERFORM SELF-DIAGNOSIS AGAIN After driving for a while, perform self-diagnosis again. Refer to “Trouble Diagnosis without CONSULT-II”, TF-62. OK or NG OK © INSPECTION END NG © 1. Perform transfer control unit input/output signal inspection. Refer to “TRANSFER CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL DESCRIPTION”, TF-90. 2. If NG, recheck transfer control unit pin terminals for damage or loose connection with harness connector. TF-106 TRANSFER MOTOR AND TRANSFER MOTOR RELAY ATX14A Diagnostic Procedure Diagnostic Procedure 1 NATF0022 GI CHECK TRANSFER MOTOR AND TRANSFER MOTOR RELAY MA EM LC EC SMT151E Refer to “Transfer Motor” and “Transfer Motor Relay”, “COMPONENT INSPECTION”, TF-150. FE OK or NG CL OK © GO TO 2. NG © Repair or replace transfer motor and transfer motor relay. MT 2 CHECK CONTINUITY Check the following. I Continuity of transfer sub-harness Refer to “TRANSFER SWITCH ASSEMBLY SUB-HARNESS CONNECTOR”, “COMPONENT INSPECTION”, TF-151. AT OK or NG OK © GO TO 3. NG © Repair or replace transfer sub-harness. 3 PD CHECK INPUT SIGNAL AX With CONSULT-II 1. Select “MAIN SIGNALS” in Data Monitor. 2. Read out ON/OFF status of “MOTOR RELAY”. SU BR ST RS SMT975D 3. When the value is different from standard value although ON/OFF switching occurs, check the following items. I PNP switch, throttle position sensor and closed throttle position switch circuits Refer to AT-105, “DTC P0705 Park/Neutral Position Switch”, AT-182, “DTC P1705 Throttle Position Sensor”. BT HA OK or NG OK © GO TO 4. SC NG © 1. Perform transfer control unit input/output signal inspection. Refer to “TRANSFER CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL DESCRIPTION”, TF-90. 2. If NG, recheck transfer control unit pin terminals for damage or loose connection with harness connector. EL TF-107 IDX TRANSFER MOTOR AND TRANSFER MOTOR RELAY ATX14A Diagnostic Procedure (Cont’d) 4 CHECK TRANSFER MOTOR RELAY POWER SOURCE 1. Disconnect transfer motor relay harness connector. 2. Turn ignition switch to “ON” position. 3. Check voltage between transfer motor relay harness connector terminals 1, 3 and body ground. Voltage: Battery voltage SMT854DA OK or NG OK © GO TO 5. NG © Check the following. I No. 55 fuse (20A) I No. 8 fuse (10A) I Harness continuity between fuse and transfer motor relay TF-108 TRANSFER MOTOR AND TRANSFER MOTOR RELAY ATX14A Diagnostic Procedure (Cont’d) 5 GI CHECK HARNESS CONTINUITY 1. Turn ignition switch to “OFF” position. 2. Check continuity between the following terminals. I Transfer control unit 41 and Transfer motor 14 I Transfer control unit 41 and Transfer motor relay 2 I Transfer control unit 14 and Transfer motor relay 4 I Transfer motor 15 and body ground Continuity should exist. MA EM LC EC FE CL MT AT PD SMT855DA OK or NG OK © GO TO 6. NG © Repair or replace harness or connector. 6 PERFORM SELF-DIAGNOSIS AGAIN AX SU BR After driving for a while, perform self-diagnosis again. Refer to “Trouble Diagnosis without CONSULT-II”, TF-62 and “Trouble Diagnosis with CONSULT-II”, TF-65. OK or NG OK © INSPECTION END NG © 1. Perform transfer control unit input/output signal inspection. Refer to “TRANSFER CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL DESCRIPTION”, TF-90. 2. If NG, recheck transfer control unit pin terminals for damage or loose connection with harness connector. ST RS BT HA SC EL IDX TF-109 TRANSFER FLUID TEMPERATURE SENSOR ATX14A Diagnostic Procedure Diagnostic Procedure 1 NATF0023 CHECK TRANSFER FLUID TEMPERATURE SENSOR Refer to “2-4WD Shift Solenoid Valve and Transfer Fluid Temperature Sensor”, “COMPONENT INSPECTION”, TF-148. OK or NG OK © GO TO 2. NG © Repair or replace fluid temperature sensor. 2 CHECK CONTINUITY Check the following. I Continuity of transfer sub-harness Refer to “TRANSFER TERMINAL CORD ASSEMBLY SUB-HARNESS CONNECTOR”, “COMPONENT INSPECTION”, TF-151. OK or NG OK © GO TO 3. NG © Repair or replace transfer sub-harness. 3 CHECK INPUT SIGNAL WITH CONSULT-II © GO TO 4. WITHOUT CONSULT-II © GO TO 5. TF-110 TRANSFER FLUID TEMPERATURE SENSOR ATX14A Diagnostic Procedure (Cont’d) 4 GI CHECK INPUT SIGNAL MA EM LC EC SMT784D With CONSULT-II 1. Start engine. 2. Select “ECU INPUT SIGNALS” in Data Monitor. 3. Read out the value of “FLUID TEMP SE”. Voltage: 20°C (68°F): Approx. 1.5V 80°C (176°F): Approx. 0.5V FE CL MT AT PD AX SU BR ST SMT974D OK or NG OK © GO TO 6. NG © Check the following. I Continuity between transfer control unit and transfer terminal cord assembly sub-harness connector RS BT HA SC EL IDX TF-111 TRANSFER FLUID TEMPERATURE SENSOR ATX14A Diagnostic Procedure (Cont’d) 5 CHECK INPUT SIGNAL Without CONSULT-II 1. Turn ignition switch to “ON” position. 2. Check voltage between transfer control unit harness connector terminals 28 and 31. Voltage: 20°C (68°F): Approx. 1.5V 80°C (176°F): Approx. 0.5V SMT785D OK or NG OK © GO TO 6. NG © Check the following. I Continuity between transfer control unit and transfer terminal cord assembly sub-harness connector 6 PERFORM SELF-DIAGNOSIS AGAIN After driving for a while, perform self-diagnosis again. Refer to “Trouble Diagnosis without CONSULT-II”, TF-62. OK or NG OK © INSPECTION END NG © 1. Perform transfer control unit input/output signal inspection. Refer to “TRANSFER CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL DESCRIPTION”, TF-90. 2. If NG, recheck transfer control unit pin terminals for damage or loose connection with harness connector. TF-112 ATP SWITCH, WAIT DETECTION SWITCH AND NEUTRAL-4LO SWITCH ATX14A Diagnostic Procedure Diagnostic Procedure 1 NATF0024 GI CHECK ATP SWITCH, WAIT DETECTION SWITCH AND NEUTRAL-4LO SWITCH MA EM LC EC SMT786D Refer to “ATP Switch, Neutral-4LO Switch and Wait Detection Switch”, “COMPONENT INSPECTION”, TF-149. FE OK or NG OK © GO TO 3. NG © GO TO 2. CL MT 2 CHECK CONTINUITY OF TRANSFER SUB-HARNESS Check the following. I Continuity of transfer sub-harness Refer to “TRANSFER SWITCH ASSEMBLY SUB-HARNESS CONNECTOR”, “COMPONENT INSPECTION”, TF-151. AT OK or NG OK © Repair or replace ATP switch, wait detection switch or neutral-4LO switch. NG © Repair or replace transfer sub-harness. 3 PD AX CHECK INPUT SIGNAL WITH CONSULT-II © GO TO 4. WITHOUT CONSULT-II © GO TO 5. SU BR ST RS BT HA SC EL IDX TF-113 ATP SWITCH, WAIT DETECTION SWITCH AND NEUTRAL-4LO SWITCH ATX14A Diagnostic Procedure (Cont’d) 4 CHECK INPUT SIGNAL With CONSULT-II 1. Select “ECU INPUT SIGNALS” in Data Monitor. 2. Read out the ON/OFF status of “ATP SW”, “NEUTRAL SW” and “WAIT DETCT SW”. SMT976D OK or NG OK © GO TO 6. NG © Check the following. I Harness continuity between transfer switch assembly sub-harness connector and transfer control unit I Continuity between transfer switch assembly sub-harness connector and body ground TF-114 ATP SWITCH, WAIT DETECTION SWITCH AND NEUTRAL-4LO SWITCH ATX14A Diagnostic Procedure (Cont’d) 5 GI CHECK INPUT SIGNAL Without CONSULT-II 1. Turn ignition switch to “OFF” position. 2. Operate 4WD shift switch and check continuity between the following terminals. Continuity: Terminal 40 (ATP switch) and body ground “4H” position: No continuity should exist. Between “4H” and “4LO”: Continuity should exist. “4LO” position: No continuity should exist. Terminal 25 (Neutral-4LO switch) and body ground “4H” position: No continuity should exist. “4LO” position: Continuity should exist. Terminal 43 (Wait detection switch) and body ground “4H” position: No continuity should exist. (*1) “4LO” position: Continuity should exist. *1: After setting from “4LO” to “4H”, continuity exists while “Wait” function is operating in “4H” position. (No continuity exists when “Wait” function is canceled.) MA EM LC EC FE CL MT AT SMT787D PD AX SU BR SMT849D OK or NG OK © GO TO 6. NG © Check the following. I Harness continuity between transfer switch assembly sub-harness connector and transfer control unit I Continuity between transfer switch assembly sub-harness connector and body ground ST RS BT HA SC EL IDX TF-115 ATP SWITCH, WAIT DETECTION SWITCH AND NEUTRAL-4LO SWITCH ATX14A Diagnostic Procedure (Cont’d) 6 PERFORM SELF-DIAGNOSIS AGAIN After driving for a while, perform self-diagnosis again. Refer to “Trouble Diagnosis without CONSULT-II”, TF-62. OK or NG OK © INSPECTION END NG © 1. Perform transfer control unit input/output signal inspection. Refer to “TRANSFER CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL DESCRIPTION”, TF-90. 2. If NG, recheck transfer control unit pin terminals for damage or loose connection with harness connector. TF-116 CLUTCH PRESSURE SWITCH ATX14A Diagnostic Procedure Diagnostic Procedure 1 NATF0025 GI CHECK MALFUNCTION Is this malfunction detected only while driving in reverse? MA Yes or No Yes © CHECK A/T PNP SWITCH “R” POSITION. Refer to AT-105, “DTC P0705 Park/Neutral Position Switch”. EM No © GO TO 2. LC 2 CHECK OTHER MALFUNCTION Are other malfunctions also detected by self-diagnosis and CONSULT-II? Refer to “Trouble Diagnosis without CONSULT-II”, TF-62 and “Trouble Diagnosis with CONSULT-II”, TF-65. Yes or No © Yes © No CHECK FOR OTHER MALFUNCTIONS. (When other malfunctions are eliminated, clutch pressure switch malfunction display may disappear.) EC FE CL GO TO 3. MT 3 CHECK 2-4WD SHIFT SOLENOID VALVE AND 4WD SHIFT SWITCH CIRCUITS Check 2-4WD shift solenoid valve and 4WD shift switch circuits. AT OK or NG OK © GO TO 4. NG © Check, repair or replace faulty parts. PD 4 CHECK INPUT SIGNAL AX WITH CONSULT-II © GO TO 5. WITHOUT CONSULT-II © GO TO 6. SU BR ST RS BT HA SC EL IDX TF-117 CLUTCH PRESSURE SWITCH ATX14A Diagnostic Procedure (Cont’d) 5 CHECK INPUT SIGNAL With CONSULT-II 1. Turn ignition switch to “ON” position. 2. Select “ECU INPUT SIGNALS” in Data Monitor. 3. Read out ON/OFF status of “CL PRES SW”. SMT788D SMT977D OK or NG OK © GO TO 7. NG © Check the following. I Continuity between transfer control unit and transfer terminal cord assembly sub-harness connector I Transfer sub-harness I Clutch pressure switch Refer to “4WD Solenoid Valve, Clutch Pressure Switch and Line Pressure Switch”, “COMPONENT INSPECTION”, TF-148. TF-118 CLUTCH PRESSURE SWITCH ATX14A Diagnostic Procedure (Cont’d) 6 GI CHECK INPUT SIGNAL Without CONSULT-II 1. Turn ignition switch to “ON” position and set 4WD shift switch to “4H” position. 2. Check voltage between transfer control unit harness connector terminal 34 and body ground. When 4WD shift switch is in “2WD”: Battery voltage should exist. When 4WD shift switch is in “AUTO” or “4H” and A/T selector lever is in “D”: “Wait” operating: Battery voltage should exist. “Wait” not operating: Approx. 0 volts should exist. MA EM LC EC FE CL SMT789D MT AT PD SMT849D OK or NG OK © GO TO 7. NG © Check the following. I Continuity between transfer control unit and transfer terminal cord assembly sub-harness connector I Transfer sub-harness I Clutch pressure switch Refer to “4WD Solenoid Valve, Clutch Pressure Switch and Line Pressure Switch”, “COMPONENT INSPECTION”, TF-148. 7 PERFORM SELF-DIAGNOSIS AGAIN AX SU BR ST RS 1. Check hydraulic parts. 2. After driving for a while, perform self-diagnosis again. Refer to “Trouble Diagnosis without CONSULT-II”, TF-62. OK or NG OK © INSPECTION END NG © 1. Perform transfer control unit input/output signal inspection. Refer to “TRANSFER CONTROL UNIT INSPECTION TABLE”, TF-90. 2. If NG, recheck transfer control unit pin terminals for damage or loose connection with harness connector. BT HA SC EL IDX TF-119 LINE PRESSURE SWITCH ATX14A Diagnostic Procedure Diagnostic Procedure 1 NATF0026 CHECK MALFUNCTION Is this malfunction detected only while driving in reverse? Yes or No Yes © CHECK A/T PNP SWITCH “R” POSITION. Refer to AT-105, “DTC P0705 Park/Neutral Position Switch”. No © GO TO 2. 2 CHECK OTHER MALFUNCTIONS Are other malfunctions also detected by self-diagnosis and CONSULT-II? Refer to “Trouble Diagnosis without CONSULT-II”, TF-62 and “Trouble Diagnosis with CONSULT-II”, TF-65. Yes or No Yes © CHECK FOR OTHER MALFUNCTIONS. (When other malfunctions are eliminated, line pressure switch malfunction display may disappear.) No © GO TO 3. 3 CHECK INPUT SIGNAL WITH CONSULT-II © GO TO 4. WITHOUT CONSULT-II © GO TO 5. TF-120 LINE PRESSURE SWITCH ATX14A Diagnostic Procedure (Cont’d) 4 GI CHECK INPUT SIGNAL MA EM LC EC SMT790D With CONSULT-II 1. Select “ECU INPUT SIGNALS” in Data Monitor. 2. Read out the ON/OFF status of “LINE PRES SW”. FE CL MT AT SMT977D OK or NG OK © GO TO 6. NG © Check the following. I Continuity between transfer control unit and transfer terminal cord assembly sub-harness connector I Transfer sub-harness I Line pressure switch Refer to “4WD Solenoid Valve, Clutch Pressure Switch and Line Pressure Switch”, “COMPONENT INSPECTION”, TF-148. PD AX SU BR ST RS BT HA SC EL IDX TF-121 LINE PRESSURE SWITCH ATX14A Diagnostic Procedure (Cont’d) 5 CHECK INPUT SIGNAL Without CONSULT-II 1. Turn ignition switch to “OFF” position. 2. Disconnect transfer control unit harness connector. 3. Check continuity between transfer control unit harness connector terminal 35 and body ground. After the vehicle has been left for at least 5 minutes in a room temperature with ignition switch “OFF”: No continuity should exist. With ignition switch in “ON”, 4WD shift switch in “AUTO” or “4H” and A/T selector lever in “D”: Continuity should exist. SMT152E SMT849D OK or NG OK © GO TO 6. NG © Check the following. I Continuity between transfer control unit and transfer terminal cord assembly sub-harness connector I Transfer sub-harness I Line pressure switch Refer to “4WD Solenoid Valve, Clutch Pressure Switch and Line Pressure Switch”, “COMPONENT INSPECTION”, TF-148. 6 PERFORM SELF-DIAGNOSIS AGAIN 1. Check hydraulic parts. 2. After driving for a while, perform self-diagnosis again. Refer to “Trouble Diagnosis without CONSULT-II”, TF-62. OK or NG OK © INSPECTION END NG © 1. Perform transfer control unit input/output signal inspection. Refer to TF-90. 2. If NG, recheck transfer control unit pin terminals for damage or loose connection with harness connector. TF-122 ABS OPERATION SIGNAL (WITHOUT VDC) ATX14A Diagnostic Procedure Diagnostic Procedure 1 NATF0027 GI CHECK INPUT SIGNAL MA WITHOUT CONSULT-II © GO TO 2. EM 2 CHECK INPUT SIGNAL Without CONSULT-II Turn ignition switch to “OFF” position. Disconnect ABS control unit harness connector. Disconnect ABS control unit and transfer control unit harness connectors. Check continuity between transfer control unit harness connector terminal 32 and ABS control unit harness connector terminal 9. Continuity should exist. 5. Check continuity between transfer control unit harness connector terminal 32, ABS control unit harness connector terminal 9 and body ground. No continuity should exist. 1. 2. 3. 4. LC EC FE CL MT AT PD AX SU BR SMT793DB ST OK or NG OK © GO TO 3. NG © Repair or replace harness or connector between ABS control unit and transfer control unit. RS BT 3 CHECK COMMUNICATION LINE Check communication line between ABS control unit and transfer control unit. (Refer to BR-147, “8. Vehicle vibrates excessively when ABS is operating”.) OK or NG OK © GO TO 4. NG © Check, repair or replace faulty parts. HA SC EL IDX TF-123 ABS OPERATION SIGNAL (WITHOUT VDC) ATX14A Diagnostic Procedure (Cont’d) 4 PERFORM SELF-DIAGNOSIS AGAIN After driving for a while, perform self-diagnosis again. Refer to “Trouble Diagnosis without CONSULT-II”, TF-62. OK or NG OK © INSPECTION END NG © 1. Perform transfer control unit input/output signal inspection. Refer to “TRANSFER CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL DESCRIPTION”, TF-90. 2. If NG, recheck transfer control unit pin terminals for damage or loose connection with harness connector. TF-124 DATA ERASE/DISPLAY ATX14A Diagnostic Procedure Diagnostic Procedure 1 NATF0028 GI CHECK TRANSFER CONTROL UNIT POWER SOURCE MA 1. Turn ignition switch to “OFF” position and perform self-diagnosis again. Refer to “Trouble Diagnosis without CONSULT-II”, TF-62 and “Trouble Diagnosis with CONSULT-II”, TF-65. 2. Turn ignition switch to “OFF” position. 3. Disconnect transfer control unit harness connector. 4. Check voltage between transfer control unit harness connector terminal 47 and body ground. Voltage: Battery voltage EM LC EC FE CL SMT794D OK or NG OK © GO TO 2. NG © Check the following. I No. 24 fuse (7.5A) I Harness continuity between fuse and transfer control unit 2 MT AT PERFORM SELF-DIAGNOSIS AGAIN After driving for a while, perform self-diagnosis again. Refer to “Trouble Diagnosis without CONSULT-II”, TF-62 and “Trouble Diagnosis with CONSULT-II”, TF-65. PD OK or NG AX OK © INSPECTION END NG © 1. Perform transfer control unit input/output signal inspection. Refer to “TRANSFER CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL DESCRIPTION”, TF-90. 2. If NG, recheck transfer control unit pin terminals for damage or loose connection with harness connector. SU BR ST RS BT HA SC EL IDX TF-125 SHIFT ACTUATOR ATX14A Diagnostic Procedure Diagnostic Procedure 1 NATF0064 SHIFT ACTUATOR Refer to “Actuator & Actuator Position Switch”, “COMPONENT INSPECTION”, TF-152. OK or NG OK © GO TO 3. NG © GO TO 2. 2 CHECK POWER SOURCE SMT825DA 1. Disconnect transfer control device terminal. 2. Turn ignition switch to “ON”. (Do not start engine.) 3. Check voltage between transfer control device harness connector 3 (or 4) and body ground while 4WD shift switch is set from 4H to 4LO (or from 4LO to 4H). Voltage: Battery voltage OK or NG OK © Repair or replace actuator. NG © 1. Recheck the following. I Continuity between ignition switch and transfer HI & LOW relays I Ignition switch and No. 3 fuse (20A) I Continuity between transfer shift HI & LOW relays and transfer control device 2. If NG, repair or replace damaged part. 3 CHECK INPUT SIGNAL WITH CONSULT-II © GO TO 4. WITHOUT CONSULT-II © GO TO 5. TF-126 SHIFT ACTUATOR ATX14A Diagnostic Procedure (Cont’d) 4 GI CHECK INPUT SIGNAL With CONSULT-II 1. Start engine (idling). 2. Select “SELF-DIAG RESULTS” in Select Diag Mode. 3. Read out self-diagnostic result. MA EM LC EC FE SMT826D CL MT AT SMT978D OK or NG OK © GO TO 7. NG © GO TO 6. PD AX SU BR ST RS BT HA SC EL IDX TF-127 SHIFT ACTUATOR ATX14A Diagnostic Procedure (Cont’d) 5 CHECK INPUT SIGNAL Without CONSULT-II 1. Start engine (idling). 2. Check voltage between transfer control unit harness connector terminal 33 (or 42) and body ground while 4WD shift switch is set from 4H to 4LO (or from 4LO to 4H). SMT828D 3. Result MTBL0202 OK or NG OK © GO TO 7. NG © GO TO 6. 6 CHECK HARNESS CONTINUITY BETWEEN TRANSFER CONTROL UNIT AND TRANSFER CONTROL DEVICE OK or NG OK © GO TO 7. NG © Repair and replace harness connector between transfer control unit and transfer control device. 7 PERFORM SELF-DIAGNOSIS AGAIN After driving for a while, perform self-diagnosis again. Refer to “Trouble Diagnosis without CONSULT-II”, TF-62. OK or NG OK © INSPECTION END NG © 1. Perform transfer control unit/output signal inspection. Refer to “TRANSFER CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL DESCRIPTION”, TF-90. 2. If NG, recheck transfer control unit pin terminals for damage or loose connection with harness connector. TF-128 SHIFT ACTUATOR POSITION SWITCH ATX14A Diagnostic Procedure Diagnostic Procedure 1 NATF0065 GI SHIFT ACTUATOR POSITION SWITCH MA Refer to “Actuator & Actuator Position Switch”, “COMPONENT INSPECTION”, TF-152. OK or NG OK © GO TO 3. NG © GO TO 2. EM LC 2 CHECK POSITION SWITCH 1. Recheck continuity of shift actuator position switch. Refer to “Actuator & Actuator Position Switch”, “COMPONENT INSPECTION”, TF-152. Continuity should exist. OK or NG FE CL OK © GO TO 3. NG © Repair or replace position switch. 3 CHECK INPUT SIGNAL MT WITH CONSULT-II © GO TO 4. WITHOUT CONSULT-II © GO TO 5. 4 EC AT CHECK INPUT SIGNAL With CONSULT-II 1. Start engine (idling). 2. Select “SELF-DIAG RESULTS” in Select Diag Mode. 3. Read out self-diagnostic result. PD AX SU BR ST SMT829DA RS BT HA SC SMT978D OK or NG OK © GO TO 7. NG © GO TO 6. EL IDX TF-129 SHIFT ACTUATOR POSITION SWITCH ATX14A Diagnostic Procedure (Cont’d) 5 CHECK INPUT SIGNAL Without CONSULT-II 1. Start engine (idling). 2. Check voltage transfer control unit harness connector terminal 27 (or 44) and body ground while 4WD shift switch is set from 4H to 4LO (or from 4LO to 4H). SMT830D 3. Result MTBL0203 OK or NG OK © GO TO 7. NG © GO TO 6. 6 CHECK HARNESS CONTINUITY BETWEEN TRANSFER CONTROL UNIT AND TRANSFER CONTROL DEVICE OK or NG OK © GO TO 7. NG © Repair and replace harness connector between transfer control unit and transfer control device. 7 PERFORM SELF-DIAGNOSIS AGAIN After driving for a while, perform self-diagnosis again. Refer to “Trouble Diagnosis without CONSULT-II”, TF-62. OK or NG OK © INSPECTION END NG © 1. Perform transfer control unit/output signal inspection. Refer to “TRANSFER CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL DESCRIPTION”, TF-90. 2. If NG, recheck transfer control unit pin terminals for damage or loose connection with harness connector. TF-130 SHIFT ACTUATOR CIRCUIT ATX14A Diagnostic Procedure Diagnostic Procedure 1 NATF0066 SHIFT ACTUATOR CIRCUIT Refer to “Transfer Shift Relay (High & Low)”, “COMPONENT INSPECTION” and “Actuator & Actuator Position Switch”, “COMPONENT INSPECTION”, TF-151, 152. OK or NG OK © GO TO 2. NG © Repair or replace transfer shift relay and actuator and actuator position switch. 2 GI MA EM LC CHECK POWER SOURCE OF TRANSFER SHIFT (HI & LOW) RELAY EC FE CL MT SMT825DA 1. Disconnect transfer control device terminal. 2. Turn ignition switch to “ON” (Do not start engine). 3. Check voltage between transfer shift HI and LOW relay terminal 5 and body ground. Voltage: Battery voltage AT PD AX SU SMT153E BR OK or NG OK © GO TO 3. ST NG © Check the following. I Continuity between ignition switch and transfer shift HI & LOW relays I Check ground circuit between transfer shift HI & LOW relays and body ground. I Ignition switch and No. 3 fuse (20A) RS BT HA SC EL IDX TF-131 SHIFT ACTUATOR CIRCUIT ATX14A Diagnostic Procedure (Cont’d) 3 1. 2. 3. 4. CHECK POWER SOURCE OF TRANSFER CONTROL DEVICE Disconnect transfer control device terminal. Turn ignition switch to “ON”. (Do not start engine.) Turn 4WD shift switch from “4H” to “4LO” (or from “4LO” to “4H”). Check voltage between transfer control device terminal 3 (or 4) and body ground. Voltage: Battery voltage SMT832D OK or NG OK © GO TO 4. NG © Check the following. I Harness and connector from transfer shift HI and LOW relays to transfer control device harness terminal I Ground circuit between transfer control device and body ground. 4 CHECK INPUT SIGNAL WITH CONSULT-II © GO TO 5. WITHOUT CONSULT-II © GO TO 6. TF-132 SHIFT ACTUATOR CIRCUIT ATX14A Diagnostic Procedure (Cont’d) 5 GI CHECK INPUT SIGNAL With CONSULT-II 1. Start engine (idling). 2. Select “SELF-DIAG RESULTS” in Select Diag Mode. 3. Read out self-diagnostic result. MA EM LC EC FE SMT835D CL MT AT SMT978D OK or NG OK © GO TO 8. NG © GO TO 7. PD AX SU BR ST RS BT HA SC EL IDX TF-133 SHIFT ACTUATOR CIRCUIT ATX14A Diagnostic Procedure (Cont’d) 6 CHECK INPUT SIGNAL Without CONSULT-II 1. Start engine (idling). 2. Check voltage between transfer control unit harness connector terminal 4 (or 13) and body ground while 4WD shift switch is set from 4H to 4LO (or from 4LO to 4H). SMT154E 3. Result MTBL0516 OK or NG OK © GO TO 8. NG © GO TO 7. 7 CHECK HARNESS CONTINUITY BETWEEN TRANSFER CONTROL UNIT AND TRANSFER CONTROL DEVICE OK or NG OK © GO TO 8. NG © Repair and replace harness connector between transfer control unit and transfer control device. 8 PERFORM SELF-DIAGNOSIS AGAIN After driving for a while, perform self-diagnosis again. Refer to “Trouble Diagnosis without CONSULT-II”, TF-62. OK or NG OK © INSPECTION END NG © 1. Perform transfer control unit/output signal inspection. Refer to “TRANSFER CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL DESCRIPTION”, TF-90. 2. If NG, recheck transfer control unit pin terminals for damage or loose connection with harness connector. TF-134 TROUBLE DIAGNOSES FOR SYMPTOMS ATX14A Symptom 1. 4WD Shift Indicator Lamp Does Not Turn ON Symptom 1. 4WD Shift Indicator Lamp Does Not Turn ON GI SYMPTOM: Although ignition switch is turned “ON”, all the 4WD shift indicator lamps do not turn ON for 1 second. MA NATF0029 1 CHECK TRANSFER CONTROL UNIT POWER SOURCE EM LC EC FE SMT994D CL MT AT SMT860D 1. Turn ignition switch to “OFF” position and disconnect transfer control unit harness connector. 2. Turn ignition switch to “ON” position. (Do not start engine.) 3. Check voltage between transfer control unit harness connector terminals 16, 22 and body ground. Voltage: Battery voltage PD AX SU BR ST SMT796D OK or NG OK © GO TO 2. NG © Check the following. I Continuity between ignition switch and transfer control unit I Ignition switch and No. 18 fuse (10A) RS BT HA SC EL IDX TF-135 TROUBLE DIAGNOSES FOR SYMPTOMS ATX14A Symptom 1. 4WD Shift Indicator Lamp Does Not Turn ON (Cont’d) 2 CHECK TRANSFER CONTROL UNIT GROUND CIRCUIT 1. Turn ignition switch to “OFF” position. 2. Disconnect transfer control unit harness connector. 3. Measure resistance between transfer control unit harness connector terminals 6, 45 and body ground. Resistance: 0Ω SMT797D OK or NG OK © GO TO 3. NG © Check continuity between transfer control unit and body ground. 3 CHECK PROCEDURES FROM THE BEGINNING AGAIN Check again. OK or NG OK © INSPECTION END NG © 1. Perform transfer control unit input/output signal inspection. Refer to “TRANSFER CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL DESCRIPTION”, TF-90. 2. If NG, recheck transfer control unit pin terminals for damage or loose connection with harness connector. TF-136 TROUBLE DIAGNOSES FOR SYMPTOMS ATX14A Symptom 2. 4WD Warning Lamp Does Not Turn ON Symptom 2. 4WD Warning Lamp Does Not Turn GI ON SYMPTOM: Although ignition switch is turned “ON”, 4WD MA warning lamp does not turn ON. =NATF0030 1 CHECK TRANSFER CONTROL UNIT POWER SOURCE EM LC EC FE SMT799D 1. Turn ignition switch to “OFF” position and disconnect transfer control unit harness connector. 2. Turn ignition switch to “ON” position. (Do not start engine.) 3. Check voltage between transfer control unit harness connector terminals 16, 22 and body ground. Voltage: Battery voltage CL MT AT PD SMT800D AX OK or NG SU OK © GO TO 2. NG © Check the following. I Continuity between ignition switch and transfer control unit I Ignition switch and No. 18 fuse (10A) BR ST RS BT HA SC EL IDX TF-137 TROUBLE DIAGNOSES FOR SYMPTOMS ATX14A Symptom 2. 4WD Warning Lamp Does Not Turn ON (Cont’d) 2 CHECK TRANSFER CONTROL UNIT GROUND CIRCUIT 1. Turn ignition switch to “OFF” position. 2. Disconnect transfer control unit harness connector. 3. Measure resistance between transfer control unit harness connector terminals 6, 45 and body ground. Resistance: 0Ω SMT803D OK or NG OK © GO TO 3. NG © Check continuity between transfer control unit and body ground. 3 CHECK 4WD WARNING LAMP CIRCUIT Check the following. I 4WD warning lamp I Continuity between ignition switch and 4WD warning lamp I Continuity between 4WD warning lamp and transfer control unit OK or NG OK © GO TO 4. NG © I Repair or replace harness or connector. I Replace 4WD warning lamp. 4 CHECK PROCEDURES FROM THE BEGINNING AGAIN Check again. OK or NG OK © INSPECTION END NG © 1. Perform transfer control unit input/output signal inspection. Refer to “TRANSFER CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL DESCRIPTION”, TF-90. 2. If NG, recheck transfer control unit pin terminals for damage or loose connection with harness connector. TF-138 TROUBLE DIAGNOSES FOR SYMPTOMS ATX14A Symptom 3. 4WD Shift Indicator Lamp Does Not Turn OFF Symptom 3. 4WD Shift Indicator Lamp Does Not Turn OFF GI SYMPTOM: When 4WD shift switch is set from “4H” to “4LO”, all the 4WD shift indicator lamps do not turn OFF. MA NATF0031 1 CHECK ATP SWITCH CIRCUIT EM LC EC FE SMT994D Check ATP switch circuit. Refer to “Diagnostic Procedure”, “ATP SWITCH, WAIT DETECTION SWITCH AND NEUTRAL-4LO SWITCH”, TF-149. OK or NG OK © GO TO 2. NG © Check, repair or replace faulty parts. 2 CL MT AT CHECK PROCEDURE FROM THE BEGINNING AGAIN Check again. OK or NG OK © INSPECTION END NG © Recheck each connector’s pin terminals for damage or loose connection. PD AX SU Symptom 4. ATP Warning Lamp Does Not Turn ON BR SYMPTOM: When 4WD shift switch is set from “4H” to “4LO” with A/T selector lever in “P” position, ATP warning lamp does not turn ON. ST NATF0032 RS BT SMT173E 1 CHECK ATP SWITCH CIRCUIT Check ATP switch circuit. Refer to “Diagnostic Procedure”, “ATP SWITCH, WAIT DETECTION SWITCH AND NEUTRAL-4LO SWITCH”, TF-149. OK or NG OK © GO TO 2. NG © Check, repair or replace faulty parts. HA SC EL IDX TF-139 TROUBLE DIAGNOSES FOR SYMPTOMS Symptom 4. ATP Warning Lamp Does Not Turn ON (Cont’d) 2 CHECK FOLLOWING ITEMS Check the following. I ATP warning lamp I Continuity between “TFCU” terminal 15 and ATP warning lamp (With VDC) I Continuity between PNP (“P” position) switch terminal 7 and ATP warning lamp (Without VDC) I Continuity between ATP warning lamp and ATP switch OK or NG OK © GO TO 4. (With VDC)/GO TO 3. (Without VDC) NG © Repair or replace ATP warning lamp, harness or connector. 3 CHECK PNP SWITCH CIRCUIT (Without VDC) Check PNP switch circuit. Refer to AT-105, “DTC P0705 Park/Neutral Position Switch”. OK or NG OK © GO TO 4. NG © Check, repair or replace faulty parts. 4 CHECK PROCEDURES FROM THE BEGINNING AGAIN Check again. OK or NG OK © INSPECTION END NG © Recheck each connector’s pin terminals for damage or loose connection. TF-140 ATX14A TROUBLE DIAGNOSES FOR SYMPTOMS ATX14A Symptom 5. 4LO Indicator Lamp Does Not Turn ON Symptom 5. 4LO Indicator Lamp Does Not Turn GI ON SYMPTOM: When 4WD shift switch is set from “4H” to MA “4LO” position, 4LO indicator lamp does not turn ON. =NATF0033 1 CHECK TRANSFER CONTROL UNIT POWER SUPPLY CIRCUIT EM LC EC FE SMT994D CL MT AT SMT851D PD AX SU BR SMT979D 1. Disconnect battery negative terminal (−), then transfer control unit connector. 2. Connect battery negative terminal (−) and turn ignition switch “ON” (with engine stopped). 3. Check voltage across transfer control unit body-side connector terminals 47, 16 and body ground. Voltage: Battery voltage ST RS OK or NG OK © GO TO 2. BT NG © Check the following. I Continuity between battery and transfer control unit I Ignition switch (Refer to EL-11, “Power Supply Routing”.) I No. 24 fuse (7.5A), No. 8 fuse (10A) and No. 18 fuse (10A) HA SC EL IDX TF-141 TROUBLE DIAGNOSES FOR SYMPTOMS ATX14A Symptom 5. 4LO Indicator Lamp Does Not Turn ON (Cont’d) 2 CHECK TRANSFER CONTROL UNIT GROUND CIRCUIT 1. Turn ignition switch “OFF”, and disconnect transfer control unit connector. 2. Check for continuity between transfer control unit body-side connector terminals 6, 45 and body ground. Continuity should exist. OK or NG OK © GO TO 3. NG © Check the following. I Continuity between transfer control unit and body ground 3 CHECK 4LO INDICATOR LAMP CIRCUIT Disconnect battery negative terminal (−) and check the following items: 1. Check condition of 4LO indicator lamp. 2. Check continuity between battery and 4LO indicator lamp. 3. Check continuity between 4LO indicator lamp and transfer control unit connector terminal 12. 4. Check condition of ATP switch. 5. Check condition of neutral-4LO switch. 6. Check continuity between neutral-4LO switch ground terminal 6 and body ground. OK or NG OK © GO TO 4. NG © Check the following. I 4LO indicator lamp I Neutral-4LO switch Refer to “ATP Switch, Neutral-4LO Switch and Wait Detection Switch”, “COMPONENT INSPECTION”, TF-149. 4 CHECK PROCEDURES FROM THE BEGINNING Check again. OK or NG OK © INSPECTION END NG © 1. Perform transfer control unit input/output signal inspection. Refer to “TRANSFER CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL DESCRIPTION”, TF-90. 2. If NG, recheck transfer control unit pin terminals for damage or loose connection with harness connector. TF-142 TROUBLE DIAGNOSES FOR SYMPTOMS ATX14A Symptom 6. 4WD Shift Indicator Lamp Does Not Indicate “4H” Symptom 6. 4WD Shift Indicator Lamp Does Not Indicate “4H” GI SYMPTOM: When 4WD shift switch is set to “4H”, 4WD shift indicator lamp does not indicate “4H”. MA NATF0034 1 CHECk 4WD WARNING LAMP EM LC EC FE SMT994D Is 4WD warning lamp turned ON? CL Yes or No Yes © Refer to “Trouble Diagnosis without CONSULT-II”, TF-62. No © GO TO 2. MT AT 2 CHECK FOLLOWING ITEMS Check the following. I Neutral-4LO switch circuit. Refer to TF-113. I Wait detection switch circuit. Refer to TF-113. I ATP switch circuit. Refer to TF-113. PD OK or NG OK © GO TO 3. NG © Check, repair or replace faulty parts. 3 AX CHECK PROCEDURES FROM THE BEGINNING AGAIN Check again. OK or NG OK © INSPECTION END NG © Recheck each connector’s pin terminals for damage or loose connection. SU BR ST RS BT HA SC EL IDX TF-143 TROUBLE DIAGNOSES FOR SYMPTOMS ATX14A Symptom 7. 4WD Shift Indicator Lamp Repeats Flickering Symptom 7. 4WD Shift Indicator Lamp Repeats Flickering =NATF0035 SYMPTOM: 4WD shift indicator lamp keeps flickering. 1 CHECK 4WD SHIFT INDICATOR LAMP SMT994D 1. Set 4WD shift switch to “2WD” position. 2. Move vehicle forward and backward. Or drive straight increasing or decreasing speed under 20 km/h (12 MPH). 3. Does 4WD shift indicator lamp keep flickering? Yes or No Yes © GO TO 2. No © INSPECTION END 2 CHECK TIGHT CORNER BRAKING SYMPTOM Drive vehicle at speed under 20 km/h (12 MPH), turning steering wheel to the limit. Does tight corner braking symptom occur? Yes or No Yes © GO TO 3. No © GO TO 4. 3 CHECK 4WD SHIFT INDICATOR LAMP Does the 4WD shift indicator lamp keep flickering when the front wheels are jacked up? Yes or No Yes © Check transfer unit operating system. No © Check tires. 4 CHECK 4WD WARNING LAMP Does 4WD warning lamp flicker? (4WD shift indicator lamp is turned OFF.) Yes or No Yes © Perform self-diagnoses. Refer to “Trouble Diagnosis without CONSULT-II”, TF-62. No © GO TO 5. 5 CHECK 4WD SHIFT INDICATOR LAMP Does 4WD shift indicator lamp keep flickering? Yes or No Yes © Check again. No © INSPECTION END TF-144 TROUBLE DIAGNOSES FOR SYMPTOMS ATX14A Symptom 8. Tight Corner Braking Symptom Symptom 8. Tight Corner Braking Symptom NATF0036 SYMPTOM: Tight corner braking symptom occurs. (Hydraulic system failure) 1 CHECK INPUT SIGNAL With CONSULT-II 1. Select “ECU INPUT SIGNALS” in Data Monitor. 2. Read out the ON/OFF status of “CLUTCH PRES SW”. GI MA EM LC EC FE CL SMT977D Without CONSULT-II Check voltage between transfer control unit harness connector terminal 34 and body ground. Refer to “TRANSFER CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL DESCRIPTION”, TF-90. MT AT OK or NG © OK © NG 2 Disassemble transfer unit and check the following. I Control valve assembly I 4WD solenoid valve I 2-4WD shift solenoid valve I Clutch piston I Clutch assembly GO TO 2. CHECK CLUTCH PRESSURE SWITCH CIRCUIT Check clutch pressure switch circuit. Refer to “Diagnostic Procedure”, “CLUTCH PRESSURE SWITCH”, TF-117. PD AX SU BR OK or NG OK © GO TO 3. NG © Check, repair or replace faulty parts. ST RS 3 CHECK PROCEDURES FROM THE BEGINNING AGAIN Check again. BT OK or NG OK © INSPECTION END NG © Recheck each connector’s pin terminals for damage or loose connection. HA SC EL IDX TF-145 TROUBLE DIAGNOSES FOR SYMPTOMS ATX14A Symptom 9. 4WD System Does Not Operate Symptom 9. 4WD System Does Not Operate =NATF0037 SYMPTOM: The vehicle cannot be put into 4WD mode. (Hydraulic system failure) 1 CHECK INPUT SIGNAL With CONSULT-II 1. Select “ECU INPUT SIGNALS” in Data Monitor. 2. Read out the ON/OFF status of “CLUTCH PRES SW”. SMT977D Without CONSULT-II Check voltage between transfer control unit harness connector terminal 34 and body ground. Refer to “TRANSFER CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL DESCRIPTION”, TF-90. OK or NG OK © 1. Check transfer fluid level. 2. Disassemble transfer unit and check the following. I Transfer motor I Main oil pump assembly I Sub-oil pump assembly I Oil strainer I Control valve assembly I 2-4WD shift solenoid valve I Oil filter element I Lip seal I Strainer O-ring I Main oil pump drive gear I Seal ring I D-ring I Clutch piston I Clutch assembly NG © GO TO 2. 2 CHECK CLUTCH PRESSURE CIRCUIT Check clutch pressure switch circuit. Refer to “Diagnostic Procedure”, “CLUTCH PRESSURE SWITCH”, TF-117. OK or NG OK © GO TO 3. NG © Check, repair or replace faulty parts. TF-146 TROUBLE DIAGNOSES FOR SYMPTOMS ATX14A Symptom 9. 4WD System Does Not Operate (Cont’d) 3 CHECK PROCEDURES FROM THE BEGINNING GI Check again. OK or NG OK © INSPECTION END NG © Recheck each connector’s pin terminals for damage or loose connection. MA EM LC EC FE CL MT AT PD AX SU BR ST RS BT HA SC EL IDX TF-147 NATF0038 COMPONENT INSPECTION ATX14A 4WD Shift Switch 4WD Shift Switch NATF0038S01 Check continuity between each terminal. Terminals Switch position Continuity 2WD Yes Except 2WD No AUTO Yes Except AUTO No 4H Yes Except 4H No 4LO Yes Except 4LO No 1-2 1 - 3, 1 - 4 SMT858D 1 - 4, 1 - 5 1 - 4, 1 - 6 2-4WD Shift Solenoid Valve and Transfer Fluid Temperature Sensor NATF0038S02 Measure resistance between terminals of transfer terminal cord assembly sub-harness connector located on rear-right of transfer unit. SMT079D Component parts Terminals Resistance 2-4WD shift solenoid valve 4-5 Approx. 20°C (68°F): Approx. 22.8 - 25.2Ω Transfer fluid temperature sensor 2-3 Approx. 20°C (68°F): Approx. 2.5 kΩ Approx. 80°C (176°F): Approx. 0.3 kΩ 4WD Solenoid Valve, Clutch Pressure Switch and Line Pressure Switch NATF0038S03 Measure resistance between terminals of transfer terminal cord assembly sub-harness connector located on rear-right of transfer unit. SMT080D TF-148 COMPONENT INSPECTION ATX14A 4WD Solenoid Valve, Clutch Pressure Switch and Line Pressure Switch (Cont’d) GI Component parts Terminals 4WD solenoid valve 6 Clutch pressure switch 7 Line pressure switch 1 Remarks Approx. 20°C (68°F): Approx. 3.0 - 3.4Ω In room temperature I 2-4WD shift solenoid valve “OFF”: No continuity Ground I 2-4WD shift solenoid valve and transfer motor “ON”: Continuity exists terminal In room temperature I Turn ignition switch to “OFF” position and leave vehicle for more than 5 minutes. (OFF): No continuity I Transfer motor “ON”: Continuity exists MA EM LC EC FE CL MT AT Front Revolution Sensor NATF0038S04 Measure resistance between terminals of front revolution sensor sub-harness connector located on rear-right of transfer unit. Terminals Resistance 16 - 17 500 - 650Ω 18 - 17 No continuity 18 - 16 No continuity PD AX SU SMT081D Transfer Dropping Resistor NATF0038S07 Check resistance between terminals. Resistance: 11.2 - 12.8 Ω BR ST RS BT SMT806D ATP Switch, Neutral-4LO Switch and Wait Detection Switch HA NATF0038S06 Measure resistance between terminals of transfer switch assembly sub-harness connector located on rear-right of transfer unit. SC EL IDX SMT083D TF-149 COMPONENT INSPECTION ATX14A ATP Switch, Neutral-4LO Switch and Wait Detection Switch (Cont’d) 4WD shift switch position Switch Terminals ATP switch 8-9 Neutral-4LO switch 12 - 13 4H (N) 4LO No continuity Continuity No continuity No continuity Continuity No continuity Wait detection switch 10 - 11 Continuity (Note) +--------------------------- NOTE: When shifting from “4LO” to “4H”, continuity exists while “Wait” function is operating. (No continuity exists when “Wait” function is canceled.) Transfer Motor NATF0038S05 Apply battery voltage directly to transfer motor assembly sub-harness connector located on rear-right of transfer unit. (Positive: Terminal 14, Negative: Terminal 15) Transfer motor should operate. SMT082D Transfer Motor Relay 1. 2. NATF0038S08 Apply battery voltage directly to terminals 3 and 4. Check continuity between terminals 1 and 2. Condition Continuity (1 - 2) Battery voltage is applied Yes No voltage is applied No SMT085D Transfer Sub-harness FRONT REVOLUTION SENSOR SUB-HARNESS CONNECTOR Check continuity between terminals shown in the figure. SMT086DB TF-150 NATF0038S09 NATF0038S0901 COMPONENT INSPECTION ATX14A Transfer Sub-harness (Cont’d) TRANSFER SWITCH ASSEMBLY SUB-HARNESS CONNECTOR GI NATF0038S0902 Check continuity between terminals shown in the figure. MA EM LC EC FE CL MT SMT087D TRANSFER TERMINAL CORD ASSEMBLY SUB-HARNESS CONNECTOR AT NATF0038S0903 Check continuity between terminals shown in the figure. Terminals on solenoid valve Terminals 6 SMT088D PD Components 4WD solenoid valve 4, 5 2-4WD shift solenoid valve 2, 3 Transfer fluid temperature sensor 7 Clutch pressure switch 1 Line pressure switch AX SU BR ST RS BT Transfer Shift Relay (High & low) Check continuity between terminals 3 and 4. Condition Continuity 12V direct current supply between terminals 1 and 2 No No current supply Yes NATF0038S10 HA SC EL IDX SMT197E TF-151 COMPONENT INSPECTION ATX14A Actuator & Actuator Position Switch Actuator & Actuator Position Switch NATF0038S11 ACTUATOR NATF0038S1101 Operation & resistance check I Apply battery voltage directly to actuator assembly. Operating check Battery positive terminal Battery negative terminal 1 4 3 2 3 4 Check Approx. 0.2Ω (When the motor is not operated.) SMT812D ACTUATOR POSITION SWITCH NATF0038S1102 Continuity check Continuity check Battery positive terminal Battery negative terminal Continuity 1 4 3 1-5 2 3 4 2-5 SMT838D TF-152 ON-VEHICLE SERVICE ATX14A Replacing Oil Seal Replacing Oil Seal FRONT CASE OIL SEAL 1. 2. 3. 4. I NATF0068 GI NATF0068S01 Drain transfer fluid. Remove exhaust front tube and heat insulator. Refer to “Removal”, TF-156. Remove front propeller shaft. Refer to PD-8, “Removal and Installation”. Remove companion flange lock nut. Do not reuse lock nut. MA Put a matchmark on top of drive pinion thread. The mark should be in line with the mark on the companion flange. Always mark top of drive pinion screw using paint. EC EM LC SMT844DB 5. I FE CL MT SMT112D 6. Remove companion flange. AT PD AX SU SMT802C 7. Remove front case oil seal. BR ST RS BT SMT803C 8. I 9. Install front case oil seal. Before installing, apply multi-purpose grease to seal lip. Install companion flange. HA SC EL IDX SMT183E TF-153 ON-VEHICLE SERVICE ATX14A Replacing Oil Seal (Cont’d) 10. Tighten nut to the specified torque. Refer to TF-158. 11. Install front propeller shaft. 12. Install exhaust front tube and heat insulator. SMT845DB SHIFT SHAFT OIL SEAL 1. 2. 3. NATF0068S02 Remove front propeller shaft. Refer to PD-8, “Removal and Installation”. Remove companion flange. Refer to “FRONT CASE OIL SEAL”, TF-153. Remove actuator lever from transfer outer shift lever. Then remove outer shift lever. SMT808D 4. I Remove shift shaft oil seal. Be careful not to damage cross shaft. 5. I 6. 7. Install shift shaft oil seal. Before installing, apply multi-purpose grease to seal lip. Install transfer control linkage. Install companion flange. Refer to “FRONT CASE OIL SEAL”, TF-153. Install front propeller shaft. SMT491A 8. SMT805C REAR OIL SEAL 1. 2. 3. I 4. NATF0068S03 Remove rear propeller shaft. Refer to PD-8, “Removal and Installation”. Remove rear oil seal. Install rear oil seal. Before installing, apply multi-purpose grease to seal lip. Install rear propeller shaft. SMT892C TF-154 ON-VEHICLE SERVICE ATX14A Transfer Motor Transfer Motor REMOVAL 1. 2. 3. I SMT874C 3. 4. 5. NATF0069 Disconnect transfer motor harness connector. Remove breather pipe from transfer motor. Remove bolts to detach transfer motor. After removing transfer motor, be sure to replace O-ring with new one. INSTALLATION 1. 2. GI NATF0070 Apply petroleum jelly or ATF to O-ring. Align width across flat-notch with oil pump groove, and install transfer motor. Tighten bolts. : 41 - 48 N·m (4.2 - 4.9 kg-m, 30 - 35 ft-lb) Install breather pipe to transfer motor. Connect transfer motor harness connector. MA EM LC EC FE CL MT AT Transfer Oil Filter REMOVAL I I I INSTALLATION SMT875C 1. 2. I NATF0071 Remove bolts to detach oil filter. When removing oil filter from transfer, avoid damaging it. Be sure to loosen bolts evenly. When removing oil filter, be sure to replace O-ring with new one. Apply petroleum jelly or ATF to O-ring. Tighten bolts evenly to install oil filter. : 7 - 9 N·m (0.7 - 0.9 kg-m, 61 - 78 in-lb) Be sure not to damage oil filter. PD AX NATF0072 SU BR ST RS BT HA SC EL IDX TF-155 REMOVAL AND INSTALLATION ATX14A Removal Removal 1. 2. 3. I 4. SMT897C 5. 6. 7. 8. 9. NATF0073 Remove exhaust front and rear tubes. Refer to FE-9, “EXHAUST SYSTEM”. Remove front and rear propeller shaft. Refer to PD-8, “Removal and Installation”. 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. Disconnect neutral-4LO switch, front revolution sensor, ATP switch, transfer motor and 4WD shift switch harness connectors. Remove center console and A/T control device. Remove floor panel for transfer. Remove upper side fixing bolt for A/T and TF. Remove actuator lever from transfer outer shift lever and remove sub-oil pump from transfer. Remove remaining fixing bolt for AT and TF. SMT808D 10. Remove transfer from transmission. WARNING: Support transfer while removing it. SMT899C SMT871C Installation I Tighten bolts securing transfer. Bolt length: 45 mm (1.77 in) Tightening torque: : 31 - 42 N·m (3.2 - 4.3 kg-m, 23 - 31 ft-lb) SMT872C TF-156 NATF0074 OVERHAUL ATX14A Transfer Gear Control Transfer Gear Control NATF0075 GI MA EM LC EC FE CL MT AT PD AX SMT809D 1. Actuator 2. Actuator lever 3. Outer shift lever SU BR ST RS BT HA SC EL IDX TF-157 OVERHAUL ATX14A Transfer Components Transfer Components NATF0076 SMT194E 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Oil seal Transfer cover Snap ring Washer Snap ring Main gear bearing Front case Check plug Check spring Check ball Internal gear Snap ring Bearing race Thrust needle bearing Planetary carrier Thrust needle bearing Sun gear 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. L-H sleeve 2-4 sleeve Radial needle bearing Front revolution sensor Retaining pin L-H fork 2-4 fork Shift fork spring Fork guide Retaining pin Shift rod Self-lock nut Companion flange Oil seal Drain plug Wait detection switch Needle bearing TF-158 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. Mainshaft Drive chain Clutch drum Clutch hub Snap ring Driven plate Drive plate Retaining plate Return spring assembly Press flange Washer Thrust needle bearing Snap ring Seal ring Front bearing Front drive shaft Rear bearing OVERHAUL ATX14A Transfer Components (Cont’d) GI MA EM LC EC FE CL MT AT PD SMT207E 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. Thrust needle bearing race Clutch piston D-ring Lip seal Oil gutter Center case Stem bleeder Mainshaft rear bearing Thrust washer Speedometer drive gear Snap ring Rear case ATP switch Neutral-4LO switch 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 79. 80. 81. 82. Oil seal Magnet Baffle plate Oil strainer O-ring Control valve assembly Lip seal (7 pieces) Filler plug Inner gear Outer gear Oil pump housing Bushing Oil pump shaft Oil pressure check plug 83. 84. 85. 86. 87. 88. 89. 90. 91. 92. 93. 94. 95. Oil pump gasket Sub-oil pump housing Outer gear Inner gear O-ring Sub-oil pump cover O-ring Transfer motor O-ring Oil filter stud O-ring O-ring Oil filter AX SU BR ST RS BT HA SC EL IDX TF-159 DISASSEMBLY ATX14A Rear Case Rear Case DISASSEMBLY NATF0077 1. 2. Remove neutral-4LO switch and ATP switch. Remove bolts. 3. Remove rear case from center case by tapping it lightly with a plastic hammer. SMT877C SMT878C Center Case DISASSEMBLY 1. Remove oil pump shaft from main oil pump. 2. Remove stem bleeder from bleeder hole. 3. I Remove lock nut from companion flange. Do not reuse lock nut. SMT883C SMT884C SMT844DB TF-160 NATF0078 DISASSEMBLY ATX14A Center Case (Cont’d) 4. Remove companion flange. GI MA EM LC SMT886CA 5. Remove bolts. EC FE CL MT SMT887C 6. I Insert screwdrivers as shown in the figure, and separate center case from front case. Then, remove center case by levering it up with a tire lever or the like. Be careful not to damage the mating surface. AT PD AX SU SMT888C 7. I Remove snap ring from mainshaft. Do not reuse snap ring. BR ST RS BT SMT889C 8. Remove C-rings from mainshaft bearing. HA SC EL IDX SMT890C TF-161 DISASSEMBLY ATX14A Center Case (Cont’d) Front Drive Shaft and Drive Chain 1. 2. I NATF0078S01 Remove oil gutter from center case. With front drive shaft held by one hand as shown in the figure, tap center case with a plastic hammer to remove it with drive chain. Do not tap drive chain with a plastic hammer. SMT900C 3. Set a puller (ST30031000) and an adapter (ST33052000). Remove front drive shaft front bearing. 4. Set the puller (ST30031000) and the adapter (ST33052000). Remove front drive shaft rear bearing. SMT175E SMT176E Mainshaft and Clutch Drum NATF0078S02 1. Remove mounting bolts to detach baffle plate. 2. Set center case to press stand. Remove mainshaft from center case. SMT903CA SMT904C TF-162 DISASSEMBLY ATX14A Center Case (Cont’d) 3. Remove thrust needle bearing from press flange. GI MA EM LC SMT905C 4. I Remove seal ring from mainshaft. Do not reuse seal ring. EC FE CL MT SMT906C 5. Set a drift (KV31103300), a support ring (KV40104710), a support ring (ST27863000) and a drift (ST35271000) to press flange as shown in the figure. Press drift until snap ring is out of place. AT PD AX SU SMT907C 6. I Remove snap ring from mainshaft. Do not reuse snap ring. BR ST RS BT SMT908C 7. Remove washer. HA SC EL IDX SMT909C TF-163 DISASSEMBLY ATX14A Center Case (Cont’d) 8. Remove press flange from mainshaft. 9. Remove return spring assembly from clutch hub. SMT910C SMT911C 10. Remove each plate from clutch drum. SMT912C 11. Remove snap ring from mainshaft. I Do not reuse snap ring. SMT913C 12. Tap mainshaft with a plastic hammer to remove it from clutch drum and clutch hub. 13. Remove needle bearing from mainshaft. SMT914C TF-164 DISASSEMBLY ATX14A Center Case (Cont’d) Clutch Piston 1. NATF0078S03 GI Remove oil pressure check plug from oil pressure check port. MA EM LC SMT915C 2. Apply air gradually from oil pressure check port, and remove clutch piston from center case. EC FE CL MT SMT916C 3. I 4. Remove lip seal and D-ring from clutch piston. Do not reuse lip seal and D-ring. Remove thrust needle bearing race from clutch piston by hooking a screwdriver edge into 4 notches of thrust needle bearing race. AT PD AX SU SMT917C Control Valve NATF0078S04 CAUTION: I Do not reuse any part that has been dropped or damaged. I Make sure valve is assembled in the proper direction. I Do not use a magnet because residual magnetism stays during disassembly. BR ST RS BT 1. Remove bolts, and detach oil strainer. HA SC EL IDX SMT918C TF-165 DISASSEMBLY ATX14A Center Case (Cont’d) 2. I Remove O-rings from oil strainer. Do not reuse O-rings. 3. Remove bolts for control valve. 4. Remove snap ring. Then push terminal assembly into center case to remove control valve assembly. 5. I I Remove lip seals from center case. Do not reuse lip seals. There are two kinds of lip seals (lip seal of large inner diameter: 5 pieces, lip seal of small inner diameter: 2 pieces). Confirm the position before disassembly. 6. Remove all bolts except for two. SMT919C SMT920C SMT921C SMT922CA SMT923C TF-166 DISASSEMBLY ATX14A Center Case (Cont’d) 7. 8. I Remove 4WD solenoid valve, clutch pressure switch, 2-4WD shift solenoid valve, line pressure switch, and transfer fluid temperature sensor from control valve assembly. Remove O-rings from each solenoid valve, switch and terminal body. Do not reuse O-rings. GI MA EM LC SMT924C 9. Place control valve with lower body facing up, remove two mounting bolts, and then remove lower body and separator plate from upper body. CAUTION: I Be careful not to drop relief balls. Detach lower body carefully. I Do not reuse separator plate. EC FE CL MT SMT925C 10. Make sure reverse balls, relief balls and relief springs, accumulator pistons and valve springs are securely installed as shown in the figure, and remove them. AT PD AX SU SMT177E 11. Remove retainer plates. BR ST RS BT SMT927C 12. Remove each control valve, spring and plug. HA SC EL IDX SMT928CA TF-167 DISASSEMBLY ATX14A Center Case (Cont’d) Mainshaft Rear Bearing 1. NATF0078S05 Remove mainshaft rear bearing from center case using a remover (ST35291000) and a remover (ST30090010). SMT929C Main Oil Pump NATF0078S06 1. Remove bolts as shown in figure to detach main oil pump. 2. Remove outer gear and inner gear. SMT930C SMT931C Sub-oil Pump 1. NATF0078S07 I Remove bolts to detach transfer motor from center case. Then remove O-ring from the transfer motor. Do not reuse O-ring. 2. Remove sub-oil pump mounting bolts. SMT932C SMT933C TF-168 DISASSEMBLY ATX14A Center Case (Cont’d) 3. Thread two bolts (M4 x 0.8) into the holes of sub-oil pump as shown in the figure, and pull out to remove sub-oil pump. GI MA EM LC SMT934C 4. I EC Remove oil pump gasket. Do not reuse gasket. FE CL MT SMT935C 5. I Remove sub-oil pump cover, outer gear, inner gear and O-ring from sub-oil pump housing. Do not reuse O-ring. AT PD AX SU SMT936C Oil Filter 1. NATF0078S08 Remove bolts for oil filter. BR ST RS BT SMT937C 2. Insert a screwdriver as shown in the figure to remove oil filter. HA SC EL IDX SMT938C TF-169 DISASSEMBLY ATX14A Center Case (Cont’d) 3. I Remove O-rings from oil filter. Do not reuse O-rings. 4. Remove oil filter stud. 5. I Remove O-ring from oil filter stud. Do not reuse O-ring. SMT939C SMT940C SMT941C Front Case DISASSEMBLY 1. 2. NATF0079 Remove rear case from center case. Refer to TF-160. Remove front case from center case. SMT895C Shift Rod Components 1. 2. NATF0079S01 Remove check plug, then check spring and check ball. Remove wait detection switch. SMT990C TF-170 DISASSEMBLY ATX14A Front Case (Cont’d) 3. Remove shift rod components together with 2-4 sleeve and L-H sleeve. GI MA EM LC SMT991C 4. Remove 2-4 sleeve and L-H sleeve from 2-4 fork and L-H fork respectively. EC FE CL MT SMT992C 5. I AT Drive out retaining pin from shift rod. Do not reuse retaining pin. PD AX SU SMT993C 6. Remove L-H fork, 2-4 fork, shift fork spring and fork guide from shift rod. BR ST RS BT SMT195E Planetary Carrier, Sun Gear and Internal Gear 1. Remove radial needle bearing from sun gear. NATF0079S02 HA SC EL IDX SMT995C TF-171 DISASSEMBLY Front Case (Cont’d) 2. I Remove bolts to detach transfer cover. Do not reuse bolts. 3. I Remove oil seal from transfer cover. Do not reuse oil seal. 4. I Remove snap ring from main gear bearing. Do not reuse snap ring. 5. Remove sun gear by tapping it lightly. 6. I 7. Remove snap ring from sun gear. Do not reuse snap ring as it is a selective part. Remove washer from sun gear. SMT996C SMT997C SMT998C SMT999C SMT001D TF-172 ATX14A DISASSEMBLY ATX14A Front Case (Cont’d) 8. Set an adapter to sun gear as shown in the figure. Remove sun gear from planetary carrier. Remove main gear bearing, bearing race and thrust needle bearing (front and rear of planetary carrier) from sun gear. GI MA EM LC EC FE CL MT SMT002DA 9. I Remove snap ring, and remove internal gear. Do not reuse snap ring. AT PD AX SU SMT004D 10. Remove front oil seal. I Do not reuse oil seal. 11. Loosen nut of outer lever assembly to pull out cotter pin, and remove outer lever. 12. Remove inner lever assembly. BR ST RS BT SMT198E HA SC EL IDX TF-173 REPAIR FOR COMPONENT PARTS ATX14A Front Case Front Case INSPECTION Planetary Carrier I I SMT006D I NATF0080S01 Measure end play of each pinion gear, and make sure the measurement is within specification shown below. If out of specification, replace planetary carrier with new one. Pinion gear end play: 0.1 - 0.7 mm (0.004 - 0.028 in) Check working face of each gear, bearing and others for damage, burrs, partial wear, dents and other abnormality. If any is found, replace planetary carrier with new one. Sun Gear I NATF0080 NATF0080S02 Check if oil passage of sun gear is clogged. For this, try to pass a 3.6 mm (0.142 in) dia. wire through oil passage as shown in the figure. Check sliding/contact surface of each gear, bearing and others for damage, burrs, partial wear, dents, and other abnormality. If any is found, replace sun gear with new one. SMT007D Internal Gear I NATF0080S03 Check internal gear teeth for damage, partial wear, dents and other abnormality. If any is found, replace internal gear with new one. SMT008D Shift Rod Components I NATF0080S04 Check working face of shift rod and fork for wear, partial wear, bending and other abnormality. If any is found, replace with new one. SMT009D TF-174 REPAIR FOR COMPONENT PARTS ATX14A Front Case (Cont’d) I Measure clearance between shift fork and sleeve. If it is out of specification, replace it with new one. Standard value: Less than 0.36 mm (0.0142 in) GI MA EM LC SMT010D EC Center Case INSPECTION Sub-oil Pump 1. 2. 3. SMT942C NATF0081 NATF0081S01 Check inner and outer circumference, tooth face, and sideface of inner and outer gears for damage or abnormal wear. Measure side clearance between oil pump housing edge and inner gear/outer gear. Make sure side clearance is within specification. If the measurement is out of specification, replace inner and outer gears together with new ones as a set. Specification: 0.015 - 0.035 mm (0.0006 - 0.0014 in) For inner gear and outer gear, refer to SDS, TF-193. FE CL MT AT PD AX SU Main Oil Pump 1. 2. 3. SMT943C Mainshaft I NATF0081S02 Check inner and outer circumference, tooth face, and sideface of inner and outer gears for damage or abnormal wear. Measure side clearance between oil pump housing edge and inner gear/outer gear. Make sure side clearance is within specification. If the measurement is out of specification, replace inner and outer gears with new ones as a set. Specification: 0.015 - 0.035 mm (0.0006 - 0.0014 in) For inner gear and outer gear, refer to SDS, TF-193. NATF0081S03 Check surfaces which contact sun gear, clutch drum, clutch hub, press flange, clutch piston, each bearing, etc. for damage, peel, partial wear, dents, bending, or other abnormal damage. If any is found, replace with new one. BR ST RS BT HA SC EL IDX SMT944C TF-175 REPAIR FOR COMPONENT PARTS ATX14A Center Case (Cont’d) Control Valve NATF0081S04 I Check oil filter screen for damage. If any is found, replace with new one. I Check resistance between terminals of 4WD solenoid valve, 2-4WD shift solenoid valve and transfer fluid temperature sensor. Resistance: Refer to “COMPONENT INSPECTION”, TF-148. SMT945C SMT946CA I Check sliding faces of control valves and plugs for abnormality. If any is found, replace the control valve assembly with new one. CAUTION: Replace control valve body together with clutch return spring as a set. Control valve: Refer to SDS, TF-193. SMT947C I I Check each control valve spring for damage or distortion, and also check its free length, outer diameter and wire diameter. If any damage or fatigue is found, replace control valve body with new one. Replace control valve body together with clutch return spring as a set. Inspection standard: Refer to SDS, TF-193. SMT948C Clutch I SMT949C NATF0081S05 Check drive plate facings and driven plate for damage, cracks or other abnormality. If any, replace with new one. I Check the thickness of drive plate facings and driven plate. Inspection standard: Refer to SDS, TF-194. CAUTION: I Measure facing thickness at 3 points to take an average. I Check all the drive and driven plates. I Check return spring for damage or deformation. TF-176 REPAIR FOR COMPONENT PARTS ATX14A Center Case (Cont’d) I Check stamped mark shown in the figure. Then, check that free length, outer diameter and wire diameter are within specifications. If any abnormality is found, replace with new return spring assembly of the same stamped number. Inspection standard: Refer to SDS, TF-194. GI MA EM LC SMT178E EC FE CL MT AT PD AX SU BR ST RS BT HA SC EL IDX TF-177 ASSEMBLY ATX14A Front Case Front Case ASSEMBLY Planetary Carrier, Sun Gear and Internal Gear 1. I NATF0082 NATF0082S01 Apply ATF to oil seal periphery, and install oil seal so that it is flush with the end face of front case. Do not reuse oil seal. SMT011D 2. I Install internal gear with its groove facing snap ring into front case. Then secure it with snap ring. Do not reuse snap ring. 3. I Install snap ring to main gear bearing. Do not reuse snap ring. 4. Set main gear bearing to front case, then press it. 5. 6. Install thrust needle bearing to sun gear. Install sun gear to planetary carrier. SMT012D SMT014D SMT015D SMT016D TF-178 ASSEMBLY ATX14A Front Case (Cont’d) 7. 8. 9. Set a support (KV40105500) to bushing replacer puller (ST30911000) as shown in the figure, and place planetary carrier on it. Install thrust needle bearing to planetary carrier with its roller facing front case. Measure “C” from the end of sun gear to the roller surface of thrust needle bearing. GI MA EM LC SMT017D SMT018D 10. Measure “D” from the end of sun gear to the main gear bearing contact surface. 11. Calculate end play “E” using “C” and “D” obtained in steps 10 and 11. Select bearing race so that the end play becomes the standard value. Calculation formula: End play “E” = “C” − “D” Standard end play: 0.1 - 0.25 mm (0.0039 - 0.0098 in) Bearing race: Refer to SDS, TF-195. 12. Set planetary carrier to press in the status described in step 8. Then install the selected bearing race to planetary carrier. EC FE CL MT AT PD AX SU SMT019D 13. Install front case to planetary carrier. Set a support ring (KV40105310) and an adapter B (KV40105230) to main gear bearing inner race, then press it. BR ST RS BT SMT020D 14. Install washer to sun gear assembly, and select proper snap ring so that end play “F” of sun gear is within specifications. Standard end play “F”: 0 - 0.15 mm (0 - 0.0059 in) Snap ring: Refer to SDS, TF-195. HA SC EL IDX SMT021D TF-179 ASSEMBLY ATX14A Front Case (Cont’d) 15. Install the selected snap ring. I Do not reuse snap rings. 16. Apply ATF to the periphery of new transfer cover oil seal, and attach it at 1.5 mm (0.059 in) from the transfer cover and face. I Do not reuse oil seal. SMT022D 17. Apply Genuine Anaerobic Liquid Gasket or equivalent to transfer cover mounting surface of front case as shown in the figure. Refer to TF-158. CAUTION: I Remove all foreign materials such as water, oil, and grease from mating surfaces of front case and transfer cover. I Prevent Liquid Gasket from entering into oil holes of front case. SMT179E 18. Align oil hole of front case with notch of transfer cover, and tighten bolts. : 49 - 58 N·m (5.0 - 5.9 kg-m, 36 - 43 ft-lb) I Do not reuse bolts. SMT024D 19. Apply petroleum jelly to radial needle bearing, and install it inside sun gear. 20. Install shift rod assembly to front case assembly. Refer to “Shift Rod Assembly”, TF-181. SMT995C TF-180 ASSEMBLY ATX14A Front Case (Cont’d) Shift Rod Assembly 1. I NATF0082S02 Install fork guide, shift fork spring, 2-4 fork, and L-H fork to shift rod, and secure them with retaining pins. Do not reuse retaining pins. GI MA EM LC SMT195E 2. Install 2-4 sleeve and L-H sleeve to each fork. EC FE CL MT SMT992C 3. While aligning L-H sleeve with planetary carrier, install shift rod assembly to front case. AT PD AX SU SMT991C 4. 5. SMT990C I 6. 7. Remove all the liquid gasket on check plug and front case, and install check ball and check spring to front case. Apply Genuine Thread Sealant or equivalent* to check plug, install it to front case, and tighten it to specified torque. *: Refer to TF-158. : 19 - 25 N·m (1.9 - 2.5 kg-m, 14 - 18 ft-lb) Remove all the liquid gasket on the switch fitting and inner side of front case, and with wait detection switch threaded one pitch into the hole, apply Genuine Thread Sealant or equivalent* to the thread, install it, and tighten it to specified torque. : 15 - 20 N·m (1.5 - 2.0 kg-m, 11 - 14 ft-lb) Wait detection switch harness connector is black. Install center case assembly to front case assembly. Refer to “Final Assembly”, TF-190. Install rear case assembly to center case. Refer to “Final Assembly”, TF-190. BR ST RS BT HA SC EL IDX TF-181 ASSEMBLY ATX14A Center Case Center Case ASSEMBLY Oil Filter 1. I 2. NATF0083 NATF0083S01 Apply ATF or petroleum jelly to new O-ring, and install it to oil filter stud. Do not reuse O-rings. Install oil filter stud to center case, and tighten it. : 26 - 35 N·m (2.6 - 3.6 kg-m, 20 - 26 ft-lb) SMT951C 3. I 4. I Apply ATF or petroleum jelly to two new O-rings, and install them to oil filter. Do not reuse O-rings. Install oil filter to center case and tighten bolts. : 7 - 9 N·m (0.7 - 0.9 kg-m, 61 - 78 in-lb) Do not knock oil filter with a tool such as a hammer. SMT939C Sub-oil Pump 1. I NATF0083S02 Install new oil pump gasket to center case by aligning it with dowel pin inside the center case. Do not reuse gaskets. SMT935C 2. Install outer gear* and inner gear to sub-oil pump housing, and measure side clearance. Refer to “Sub-oil Pump”, “INSPECTION”, TF-175. 3. Set new O-ring to sub-oil pump housing, and install sub-oil pump cover. I Do not reuse O-rings. * Identification mark “H” is placed on the side of sub-oil pump cover. SMT936C 4. Align dowel pin hole and mounting bolt hole of sub-oil pump assembly with center case. Then tighten bolts. : 7 - 9 N·m (0.7 - 0.9 kg-m, 61 - 78 in-lb) SMT955C TF-182 ASSEMBLY ATX14A Center Case (Cont’d) 5. 6. Apply ATF or petroleum jelly to new O-ring and install it to transfer motor. Fit double-flat end of transfer motor shaft into slot of sub-oil pump assembly. Then tighten bolts. : 42 - 48 N·m (4.2 - 4.9 kg-m, 31 - 35 ft-lb) GI MA EM LC SMT956C Main Oil Pump 1. EC NATF0083S03 Install inner gear and outer gear in the main oil pump housing with their identification marks facing toward center case mounting surface side. Then, measure the side clearance. Refer to “Main Oil Pump”, “Center Case”, TF-175. FE CL MT SMT957C 2. 3. Install main oil pump assembly to center case assembly, and tighten bolts. : 7 - 9 N·m (0.7 - 0.9 kg-m, 61 - 78 in-lb) Install oil pump shaft to main oil pump, then install rear case assembly to center case. Refer to “Final Assembly”, TF-190. AT PD AX SU SMT930C Control Valve 1. SMT928C NATF0083S04 Clean upper body, control valves and springs with cleaning agent, and apply air blow. 2. Dip control valves in ATF, and apply ATF to the valve-mounting area of upper body. 3. Install each control valve, spring, and plug to upper body, and fix it with retainer plates. CAUTION: I To insert control valves into upper body, place upper body on a level surface in order to prevent flaw or damage. I Make sure each control valve is smoothly inserted. 4. Install reverse balls, relief balls and relief springs, accumulator pistons and valve springs to upper body. BR ST RS BT HA SC EL IDX SMT177E TF-183 ASSEMBLY ATX14A Center Case (Cont’d) 5. I Install lower body and separator plate to upper body. Do not reuse separator plates. 6. With lower body down, tighten two bolts in the position shown in the figure. Apply ATF or petroleum jelly to new O-ring, and install it to 2-4WD shift solenoid valve, terminal body, line pressure switch and 4WD solenoid valve. Install them to control valve assembly. Do not reuse O-rings. SMT925C 7. I SMT962CA 8. I I Apply ATF or petroleum jelly to lip seals, and install them to center case. Do not reuse lip seals. There are 2 kinds of lip seals (lip seal of large inner diameter: 5 pieces, lip seal of small inner diameter: 2 pieces). Confirm the position before installation. SMT922CA 9. Install bolts as shown in the figure, and tighten them to specified torque. Bolt symbol Length under head mm (in) Q’ty a b *c d e f g 38 (1.50) 43.5 (1.713) 62 (2.44) 19 (0.75) 47 (1.85) 40 (1.57) 52 (2.05) 16 3 2 1 2 1 1 Tightening torque N·m (kg-m, in-lb) SMT180E *: Tighten with oil strainer. TF-184 6.9 - 8.8 (0.70 - 0.90, 61.1 - 77.9) ASSEMBLY ATX14A Center Case (Cont’d) 10. Install control valve assembly to center case, and tighten bolts. : 6.9 - 8.8 N·m (0.70 - 0.90 kg-m, 61.1 - 77.9 in-lb) GI MA EM LC SMT920C 11. Remove terminal from center case installation hole, and secure terminal body with snap ring. EC FE CL MT SMT921C 12. Apply ATF or petroleum jelly to O-rings, and install them to oil strainer. CAUTION: Do not reuse O-rings. 13. Install oil strainer to control valve assembly. 14. Install mainshaft and clutch drum to center case. Refer to “Mainshaft and Clutch Drum”, TF-186. 15. Install front case assembly and rear case assembly. Refer to “Final Assembly”, TF-190. AT PD AX SU SMT919C Clutch Piston 1. I NATF0083S05 Apply ATF to D-ring and lip seal, and install them to clutch piston. Do not reuse lip seal and D-ring. BR ST RS BT SMT917C 2. Set clutch piston to a clutch piston attachment (KV31103400). HA SC EL IDX SMT969C TF-185 ASSEMBLY ATX14A Center Case (Cont’d) 3. 4. Set the clutch piston attachment to center case, and install clutch piston, tap it lightly. Install slide needle bearing race to clutch piston. SMT970C 5. 6. Remove all the liquid gasket from oil pressure check port and inside center case. With oil pressure check plug threaded in 1 or 2 pitches, apply Genuine Thread Sealant or equivalent to the thread of plug, and tighten. Refer to TF-158. : 10 - 17 N·m (1.0 - 1.7 kg-m, 87 - 148 in-lb) Install mainshaft and clutch drum. Refer to “Mainshaft and Clutch Drum”, TF-186. SMT915C Mainshaft and Clutch Drum NATF0083S06 1. Install drive plates, driven plates and press flange to clutch hub. 2. Place clutch hub on a surface plate and measure dimension “A” between snap ring mounting surface of press flange and clutch drum sliding face of clutch hub. CAUTION: Measure at least 2 points, and take an average. SMT972C 3. 4. SMT973C 5. I Measure dimension “B” between the gear end of mainshaft and the snap ring mounting portion. Calculate end play using dimension “A” and dimension “B” (obtained in steps 2 and 3), and select proper retaining plate so that the end play is within specifications. Calculation formula: End play = B − A − Retaining plate thickness Standard end play: 0.2 - 0.5 mm (0.008 - 0.020 in) Retaining plate: Refer to SDS, TF-194. Install clutch drum, needle bearing and clutch hub to mainshaft, and secure them with snap ring. Do not reuse snap ring. SMT974C TF-186 ASSEMBLY ATX14A Center Case (Cont’d) 6. Install each clutch to clutch drum. GI MA EM LC SMT975C 7. Align the notch of return spring assembly with the pin of clutch hub, and install it. EC FE CL MT SMT911C 8. Install press flange (with the holes indicated by arrows aligned with pins of clutch hub). AT PD AX SU SMT977C 9. Install washer. BR ST RS BT SMT909C 10. Pass mainshaft through snap ring. Set a drift (KV31103300), a support ring (KV40104710), a support ring (ST27863000) and a drift (ST35271000) to press flange at the position shown in the figure, and press snap ring until it fits into snap ring groove on mainshaft. I Do not reuse snap ring. HA SC EL IDX SMT907C TF-187 ASSEMBLY ATX14A Center Case (Cont’d) 11. Fix snap ring to mainshaft. SMT908C 12. Install thrust needle bearing to press flange. SMT905C 13. Apply petroleum jelly to new seal rings, and install them to mainshaft. Measure clearance between seal ring and groove using feeler gauge. Standard clearance: 0.05 - 0.30 mm (0.0020 - 0.0118 in) Limit clearance: 0.30 mm (0.0118 in) I Pass seal ring from mainshaft rear end to install it. Seal ring dimension: Refer to SDS, TF-195. SMT982C 14. Install mainshaft rear bearing to center case. SMT983C 15. Place puller (ST30911000) to mainshaft rear bearing inner race, and set it to press stand. 16. Place adapter (ST33061000) to the tip of mainshaft, and press mainshaft into center case. SMT984C TF-188 ASSEMBLY ATX14A Center Case (Cont’d) 17. Install baffle plate to center case, and tighten bolts. : 3.7 - 5.0 N·m (0.38 - 0.51 kg-m, 33.0 - 44.3 in-lb) 18. Install front drive shaft and drive chain. Refer to “Front Drive Shaft and Drive Chain” below. 19. Install front case assembly and rear case assembly. Refer to “Final Assembly”, TF-190. GI MA EM LC SMT903CA Front Drive Shaft and Drive Chain 1. EC NATF0083S07 Place a base (ST30032000) to front drive shaft rear bearing inner race, and press it using a drift (KV40100621). FE CL MT SMT986C 2. Place base (ST30032000) to front drive shaft front bearing inner race, and press it using the drift (KV40100621). AT PD AX SU SMT987C 3. 4. I Install drive chain temporarily to front drive shaft and drive gear of clutch drum. Tap front drive shaft with a plastic hammer while keeping it upright and press-fit front drive shaft rear bearing. Be careful not to tap drive chain with a hammer. BR ST RS BT SMT988C 5. 6. Align claw of oil gutter with center case, and install it. Install front case assembly and rear case assembly. Refer to “Final Assembly”, TF-190. HA SC EL IDX SMT989C TF-189 ASSEMBLY ATX14A Final Assembly Final Assembly NATF0084 1. Install C-rings to mainshaft rear bearing. 2. Check speedometer drive gear teeth for abnormal wear. Set speedometer drive gear properly on mainshaft, and secure it with snap ring. Do not reuse snap ring. SMT891C I SMT889C 3. Apply Genuine Anaerobic Liquid Gasket or equivalent to the entire center case mounting surface of front case as shown in the figure. Refer to TF-158. CAUTION: Remove all foreign materials such as water, oil and grease from center case and front case mating surfaces. SMT181E 4. Make sure the two claws of oil gutter are securely attached to slots in center case. SMT894C TF-190 ASSEMBLY ATX14A Final Assembly (Cont’d) 5. With the claws of oil gutter held by a finger, install center case assembly to front case assembly. CAUTION: Pay careful attention so that mainshaft end does not damage radial needle bearing in sun gear assembly. 6. Tap center case lightly with a rubber hammer or the like and press-fit front drive shaft bearing into front case. GI MA EM LC SMT895C 7. 8. I Make sure oil gutter rear end protrudes from point “A” in the figure. Tighten bolts to specified torque. : 42 - 48 N·m (4.2 - 4.9 kg-m, 31 - 35 ft-lb) Be sure to install air breather hose clamp, connector bracket and harness clip. EC FE CL MT SMT896C 9. Fit double-flat end of oil pump shaft into slot of main oil pump and install it. NOTE: When oil pump shaft is rotated slightly, it drops into position where both parts fit. AT PD AX SU SMT883C 10. Install stem bleeder to center case. BR ST RS BT SMT884C 11. Remove rear oil seal. I Do not reuse oil seal. HA SC EL IDX SMT881C TF-191 ASSEMBLY ATX14A Final Assembly (Cont’d) 12. Apply ATF to the circumference of new rear oil seal, and tap it using a drift as shown in the figure so that it is aligned with case tip face. I Apply multi-purpose grease to oil seal lip. SMT882C 13. Apply Genuine Anaerobic Liquid Gasket or equivalent to entire rear case mounting surface of center case as shown in the figure. Refer to TF-158. CAUTION: I Remove all foreign materials such as water, oil, and grease from center case and rear case mating surfaces. I Be careful not to allow Liquid Gasket to clog bleeder hole. 14. Install rear case to center case, and tighten bolts to specified torque. : 42 - 48 N·m (4.2 - 4.9 kg-m, 31 - 35 ft-lb) I Be sure to attach harness clips. SMT182E 15. Remove all the gasket fluid from switch mounting area and inside rear case, with ATP switch and neutral-4LO switch threaded in 1 to 2 pitches, apply Genuine Thread Sealant or equivalent to the thread of the switches and tighten it to specified torque. : 15 - 20 N·m (1.5 - 2.0 kg-m, 11 - 14 ft-lb) 16. Install rear case assembly to center case assembly. SMT880C 17. Install companion flange to front drive shaft, and tighten lock nut. : 226 - 324 N·m (23.0 - 33.0 kg-m, 166 - 239 ft-lb) I Do not reuse lock nut. SMT845DB TF-192 SERVICE DATA AND SPECIFICATIONS (SDS) ATX14A General Specifications General Specifications NATF0085 Transfer model GI ATX14A High 1.000 Low 2.596 MA Gear ratio Sun gear 57 Internal gear 91 EM Planetary gear Number of teeth Front drive sprocket 35 Front drive shaft 35 Fluid capacity  (US qt, Imp qt)* LC EC 3.0 (3-1/8, 2-5/8) *: Refer to MA-12, “Fluids and Lubricants”. FE Inner Gear and Outer Gear NATF0086 SUB-OIL PUMP NATF0086S01 Allowable clearance Part No.* Gear thickness CL 0.015 - 0.035 mm (0.0006 - 0.0014 in) MT mm (in) Inner gear Outer gear 9.27 - 9.28 (0.3650 - 0.3654) 31346 0W462 31347 0W462 9.28 - 9.29 (0.3654 - 0.3657) 31346 0W461 31347 0W461 9.29 - 9.30 (0.3657 - 0.3661) 31346 0W460 31347 0W460 AT *: Always check with the Parts Department for the latest parts information. MAIN OIL PUMP NATF0086S02 Allowable clearance AX Part No.* Gear thickness PD 0.015 - 0.035 mm (0.0006 - 0.0014 in) mm (in) Inner gear Outer gear 14.67 - 14.68 (0.5776 - 0.5780) 31346 0W412 31347 0W412 14.68 - 14.69 (0.5780 - 0.5783) 31346 0W411 31347 0W411 14.69 - 14.70 (0.5783 - 0.5787) 31346 0W410 31347 0W410 SU BR *: Always check with the Parts Department for the latest parts information. ST Control Valve NATF0087 VALVE NATF0087S01 Mounting position Part name Part No.* Outer dia. mm (in) Overall length mm (in) L1 2-4 shift valve 31772 21X00 8.0 (0.315) 38.5 (1.516) L2 Clutch valve 31772 80X11 10.0 (0.394) 40.0 (1.575) L4 Pilot valve 31772 80X11 10.0 (0.394) 40.0 (1.575) L5 Regulator valve 31741 0W410 12.0 (0.472) 68.0 (2.677) RS BT HA *: Always check with the Parts Department for the latest parts information. SC SPRING NATF0087S02 Mounting position Part name Part No.* Free length mm (in) Outer dia. mm (in) L1 2-4 shift valve spring 31742 0W400 31.85 (1.2539) 7.0 (0.276) Wire dia. mm (in) 0.6 (0.024) Winding direction EL Clockwise IDX TF-193 SERVICE DATA AND SPECIFICATIONS (SDS) ATX14A Control Valve (Cont’d) Mounting position Part name Part No.* Free length mm (in) Outer dia. mm (in) L2 Clutch valve spring 31742 0W405 40.6 (1.598) 9.0 (0.354) 0.8 (0.031) Clockwise L4 Pilot valve spring 31742 0W410 28.1 (1.106) 9.0 (0.354) 1.2 (0.047) Clockwise L5 Regulator valve spring 31742 0W415 39.7 (1.563) 11.0 (0.433) 1.3 (0.051) Clockwise Wire dia. mm (in) Winding direction *: Always check with the Parts Department for the latest parts information. Clutch NATF0088 DRIVE PLATE NATF0088S01 Part No.* Quantity 31532 0W410 8 Initial thickness mm (in) Limit value 2.0 (0.079) mm (in) 1.8 (0.071) *: Always check with the Parts Department for the latest parts information. DRIVEN PLATE NATF0088S04 Part No.* Quantity 31536 0W410 14 Initial thickness mm (in) Limit value 2.0 (0.079) mm (in) 0 (0) (steel plate) *: Always check with the Parts Department for the latest parts information. RETURN SPRING NATF0088S02 Stamped mark Part No.* Free length mm (in) 1 31521 0W401 37.3 (1.496) 2 31521 0W402 37.8 (1.488) 3 31521 0W403 38.4 (1.512) 4 31521 0W404 38.9 (1.531) 5 31521 0W405 39.4 (1.551) 6 31521 0W406 40.0 (1.575) 7 31521 0W407 36.8 (1.449) 8 31521 0W408 40.5 (1.594) Outer dia. mm (in) 12.0 (0.472) Wire dia. mm (in) Winding direction 1.8 (0.071) Clockwise *: Always check with the Parts Department for the latest parts information. RETAINING PLATE NATF0088S03 Standard end play Measured value mm (in) 0.2 - 0.5 mm (0.008 - 0.020 in) Part No.* Thickness mm (in) 2.30 - 2.50 (0.0906 - 0.0984) 31537 0W410 2.1 (0.083) 2.50 - 2.70 (0.0984 - 0.1063) 31537 0W411 2.3 (0.091) 2.70 - 2.90 (0.1063 - 0.1142) 31537 0W412 2.5 (0.098) 2.90 - 3.10 (0.1142 - 0.1220) 31537 0W413 2.7 (0.106) 3.10 - 3.30 (0.1220 - 0.1299) 31537 0W414 2.9 (0.114) 3.30 - 3.50 (0.1299 - 0.1378) 31537 0W415 3.1 (0.122) 3.50 - 3.70 (0.1378 - 0.1457) 31537 0W416 3.3 (0.130) 3.70 - 3.90 (0.1457 - 0.1535) 31537 0W417 3.5 (0.138) 3.90 - 4.10 (0.1535 - 0.1614) 31537 0W418 3.7 (0.146) 4.10 - 4.30 (0.1614 - 0.1693) 31537 0W419 3.9 (0.154) TF-194 SERVICE DATA AND SPECIFICATIONS (SDS) ATX14A Clutch (Cont’d) Standard end play Measured value GI 0.2 - 0.5 mm (0.008 - 0.020 in) mm (in) Part No.* Thickness mm (in) 4.30 - 4.50 (0.1693 - 0.1772) 31537 0W420 4.1 (0.161) 4.50 - 4.70 (0.1772 - 0.1850) 31537 0W421 4.3 (0.169) 4.70 - 4.90 (0.1850 - 0.1929) 31537 0W422 4.5 (0.177) 4.90 - 5.10 (0.1929 - 0.2008) 31537 0W423 4.7 (0.185) MA EM LC *: Always check with the Parts Department for the latest parts information. Seal Ring (Mainshaft side) Standard clearance Limit clearance NATF0089 Part No.* Outer dia. 31525 0W410 mm (in) Inner dia. 40.8 (1.606) mm (in) Thickness 36.9 (1.453) FE mm (in) 1.97 (0.0776) CL *: Always check with the Parts Department for the latest parts information. Bearing Race (Thrust needle bearing side) Standard end play End play (Dimension “E”) EC 0.05 - 0.30 mm (0.0020 - 0.0118 in) 0.30 mm (0.0118 in) NATF0090 MT 0.1 - 0.25 mm (0.0039 - 0.0098 in) mm (in) Part No.* Thickness mm (in) 1.785 - 1.800 (0.0703 - 0.0709) 31439 0W410 1.6 (0.063) 1.800 - 1.900 (0.0709 - 0.0748) 31439 0W411 1.7 (0.067) 1.900 - 2.000 (0.0748 - 0.0787) 31439 0W412 1.8 (0.071) 2.000 - 2.100 (0.0787 - 0.0827) 31439 0W413 1.9 (0.075) 2.100 - 2.200 (0.0827 - 0.0866) 31439 0W414 2.0 (0.079) 2.200 - 2.270 (0.0866 - 0.0894) 31439 0W415 2.1 (0.083) AT PD AX *: Always check with the Parts Department for the latest parts information. Snap Ring (Sun gear side) Standard end play End play (Dimension “F”) NATF0091 SU 0 - 0.15 mm (0 - 0.0059 in) mm (in) Part No.* Thickness mm (in) 2.40 - 2.50 (0.0945 - 0.0984) 33112 0W411 2.4 (0.094) 2.50 - 2.60 (0.0984 - 0.1024) 33112 0W412 2.5 (0.098) 2.60 - 2.70 (0.1024 - 0.1063) 33112 0W413 2.6 (0.102) *: Always check with the Parts Department for the latest parts information. BR ST RS BT HA SC EL IDX TF-195 NOTES ALPHABETICAL INDEX SECTION IDX GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL ALPHABETICAL INDEX A ABS - Wiring diagram ....................................BR-37 ABS sensor rotor ........................................AX-6, 20 ABS/TCS C/U signal ............................EC-583, 585 A/C air flow.............................................HA-29, 207 A/C component layout............................HA-21, 205 A/C compressor clutch removal and installation.........................................HA-175, 258 A/C compressor description .........................HA-200 A/C compressor precaution .....................HA-7, 191 A/C compressor special service tool......HA-11, 195 A/C control linkage adjustment (manual A/C) ..........................................HA-225, 242, 244 A/C control operation (auto A/C) ....................HA-26 A/C control operation (manual A/C) .............HA-206 A/C diagnostic work flow (auto A/C) ..............HA-79 A/C diagnostic work flow (manual A/C)........HA-216 A/C HFC134a (R134a) system precaution .............................................HA-3, 187 A/C HFC134a (R134a) system service procedure..........................................HA-170, 253 A/C HFC134a (R134a) system service tools ....................................................HA-12, 196 A/C HFC134a system service equipment precaution....................................HA-8, 192 A/C lubricant (R134a) ..........................HA-172, 255 A/C operational check ............................HA-80, 217 A/C performance chart .........................HA-138, 236 A/C performance test diagnoses .........HA-136, 234 A/C relay ..............................................HA-132, 251 A/C self-diagnoses (auto A/C)........................HA-48 A/C service data specification..............HA-186, 269 A/C switch ....................................................HA-251 A/C system description (auto A/C) .................HA-25 A/C trouble diagnoses (auto A/C) ..................HA-31 A/C trouble diagnoses (manual A/C) ...........HA-209 A/C, A - Wiring diagram ...........................HA-35, 40 A/C, M - Wiring diagram ..............................HA-213 Accelerator control system ...............................FE-3 Accelerator pedal position (APP) sensor.......................................EC-708, 715, 731 Accelerator pedal released position learning .......................................................EC-81 Actuator lever (Transfer) ...............................TF-157 Air bag ............................................................RS-11 Air bag disposal..............................................RS-25 Air bag precautions ...........................................GI-3 Air bleeding for brake system ..........................BR-9 Air cleaner filter replacement .........................MA-18 Air conditioner cut control ..............................EC-40 Air flow meter - See Mass air flow sensor.......................EC-194, 203, 211, 219, 478 Air mix door control linkage adjustment.......HA-104 Air mix. door motor ..............................HA-100, 167 Air spoiler, rear................................................BT-36 All-mode 4WD system ....................................TF-43 Alternator ........................................................SC-30 Ambient sensor ............................................HA-155 Angular tightening application..........................EM-3 Antenna - See Power antenna .....................EL-203 Anti-lock brake system - Wiring diagram .......................................................BR-37 APPS1 - Wiring diagram ..............................EC-711 APPS2 - Wiring diagram ..............................EC-718 APPS3 - Wiring diagram ..............................EC-734 ASC/BS - Wiring diagram ............................EC-688 ASC/SW - Wiring diagram ...........................EC-681 ASCBOF - Wiring diagram ...........................EC-776 ASCD..............................................................EC-62 ASCD (automatic speed control device) ......EL-256 ASCD brake switch ..............................EC-685, 775 ASCD clutch switch..............................EC-685, 775 ASCD steering switch ..................................EC-679 ASCIND - Wiring diagram ............................EC-784 A/T - Wiring diagram - AT - FTS ...................AT-113 A/T - Wiring diagram - AT - MAIN.................AT-102 A/T - Wiring diagram - AT - PNP/SW............AT-107 A/T - Wiring diagram - AT - VSS A/T ............AT-119 A/T fluid temperature sensor .........................AT-116 A/T self-diagnoses...........................................AT-48 A/T shift lock system .....................................AT-265 A/T shift lock system - Wiring diagram .........AT-266 A/T trouble diagnoses .....................................AT-55 A/T Wiring diagram - AT - ENG SS ..............AT-123 A/T Wiring diagram AT - 1ST ........................AT-129 A/T Wiring diagram AT - 2ND .......................AT-135 A/T Wiring diagram AT - 3RD .......................AT-141 A/T Wiring diagram AT - 4TH........................AT-148 A/T Wiring diagram AT - BA/FTS ..................AT-195 A/T Wiring diagram AT - CAN .......................AT-207 A/T Wiring diagram AT - LPSV .....................AT-170 A/T Wiring diagram AT - NONDTC ...............AT-218 A/T Wiring diagram AT - OVRCSV ...............AT-190 A/T Wiring diagram AT - SSV/A ....................AT-175 A/T Wiring diagram AT - SSV/B ....................AT-179 A/T Wiring diagram AT - TCCSIG .................AT-162 A/T Wiring diagram AT - TCV .......................AT-156 A/T Wiring diagram AT - TPS........................AT-185 A/T Wiring diagram AT - VSSMTR................AT-202 ATP switch ....................................................TF-149 ATP warning lamp.........................................TF-139 Audio .............................................................EL-191 AUDIO - Wiring diagram ...............................EL-192 Audio and A/C control removal and installation - See Instrument panel .............BT-22 AUT/DP - Wiring diagram .............................EL-226 Auto air conditioner - Wiring diagram ......HA-35, 40 Automatic amplifier...................................HA-44, 89 Automatic drive positioner ............................EL-221 Automatic speed control system - See ASCD ........................................................EL-256 Automatic transmission fluid replacement................................................MA-23 Automatic transmission number ......................GI-45 Axle ................................................................MA-29 Axle housing (rear) .........................................AX-20 IDX-2 ALPHABETICAL INDEX B Back door ........................................................BT-16 Back door opener - See Back door ................BT-16 Back door trim.................................................BT-35 Back-up lamp ..................................................EL-78 Back-up lamp switch (M/T) ..............................MT-5 BACK/L - Wiring diagram................................EL-78 Ball joint (front) ...............................................SU-15 Basic inspection ...........................................EC-131 Battery ..............................................................SC-4 Battery/Starting/Charging System Tester................................................SC-7, 13, 23 Baulk ring (M/T) ..............................................MT-11 Blower motor ........................................HA-114, 227 Blower resistor..............................................HA-227 Body alignment ...............................................BT-62 Brake booster .................................................BR-19 Brake control valve (Proportioning valve) ..........................................................BR-12 Brake fluid change ...........................................BR-8 Brake fluid level .............................................MA-27 Brake fluid level and line check .......................BR-8 Brake hydraulic line ........................................BR-10 Brake inspection ............................................MA-27 Brake lines and cables inspection .................MA-27 Brake lining wear temporary checking ..........MA-28 Brake master cylinder ....................................BR-15 Brake pedal ....................................................BR-13 Brake switch .................................................EC-702 BRK/SW - Wiring diagram ...........................EC-704 Bulb specifications ........................................EL-536 Bumper, front ..................................................BT-13 Bumper, rear ...................................................BT-16 BYPS/V - Wiring diagram ....................EC-663, 670 C Camshaft inspection ......................................EM-45 Camshaft position sensor (PHASE) .............EC-357 CAN (Controller Area Network) ...EL-447, 452, 476, 498, 511 CAN - Wiring diagram ...EC-173, EL-453, 477, 499, 512 CAN communication ...EC-57, 172, BR-91, EL-447, 452, 476, 498, 511 Canister - See EVAP canister ........................EC-41 Center bearing assembly (propeller shaft) ...........................................................PD-11 Center bearing disassembly (propeller shaft) .............................................................PD-9 Center case (Transfer)............................TF-17, 160 CHARGE - Wiring diagram ............................SC-22 Charging system ............................................SC-21 Chassis and body maintenance ....................MA-22 CHIME - Wiring diagram...............................EL-151 CIGAR - Wiring diagram ...............................EL-175 Cigarette lighter.............................................EL-175 Circuit breaker.................................................EL-18 Clock .............................................................EL-176 CLOCK - Wiring diagram ..............................EL-176 Closed loop control (Bank 1) .......................EC-575 Closed loop control (Bank 2) .......................EC-575 Clutch cover ....................................................CL-12 Clutch disc ......................................................CL-12 Clutch drum (Transfer)..................................TF-162 Clutch fluid level.............................................MA-22 Clutch force release limit adjustment .............TF-76 Clutch master cylinder ......................................CL-8 Clutch operating cylinder ..................................CL-9 Clutch pedal ......................................................CL-5 Clutch pressure switch (Transfer).................TF-148 Clutch release bearing....................................CL-10 Clutch withdrawal lever...................................CL-10 Coil spring (front)............................................SU-10 Coil spring (rear) ............................................SU-40 Collision diagnosis..........................................RS-63 Combination lamp, front, removal and installation ...................................................BT-13 Combination lamp, rear, removal and installation ...................................................BT-36 Combination meter........................................EL-123 Combination meter removal and installation - See Instrument panel......................BT-22 Combination switch .........................................EL-32 COMPAS - Wiring diagram ...........................EL-136 Compass .......................................................EL-135 Component Location (auto A/C).....................HA-31 Component Location (manual A/C) ..............HA-209 Compression pressure ...................................EM-14 Compressor clutch removal and installation.........................................HA-175, 258 Compressor description ...............................HA-200 Compressor precaution ............................HA-7, 191 Compressor special service tool ............HA-11, 195 Connecting rod...............................................EM-67 Connecting rod bearing clearance.................EM-71 Connecting rod bushing clearance ................EM-72 Connector inspection .......................................GI-21 Console box - See Instrument panel ..............BT-22 CONSULT for ABS .........................................BR-43 CONSULT for all-mode 4WD..........................TF-65 CONSULT for engine ....................................EC-111 CONSULT for VDC.......................................BR-106 CONSULT-II general information.....................GI-39 Control valve (A/T) ........................................AT-301 Control valve (Transfer) ................................TF-165 Controller Area Network (CAN) ...EL-447, 452, 476, 498, 511 Converter housing installation.......................AT-277 Coolant mixture ratio......................................MA-13 Coolant replacement ......................................MA-15 Cooling circuit (engine) ...................................LC-11 Counter gear (M/T) .........................................MT-11 Counter gear (Transfer) ..................................TF-18 Coupling sleeve (M/T) ....................................MT-11 Crankcase emission control system See positive crankcase ventilation .............EC-56 Crankshaft ......................................................EM-69 IDX-3 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL ALPHABETICAL INDEX Crankshaft position sensor (POS) ...............EC-350 Cruise control - See ASCD ...........................EL-256 Cylinder block ................................................EM-63 Cylinder head .................................................EM-41 Cylinder head bolt tightening .........................EM-52 D Data link connector for Consult ....................EC-111 Daytime light system.......................................EL-50 Daytime running light - See Daytime light system .................................................EL-50 DEF - Wiring diagram ...................................EL-179 Detonation sensor - See Knock sensor .......EC-345 Diagnostic trouble code (DTC) for OBD system ..................................................EC-10, 86 Diagnostic trouble code (DTC) inspection priority chart .......................................EC-137 Differential carrier assembly.....................PD-31, 58 Differential carrier disassembly ......................PD-45 Differential gear oil replacement ....................MA-26 Dimensions ......................................................GI-46 D/LOCK - Wiring diagram .............................EL-278 Dome light - See Interior lamp .......................EL-97 Door glass .......................................................BT-19 Door lock .........................................................BT-19 Door mirror ......................................................BT-61 Door trim .........................................................BT-31 Door, front .......................................................BT-19 Door, rear ........................................................BT-21 Drive belt inspection ......................................MA-14 Drive chain (Transfer) .............................TF-18, 162 Drive pinion diff. inspection ......................PD-24, 48 Drive pinion height ...................................PD-26, 54 Drive plate runout ..........................................EM-73 Drive shaft ......................................................MA-30 Drive shaft (front)............................................AX-12 Dropping resistor (A/T)..................................AT-173 DTC work support ........................................EC-123 DTRL - Wiring diagram ...................................EL-55 E ECM input/output signal ...............................EC-149 ECM power supply ...............................EC-164, 473 ECM/PW - Wiring diagram ...........................EC-475 ECTS - Wiring diagram ................................EC-238 Electric sun roof ............................................EL-207 Electric throttle control actuator ...........EC-494, 496 Electrical diagnoses.........................................GI-24 Electrical ignition system ................................EC-39 Electrical unit ................................................Foldout Electrical units location .................................EL-517 Engine compartment.......................................BT-63 Engine control circuit diagram........................EC-31 Engine control component parts location .......................................................EC-26 Engine control module (ECM) ......................EC-471 Engine control system diagram and chart ............................................................EC-34 Engine coolant temperature sensor (ECTS)..............................................EC-236, 249 Engine fail-safe system ................................EC-138 Engine oil filter replacement ..........................MA-19 Engine oil precautions .......................................GI-7 Engine oil replacement ..................................MA-18 Engine outer component parts ......................EM-10 Engine removal ..............................................EM-59 Engine room - See Engine compartment................................................BT-63 Engine serial number ......................................GI-45 ETC1 - Wiring diagram ................................EC-498 ETC2 - Wiring diagram ................................EC-506 ETC3 - Wiring diagram.................................EC-511 EVAP canister.................................................EC-42 EVAP canister purge volume control solenoid valve.............................EC-41, 396, 616 EVAP canister vent control valve .........................................EC-403, 628, 636 EVAP control system (small leak) diagnosis ..................EC-381, 425, 438, 601, 645 EVAP control system pressure sensor ...............................................EC-410, 416 EVAP control system purge flow monitoring diagnosis.........................................EC-371 EVAP vapor lines inspection..........................MA-21 Evaporative emission (EVAP) system............EC-41 Exhaust system ................................................FE-9 Exhaust system inspection ............................MA-22 Exterior ............................................................BT-36 F 4LO indicator lamp........................................TF-141 4WD shift indicator lamp...............................TF-135 4WD shift switch ...........................................TF-148 4WD solenoid valve ......................................TF-148 4WD warning lamp .........................................TF-46 Fan control amp............................................HA-118 Fan switch ....................................................HA-227 F/FOG - Wiring diagram .................................EL-80 Final drive disassembly ..................................PD-44 Final drive pre-inspection ...............................PD-44 Final drive removal and installation ...............PD-44 Finisher, interior - See Trim ............................BT-29 Fluid temperature sensor (A/T) .....................AT-116 Fluids..............................................................MA-12 Flywheel (clutch) .............................................CL-13 Flywheel runout..............................................EM-73 Fog lamp, front................................................EL-79 Fog lamp, front, removal and installation ...................................................BT-13 Fork rod (M/T) ................................................MT-13 Forward clutch...............................................AT-320 F/PUMP - Wiring diagram ............................EC-765 Freeze frame data ..........................................EC-87 Front axle..........................................................AX-2 Front bumper ..................................................BT-13 IDX-4 ALPHABETICAL INDEX Front case (Transfer) ..............................TF-17, 170 Front combination lamp removal and installation ...................................................BT-13 Front disc brake .............................................BR-22 Front door .......................................................BT-19 Front drive shaft (Transfer).....................TF-18, 162 Front final drive disassembly (4WD) ..............PD-19 Front final drive pre-inspection (4WD) ...........PD-19 Front final drive removal and installation (4WD)...................................................PD-19 Front fog lamp.................................................EL-79 Front fog lamp removal and installation .........BT-13 Front revolution sensor (Transfer) ................TF-149 Front seat ........................................................BT-43 Front seat belt ..................................................RS-5 Front suspension ..............................................SU-3 Front washer .................................................EL-163 Front wiper ....................................................EL-163 Fuel cut control (at no load & high engine speed) .............................................EC-41 Fuel filler lid.....................................................BT-16 Fuel filter replacement ...................................MA-17 Fuel gauge ....................................................EL-123 Fuel injection system ...........................EC-304, 312 Fuel injection system (Bank 1) ............EC-304, 312 Fuel injection system (Bank 2) ............EC-304, 312 Fuel level sensor..........................EC-454, 456, 458 Fuel line inspection ........................................MA-17 Fuel precautions ................................................GI-8 Fuel pressure check .......................................EC-64 Fuel pressure regulator ..................................EC-65 Fuel pressure release ....................................EC-64 Fuel pump ....................................................EC-763 Fuel system ......................................................FE-4 Fuel tank temperature sensor ..............EC-319, 322 Fuel tank vacuum relief valve ........................EC-42 FUELB1 - Wiring diagram ....................EC-306, 314 FUELB2 - Wiring diagram ....................EC-307, 315 Fuse ................................................................EL-18 Fuse and fusible link box .............................Foldout Fuse block ....................................................Foldout Fusible link ......................................................EL-18 G Garage jack and safety stand .........................GI-48 Gauges..........................................................EL-123 Gear components (M/T) .................................MT-11 Generator - See Alternator .............................SC-30 Generic scan tool (GST) ..............................EC-125 Glass ...............................................................BT-19 Glass hatch opener, electric .........................EL-214 Grease ...........................................................MA-12 Ground distribution..........................................EL-19 H Harness connector ............................................EL-7 Harness connector inspection .........................GI-21 Harness layout ..............................................EL-520 Hazard warning lamp ......................................EL-83 Headlamp ........................................................EL-35 Headlining - See Roof trim .............................BT-34 Heated oxygen sensor 1 (bank 1)....................EC-256, 264, 278, 541, 549 Heated oxygen sensor 1 (bank 2)....................EC-256, 264, 278, 541, 549 Heated oxygen sensor 2 (bank 1) ............................EC-287, 295, 557, 566 Heated oxygen sensor 2 (bank 2) ............................EC-287, 295, 557, 566 Heated oxygen sensor 2 heater (bank 1) ............................................EC-179, 187 Heated oxygen sensor 2 heater (bank 2) ............................................EC-179, 187 Heated oxygen sensor heater..............EC-179, 187 Heated seat .......................................BT-46, EL-217 Height (Dimensions) ........................................GI-46 HFC134a (R134a) system precaution .....HA-3, 187 HFC134a (R134a) system service procedure..........................................HA-170, 253 HFC134a (R134a) system service tools ....................................................HA-12, 196 HFC134a system service equipment precaution .............................................HA-8, 192 High clutch.....................................................AT-317 H/LAMP - Wiring diagram ...............................EL-39 Homelink universal transceiver .....................EL-371 Hood................................................................BT-13 Horn ..............................................................EL-174 HORN - Wiring diagram................................EL-174 How to erase DTC for OBD system.............EC-100 HSEAT - Wiring diagram...............................EL-217 GI MA EM LC EC FE CL MT AT TF PD AX SU I BR IATS - Wiring diagram..........................EC-228, 233 Identification plate............................................GI-45 Idle air volume learning ..................................EC-81 Idle mixture ratio.............................................EC-69 Idle speed...............................................EC-69, 131 IGN/SG - Wiring diagram .............................EC-749 Ignition control system .................................EC-748 Ignition timing .........................................EC-69, 131 ILL - Wiring diagram .......................................EL-91 Illumination ......................................................EL-88 In vehicle sensor ..........................................HA-158 In-cabin Microfilter ................................HA-184, 267 INJECT - Wiring diagram .............................EC-759 Injector ..........................................................EC-758 Injector removal and installation ....................EC-66 Instrument panel .............................................BT-22 INT/L - Wiring diagram..................................EL-100 Intake air temparature sensor......EC-226, 231, 252 Intake door control linkage adjustment ........................................HA-113, 225 Intake door motor .................................HA-105, 220 Intake manifold...............................................EM-12 IDX-5 ST RS BT HA SC EL ALPHABETICAL INDEX Intake sensor ................................................HA-165 Intake valve timing control ...................EC-175, 485 Intake valve timing control (Bank 1) ....EC-175, 485 Intake valve timing control (Bank 2) ....EC-175, 485 Intake valve timing control solenoid valve .........................................................EC-178 Intake valve timing control solenoid valve (Bank 1)...........................................EC-488 Intake valve timing control solenoid valve (Bank 2)...........................................EC-488 Integrated homelink transmitter ....................EL-371 Interior .............................................................BT-29 Interior lamp ....................................................EL-97 Interior lamp on-off control..............................EL-98 Internal gear (Transfer) .................................TF-171 IVCB1 - Wiring diagram ...............................EC-490 IVCB2 - Wiring diagram ...............................EC-491 J Jacking points ..................................................GI-47 Journal bearing assembly (propeller shaft) ...........................................................PD-11 Journal bearing disassembly (propeller shaft) ...........................................................PD-10 Junction box (J/B).........................................Foldout K KEYLES - Wiring diagram ............................EL-304 Keyless entry system - See Multi-remote control system ..................................EL-299 Knock sensor (KS) .......................................EC-345 Knuckle spindle ..............................................AX-10 KS - Wiring diagram .....................................EC-346 L Length (Dimensions) .......................................GI-46 License lamp ...................................................EL-66 Lifting points ....................................................GI-49 Limited slip diff. adjustment............................PD-51 Limited slip diff. assembly ..............................PD-52 Limited slip diff. disassembly..........................PD-49 Limited slip diff. inspection .............................PD-50 Line pressure solenoid valve ........AT-153, 167, 173 Line pressure switch (Transfer) ....................TF-148 Line pressure test (A/T) ..................................AT-64 Liquid gasket application .................................EM-3 LOAD - Wiring diagram ................................EC-787 Location of electrical units ............................EL-517 Lock, door .......................................................BT-19 Low and reverse brake .................................AT-324 Low tire pressure warning system .................SU-16 Low tire pressure warning system trouble diagnoses .......................................SU-25 Low tire pressure warning system Wiring diagram............................................SU-18 Lubricant (R134a) A/C .........................HA-172, 255 Lubricants.......................................................MA-12 Lubrication circuit (engine) ...............................LC-3 Lubrication-locks, hinges and hood latches ........................................................MA-30 Luggage room lamp ........................................EL-97 M MAFS - Wiring diagram ......................EC-198, 207, 214, 222, 480 Magnet clutch...............................HA-125, 175, 258 MAIN - Wiring diagram.................................EC-165 Main drive gear (M/T) .....................................MT-11 Main gear (Transfer) .......................................TF-18 Main oil pump (Transfer)...............................TF-168 Mainshaft (M/T)...............................................MT-11 Mainshaft (Transfer)................................TF-18, 162 Maintenance (engine) ....................................MA-14 MAJOR OVERHALL......................................AT-281 Major overhaul (Transfer) .......................TF-16, 157 Malfunction indicator lamp (MIL) ..................EC-102 Manual air conditioner - Wiring diagram ......HA-213 Manual transmission number ..........................GI-45 Manual transmission oil replacement ............MA-22 Mass air flow sensor (MAFS) .....................EC-194, 203, 211, 219, 478 Master cylinder (brake) ..................................BR-15 Master cylinder (clutch) ....................................CL-8 Meter .............................................................EL-123 METER - Wiring diagram..............................EL-128 MIL & Data link connectors circuit ...............EC-791 MIL/DL - Wiring diagram ..............................EC-791 MIRROR - Wiring diagram............................EL-213 Mirror defogger .............................................EL-177 Mirror, door......................................................BT-61 Mirror, out side ................................................BT-61 Misfire ...........................................................EC-335 Mode door control linkage adjustment...HA-99, 244 Mode door motor ............................................HA-92 Model variation ................................................GI-43 Molding - See Exterior ....................................BT-36 M/T major overhaul ........................................MT-10 M/T removal and installation ............................MT-7 Multi-remote control system..........................EL-299 Multiplex communication ..............................HA-168 Multiport fuel injection (MFI) system ..............EC-37 Multiport fuel injection precautions ....................GI-6 N NATS (Nissan anti-theft system)...................EL-375 NATS - Wiring diagram .................................EL-377 NAVI - wiring diagram ...................................EL-404 Navigation System ........................................EL-395 Neutral-4LO switch .......................................TF-149 IDX-6 ALPHABETICAL INDEX NVH troubleshooting (AX) ..........................AX-3, 19 NVH troubleshooting (BR)................................BR-7 NVH troubleshooting (CL) ................................CL-4 NVH troubleshooting (M/T) ..............................MT-4 NVH troubleshooting (PD)................................PD-4 NVH troubleshooting (ST).................................ST-6 NVH troubleshooting (SU) .........................SU-4, 37 NVH troubleshooting (Transfer) ......................TF-10 NVIS (Nissan vehicle immobilizer system) ......................................................EL-375 O O2H1B1 - Wiring diagram ............................EC-182 O2H1B2 - Wiring diagram ............................EC-183 O2H2B1 - Wiring diagram ............................EC-190 O2H2B2 - Wiring diagram ............................EC-191 O2S1B1 - Wiring diagram............EC-258, 267, 281 O2S1B2 - Wiring diagram............EC-259, 268, 282 O2S2B1 - Wiring diagram ...EC-289, 298, 560, 569 O2S2B2 - Wiring diagram ...EC-290, 299, 561, 570 Oil change (capacity) .....................................MA-12 Oil filter (Transfer) .........................................TF-155 Oil pan (engine) .............................................EM-16 Oil pressure (engine) ........................................LC-5 Oil pump (A/T)...............................................AT-297 Oil pump (engine) .............................................LC-6 Oil pump regulator valve (engine) ....................LC-7 Oil seal replacement (engine)........................EM-39 Oil seal replacement (front final drive 4WD)...........................................................PD-16 Oil seal replacement (front of final drive) ...........................................................PD-41 On board diagnostic system ..........................EC-85 Operating cylinder (clutch)................................CL-9 ORVR (On-board Refueling Vapor Recovery)....................................................EC-47 Out side mirror ................................................BT-61 Overdrive control switch................................AT-263 Overheat .......................................................EC-587 Overrun clutch ...............................................AT-320 Overrun clutch solenoid valve.......................AT-192 P P/ANT - Wiring diagram................................EL-204 Park/Neutral position switch .........................EC-696 Park/neutral position switch (A/T) .........AT-109, 263 Park/neutral position switch (M/T)....................MT-5 Parking brake control .....................................BR-30 Parking lamp ...................................................EL-66 PCV (positive crankcase ventilation) .............EC-56 Periodic maintenance ......................................MA-7 PGC/V - Wiring diagram ......................EC-399, 619 PHASE - Wiring diagram .............................EC-359 Pinion bearing preload diff. ............................PD-26 Pinion gear height diff. .............................PD-26, 54 Piston assembly .............................................EM-73 Piston pin inspection ......................................EM-65 Piston ring inspection.....................................EM-66 Piston to bore clearance ................................EM-68 Planetary carrier (Transfer)...........................TF-171 PNP/SW - Wiring diagram ...........................EC-698 POS - Wiring diagram ..................................EC-352 POWER - Wiring diagram...............................EL-12 Power antenna ..............................................EL-203 Power door lock ............................................EL-276 Power door mirror .........................................EL-213 Power seat ....................................................EL-215 Power steering fluid level .....................MA-29, ST-8 Power steering gear........................................ST-17 Power steering hydraulic pressure .................ST-10 Power steering oil pump .................................ST-27 Power steering pressure (PSP) sensor .......EC-466 Power steering system bleeding.......................ST-9 Power supply routing.......................................EL-11 Power transistor & ignition coil.....................EC-748 Power window ...............................................EL-257 PRE/SE - Wiring diagram ....................EC-412, 418 Precautions (General) .......................................GI-4 Pressure plate - See Clutch cover .................CL-12 Pressure test (A/T) ..........................................AT-64 Propeller shaft ..................................................PD-3 Propeller shaft greasing .................................MA-25 Propeller shaft inspection ..............................MA-25 Propeller shaft on vehicle service ....................PD-8 Propeller shaft vibration ...................................PD-8 PS/SEN - Wiring diagram ............................EC-467 GI MA EM LC EC FE CL MT AT TF PD R AX Rack retainer adjustment ..................................ST-8 Radiator ....................................................LC-21, 23 Radio - See Audio.........................................EL-191 Rear air spoiler ...............................................BT-36 Rear axle ........................................................AX-18 Rear bumper ...................................................BT-16 Rear case (Transfer)...............................TF-17, 160 Rear combination lamp removal and installation ...................................................BT-36 Rear cover packing replacement diff. ............PD-17 Rear door ........................................................BT-21 Rear drum brake ............................................BR-26 Rear heated oxygen sensor (HO2S) ...........EC-557 Rear seat ........................................................BT-47 Rear seat belt ...................................................RS-6 Rear side window ...........................................BT-60 Rear suspension ............................................SU-37 Rear washer..................................................EL-168 Rear window defogger ..................................EL-177 Rear wiper.....................................................EL-168 Refregerant pressure sensor ...............HA-132, 251 Refrigerant connection precaution ...........HA-5, 189 Refrigerant discharging evacuating charging ....................................................HA-170 Refrigerant general precaution ................HA-4, 188 Refrigerant lines ...................................HA-179, 262 Refrigerant pressure sensor.........................EC-770 IDX-7 SU BR ST RS BT HA SC EL ALPHABETICAL INDEX Refrigeration cycle .................................HA-16, 200 Release bearing (clutch).................................CL-10 REMOTE - Wiring diagram ...........................EL-202 Removal and installation (A/T)......................AT-276 Removal and installation (Transfer)........TF-15, 156 Reverse clutch...............................................AT-314 Reverse idler shaft (M/T)................................MT-11 Reverse lamp switch (M/T) - See Back-up lamp switch (M/T)...........................MT-5 Reverse main gear (M/T) ...............................MT-11 Revolution sensor (A/T) ................................AT-121 Ring gear diff. inspection .........................PD-24, 48 Road wheel size ..............................................GI-46 Roof trim .........................................................BT-34 Room lamp - See Interior lamp ......................EL-97 RP/SEN - Wiring diagram ............................EC-771 S SAE J1930 terminology list .............................GI-54 Screw jack .......................................................GI-47 Seal - See Exterior .........................................BT-36 SEAT - Wiring diagram .................................EL-215 Seat belt inspection .............................MA-31, RS-8 Seat belt pre-tensioner .....................................RS-3 Seat belt pre-tensioner disposal ....................RS-25 Seat belt, front ..................................................RS-5 Seat belt, rear...................................................RS-6 Seat, front .......................................................BT-43 Seat, rear ........................................................BT-47 Self-diagnosis (Transfer).................................TF-62 SEN/PW - Wiring diagram ...........................EC-598 SHIFT - Wiring diagram ................................AT-266 Shift control (Transfer) ..............................TF-19, 31 Shift control components (M/T) ......................MT-13 Shift fork (M/T) ...............................................MT-13 Shift lever .......................................................MT-13 Shift lock system ...........................................AT-265 Shift schedule................................................AT-356 Shift solenoid valve A (A/T) ..AT-131, 143, 153, 177 Shift solenoid valve B (A/T)..AT-131, 137, 153, 181 Shock absorber (rear) ....................................SU-40 Side air bag ....................................................RS-22 Side bearing preload (front final drive 4WD)...........................................................PD-25 Side trim ..........................................................BT-29 Side window - See Rear side window ............BT-60 Smart entrance control unit ..........................EL-362 SMJ (super multiple junction) .......................Foldout Spare tire size .................................................GI-46 Spark plug replacement .................................MA-20 Speedometer.................................................EL-123 Spiral cable.....................................................RS-18 Splice location.......................EL-452, 476, 498, 511 Spot lamp ........................................................EL-97 Spring (Wheelarch) height ...............................SU-7 SROOF - Wiring diagram .............................EL-208 SRS - See Supplemental Restraint System ........................................................RS-11 SRS - Wiring diagram ....................................RS-38 Stabilizer bar (front)........................................SU-13 Stabilizer bar (rear) ........................................SU-42 Stall test (A/T) .................................................AT-61 Standardized relay ............................................EL-9 START - Wiring diagram.................................SC-11 Starter .............................................................SC-19 Starting system...............................................SC-10 Steering gear, linkage and transfer gear inspection ...........................................MA-28 Steering linkage ..............................................ST-17 Steering switch................................................EL-34 Steering transfer gear .....................................ST-15 Steering wheel and column.............................ST-11 Steering wheel play ..........................................ST-7 Steering wheel turning force .............................ST-9 Stop lamp ........................................................EL-76 Stop lamp switch..........................EC-685, 702, 775 STOP/L - Wiring diagram................................EL-76 Striking rod (M/T) ...........................................MT-13 Strut (front) .....................................................SU-10 Sub-gear (M/T) ...............................................MT-11 Sub-oil pump (Transfer) ................................TF-168 Sun gear (Transfer).......................................TF-171 Sunload sensor ............................................HA-162 Sunroof............................................................BT-48 Sunroof, electric ............................................EL-207 Supplemental Restraint System .....................RS-11 Supplemental restraint system - Wiring diagram .......................................................RS-38 Suspension ....................................................MA-29 S/VCSW - Wiring diagram ...........................EC-579 Swirl control valve control solenoid valve .................................................EC-514, 535 Swirl control valve control vacuum check switch .............................................EC-577 SWL/V - Wiring diagram ......................EC-518, 537 Symbols and abbreviations .............................GI-10 Symptom matrix chart ..................................EC-139 Synchronizer (M/T) .........................................MT-11 System readiness test (SRT) code ................EC-87 T 2-4WD shift solenoid valve ...........................TF-148 T&FLID - Wiring diagram ..............................EL-214 Tachometer ...................................................EL-123 Tail lamp ..........................................................EL-66 TAIL/L - Wiring diagram ..................................EL-69 TCM circuit diagram ........................................AT-13 TCM inspection table ......................................AT-95 Temperature control cable and linkage adjustment ................................................HA-242 TFTS - Wiring diagram.................................EC-324 Theft warning system....................................EL-328 Thermometer.................................................EL-135 Thermostat ......................................................LC-18 Three way catalyst function (Bank 1) ..........EC-366 Three way catalyst function (Bank 2) ..........EC-366 Three way catalyst precautions.........................GI-6 Throttle body ..................................................EM-12 IDX-8 ALPHABETICAL INDEX Throttle control motor ...................................EC-509 Throttle control motor relay ..........................EC-504 Throttle position sensor (TPS)................EC-241, 327, 592, 594, 596, 723 Throttle valve closed position learning...........EC-81 Throwout bearing - See Clutch release bearing ........................................................CL-10 Tie-rod .............................................................ST-21 Tie-rod ball joints.............................................ST-21 Tightening torque of standard bolts.................GI-52 Timing chain...................................................EM-21 Tire rotation ....................................................MA-26 Tire size ...........................................................GI-46 Tooth contact (front final drive 4WD) .............PD-30 Tooth contact diff. ...........................................PD-57 Torque converter clutch solenoid valve ..................................................AT-158, 167 Torque converter installation .........................AT-277 Tow truck towing ..............................................GI-49 Towing point.....................................................GI-51 TPS1 - Wiring diagram.................................EC-330 TPS2 - Wiring diagram.................................EC-244 TPS3 - Wiring diagram.................................EC-726 Transfer case ..................................................TF-17 Transfer control unit inspection table..............TF-90 Transfer dropping resistor.............................TF-149 Transfer fluid replacement (All-mode 4WD model) ...............................................MA-24 Transfer fluid replacement (Part time 4WD model) ...............................................MA-24 Transfer fluid temperature sensor.................TF-148 Transfer motor...............................................TF-155 Transfer motor relay......................................TF-150 Transfer serial number ....................................GI-46 Transmission case (M/T)................................MT-10 TRANSMT - Wiring diagram .........................EL-371 Tread-FR&RR (Dimensions)............................GI-46 Trim .................................................................BT-29 TRNSCV - Wiring diagram ...........................EL-371 Trouble diagnoses ...........................................GI-34 Turbine revolution sensor..............................AT-209 TURN - Wiring diagram ..................................EL-85 Turn signal lamp .............................................EL-83 Two trip detection logic ..................................EC-85 Two-pole lift .....................................................GI-49 U Under body .....................................................BT-65 V Vacuum cut valve ...........................................EC-41 Vacuum cut valve bypass valve.....EC-41, 661, 667 Vacuum hose (brake system).........................BR-21 Vacuum hose drawing (Engine control) .........EC-35 Valve clearance..............................................EM-54 Valve guide.....................................................EM-46 Valve seat.......................................................EM-47 Valve spring....................................................EM-49 Vanity mirror lamp ...........................................EL-97 VDC (vehicle dynamics control) .....................BR-89 Vehicle identification number...........................GI-44 Vehicle recovery (freeing a stuck vehicle).........................................................GI-51 Vehicle security (theft warning) system ........EL-328 Vehicle speed sensor (VSS) ........................EC-460 VEHSEC - Wiring Diagram ...........................EL-336 VENT/V - Wiring diagram ............EC-405, 630, 639 VIAS .............................................................EC-739 VIAS/V - Wiring diagram ..............................EC-741 Viscosity number (SAE) .................................MA-13 W Wait detection switch ....................................TF-149 WARN - Wiring diagram ...............................EL-140 Warning chime ..............................................EL-149 Warning lamps ..............................................EL-139 Washer, front.................................................EL-163 Washer, rear..................................................EL-168 Water pump ....................................................LC-13 Water temperature gauge .............................EL-123 Weatherstrip - See Exterior ............................BT-36 Wheel balance ...............................................MA-26 Wheel bearing (front)........................................AX-4 Wheel bearing (rear) ......................................AX-19 Wheel hub (front)..............................................AX-6 Wheel sensor (VDC) ....................................BR-142 Wheel sensors (ABS)...............................BR-56, 80 Wheel size .......................................................GI-46 Wheelarch height .............................................SU-7 Wheelbase (Dimensions) ................................GI-46 Width (Dimensions) .........................................GI-46 WINDOW - Wiring diagram ..........................EL-261 Window, door ..................................................BT-19 Window, rear side ...........................................BT-60 Window, side - See Rear side window ...........BT-60 Windshield.......................................................BT-58 WIP/R - Wiring diagram ................................EL-170 WIPER - Wiring diagram ..............................EL-165 Wiper, front....................................................EL-163 Wiper, rear ....................................................EL-168 Wiring Diagram (Cell code) list .....................EL-537 Wiring diagram (Transfer) ...............................TF-53 Wiring diagrams ...............................................GI-11 Withdrawal lever (clutch) ................................CL-10 Wrist pin - See Piston pin inspection.............EM-65 IDX-9 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL NOTES HEATER & AIR CONDITIONER SECTION HA GI MA EM LC EC FE CONTENTS AUTO PRECAUTIONS ...............................................................3 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″...............3 Precautions for Working with HFC-134a (R-134a) .....3 General Refrigerant Precautions .................................4 Precautions for Leak Detection Dye............................4 Precaution for Identification Label on Vehicle .............5 Precautions for Refrigerant Connection ......................5 Precautions for Servicing Compressor........................7 Precautions for Service Equipment .............................8 Wiring Diagrams and Trouble Diagnoses..................10 PREPARATION .............................................................11 Special Service Tools ................................................11 HFC-134a (R-134a) Service Tools and Equipment..................................................................12 DESCRIPTION ...............................................................16 Refrigeration System .................................................16 V-6 Variable Displacement Compressor....................17 Component Layout ....................................................21 Introduction ................................................................22 Features.....................................................................22 Overview of Control System......................................25 Control Operation ......................................................26 Discharge Air Flow.....................................................29 System Description....................................................30 TROUBLE DIAGNOSES................................................31 Component Location..................................................31 Circuit Diagram (Without Navigation System)...........34 Wiring Diagram - A/C, A - (Without Navigation System)......................................................................35 Circuit Diagram (With Navigation System)................39 Wiring Diagram - A/C, A - (With Navigation System)......................................................................40 Auto Amp. Terminals and Reference Value...............44 Self-diagnosis ............................................................48 How to Perform Trouble Diagnoses for Quick and Accurate Repair ..................................................79 CL Operational Check .....................................................80 A/C System................................................................88 Mode Door Motor.......................................................92 Air Mix Door Motor ..................................................100 Intake Door Motor....................................................105 Blower Motor............................................................114 Magnet Clutch..........................................................125 Insufficient Cooling ..................................................133 Insufficient Heating ..................................................143 Noise........................................................................146 Self-diagnosis ..........................................................147 Memory Function .....................................................150 ECON (ECONOMY) Mode ......................................153 Ambient Sensor Circuit............................................155 In-vehicle Sensor Circuit..........................................158 Sunload Sensor Circuit............................................162 Intake Sensor Circuit ...............................................165 Air Mix Door Motor PBR Circuit ..............................167 Multiplex Communication Circuit .............................168 SERVICE PROCEDURE..............................................170 HFC-134a (R-134a) Service Procedure ..................170 Maintenance of Lubricant Quantity in Compressor .............................................................172 Compressor .............................................................175 Compressor Clutch ..................................................175 Refrigerant Lines .....................................................179 Checking for Refrigerant Leaks...............................180 Electronic Refrigerant Leak Detector ......................180 Fluorescent Dye Leak Detector...............................183 Belt...........................................................................184 In-cabin Microfilter ...................................................184 SERVICE DATA AND SPECIFICATIONS (SDS) .......186 Auto..........................................................................186 MT AT TF PD AX SU BR ST RS BT SC EL MANUAL PRECAUTIONS ...........................................................187 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″...........187 IDX CONTENTS Precautions for Working with HFC-134a (R-134a) .187 General Refrigerant Precautions .............................188 Precautions for Leak Detection Dye........................188 Precaution for Identification Label on Vehicle .........189 Precautions for Refrigerant Connection ..................189 Precautions for Servicing Compressor....................191 Precautions for Service Equipment .........................192 Wiring Diagrams and Trouble Diagnoses................194 PREPARATION ...........................................................195 Special Service Tools ..............................................195 HFC-134a (R-134a) Service Tools and Equipment................................................................196 DESCRIPTION .............................................................200 Refrigeration System ...............................................200 V-6 Variable Displacement Compressor..................201 Component Layout ..................................................205 Control Operation ....................................................206 Discharge Air Flow...................................................207 System Description..................................................208 TROUBLE DIAGNOSES..............................................209 Component Location................................................209 Wiring Diagram - HEATER -....................................211 Circuit Diagram - Air Conditioner.............................212 Wiring Diagram - A/C, M - .......................................213 How to Perform Trouble Diagnoses for Quick and Accurate Repair ................................................216 (Cont’d) Operational Check ...................................................217 Intake Door ..............................................................219 Blower Motor............................................................226 Insufficient Cooling ..................................................233 Insufficient Heating ..................................................241 Air Outlet..................................................................243 Magnet Clutch..........................................................245 Noise........................................................................252 SERVICE PROCEDURE..............................................253 HFC-134a (R-134a) Service Procedure ..................253 Maintenance of Lubricant Quantity in Compressor .............................................................255 Compressor .............................................................258 Compressor Clutch ..................................................258 Refrigerant Lines .....................................................262 Checking for Refrigerant Leaks...............................263 Electronic Refrigerant Leak Detector ......................263 Fluorescent Dye Leak Detector...............................266 Belt...........................................................................267 In-cabin Microfilter ...................................................267 SERVICE DATA AND SPECIFICATIONS (SDS) .......269 Manual .....................................................................269 HA-2 PRECAUTIONS AUTO Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” GI NAHA0153 The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS composition which is available to NISSAN MODEL R50 is as follows: 쐌 For a frontal collision The Supplemental Restraint System consists of driver air bag module (located in the center of the steering wheel), front passenger air bag module (located on the instrument panel on passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. 쐌 For a side collision The Supplemental Restraint System consists of side air bag module (located in the outer side of front seat), side curtain air bag module (locating in the headlining side of front and rear seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision). WARNING: 쐌 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. 쐌 Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connector (and by yellow harness protector or yellow insulation tape before the harness connectors). Precautions for Working with HFC-134a (R-134a) NAHA0154 WARNING: 쐌 CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. If the refrigerants are mixed and compressor failure is likely to occur, refer to “CONTAMINATED REFRIGERANT” below. To determine the purity of HFC-134a (R-134a) in the vehicle and recovery tank, use Refrigerant Recovery/Recycling Recharging equipment (ACR4) (J-39500-NI) and Refrigerant Identifier. 쐌 Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components. If lubricant other than that specified is used, compressor malfunction is likely to occur. 쐌 The specified HFC-134a (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 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 A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Remove HFC-134a (R-134a) from the A/C system, using certified service equipment meeting requirements of SAE J2210 HFC-134a (R-134a) recycling equipment, or J2209 HFC-134a (R-134a) recovery equipment. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers. e) Do not allow lubricant (Nissan A/C System Oil Type S) to come in contact with styrofoam parts. Damage may result. MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SC CONTAMINATED REFRIGERANT NAHA0154S01 If a refrigerant other than pure HFC-134a (R-134a) is identified in a vehicle, your options are: 쐌 Explain to the customer that environmental regulations prohibit the release of contaminated refrigerant into the atmosphere. 쐌 Explain that recovery of the contaminated refrigerant could damage your service equipment and refrigerant supply. HA-3 EL IDX PRECAUTIONS AUTO Precautions for Working with HFC-134a (R-134a) (Cont’d) 쐌 쐌 쐌 Suggest the customer return the vehicle to the location of previous service where the contamination may have occurred. If you choose to perform the repair, recover the refrigerant using only dedicated equipment and containers. Do not recover contaminated refrigerant into your existing service equipment. If your facility does not have dedicated recovery equipment, you may contact a local refrigerant product retailer for available service. This refrigerant must be disposed of in accordance with all federal and local regulations. In addition, replacement of all refrigerant system components on the vehicle is recommended. If the vehicle is within the warranty period, the air conditioner warranty is void. Please contact Nissan Customer Affairs for further assistance. General Refrigerant Precautions NAHA0155 WARNING: 쐌 Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the refrigerant every time an air conditioning system is discharged. 쐌 Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or air conditioning system. 쐌 Do not store or heat refrigerant containers above 52°C (125°F). 쐌 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. 쐌 Do not intentionally drop, puncture, or incinerate refrigerant containers. 쐌 Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns. 쐌 Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent suffocation. 쐌 Do not pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air conditioning systems with compressed air during repair. Some mixtures of air and HFC-134a (R-134a) have been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury or property damage. Additional health and safety information may be obtained from refrigerant manufacturers. Precautions for Leak Detection Dye 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 NAHA0247 The A/C system contains a fluorescent leak detection dye used for locating refrigerant leaks. An ultraviolet (UV) lamp is required to illuminate the dye when inspecting for leaks. Always wear fluorescence enhancing UV safety glasses to protect your eyes and enhance the visibility of the fluorescent dye. A compressor shaft seal should not be repaired because of dye seepage. The compressor shaft seal should only be repaired after confirming the leak with an electronic refrigerant leak detector (J-41995). Always remove any dye from the leak area after repairs are complete to avoid a misdiagnosis during a future service. Do not allow dye to come into contact with painted body panels or interior components. If dye is spilled, clean immediately with the approved dye cleaner. Fluorescent dye left on a surface for an extended period of time cannot be removed. Do not spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.). Do not use more than one refrigerant dye bottle (1/4 ounce /7.4 cc) per A/C system. Leak detection dyes for HFC-134a (R-134a) and CFC-12 (R-12) A/C systems are different. Do not use HFC-134a (R-134a) leak detection dye in CFC-12 (R-12) A/C system or CFC-12 (R-12) leak detection dye in HFC-134a (R-134a) A/C systems or A/C system damage may result. The fluorescent properties of the dye will remain for over three (3) years unless a compressor failure occurs. HA-4 PRECAUTIONS AUTO Precaution for Identification Label on Vehicle Precaution for Identification Label on Vehicle 쐌 쐌 쐌 NAHA0248 Vehicles with factory installed fluorescent dye have this identification label on the under side of hood. Vehicles with factory installed fluorescent dye have a green label. Vehicles without factory installed fluorescent dye have a blue label. GI MA EM LC SHA436FA Precautions for Refrigerant Connection EC NAHA0156 A new type refrigerant connection has been introduced to all refrigerant lines except the following location. 쐌 Expansion valve to evaporator FEATURES OF NEW TYPE REFRIGERANT CONNECTION 쐌 쐌 FE NAHA0156S01 The O-ring has been relocated. It has also been provided with a groove for proper installation. This eliminates the chance of the O-ring being caught in, or damaged by, the mating part. The sealing direction of the O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing characteristics. The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby facilitating piping connections. CL MT AT TF PD AX SU BR ST SHA815E RS BT SC EL IDX HA-5 PRECAUTIONS AUTO Precautions for Refrigerant Connection (Cont’d) O-RING AND REFRIGERANT CONNECTION NAHA0156S02 RHA068I CAUTION: The new and former refrigerant connections use different O-ring configurations. Do not confuse O-rings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or around, the connection. O-Ring Part Numbers and Specifications Connection type NAHA0156S0201 O-ring size New Part number D mm (in) W mm (in) 92471 N8210 6.8 (0.268) 1.85 (0.0728) 92470 N8200 6.07 (0.2390) 1.78 (0.0701) 92472 N8210 10.9 (0.429) 2.43 (0.0957) 92475 71L00 11.0 (0.433) 2.4 (0.094) 92473 N8210 13.6 (0.535) 2.43 (0.0957) 92475 72L00 14.3 (0.563) 2.3 (0.0906) 92474 N8210 16.5 (0.650) 2.43 (0.0957) 92477 N8200 17.12 (0.6740) 1.78 (0.0701) 8 Former New 12 Former New 16 Former SHA814E New 19 Former 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. HA-6 PRECAUTIONS AUTO Precautions for Refrigerant Connection (Cont’d) CAUTION: When replacing or cleaning refrigerant cycle components, observe the following. 쐌 When the compressor is removed, store it in the same position as it is when mounted on the car. Malfunction to do so will cause lubricant to enter the low pressure chamber. 쐌 When connecting tubes, always use a torque wrench and a back-up wrench. 쐌 After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture. 쐌 When installing an air conditioner in the vehicle, connect the pipes as the final stage of the operation. Do not remove the seal caps of pipes and other components until just before required for connection. 쐌 Allow components stored in cool areas to warm to working area temperature before removing seal caps. This prevents condensation from forming inside A/C components. 쐌 Thoroughly remove moisture from the refrigeration system before charging the refrigerant. 쐌 Always replace used O-rings. 쐌 When connecting tube, apply lubricant to circle of the O-rings shown in illustration. Be careful not to apply lubricant to threaded portion. Lubricant name: Nissan A/C System Oil Type S Part number: KLH00-PAGS0 쐌 O-ring must be closely attached to dented portion of tube. 쐌 When replacing the O-ring, be careful not to damage O-ring and tube. 쐌 Connect tube until you hear it click, then tighten the nut or bolt by hand until snug. Make sure that the O-ring is installed to tube correctly. 쐌 After connecting line, conduct leak test and make sure that there is no leakage from connections. When the gas leaking point is found, disconnect that line and replace the O-ring. Then tighten connections of seal seat to the specified torque. GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS RHA861F Precautions for Servicing Compressor 쐌 쐌 쐌 쐌 쐌 쐌 BT NAHA0157 Plug all openings to prevent moisture and foreign matter from entering. When the compressor is removed, store it in the same position as it is when mounted on the car. When replacing or repairing compressor, follow “Maintenance of Lubricant Quantity in Compressor” exactly. Refer to HA-172. Keep friction surfaces between clutch and pulley clean. If the surface is contaminated, with lubricant, 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 usual operation. HA-7 SC EL IDX PRECAUTIONS AUTO Precautions for Service Equipment Precautions for Service Equipment RECOVERY/RECYCLING EQUIPMENT NAHA0158 NAHA0158S01 Be certain to follow the manufacturers instructions for machine operation and machine maintenance. Never introduce any refrigerant other than that specified into the machine. ELECTRONIC LEAK DETECTOR NAHA0158S02 Be certain to follow the manufacturer’s instructions for tester operation and tester maintenance. VACUUM PUMP NAHA0158S03 The lubricant contained inside the vacuum pump is not compatible with the specified lubricant for HFC-134a (R-134a) A/C systems. The vent side of the vacuum pump is exposed to atmospheric pressure. So the vacuum pump lubricant may migrate out of the pump into the service hose. This is possible when the pump is switched off after evacuation (vacuuming) and hose is connected to it. To prevent this migration, use a manual valve placed near the hose-to-pump connection, as follows. 쐌 Usually vacuum pumps have a manual isolator valve as part of the pump. Close this valve to isolate the service hose from the pump. 쐌 For pumps without an isolator, use a hose equipped with a manual shut-off valve near the pump end. Close the valve to isolate the hose from the pump. 쐌 If the hose has an automatic shut off valve, disconnect the 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. RHA270DA MANIFOLD GAUGE SET NAHA0158S04 Be certain that the gauge face indicates R-134a or 134a. Be sure the gauge set has 1/2″-16 ACME threaded connections for service hoses. Confirm the set has been used only with refrigerant HFC134a (R-134a) and specified lubricants. SHA533D SERVICE HOSES NAHA0158S05 Be certain that the service hoses display the markings described (colored hose with black stripe). All hoses must include positive shut off devices (either manual or automatic) near the end of the hoses opposite the manifold gauge. RHA272D HA-8 PRECAUTIONS AUTO Precautions for Service Equipment (Cont’d) SERVICE COUPLERS NAHA0158S06 Never attempt to connect HFC-134a (R-134a) service couplers to an CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers will not properly connect to the CFC-12 (R-12) system. However, if an improper connection is attempted, discharging and contamination may occur. Shut-off valve rotation A/C service valve Clockwise Open Counterclockwise Close GI MA EM LC RHA273D REFRIGERANT WEIGHT SCALE EC NAHA0158S07 Verify that no refrigerant other than HFC-134a (R-134a) and specified lubricants have been used with the scale. If the scale controls refrigerant flow electronically, the hose fitting must be 1/2″-16 ACME. FE CL MT RHA274D CALIBRATING ACR4 WEIGHT SCALE AT NAHA0158S08 Calibrate the scale every three months. To calibrate the weight scale on the ACR4 (J-39500-NI): 1. Press Shift/Reset and Enter at the same time. 2. Press 8787. “A1” will be displayed. 3. Remove all weight from the scale. 4. Press 0, then press Enter. “0.00” will be displayed and change to “A2”. 5. Place a known weight (dumbbell or similar weight), between 4.5 and 8.6 kg (10 and 19 lb) on the center of the weight scale. 6. Enter the known weight using four digits. (Example 10 lb = 10.00, 10.5 lb = 10.50) 7. Press Enter — the display returns to the vacuum mode. 8. Press Shift/Reset and Enter at the same time. 9. Press 6 — the known weight on the scale is displayed. 10. Remove the known weight from the scale. “0.00” will be displayed. 11. Press Shift/Reset to return the ACR4 to the program mode. TF PD AX SU BR ST RS BT CHARGING CYLINDER NAHA0158S09 Using a charging cylinder is not recommended. Refrigerant may be vented into air from cylinder’s top valve when filling the cylinder with refrigerant. Also, the accuracy of the cylinder is generally less than that of an electronic scale or of quality recycle/recharge equipment. SC EL IDX HA-9 PRECAUTIONS AUTO Wiring Diagrams and Trouble Diagnoses Wiring Diagrams and Trouble Diagnoses NAHA0159 When you read wiring diagrams, refer to the following: 쐌 GI-11, “HOW TO READ WIRING DIAGRAMS” 쐌 EL-12, “Wiring Diagram — POWER —”. When you perform trouble diagnoses, refer to the following: 쐌 GI-34, “HOW TO FOLLOW TROUBLE DIAGNOSES” 쐌 GI-24, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT” HA-10 PREPARATION AUTO Special Service Tools Special Service Tools NAHA0160 GI The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name MA Description KV99106100 (J-41260) Clutch disc wrench Removing center bolt EM LC EC NT232 FE CL MT AT TF PD NT378 KV99232340 (J-38874) or KV992T0001 ( — ) Clutch disc puller Removing clutch disc AX SU BR NT376 KV99106200 (J-41261) Pulley installer Installing pulley ST RS NT235 BT SC EL IDX HA-11 PREPARATION AUTO HFC-134a (R-134a) Service Tools and Equipment HFC-134a (R-134a) Service Tools and Equipment =NAHA0161 Never mix HFC-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 HFC-134a (R-134a). This is to avoid mixed use of the refrigerants/lubricant. Adapters that convert one size fitting to another must never be used: refrigerant/lubricant contamination will occur and compressor malfunction will result. Tool number (Kent-Moore No.) Tool name Description HFC-134a (R-134a) refrigerant Container color: Light blue Container marking: HFC-134a (R-134a) Fitting size: Thread size 쐌 Large container 1/2″-16 ACME NT196 KLH00-PAGS0 ( — ) Nissan A/C System Oil Type S Type: Poly alkylene glycol oil (PAG), type S Application: HFC-134a (R-134a) swash plate (piston) compressors (Nissan only) Lubricity: 40 m
(1.4 US fl oz, 1.4 Imp fl oz) NT197 (J-39500-NI) Recovery/Recycling Recharging equipment (ACR4) Function: Refrigerant Recovery and Recycling and Recharging NT195 (J-41995) Electrical leak detector Power supply: 쐌 DC 12V (Cigarette lighter) AHA281A HA-12 PREPARATION AUTO HFC-134a (R-134a) Service Tools and Equipment (Cont’d) Tool number (Kent-Moore No.) Tool name GI Description (J-43926) Refrigerant dye leak detection kit Kit includes: (J-42220) UV lamp and UV safety glasses (J-41459) Refrigerant dye injector (J-41447) qty. 24 R-134a refrigerant dye (J-43872) Refrigerant dye cleaner Power supply: DC 12V (Battery terminal) MA EM LC EC FE ZHA200H (J-42220) Fluorescent dye leak detector UV lamp UV safety glasses Power supply: DC12V (Battery terminal) For checking refrigerant leak when fluorescent dye is installed in A/C system. Includes: UV lamp and UV safety glasses CL MT SHA438F (J-41447) R-134a Fluorescent Leak Detection Dye (Box of 24, 1/4 ounce bottles) AT Dye Application: For R-134a PAG oil Container: 1/4 ounce (7.4 cc) bottle (Includes self-adhesive dye identification labels for affixing to vehicle after charging system with dye.) TF PD SHA439F (J-41459) R-134a Dye Injector Use with J-41447, 1/4 ounce bottle AX Dye injector For injecting 1/4 ounce of Fluorescent Leak Detection Dye into A/C system. SU BR SHA440F (J-43872) Dye cleaner For cleaning dye spills. ST RS BT SHA441F (J-39183) Manifold gauge set (with hoses and couplers) Identification: 쐌 The gauge face indicates R-134a. Fitting size: Thread size 쐌 1/2″-16 ACME SC EL NT199 IDX HA-13 PREPARATION AUTO HFC-134a (R-134a) Service Tools and Equipment (Cont’d) Tool number (Kent-Moore No.) Tool name Description Service hoses 쐌 High side hose (J-39501-72) 쐌 Low side hose (J-39502-72) 쐌 Utility hose (J-39476-72) Hose color: 쐌 Low hose: Blue with black stripe 쐌 High hose: Red with black stripe 쐌 Utility hose: Yellow with black stripe or green with black stripe Hose fitting to gauge: 쐌 1/2″-16 ACME NT201 Service couplers 쐌 High side coupler (J-39500-20) 쐌 Low side coupler (J-39500-24) Hose fitting to service hose: 쐌 M14 x 1.5 fitting is optional or permanently attached. NT202 (J-39650) Refrigerant weight scale For measuring of refrigerant Fitting size: Thread size 쐌 1/2″-16 ACME NT200 (J-39649) Vacuum pump (Including the isolator valve) Capacity: 쐌 Air displacement: 4 CFM 쐌 Micron rating: 20 microns 쐌 Oil capacity: 482 g (17 oz) Fitting size: Thread size 쐌 1/2″-16 ACME NT203 COMMERCIAL SERVICE TOOL Tool name NAHA0161S01 Description Refrigerant identifier equipment For checking refrigerant purity and for system contamination NT765 HA-14 PREPARATION AUTO HFC-134a (R-134a) Service Tools and Equipment (Cont’d) Tool name GI Description Power tool Loosening bolts and nuts MA EM LC PBIC0190E EC FE CL MT AT TF PD AX SU BR ST RS BT SC EL IDX HA-15 DESCRIPTION AUTO Refrigeration System Refrigeration System REFRIGERATION CYCLE Refrigerant Flow NAHA0162 NAHA0162S01 The refrigerant flows in the standard pattern, that is, through the compressor, the condenser, the liquid tank, through the evaporator, and back to the compressor. The refrigerant evaporation through the evaporator coil is controlled by an externally equalized expansion valve, located inside the evaporator case. Freeze Protection NAHA0162S02 Under usual operating conditions, when the a/c is switched on, the compressor runs continuously, and the evaporator pressure, and therefore temperature, is controlled by the V-6 variable displacement compressor to prevent freeze up. Refrigerant System Protection NAHA0162S03 Refrigerant Pressure Sensor NAHA0162S0301 The refrigerant system is protected against excessively high or low pressures by the refrigerant pressure sensor, located on the condenser. If the system pressure rises above, or falls below the specifications, the refrigerant pressure sensor detects the pressure inside the refrigerant line and sends the voltage signal to the ECM. ECM makes the A/C relay go OFF and stops the compressor when pressure on the high pressure side detected by refrigerant pressure sensor is over about 2,746 kPa (28 kg/cm2, 398 psi) or below about 177 kPa (1.8 kg/cm2, 26 psi). Pressure Relief Valve NAHA0162S0302 The refrigerant system is also protected by a pressure relief valve, located in the rear head of the compressor. When the pressure of refrigerant in the system increases to an unusual level [more than 3,727 kPa (38 kg/cm2, 540 psi)], the release port on the pressure relief valve automatically opens and releases refrigerant into the atmosphere. RHA031I HA-16 DESCRIPTION AUTO V-6 Variable Displacement Compressor V-6 Variable Displacement Compressor GENERAL INFORMATION GI =NAHA0163 1. The V-6 variable compressor differs from previous units. The vent temperatures of the V-6 variable compress do not drop too far below 5°C (41°F) when: 쐌 evaporator intake air temperature is less than 20°C (68°F) 쐌 engine is running at speeds less than 1,500 rpm. This is because the V-6 compressor provides a means of “capacity” control. 2. The V-6 variable compressor provides refrigerant control under varying conditions. During cold winters, it may not produce high refrigerant pressure discharge (compared to previous units) when used with air conditioning systems. 3. A “clanking” sound may occasionally be heard during refrigerant charge. The sound indicates that the tilt angle of the swash plate has changed and is not a problem. 4. For air conditioning systems with the V-6 compressor, the clutch remains engaged unless: the system main switch, fan switch or ignition switch is turned OFF. When ambient (outside) temperatures are low or when the amount of refrigerant is insufficient, the clutch is disengaged to protect the compressor. 5. A constant range of suction pressure is maintained when engine speed is greater than a certain value. It normally ranges from 147 to 177 kPa (1.5 to 1.8 kg/cm2, 21 to 26 psi) under varying conditions. In previous compressors, however, suction pressure was reduced with increases in engine speed. MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SC EL IDX HA-17 DESCRIPTION AUTO V-6 Variable Displacement Compressor (Cont’d) DESCRIPTION General =NAHA0164 NAHA0164S01 The variable compressor is basically a swash plate type that changes piston stroke in response to the required cooling capacity. The tilt of the swash plate allows the piston’s stroke to change so that refrigerant discharge can be continuously changed from 14.5 to 184 cm3 (0.885 to 11.228 cu in). RHA037DD HA-18 DESCRIPTION AUTO V-6 Variable Displacement Compressor (Cont’d) Operation =NAHA0164S02 1. Operation Control Valve NAHA0164S0201 Operation control valve is located in the suction port (low-pressure) side, and opens or closes in response to changes in refrigerant suction pressure. Operation of the valve controls the internal pressure of the crankcase. The angle of the swash plate is controlled between the crankcase’s internal pressure and the piston cylinder pressure. 2. Maximum Cooling NAHA0164S0202 Refrigerant pressure on the low-pressure side increases with an increase in heat loads. When this occurs, the control valve’s bellows compress to open the low-pressure side valve and close the high-pressure side valve. This causes the following pressure changes: 쐌 the crankcase’s internal pressure to equal the pressure on the low-pressure side; 쐌 the cylinder’s internal pressure to be greater than the crankcase’s internal pressure. Under this condition, the swash plate is set to the maximum stroke position. GI MA EM LC EC FE CL MT AT TF PD AX RHA473C SU BR ST RS BT SC EL IDX HA-19 DESCRIPTION AUTO V-6 Variable Displacement Compressor (Cont’d) 3. Capacity Control =NAHA0164S0203 쐌 Refrigerant pressure on suction side is low during high speed driving or when ambient or interior temperature is low. 쐌 The bellows expands when refrigerant pressure on the suction pressure side drops below approximately 177 kPa (1.8 kg/cm2, 26 psi). Since suction pressure is low, it makes the suction port close and the discharge port open. Thus, crankcase pressure becomes high as high pressure enters the crankcase. 쐌 The force acts around the journal pin near the swash plate, and is generated by the pressure difference before and behind the piston. The drive lug and journal pin are located where the piston generates the highest pressure. Piston pressure is between suction pressure Ps and discharge pressure Pd, which is near suction pressure Ps. If crankcase pressure Pc rises due to capacity control, the force around the journal pin makes the swash plate angle decrease and also the piston stroke decrease. In other words, crankcase pressure increase triggers pressure difference between the piston and the crankcase. The pressure difference changes the angle of the swash plate. RHA474C HA-20 DESCRIPTION AUTO Component Layout Component Layout NAHA0166 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SC EL RHA451G HA-21 IDX DESCRIPTION AUTO Introduction Introduction AIR CONDITIONER LAN SYSTEM OVERVIEW CONTROL SYSTEM NAHA0167 NAHA0167S01 The LAN system consists of auto amp., mode door motor and air mix door motor. A configuration of these components is shown in the diagram below. RHA439G Features CAN COMMUNICATION SYSTEM DESCRIPTION NAHA0168 NAHA0168S10 CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. SYSTEM CONSTRUCTION (LAN) NAHA0168S01 A small network is constructed between the auto amplifier, mode door motor and air mix door motor. The auto amplifier and motors are connected by data transmission lines and motor power supply lines. The LAN network is built through the ground circuits of the two motors. Addresses, motor opening angle signals, motor stop signals and error checking messages are all transmitted through the data transmission lines connecting the auto amplifier and two motors. The following functions are contained in LCUs built into the mode door motor and the air mix door motor. 쐌 Address 쐌 Motor opening angle signals 쐌 Data transmission 쐌 Motor stop and drive decision 쐌 Opening angle sensor (PBR function) 쐌 Comparison 쐌 Decision (Auto amplifier indicated value and motor opening angle comparison) RHA440GA Operation NAHA0168S0101 The auto amplifier receives data from each of the sensors. The amplifier sends mode door and air mix door opening angle data to the mode door motor LCU and air mix door motor LCU. The mode door motor and air mix door motor read their respective signals according to the address signal. HA-22 DESCRIPTION AUTO Features (Cont’d) Opening angle indication signals received from the auto amplifier and each of the motor position sensors are compared by the LCUs in each motor with the existing decision and opening angles. Subsequently, HOT/ COLD or DEFROST/VENT operation is selected. The new selection data is returned to the auto amplifier. GI MA EM LC EC RHA441GA Transmission Data and Transmission Order FE NAHA0168S0102 Amplifier data is transmitted consecutively to each of the door motors following the form shown in figure below. Start: Initial compulsory signal sent to each of the door motors. Address: Data sent from the auto amplifier is selected according to data-based decisions made by the mode door motor and air mix door motor. If the addresses are identical, the opening angle data and error check signals are received by the door motor LCUs. The LCUs then make the appropriate error decision. If the opening angle data is usual, door control begins. If an error exists, the received data is rejected and corrected data received. Finally, door control is based upon the corrected opening angle data. Opening angle: Data that shows the indicated door opening angle of each door motor. Error check: Procedure by which sent and received data is checked for errors. Error data is then compiled. The error check prevents corrupted data from being used by the mode door motor and air mix door motor. Error data can be related to the following problems. 쐌 Unusual electrical frequency 쐌 Poor electrical connections 쐌 Signal leakage from transmission lines 쐌 Signal level fluctuation Stop signal: At the end of each transmission, a stop operation, in-operation, or internal problem message is delivered to the auto amplifier. This completes one data transmission and control cycle. CL MT AT TF PD AX SU BR ST RS BT SC RHA442G EL IDX HA-23 DESCRIPTION AUTO Features (Cont’d) Air Mix Door Control (Automatic Temperature Control) NAHA0168S0103 The air mix door is automatically controlled so that in-vehicle temperature is maintained at a predetermined value by: The temperature setting, ambient temperature, in-vehicle temperature and amount of sunload. Fan Speed Control NAHA0168S0104 Blower speed is automatically controlled based on temperature setting, ambient temperature, in-vehicle temperature, intake temperature, amount of sunload and air mix door position. With FAN switch set to “AUTO”, the blower motor starts to gradually increase air flow volume. When engine coolant temperature is low, the blower motor operation is delayed to prevent cool air from flowing. Intake Door Control NAHA0168S0105 The intake doors are automatically controlled by: The temperature setting, ambient temperature, in-vehicle temperature, intake temperature, amount of sunload and ON-OFF operation of the compressor. Outlet Door Control NAHA0168S0106 The outlet door is automatically controlled by: The temperature setting, ambient temperature, in-vehicle temperature, intake temperature and amount of sunload. Magnet Clutch Control NAHA0168S0107 RHA197I The ECM controls compressor operation using input signals from the throttle position sensor, refrigerant pressure sensor and auto amplifier. Self-diagnostic System NAHA0168S0108 The self-diagnostic system is built into the auto amplifier (LCU) to quickly locate the cause of problems. HA-24 DESCRIPTION AUTO Overview of Control System Overview of Control System =NAHA0169 The control system consists of input sensors, switches, the automatic amplifier (microcomputer) and outputs. The relationship of these components is shown in the diagram below: GI MA EM LC EC FE CL MT AT TF PD AX RHA198I SU BR ST RS BT SC EL IDX HA-25 DESCRIPTION AUTO Control Operation Control Operation WITHOUT NAVIGATION SYSTEM Except LE Grade NAHA0170 NAHA0170S10 NAHA0170S1010 RHA452G Display Screen Displays the operational status of the system. AUTO Switch The compressor, intake doors, air mix door, outlet doors, and blower speed are automatically controlled so that the in-vehicle temperature will reach, and be maintained at the set temperature selected by the operator. ECON Switch By pressing the ECON switch, the display should indicate ECON and the compressor always turns OFF. With the compressor OFF, the system will not remove heat (cool) or de-humidify. The system will maintain the invehicle temperature at the set temperature when the set temperature is above the ambient (outside) temperature. The system will set the intake doors to the outside air position. Temperature Switch (Potentio Temperature Control) Increases or decreases the set temperature. OFF Switch The compressor and blower are OFF, the intake doors are set to the outside air position, and the air outlet doors are set to the foot (80% foot and 20% defrost) position. FAN Switch Manual control of the blower speed. Four speeds are available for manual control (as shown on the display screen): low , medium low , medium high , high Recirculation (REC) Switch OFF position: Set the inlet to automatic control. ON position: Interior air is recirculated inside the vehicle. Compressor turns ON automatically. Defroster (DEF) Switch Positions the air outlet doors to the defrost position. Also positions the intake doors to the outside air position. MODE Switch Controls the air discharge outlets. When switched to D/F, compressor turns ON and the intake doors are set to the FRE (Fresh) position automatically. HA-26 DESCRIPTION AUTO Control Operation (Cont’d) LE Grade NAHA0170S1011 GI MA EM LC EC FE CL RHA140IA Display Screen Displays the operational status of the system. AUTO Switch The compressor, intake doors, air mix door, outlet doors, and blower speed are automatically controlled so that the in-vehicle temperature will reach, and be maintained at the set temperature selected by the operator. ECON Switch By pressing the ECON switch, the display should indicate ECON and the compressor always turns OFF. With the compressor OFF, the system will not remove heat (cool) or de-humidify. The system will maintain the invehicle temperature at the set temperature when the set temperature is above the ambient (outside) temperature. The system will set the intake doors to the outside air position. OFF Switch The compressor and blower are OFF, the intake doors are set to the outside air position, and the air outlet doors are set to the foot (80% foot and 20% defrost) position. FAN Switch Manually controls the blower speed. Four speeds are available for manual control (as shown on the display screen): low , medium low , medium high , high RECIRCULATION (REC) Switch OFF position: Outside air is drawn into the passenger compartment. ON position: Interior air is recirculated inside the vehicle. Compressor turns ON automatically. DEFROSTER (DEF) Switch Positions the air outlet doors to the defrost position. Also positions the intake doors to the outside air position. MODE Switch Controls the air discharge outlets. When switched to D/F, compressor turns ON and the intake doors are set to the FRE (Fresh) position automatically. Temperature Dial (Potentio Temperature Control) Increases or decreases the set temperature. Rear Window Defogger Switch When illumination is ON, rear window is defogged. MT AT TF PD AX SU BR ST RS BT SC EL IDX HA-27 DESCRIPTION AUTO Control Operation (Cont’d) WITH NAVIGATION SYSTEM NAHA0170S11 RHA085I Display Screen NAHA0170S1101 Displays the operational status of the system. AUTO Switch NAHA0170S1102 The compressor, intake doors, air mix door, outlet doors, and blower speed are automatically controlled so that the in-vehicle temperature will reach, and be maintained at the set temperature selected by the operator. ECON Switch NAHA0170S1103 By pressing the ECON switch, the display should indicate ECON and the compressor always turns OFF. With the compressor OFF, the system will not remove heat (cool) or de-humidify. The system will maintain the invehicle temperature at the set temperature when the set temperature is above the ambient (outside) temperature. The system will set the intake doors to the outside air position. OFF Switch NAHA0170S1104 The compressor and blower are OFF, the intake doors are set to the outside air position, and the air outlet doors are set to the foot (80% foot and 20% defrost) position. FAN Switch NAHA0170S1105 Manually controls the blower speed. Four speeds are available for manual control (as shown on the display screen): low , medium low , medium high , high Recirculation (REC) Switch NAHA0170S1106 OFF position: Set the inlet to automatic control. ON position: Interior air is recirculated inside the vehicle. Compressor turns ON automatically. Defroster (DEF) Switch NAHA0170S1107 Positions the air outlet doors to the defrost position. Also positions the intake doors to the outside air position. MODE Switch NAHA0170S1108 Controls the air discharge outlets. When switched to D/F, compressor turns ON and the intake doors are set to the FRE (Fresh) position automatically. Temperature Dial (Potentio Temperature Control) Increases or decreases the set temperature. HA-28 NAHA0170S1109 DESCRIPTION AUTO Discharge Air Flow Discharge Air Flow NAHA0171 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SC EL RHA043G HA-29 IDX DESCRIPTION AUTO System Description System Description NAHA0246 SWITCHES AND THEIR CONTROL FUNCTIONS NAHA0246S01 RHA044GA MODE SW VENT B/L FOOT DEF SW D/F ON OFF AUTO SW ECON SW REC SW ON Temperature SW or dial OFF Position or switch Door 18.0°C (60°F) — Ventilator door A B C C C — — Foot door A B C C A — — Defroster door A A B C C — — Air mix door Intake door — — — AUTO AUTO — C — C A *1: Automatically controlled when REC switch is OFF. HA-30 AUTO*1 A AUTO — 32.0°C (90°F) B TROUBLE DIAGNOSES AUTO Component Location Component Location ENGINE COMPARTMENT NAHA0172 GI NAHA0172S01 MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SC EL RHA069I HA-31 IDX TROUBLE DIAGNOSES AUTO Component Location (Cont’d) PASSENGER COMPARTMENT Without Navigation System NAHA0172S02 NAHA0172S0201 RHA498GC HA-32 TROUBLE DIAGNOSES AUTO Component Location (Cont’d) With Navigation System NAHA0172S0202 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SC EL RHA857HA HA-33 IDX TROUBLE DIAGNOSES AUTO Circuit Diagram (Without Navigation System) Circuit Diagram (Without Navigation System) NAHA0173 MHA187B HA-34 TROUBLE DIAGNOSES AUTO Wiring Diagram — A/C, A — (Without Navigation System) Wiring Diagram — A/C, A — (Without Navigation System) GI NAHA0174 MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SC EL MHA188B HA-35 IDX TROUBLE DIAGNOSES AUTO Wiring Diagram — A/C, A — (Without Navigation System) (Cont’d) MHA189B HA-36 TROUBLE DIAGNOSES AUTO Wiring Diagram — A/C, A — (Without Navigation System) (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SC EL MHA190B IDX HA-37 TROUBLE DIAGNOSES AUTO Wiring Diagram — A/C, A — (Without Navigation System) (Cont’d) MHA191B HA-38 TROUBLE DIAGNOSES AUTO Circuit Diagram (With Navigation System) Circuit Diagram (With Navigation System) NAHA0257 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SC EL MHA192B HA-39 IDX TROUBLE DIAGNOSES AUTO Wiring Diagram — A/C, A — (With Navigation System) Wiring Diagram — A/C, A — (With Navigation System) NAHA0258 MHA193B HA-40 TROUBLE DIAGNOSES AUTO Wiring Diagram — A/C, A — (With Navigation System) (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SC EL MHA194B IDX HA-41 TROUBLE DIAGNOSES AUTO Wiring Diagram — A/C, A — (With Navigation System) (Cont’d) MHA195B HA-42 TROUBLE DIAGNOSES AUTO Wiring Diagram — A/C, A — (With Navigation System) (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SC EL MHA196B IDX HA-43 TROUBLE DIAGNOSES AUTO Auto Amp. Terminals and Reference Value Auto Amp. Terminals and Reference Value INSPECTION OF AUTO AMP. NAHA0175 NAHA0175S01 쐌 Measure voltage between each terminal and body ground by following “AUTO AMP. INSPECTION TABLE”. 쐌 Pin connector terminal layout RHA464GA RHA141I RHA858H RHA839H AUTO AMP. INSPECTION TABLE Without Navigation System NAHA0175S02 NAHA0175S0201 TERMINAL NO. ITEM CONDITION Voltage V 1 Intake sensor — — 2 Ambient sensor — — 3 In-vehicle sensor — — HA-44 TROUBLE DIAGNOSES AUTO Auto Amp. Terminals and Reference Value (Cont’d) TERMINAL NO. ITEM Voltage V CONDITION AUTO SW: ON 6 Compressor feedback signal AUTO SW: ON 8 Intake door position switch Approximately 0 Disconnect refrigerant pressure sensor connector Approximately 5 FRESH or 20% FRESH Approximately 0 RECIRCULATION Approximately 5 Intake door position Sensor ground 12 Sunload sensor 13 Water temperature signal — — 14 Ground (for Canada) — Approximately 0 16 A/C LAN signal — Approximately 5.5 18 Intake door position switch Intake door position switch 21 Power supply for mode door motor and air mix door motor 22 Compressor ON signal 24 Power supply for illumination MA EM 11 19 GI — — Intake door position Intake door position LC Approximately 0 — 20% FRE or RECIRCULATION Approximately 0 FRESH Approximately 5 RECIRCULATION or FRESH Approximately 0 20% FRE Approximately 5 — Approximately 12 ON Approximately 0 OFF Approximately 5 OFF Approximately 0 1st Approximately 12 Compressor Lighting switch 25 Illumination ground — Approximately 0 26 Power supply for BAT — BATTERY VOLTAGE EC FE CL MT AT TF PD AX SU BR ST RS BT SC EL IDX HA-45 TROUBLE DIAGNOSES AUTO Auto Amp. Terminals and Reference Value (Cont’d) TERMINAL NO. ITEM 27 Power supply for IGN 28 Power supply for intake door motor 30 31 Voltage V CONDITION — Approximately 12 FRE , REC Approximately 12 REC , FRE Approximately 0 Rear window defogger switch: ON Approximately 12 Rear window defogger switch: OFF Approximately 0 Rear window defogger switch: ON Approximately 0 Rear window defogger switch: OFF Approximately 12 Intake door position Rear defogger feedback signal Rear defogger ON signal 32 Ground — Approximately 0 33 Power source for A/C Ignition voltage feedback Approximately 12 34 Blower motor feedback Fan speed: Low Approximately 7 - 10 35 Fan control AMP. control signal 36 Power supply for intake door motor Fan speed Low, Middle low or Middle high Approximately 2.5 3.0 High Approximately 9 - 10 FRE , REC Approximately 0 REC , FRE Approximately 12 Intake door position With Navigation System NAHA0175S0202 TERMINAL NO. ITEM CONDITION Voltage V 1 Intake sensor — — 2 Ambient sensor — — 3 In-vehicle sensor — — 6 Intake door position switch RECIRCULATION Approximately 5 FRESH or 20% FRESH Approximately 0 Intake door position 7 Multiplex communication signal (AMP , NAVI) — — 8 Multiplex communication signal (NAVI , AMP) — — 9 Sensor ground 10 Sunload sensor — — HA-46 Approximately 0 — TROUBLE DIAGNOSES AUTO Auto Amp. Terminals and Reference Value (Cont’d) TERMINAL NO. ITEM 11 Engine coolant temperature signal — — 14 A/C LAN signal — Approximately 5.5 AUTO SW: ON Approximately 0 17 Compressor feedback signal AUTO SW: ON 18 19 Intake door position switch Intake door position switch 20 Multiplex communication signal (CLK) 21 Power supply for door motor 22 Compressor ON signal 24 Power supply for BAT 25 Power supply for IGN 26 Power supply for intake door motor Voltage V CONDITION Intake door position Intake door position Disconnect refrigerant pressure sensor connector Approximately 5 FRESH Approximately 5 RECIRCULATION or 20% FRESH Approximately 0 20% FRESH Approximately 5 RECIRCULATION or FRESH Approximately 0 — — Approximately 12 Compressor: ON Approximately 0 Compressor: OFF Approximately 5 — BATTERY VOLTAGE — LC FE CL MT AT TF Approximately 12 FRE , REC Approximately 12 REC , FRE Approximately 0 Intake door position — Approximately 0 33 Power source for A/C — Approximately 12 34 Blower motor feedback Fan speed: Low Approximately 7 - 10 Fan speed: Low, Middle low or Middle high Approximately 2.5 3.0 Fan speed: High Approximately 9 - 10 Fan control amp. control signal Power supply for intake door motor EM — Ground 36 MA EC 32 35 GI REC , FRE Approximately 12 FRE , REC Approximately 0 Intake door position PD AX SU BR ST RS BT SC EL IDX HA-47 TROUBLE DIAGNOSES AUTO Self-diagnosis Self-diagnosis INTRODUCTION AND GENERAL DESCRIPTION =NAHA0176 NAHA0176S01 The self-diagnostic system diagnoses sensors, door motors, blower motor, etc. by system line. Refer to applicable sections (items) for details. Shifting from normal control to the self-diagnostic system is accomplished by starting the engine (turning the ignition switch from “OFF” to “ON”) and pressing “ ” switch for at least ” switch must be pressed within 10 seconds after starting the engine (ignition switch is 5 seconds. The “ turned “ON”). This system will be canceled by either pressing (AUTO) switch or turning the ignition switch “OFF”. Shifting from one step to another is accomplished by means of pushing (HOT) or (COLD) switch, as required. Additionally shifting from STEP 5 to AUXILIARY MECHANISM is accomplished by means of pushing (fan) UP switch. Without Navigation System (Except LE Grade) NAHA0176S0101 RHA453GA HA-48 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) STEP-BY-STEP PROCEDURE Without Navigation System (Except LE Grade) 1 =NAHA0176S02 NAHA0176S0201 MA SET IN SELF-DIAGNOSTIC MODE 1. Turn ignition switch ON. 2. Set in self-diagnostic mode as follows. Within 10 seconds after starting engine (ignition switch is turned “ON”.), press switch for at least 5 seconds. 䊳 GI EM GO TO 2. LC 2 STEP 1 - ALL LEDs AND SEGMENT ARE CHECKED EC Do all LEDs and segments illuminate? FE CL MT AT RHA454G TF Yes or No PD Yes 䊳 GO TO 3. No 䊳 switch, LED or fluorescent display tube. Malfunctioning Replace A/C auto amp. 3 CHECK TO ADVANCE SELF-DIAGNOSIS STEP 2 1. Press (HOT) switch. 2. Advance to self-diagnosis STEP 2? SU Yes or No BR ST Yes 䊳 GO TO 4. No 䊳 Malfunctioning (HOT) switch. Replace A/C auto amp. 4 AX CHECK TO RETURN SELF-DIAGNOSIS STEP 1 1. Press (COLD) switch. 2. Return to self-diagnosis STEP 1? RS BT Yes or No Yes 䊳 GO TO 5. No 䊳 Malfunctioning (COLD) switch. Replace A/C auto amp. SC EL IDX HA-49 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) 5 STEP 2 - SENSOR CIRCUITS ARE CHECKED FOR OPEN OR SHORT CIRCUIT Press (HOT) switch. appear on the display? Does code No. RHA970DB Yes or No Yes 䊳 GO TO 6. No 䊳 GO TO 13. 6 STEP 3 - MODE DOOR AND INTAKE DOOR POSITIONS ARE CHECKED Press (HOT) switch. Does code No. appear on the display? RHA869DD Yes or No Yes 䊳 GO TO 7. No 䊳 GO TO 14. HA-50 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) 7 GI STEP 4 - OPERATION OF EACH ACTUATOR IS CHECKED Press (HOT) switch. Engine running. Press DEF switch, code No. of each actuator test is indicated on the display. MA EM LC EC RHA495A 䊳 FE GO TO 8. CL MT AT TF PD AX SU BR ST RS BT SC EL IDX HA-51 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) 8 CHECK ACTUATORS Refer to the following chart and confirm discharge air flow, air temperature, blower motor voltage and compressor operation. Checks must be made visually, by listening to any noise, or by touching air outlets with your hand, etc. for improper operation. MTBL0200 MTBL0044 OK or NG OK 䊳 GO TO 9. NG 䊳 쐌 Air outlet does not change. Go to “Mode Door Motor” (HA-92). 쐌 Intake door does not change. Go to “Intake Door Motor” (HA-105). 쐌 Discharge air temperature does not change. Go to “Air Mix Door Motor” (HA-100). 쐌 Blower motor operation is malfunctioning. Go to “Blower Motor” (HA-114). 쐌 Magnet clutch does not engage. Go to “Magnet Clutch” (HA-125). HA-52 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) 9 GI STEP 5 - TEMPERATURE OF EACH SENSOR IS CHECKED Press (HOT) switch. Code No. appears on the display. MA EM LC EC RHA492A 䊳 FE GO TO 10. CL 10 CHECK AMBIENT SENSOR Press (DEF) switch one time, temperature detected by ambient sensor is indicated on the display. ECON shown in display indicates negative temperature reading. NOTE: If temperature shown on display greatly differs from actual temperature, check sensor circuit first, then inspect sensor. MT AT TF PD AX RHA499G SU OK or NG OK 䊳 GO TO 11. NG 䊳 Go to Ambient Sensor Circuit (HA-155). BR ST RS BT SC EL IDX HA-53 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) 11 CHECK IN-VEHICLE SENSOR Press (DEF) switch the second time, temperature detected by in-vehicle sensor is indicated on the display screen. ECON shown in display indicates negative temperature reading. NOTE: If temperature shown on display greatly differs from actual temperature, check sensor circuit first, then inspect sensor. RHA500G OK or NG OK 䊳 GO TO 12. NG 䊳 Go to In-vehicle Sensor Circuit (HA-158). 12 CHECK INTAKE SENSOR Press (DEF) switch the third time, temperature detected by intake sensor is indicated on the display. NOTE: If temperature shown on display greatly differs from actual temperature, check sensor circuit first, then inspect sensor. RHA500GB OK or NG OK 䊳 (DEF) switch the fourth time. Display returns to original presentation 5. 1. Press 2. Turn ignition switch OFF or (AUTO) switch ON. 3. END NG 䊳 Go to Intake Sensor Circuit (HA-165). HA-54 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) 13 GI CHECK MALFUNCTIONING SENSOR Refer to the following chart for malfunctioning code No. (If two or more sensors malfunction, corresponding code Nos. blink respectively two times.) MA EM LC EC FE CL MTBL0083 *1: Conduct self-diagnosis STEP 2 under sunshine. When conducting indoors, aim a light (more than 60W) at sunload sensor, otherwise Code No. sunload sensor is functioning properly. *2: HA-155 *3: HA-158 *4: HA-165 *5: HA-162 *6: HA-167 will indicate despite that MT AT TF PD AX SU RHA455G BR ST RS BT RHA501A 䊳 INSPECTION END SC EL IDX HA-55 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) 14 CHECK MALFUNCTIONING DOOR MOTOR POSITION SWITCH Mode or (and) intake door motor position switch(es) is (are) malfunctioning. (If two or more mode or intake doors are out of order, corresponding code numbers blink respectively two times.) MTBL0514 *1: If mode door motor harness connector is disconnected, the following display pattern will appear. , , , , , Return to *2: If intake door motor harness connector is disconnected, the following display pattern will appear. , , , Return to *3: HA-92 *4: HA-105 RHA168DA RHA498A 䊳 INSPECTION END HA-56 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) AUXILIARY MECHANISM: TEMPERATURE SETTING TRIMMER =NAHA0176S03 The trimmer compensates for differences in range of ±3°C (±6°F) between temperature setting (displayed digitally) and temperature felt by driver. Operating procedures for this trimmer are as follows: 쐌 Begin Self-diagnosis STEP 5 mode. 쐌 Press (fan) UP switch to set system in auxiliary mode. 쐌 Display shows “ ” in auxiliary mechanism. It takes approximately 3 seconds. 쐌 Press either (HOT) or (COLD) switch as desired. Temperature will change at a rate of 0.5°C (1°F) each time a switch is pressed. Without Navigation System (Except LE Grade) NAHA0176S0301 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SC EL SHA197E When battery cable is disconnected, trimmer operation is canceled. Temperature set becomes that of initial condition, i.e. 0°C (0°F). HA-57 IDX TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) INTRODUCTION AND GENERAL DESCRIPTION NAHA0176S07 The self-diagnostic system diagnoses sensors, door motors, blower motor, etc. by system line. Refer to applicable sections (items) for details. Shifting from usual control to the self-diagnostic system is accomplished by starting the engine (turning the ignition switch from “OFF” to “ON”) and pressing “ ” switch for at least 5 seconds. The “ ” switch must be pressed within 10 seconds after starting the engine (ignition switch is turned (AUTO) switch or turning the ignition switch “OFF”. “ON”). This system will be canceled by either pressing Shifting from one step to another is accomplished by means of turning temperature dial, as required. Additionally shifting from STEP 5 to AUXILIARY MECHANISM is accomplished by means of pushing (fan) UP switch. Without Navigation System (LE Grade) NAHA0176S0702 RHA142I HA-58 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) STEP-BY-STEP PROCEDURE Without Navigation System (LE Grade) 1 =NAHA0176S08 NAHA0176S0802 MA SET IN SELF-DIAGNOSTIC MODE 1. Turn ignition switch ON. 2. Set in self-diagnostic mode as follows. Within 10 seconds after starting engine (ignition switch is turned “ON”.), press switch for at least 5 seconds. 䊳 GI EM GO TO 2. LC 2 STEP 1 - ALL LEDs AND SEGMENT ARE CHECKED EC Do all LEDs and segments illuminate? FE CL MT RHA143I AT Yes or No Yes 䊳 GO TO 3. No 䊳 Malfunctioning switch, LED or fluorescent display tube. Replace A/C auto amp. 3 TF VERIFY ADVANCE TO SELF-DIAGNOSIS STEP 2 AX 1. Turn the temperature dial clockwise. 2. Does advance to self-diagnosis STEP 2? Yes or No Yes 䊳 GO TO 4. No 䊳 Malfunctioning temperature dial. Replace A/C auto amp. 4 PD VERIFY RETURN TO SELF-DIAGNOSIS STEP 1 1. Turn the temperature dial counterclockwise. 2. Does return to self-diagnosis STEP 1? SU BR ST RS Yes or No Yes 䊳 GO TO 5. No 䊳 Malfunctioning temeprature dial. Replace A/C auto amp. BT SC EL IDX HA-59 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) 5 STEP 2 - SENSOR CIRCUITS ARE CHECKED FOR OPEN OR SHORT CIRCUIT Turn the temperature dial clockwise, go to STEP 2. appear on the display? Does code No. RHA970DB Yes or No Yes 䊳 GO TO 6. No 䊳 GO TO 13. 6 STEP 3 - MODE DOOR AND INTAKE DOOR POSITIONS ARE CHECKED Turn the temperature dial clockwise, go to STEP 3. Does code No. appear on the display? RHA869DD Yes or No Yes 䊳 GO TO 7. No 䊳 GO TO 14. HA-60 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) 7 GI STEP 4 - OPERATION OF EACH ACTUATOR IS CHECKED Turn the temperature dial clockwise, go to STEP 4. Engine running. Press DEF switch, code No. of each actuator test is indicated on the display. MA EM LC EC RHA495A 䊳 FE GO TO 8. CL MT AT TF PD AX SU BR ST RS BT SC EL IDX HA-61 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) 8 CHECK ACTUATORS Refer to the following chart and confirm discharge air flow, air temperature, blower motor voltage and compressor operation. Checks must be made visually, by listening to any noise, or by touching air outlets with your hand, etc. for improper operation. MTBL0200 MTBL0044 OK or NG OK 䊳 GO TO 9. NG 䊳 쐌 Air outlet does not change. Go to “Mode Door Motor” (HA-92). 쐌 Intake door does not change. Go to “Intake Door Motor” (HA-105). 쐌 Discharge air temperature does not change. Go to “Air Mix Door Motor” (HA-100). 쐌 Blower motor operation is malfunctioning. Go to “Blower Motor” (HA-114). 쐌 Magnet clutch does not engage. Go to “Magnet Clutch” (HA-126). HA-62 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) 9 GI STEP 5 - TEMPERATURE OF EACH SENSOR IS CHECKED Turn the temperature dial clockwise, go to STEP 5. Code No. appears on the display. MA EM LC EC RHA492A 䊳 FE GO TO 10. CL 10 CHECK AMBIENT SENSOR Press (DEF) switch one time, temperature detected by ambient sensor is indicated on the display. ECON shown in display indicates negative temperature reading. NOTE: If temperature shown on display greatly differs from actual temperature, check sensor circuit first, then inspect sensor. MT AT TF PD AX RHA499G SU OK or NG OK 䊳 GO TO 11. NG 䊳 Go to Ambient Sensor Circuit (HA-155). BR ST RS BT SC EL IDX HA-63 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) 11 CHECK IN-VEHICLE SENSOR Press (DEF) switch the second time, temperature detected by in-vehicle sensor is indicated on the display screen. ECON shown in display indicates negative temperature reading. NOTE: If temperature shown on display greatly differs from actual temperature, check sensor circuit first, then inspect sensor. RHA500G OK or NG OK 䊳 GO TO 12. NG 䊳 Go to In-vehicle Sensor Circuit (HA-158). 12 CHECK INTAKE SENSOR Press (DEF) switch the third time, temperature detected by intake sensor is indicated on the display. NOTE: If temperature shown on display greatly differs from actual temperature, check sensor circuit first, then inspect sensor. RHA500GB OK or NG OK 䊳 (DEF) switch the fourth time. Display returns to original presentation 5. 1. Press 2. Turn ignition switch OFF or (AUTO) switch ON. 3. END NG 䊳 Go to Intake Sensor Circuit (HA-165). HA-64 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) 13 GI CHECK MALFUNCTIONING SENSOR Refer to the following chart for malfunctioning code No. (If two or more sensors malfunction, corresponding code Nos. blink respectively two times.) MA EM LC EC FE CL MTBL0083 *1: Conduct self-diagnosis STEP 2 under sunshine. When conducting indoors, aim a light (more than 60W) at sunload sensor, otherwise Code No. sunload sensor is functioning properly. *2: HA-156 *3: HA-159 *4: HA-166 *5: HA-162 *6: HA-167 will indicate despite that MT AT TF PD AX SU RHA455G BR ST RS BT RHA501A 䊳 INSPECTION END SC EL IDX HA-65 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) 14 CHECK MALFUNCTIONING DOOR MOTOR POSITION SWITCH Mode or (and) intake door motor position switch(es) is (are) malfunctioning. (If two or more mode or intake doors are out of order, corresponding code numbers blink respectively two times.) MTBL0508 *1: If mode door motor harness connector is disconnected, the following display pattern will appear. , , , , , Return to *2: If intake door motor harness connector is disconnected, the following display pattern will appear. , , , Return to *3: HA-93 *4: HA-106 RHA168DA RHA498A 䊳 INSPECTION END HA-66 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) AUXILIARY MECHANISM: TEMPERATURE SETTING TRIMMER =NAHA0176S09 The trimmer compensates for differences in range of ±3°C (±6°F) between temperature setting (displayed digitally) and temperature felt by driver. Operating procedures for this trimmer are as follows: 쐌 Begin Self-diagnosis STEP 5 mode. 쐌 Press (fan) UP switch to set system in auxiliary mode. 쐌 Display shows “ ” in auxiliary mechanism. It takes approximately 3 seconds. 쐌 Turn temperature dial clockwise or counter clockwide. Temperature will change at a rate of 0.5°C (1°F) each time a switch is pressed. Without Navigation System (LE Grade) NAHA0176S0902 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SC EL SHA330F When battery cable is disconnected, trimmer operation is canceled. Temperature set becomes that of initial condition, i.e. 0°C (0°F). HA-67 IDX TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) INTRODUCTION AND GENERAL DESCRIPTION NAHA0176S04 The self-diagnostic system diagnoses sensors, door motors, blower motor, etc. by system line. Refer to applicable sections (items) for details. Shifting from usual control to the self-diagnostic system is accomplished by starting the engine (turning the ignition switch from “OFF” to “ON”) and pressing “ ” switch for at least 5 seconds. The “ ” switch must be pressed within 10 seconds after starting the engine (ignition switch is turned (AUTO) switch or turning the ignition switch “OFF”. “ON”). This system will be canceled by either pressing Shifting from one step to another is accomplished by means of turning temperature dial, as required. Additionally shifting from STEP 5 to AUXILIARY MECHANISM is accomplished by means of pushing (fan) UP switch. With Navigation System NAHA0176S0401 RHA094I HA-68 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) STEP-BY-STEP PROCEDURE With Navigation System 1 NAHA0176S05 NAHA0176S0501 MA SET IN SELF-DIAGNOSTIC MODE 1. Turn ignition switch ON. 2. Set in self-diagnostic mode as follows. Within 10 seconds after starting engine (ignition switch is turned “ON”.), press switch for at least 5 seconds. 䊳 GI EM GO TO 2. LC 2 STEP 1 - ALL LEDs AND DISPLAY SCREEN ARE CHECKED EC When switch’s LED and display are functioning properly in STEP-1, LED and display will come on. FE CL MT RHA095I AT OK or NG OK 䊳 GO TO 3. NG 䊳 switch, LED or fluorescent display tube. Malfunctioning Go to “Main Power Supply and Ground Circuit Check”, HA-89. TF PD 3 VERIFY ADVANCE TO SELF-DIAGNOSIS STEP 2 AX 1. Turn temperature dial clockwise. 2. Does advance to self-diagnosis STEP 2? Yes or No Yes 䊳 GO TO 4. No 䊳 Malfunctioning temperature dial. Check Display & NAVI control unit. 4 VERIFY RETURN TO SELF-DIAGNOSIS STEP 1 1. Turn temperature dial counterclockwise. 2. Does return to self-diagnosis STEP 1? SU BR ST RS Yes or No Yes 䊳 GO TO 5. No 䊳 Malfunctioning temperature dial. Check Display & NAVI control unit. BT SC EL IDX HA-69 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) 5 STEP 2 - SENSOR CIRCUITS ARE CHECKED FOR OPEN OR SHORT CIRCUIT Turn temperature dial clockwise. appear on the display? Does code No. RHA970DB Yes or No Yes 䊳 GO TO 6. No 䊳 GO TO 14. 6 STEP 3 - MODE DOOR AND INTAKE DOOR POSITIONS ARE CHECKED Turn temperature dial clockwise. Does code No. appear on the display? RHA869DD Yes or No Yes 䊳 GO TO 7. No 䊳 GO TO 15. HA-70 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) 7 GI STEP 4 - OPERATION OF EACH ACTUATOR IS CHECKED Turn temperature dial clockwise. Engine running. Press DEF switch, code No. of each actuator test is indicated on the display. MA EM LC EC RHA495A 䊳 FE GO TO 8. CL MT AT TF PD AX SU BR ST RS BT SC EL IDX HA-71 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) 8 CHECK ACTUATORS Refer to the following chart and confirm discharge air flow, air temperature, blower motor voltage and compressor operation. Checks must be made visually, by listening to any noise, or by touching air outlets with your hand, etc. for improper operation. MTBL0200 MTBL0044 OK or NG OK 䊳 GO TO 9. NG 䊳 쐌 Air outlet does not change. Go to “Mode Door Motor” (HA-94). 쐌 Intake door does not change. Go to “Intake Door Motor” (HA-107). 쐌 Blower motor operation is malfunctioning. Go to “Blower Motor” (HA-116). 쐌 Magnet clutch does not engage. Go to “Magnet Clutch” (HA-127). 쐌 Discharge air temperature does not change. Go to “Air Mix Door Motor” (HA-102). HA-72 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) 9 GI STEP 5 - TEMPERATURE OF EACH SENSOR IS CHECKED Turn temperature dial clcokwise. Code No. appears on the display. MA EM LC EC RHA492A 䊳 FE GO TO 10. CL 10 CHECK AMBIENT SENSOR Press (DEF) switch one time, temperature detected by ambient sensor is indicated on the display. ECON shown in display indicates negative temperature reading. NOTE: If temperature shown on display greatly differs from actual temperature, check sensor circuit first, then inspect sensor. MT AT TF PD AX RHA861H OK or NG OK 䊳 GO TO 11. NG 䊳 Go to Ambient Sensor Circuit (HA-155). SU BR ST RS BT SC EL IDX HA-73 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) 11 CHECK IN-VEHICLE SENSOR Press (DEF) switch the second time, temperature detected by in-vehicle sensor is indicated on the display screen. ECON shown in display indicates negative temperature reading. NOTE: If temperature shown on display greatly differs from actual temperature, check sensor circuit first, then inspect sensor. RHA862H OK or NG OK 䊳 GO TO 12. NG 䊳 Go to In-vehicle Sensor Circuit (HA-158). 12 CHECK INTAKE SENSOR Press (DEF) switch the third time, temperature detected by intake sensor is indicated on the display. NOTE: If temperature shown on display greatly differs from actual temperature, check sensor circuit first, then inspect sensor. RHA862HA OK or NG OK 䊳 GO TO 13. NG 䊳 Go to Intake Sensor Circuit (HA-165). HA-74 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) 13 GI DETECTS MULTIPLEX COMMUNICATION ERROR Press REC switch. appears on the display Does code No. MA EM LC MTBL0509 Yes or No Yes 䊳 INSPECTION END No 䊳 1. Go to “Multiplex Communication Circuit”, HA-168. 2. Go to “OPERATIONAL CHECK”, HA-85. Confirm that A/C system is in good order. EC FE CL MT AT TF PD AX SU BR ST RS BT SC EL IDX HA-75 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) 14 CHECK MALFUNCTIONING SENSOR Refer to the following chart for malfunctioning code No. (If two or more sensors malfunction, corresponding code Nos. blink respectively two times.) MTBL0083 *1: Conduct self-diagnosis STEP 2 under sunshine. When conducting indoors, aim a light (more than 60W) at sunload sensor, otherwise Code No. sunload sensor is functioning properly. *2: HA-155 *3: HA-158 *4: HA-165 *5: HA-162 *6: HA-167 will indicate despite that RHA455G RHA501A 䊳 INSPECTION END HA-76 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) 15 GI CHECK MALFUNCTIONING DOOR MOTOR POSITION SWITCH Mode or (and) intake door motor position switch(es) is (are) malfunctioning. (If two or more mode or intake doors are out of order, corresponding code numbers blink respectively two times.) MA EM LC EC FE CL MTBL0508 *1: If mode door motor harness connector is disconnected, the following display pattern will appear. , , , , , Return to *2: If intake door motor harness connector is disconnected, the following display pattern will appear. , , , Return to *3: HA-94 *4: HA-107 MT AT TF PD AX SU RHA168DA BR ST RS BT RHA498A 䊳 INSPECTION END SC EL IDX HA-77 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) AUXILIARY MECHANISM: TEMPERATURE SETTING TRIMMER With Navigation System =NAHA0176S06 NAHA0176S0601 The trimmer compensates for differences in range of ±3°C (±6°F) between temperature setting (displayed digitally) and temperature felt by driver. Operating procedures for this trimmer are as follows: 쐌 Begin Self-diagnosis STEP 5 mode. 쐌 Press (fan) UP switch to set system in auxiliary mode. 쐌 Display shows “ ” in auxiliary mechanism. It takes approximately 3 seconds. 쐌 Turn the temperature dial clockwise or counterclockwise: Temperature will change at a rate of 0.5°C (1°F). RHA863H When battery cable is disconnected, trimmer operation is canceled. Temperature set becomes that of initial condition, i.e. 0°C (0°F). HA-78 TROUBLE DIAGNOSES AUTO How to Perform Trouble Diagnoses for Quick and Accurate Repair How to Perform Trouble Diagnoses for Quick and Accurate Repair GI =NAHA0177 WORK FLOW NAHA0177S01 MA EM LC EC SHA900E FE *1: Operational Check (HA-80) CL SYMPTOM TABLE NAHA0177S02 Symptom Reference Page 쐌 A/C system does not come on. 쐌 Go to Trouble Diagnosis Procedure for A/C system. HA-88 쐌 Go to Trouble Diagnosis Procedure for Mode Door Motor. (LAN) HA-92 쐌 Go to Trouble Diagnosis Procedure for Air Mix Door Motor. (LAN) HA-100 쐌 Air outlet does not change. 쐌 Mode door motor does not operate normally. 쐌 Discharge air temperature does not change. 쐌 Air mix door motor does not operate normally. MT AT TF PD AX 쐌 Intake door does not change. 쐌 Go to Trouble Diagnosis Procedure for Intake Door Motor. HA-105 쐌 Blower motor operation is malfunctioning under out of starting fan speed control. 쐌 Go to Trouble Diagnosis Procedure for Blower Motor. HA-114 BR 쐌 Magnet clutch does not engage. 쐌 Go to Trouble Diagnosis Procedure for Magnet Clutch. HA-125 ST 쐌 Insufficient cooling. 쐌 Go to Trouble Diagnosis Procedure for Insufficient Cooling. HA-133 쐌 Insufficient heating. 쐌 Go to Trouble Diagnosis Procedure for Insufficient Heating. HA-143 쐌 Noise. 쐌 Go to Trouble Diagnosis Procedure for Noise. HA-146 쐌 Self-diagnosis can not be performed. 쐌 Go to Trouble Diagnosis Procedure for Self-diagnosis. HA-147 쐌 Memory function does not operate. 쐌 Go to Trouble Diagnosis Procedure for Memory Function. HA-150 쐌 ECON mode does not operate. 쐌 Go to Trouble Diagnosis Procedure for ECON (ECONOMY) — mode. HA-153 쐌 A/C system cannot be controlled. 쐌 Go to Trouble Diagnosis Procedure for Multiplex Communication Circuit. HA-168 쐌 Intake door motor does not operate normally. 쐌 Blower motor operation is malfunctioning. SU RS BT SC EL IDX HA-79 TROUBLE DIAGNOSES AUTO Operational Check Operational Check NAHA0178 The purpose of the operational check is to confirm that the system operates properly. CONDITIONS: 쐌 NAHA0178S01 Engine running and at normal operating temperature. PROCEDURE: (WITHOUT NAVIGATION SYSTEM, EXCEPT LE GRADE) NAHA0178S02 1. Check Memory Function NAHA0178S0201 1. 2. 3. 4. 5. 6. RHA232I Set the temperature 90°F or 32°C. Press OFF switch. Turn the ignition off. Turn the ignition on. Press the AUTO switch. Confirm that the set temperature remains at previous temperature. 7. Press OFF switch. If NG, go to trouble diagnosis procedure for memory function (HA150). If OK, continue with next check. 2. Check Blower NAHA0178S0202 1. Press fan switch (up side) one time. Blower should operate on low speed. The fan symbol should have one blade lit . 2. Press fan switch (up side) one more time, and continue checking blower speed and fan symbol until all speeds are checked. 3. Leave blower on MAX speed . If NG, go to trouble diagnosis procedure for blower motor (HA-114). If OK, continue with next check. RHA457G 3. Check Discharge Air 1. 2. Press mode switch four times and DEF button. Each position indicator should change shape. RHA458G HA-80 NAHA0178S0203 TROUBLE DIAGNOSES AUTO Operational Check (Cont’d) 3. Confirm that discharge air comes out according to the air distribution table at left. Refer to “Discharge Air Flow” (HA-29). NOTE: Confirm that the compressor clutch is engaged (visual inspection) and intake door position is at FRESH when the DEF is selected. Intake door position is checked in the next step. If NG, go to trouble diagnosis procedure for mode door motor (HA-92). If OK, continue with next check. GI MA EM LC EC FE CL MT RHA654F 4. Check Recirculation AT NAHA0178S0204 1. Press REC switch. Recirculation indicator should illuminate. 2. Listen for intake door position change (you should hear blower sound change slightly). If NG, go to trouble diagnosis procedure for intake door (HA-105). If OK, continue with next check. TF PD AX SU RHA459G 5. Check Temperature Decrease NAHA0178S0205 1. Press the temperature decrease button until 18°C (60°F) is displayed. 2. Check for cold air at discharge air outlets. If NG, go to trouble diagnosis procedure for insufficient cooling (HA-133). If OK, continue with next check. BR ST RS BT RHA233I 6. Check Temperature Increase NAHA0178S0206 1. Press the temperature increase button until 32°C (90°F) is displayed. 2. Check for hot air at discharge air outlets. If NG, go to trouble diagnosis procedure for insufficient heating (HA-143). If OK, continue with next check. SC EL IDX RHA234I HA-81 TROUBLE DIAGNOSES AUTO Operational Check (Cont’d) 7. Check ECON (Economy) Mode NAHA0178S0207 1. 2. 3. RHA462G Set the temperature 75°F or 25°C. Press ECON switch. Display should indicate ECON (no AUTO). Confirm that the compressor clutch is not engaged (visual inspection). (Discharge air and blower speed will depend on ambient, invehicle and set temperatures.) If NG, go to trouble diagnosis procedure for ECON (Economy) mode (HA-153). If OK, continue with next check. 8. Check AUTO Mode NAHA0178S0208 1. 2. Press AUTO switch. Display should indicate AUTO (no ECON). Confirm that the compressor clutch engages (audio or visual inspection). (Discharge air and blower speed will depend on ambient, invehicle and set temperatures.) If NG, go to trouble diagnosis procedure for A/C system (HA-88), then if necessary, trouble diagnosis procedure for magnet clutch (HA-125). RHA463G If all operational check are OK (symptom can not be duplicated), go to “Incident Simulation Tests” (GI-25) and perform tests as outlined to simulate driving conditions environment. If symptom appears, refer to “Symptom Table” (HA-79) and perform applicable trouble diagnosis procedures. PROCEDURE: (WITHOUT NAVIGATION SYSTEM, LE GRADE) NAHA0178S04 1. Check Memory Function NAHA0178S0401 1. 2. 3. 4. 5. 6. RHA144I Set the temperature 90°F or 32°C. Press OFF switch. Turn the ignition off. Turn the ignition on. Press the AUTO switch. Confirm that the set temperature remains at previous temperature. 7. Press OFF switch. If NG, go to trouble diagnosis procedure for memory function (HA151). If OK, continue with next check. HA-82 TROUBLE DIAGNOSES AUTO Operational Check (Cont’d) 2. Check Blower NAHA0178S0402 Press fan switch (up side) one time. Blower should operate on low speed. The fan symbol should have one blade lit . 2. Press fan switch (up side) one more time, and continue checking blower speed and fan symbol until all speeds are checked. 3. Leave blower on MAX speed . If NG, go to trouble diagnosis procedure for blower motor (HA-115). If OK, continue with next check. GI 1. MA EM LC RHA145I 3. Check Discharge Air 1. 2. EC NAHA0178S0403 Press MODE switch four times and DEF button. Each position indicator should change shape. FE CL MT RHA146I 3. Confirm that discharge air comes out according to the air distribution table at left. Refer to “Discharge Air Flow” (HA-93). NOTE: Confirm that the compressor clutch is engaged (visual inspection) and intake door position is at FRESH when the DEF is selected. Intake door position is checked in the next step. If NG, go to trouble diagnosis procedure for mode door motor (HA-93). If OK, continue with next check. AT TF PD AX SU BR ST RS BT RHA654F 4. Check Recirculation NAHA0178S0404 1. Press REC switch. Recirculation indicator should illuminate. 2. Listen for intake door position change (you should hear blower sound change slightly). If NG, go to trouble diagnosis procedure for intake door (HA-106). If OK, continue with next check. SC EL IDX RHA147I HA-83 TROUBLE DIAGNOSES AUTO Operational Check (Cont’d) 5. Check Temperature Decrease NAHA0178S0405 1. Turn temperature dial counterclockwise until 18°C (60°F) is displayed. 2. Check for cold air at discharge air outlets. If NG, go to trouble diagnosis procedure for insufficient cooling (HA-134). If OK, continue with next check. RHA148I 6. Check Temperature Increase NAHA0178S0406 1. Turn the temperature dial clockwise until 32°C (90°F) is displayed. 2. Check for hot air at discharge air outlets. If NG, go to trouble diagnosis procedure for insufficient heating (HA-144). If OK, continue with next check. RHA149I 7. Check ECON (Economy) Mode NAHA0178S0407 1. 2. 3. RHA150I Set the temperature 75°F or 25°C. Press ECON switch. Display should indicate ECON (no AUTO). Confirm that the compressor clutch is not engaged (visual inspection). (Discharge air and blower speed will depend on ambient, invehicle and set temperatures.) If NG, go to trouble diagnosis procedure for ECON (Economy) mode (HA-154). If OK, continue with next check. 8. Check AUTO Mode NAHA0178S0408 1. 2. Press AUTO switch. Display should indicate AUTO (no ECON). Confirm that the compressor clutch engages (audio or visual inspection). (Discharge air and blower speed will depend on ambient, invehicle and set temperatures.) If NG, go to trouble diagnosis procedure for A/C system (HA-88), then if necessary, trouble diagnosis procedure for magnet clutch (HA-126). RHA144I If all operational check are OK (symptom can not be duplicated), go to “Incident Simulation Tests” (GI section) and perform tests as outlined to simulate driving conditions environment. If symptom appears, refer to “Symptom Table” (HA-79) and perform applicable trouble diagnosis procedures. HA-84 TROUBLE DIAGNOSES AUTO Operational Check (Cont’d) PROCEDURE: (WITH NAVIGATION SYSTEM) 1. Check Memory Function NAHA0178S03 NAHA0178S0301 1. 2. 3. 4. 5. 6. RHA235I GI Set the temperature 90°F or 32°C. Press OFF switch. Turn the ignition off. Turn the ignition on. Press the AUTO switch. Confirm that the set temperature remains at previous temperature. 7. Press OFF switch. If NG, go to trouble diagnosis procedure for memory function (HA152). If OK, continue with next check. MA EM LC EC FE CL MT 2. Check Blower AT NAHA0178S0302 1. Press fan switch (up side) one time. Blower should operate on low speed. The fan symbol should have one blade lit . 2. Press fan switch (up side) one more time, and continue checking blower speed and fan symbol until all speeds are checked. 3. Leave blower on MAX speed . If NG, go to trouble diagnosis procedure for blower motor (HA-116). If OK, continue with next check. TF PD AX SU RHA086I 3. Check Discharge Air 1. 2. Press MODE switch four times and D/F button. Each position indicator should change shape. NAHA0178S0303 BR ST RS BT RHA087I SC EL IDX HA-85 TROUBLE DIAGNOSES AUTO Operational Check (Cont’d) 3. Confirm that discharge air comes out according to the air distribution table at left. Refer to “Discharge Air Flow” (HA-29). NOTE: Confirm that the compressor clutch is engaged (visual inspection) and intake door position is at FRESH when the DEF is selected. Intake door position is checked in the next step. If NG, go to trouble diagnosis procedure for mode door motor (HA-94). If OK, continue with next check. RHA654F 4. Check Recirculation NAHA0178S0304 1. Press REC switch. Recirculation indicator should illuminate. 2. Listen for intake door position change (you should hear blower sound change slightly). If NG, go to trouble diagnosis procedure for intake door (HA-107). If OK, continue with next check. RHA088I 5. Check Temperature Decrease NAHA0178S0305 1) Turn the temperature dial counterclockwise until 18°C (60°F) is displayed. 2) Check for cold air at discharge air outlets. If NG, go to trouble diagnosis procedure for insufficient cooling (HA-135). If OK, continue with next check. RHA236I 6. Check Temperature Increase 1) NAHA0178S0306 Turn the temperature dial clockwise until 32°C (90°F) is displayed. 2) Check for hot air at discharge air outlets. If NG, go to trouble diagnosis procedure for insufficient heating (HA-145). If OK, continue with next check. RHA237I HA-86 TROUBLE DIAGNOSES AUTO Operational Check (Cont’d) 7. Check ECON (Economy) Mode NAHA0178S0307 1. 2. Press ECON switch. Display should indicate ECON (no AUTO). Confirm that the compressor clutch is not engaged (visual inspection). (Discharge air and blower speed will depend on ambient, invehicle and set temperatures.) If NG, go to trouble diagnosis procedure for ECON (Economy) mode (HA-155). If OK, continue with next check. GI MA EM LC RHA090I 8. Check AUTO Mode 1. 2. RHA091I EC NAHA0178S0308 Press AUTO switch. Display should indicate AUTO (no ECON). Confirm that the compressor clutch engages (audio or visual inspection). (Discharge air and blower speed will depend on ambient, invehicle and set temperatures.) If NG, go to trouble diagnosis procedure for A/C system (HA-88), then if necessary, trouble diagnosis procedure for magnet clutch (HA-127). If all operational check are OK (symptom can not be duplicated), go to GI-25 “Incident Simulation Tests” (GI section) and perform tests as outlined to simulate driving conditions environment. If symptom appears, refer to “Symptom Table” (HA-79) and perform applicable trouble diagnosis procedures. FE CL MT AT TF PD AX SU BR ST RS BT SC EL IDX HA-87 TROUBLE DIAGNOSES AUTO A/C System A/C System TROUBLE DIAGNOSIS PROCEDURE FOR A/C SYSTEM =NAHA0179 SYMPTOM: 쐌 A/C system does not come on. INSPECTION FLOW RHA238I *1: HA-89 *2: HA-80 *3: HA-168 HA-88 TROUBLE DIAGNOSES AUTO A/C System (Cont’d) MAIN POWER SUPPLY AND GROUND CIRCUIT CHECK GI NAHA0180 Component Description NAHA0180S01 RHA464GA Automatic Amplifier (Auto Amp.) NAHA0180S0101 The auto amplifier has a built-in microcomputer which processes information sent from various sensors needed for air conditioner operation. The air mix door motor, mode door motor, intake door motor, blower motor and compressor are then controlled. The auto amplifier is unitized with control mechanisms. Signals from various switches and Potentio Temperature Control (PTC) are directly entered into auto amplifier. Self-diagnostic functions are also built into auto amplifier to provide quick check of malfunctions in the auto air conditioner system. MA EM LC EC FE CL MT RHA141I AT TF PD AX SU RHA858H BR ST RS BT SC EL IDX HA-89 TROUBLE DIAGNOSES AUTO A/C System (Cont’d) Potentio Temperature Control (PTC) NAHA0180S0102 The PTC is built into the A/C auto amp. It can be set at an interval of 0.5°C (1.0°F) in the 18°C (60°F) to 32°C (90°F) temperature range by pushing the temperature button. The set temperature is digitally displayed. RHA464GA RHA141I RHA098I DIAGNOSTIC PROCEDURE SYMPTOM: 쐌 A/C system does not come on. RHA817H HA-90 NAHA0181 TROUBLE DIAGNOSES AUTO A/C System (Cont’d) Auto Amp. Check NAHA0181S01 Check power supply circuit for auto amp. with ignition switch ON. Measure voltage across terminal Nos. 26, 27, 33 (24, 25, 33) and body ground. GI MA Voltmeter terminal Voltage (+) (−) EM 26 (24) 27 (25) Body ground Approx. 12V LC 33 (33) EC If OK, check auto amp. 쐌 If NG, check 7.5A fuses [Nos. 11 and 24, located in the fuse block — junction box (J/B)] and 15A fuses [Nos. 1 and 2, located in the fuse block — junction box (J/B)]. 쐌 If fuses are OK, check for open circuit in wiring harness. Repair or replace as necessary. 쐌 If fuses are NG, replace fuse and check wiring harness for short circuit. Repair or replace as necessary. RHA818HA Check body ground circuit for auto amp. with ignition switch OFF. Check for continuity between terminal Nos. 32, 14 and body ground. FE CL MT AT TF Ohmmeter terminal Continuity (+) (−) PD 32 Body ground 14 (Canada only) NOTE: If OK, replace auto amp. If NG, repair or replace harness. Yes AX SU BR ST RS BT SHA967EE SC EL IDX RHA868H HA-91 TROUBLE DIAGNOSES AUTO Mode Door Motor Mode Door Motor TROUBLE DIAGNOSIS PROCEDURE FOR MODE DOOR MOTOR (LAN) =NAHA0182 SYMPTOM: 쐌 Air outlet does not change. 쐌 Mode door motor does not operate normally. Inspection Flow NAHA0182S01 Without Navigation System (Except LE Grade) NAHA0182S0101 SHA245F *1: *2: *3: *4: *5: HA-29 HA-80 HA-48 HA-49 HA-155 *6: *7: *8: *9: HA-158 HA-162 HA-167 STEP-BY-STEP PROCEDURE (HA-49), see No. 13. HA-92 *10: *11: *12: *13: *14: HA-96 HA-99 HA-80 HA-79 HA-165 TROUBLE DIAGNOSES AUTO Mode Door Motor (Cont’d) Without Navigation System (LE Grade) NAHA0182S0103 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS RHA152I *1: *2: *3: *4: *5: HA-29 HA-82 HA-59 HA-59 HA-155 *6: *7: *8: *9: HA-158 HA-162 HA-167 STEP-BY-STEP PROCEDURE (HA-59), see No. 13. *10: *11: *12: *13: *14: HA-96 HA-99 HA-82 HA-79 HA-165 BT SC EL IDX HA-93 TROUBLE DIAGNOSES AUTO Mode Door Motor (Cont’d) With Navigation System NAHA0182S0102 RHA109I *1: *2: *3: *4: *5: HA-29 HA-85 HA-69 HA-69 HA-155 *6: *7: *8: *9: HA-158 HA-162 HA-167 STEP-BY-STEP PROCEDURE (HA-69), see No. 13. HA-94 *10: *11: *12: *13: *14: HA-96 HA-99 HA-85 HA-79 HA-165 TROUBLE DIAGNOSES AUTO Mode Door Motor (Cont’d) SYSTEM DESCRIPTION Component Parts =NAHA0183 GI NAHA0183S01 Mode door control system components are: 1) Auto amp. 2) Mode door motor (LCU) 3) In-vehicle sensor 4) Ambient sensor 5) Sunload sensor 6) Intake sensor MA EM LC System Operation NAHA0183S02 The auto amplifier receives data from each of the sensors. The amplifier sends mode door and air mix door opening angle data to the mode door motor LCU and air mix door motor LCU. The mode door motor and air mix door motor read their respective signals according to the address signal. Opening angle indication signals received from the auto amplifier and each of the motor position sensors are compared by the LCUs in each motor with the existing decision and opening angles. Subsequently, HOT/ COLD or DEFROST/VENT operation is selected. The new selection data is returned to the auto amplifier. EC FE CL MT AT TF PD AX SU BR ST RS RHA870H BT SC EL IDX HA-95 TROUBLE DIAGNOSES AUTO Mode Door Motor (Cont’d) Mode Door Control Specification NAHA0183S03 RHA135G COMPONENT DESCRIPTION NAHA0184 The mode door motor is attached to the heater unit. It rotates so that air is discharged from the outlet set by the auto amplifier. Motor rotation is conveyed to a link which activates the mode door. RHA505G DIAGNOSTIC PROCEDURE FOR MODE DOOR MOTOR AND AIR MIX DOOR MOTOR CIRCUIT NAHA0185 SYMPTOM: Mode door motor and/or air mix door motor does not operate normally. RHA488GA HA-96 TROUBLE DIAGNOSES AUTO Mode Door Motor (Cont’d) 1 GI CHECK POWER SUPPLY FOR AUTO AMP. (LCU) SIDE Do approx. 12 volts exist between auto amp. (LCU) harness terminal No. 21 and body ground? MA EM LC EC RHA819HB NOTE: If the result is NG or No after checking circuit continuity, repair harness or connector. FE Yes or No CL Yes 䊳 GO TO 2. No 䊳 Replace auto amp. (LCU). MT 2 CHECK SIGNAL FOR AUTO AMP. (LCU) SIDE AT Do approx. 5.5 volts exist between auto amp. (LCU) terminal No. 16 or 14 and body ground? TF PD AX RHA820H NOTE: If the result is NG or No after checking circuit continuity, repair harness or connector. Yes or No Yes 䊳 GO TO 3. No 䊳 Replace auto amp. (LCU). SU BR ST RS BT SC EL IDX HA-97 TROUBLE DIAGNOSES AUTO Mode Door Motor (Cont’d) 3 CHECK POWER SUPPLY FOR MOTOR SIDE Do approx. 12 volts exist between door motor (LCU) harness terminal No. 21 and body ground? RHA489GC Yes or No Yes 䊳 GO TO 4. No 䊳 Repair harness or connector. 4 CHECK SIGNAL FOR MOTOR SIDE Do approx. 5.5 volts exist between door motor (LCU) terminal No. 16 and body ground? RHA490G Yes or No Yes 䊳 GO TO 5. No 䊳 Repair harness or connector. 5 CHECK MOTOR GROUND CIRCUIT Does continuity exist between door motor (LCU) harness terminal No. 32 and body ground? RHA491G Yes or No Yes 䊳 GO TO 6. No 䊳 Repair harness or connector. HA-98 TROUBLE DIAGNOSES AUTO Mode Door Motor (Cont’d) 6 GI CHECK MOTOR OPERATION Disconnect and reconnect the motor connector and confirm the motor operation. MA OK or NG OK (Return to operate normally) 䊳 Poor contacting the motor connector NG (Does not operate normally) 䊳 GO TO 7. EM LC 7 CHECK MODE DOOR MOTOR OPERATION EC 1. Disconnect the mode door motor and air mix door motor connector. 2. Reconnect the mode door motor and confirm the motor operation. OK or NG OK (Mode door motor operates normally) 䊳 Replace the air mix door motor. NG (Mode door motor does not operate normally) 䊳 GO TO 8. 8 FE CL MT CHECK AIR MIX DOOR MOTOR OPERATION AT 1. Disconnect the mode door motor connector. 2. Reconnect the air mix door motor and confirm the air mix door motor operation. TF OK or NG OK (Air mix door motor operates normally) 䊳 Replace mode door motor. NG (Air mix door motor does not operate normally) 䊳 Replace auto amp. PD AX SU CONTROL LINKAGE ADJUSTMENT Mode Door 1. 2. RHA505G 3. 4. 5. NAHA0186 NAHA0186S01 Install mode door motor on heater unit and connect it to main harness. Set up code No. in Self-diagnosis STEP 4. Refer to HA-49 (Without navigation system, except LE grade), HA-59 (Without navigation system, LE grade) or HA-69 (With navigation system). Move side link by hand and hold mode door in DEF mode. Attach mode door motor rod to side link rod holder. Make sure mode door operates properly when changing from code No. to by pushing DEF switch. VENT B/L B/L FOOT D/F DEF BR ST RS BT SC EL IDX HA-99 TROUBLE DIAGNOSES AUTO Air Mix Door Motor Air Mix Door Motor TROUBLE DIAGNOSIS PROCEDURE FOR AIR MIX DOOR (LAN) =NAHA0187 SYMPTOM: 쐌 Discharge air temperature does not change. 쐌 Air mix door motor does not operate. Inspection Flow NAHA0187S01 Without Navigation System (Except LE Grade) NAHA0187S0101 RHA239I *1: *2: *3: *4: *5: HA-48 HA-155 HA-158 HA-162 HA-167 *6: STEP-BY-STEP PROCEDURE (HA-49), see No. 13. *7: HA-96 *8: HA-104 *9: HA-104 HA-100 *10: *12: *13: *14: *15: HA-80 HA-80 HA-79 HA-165 HA-49 TROUBLE DIAGNOSES AUTO Air Mix Door Motor (Cont’d) Without Navigation System (LE Grade) NAHA0187S0103 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS RHA153IA *1: *2: *3: *4: *5: HA-59 HA-155 HA-158 HA-162 HA-167 *6: STEP-BY-STEP PROCEDURE (HA-59), see No. 13. *7: HA-96 *8: HA-104 *9: HA-104 *10: *12: *13: *14: *15: HA-82 HA-82 HA-79 HA-165 HA-59 BT SC EL IDX HA-101 TROUBLE DIAGNOSES AUTO Air Mix Door Motor (Cont’d) With Navigation System NAHA0187S0102 RHA240I *1: *2: *3: *4: *5: HA-69 HA-155 HA-158 HA-162 HA-167 *6: STEP-BY-STEP PROCEDURE (HA-69), see No. 13. *7: HA-96 *8: HA-104 *9: HA-104 HA-102 *10: *12: *13: *14: *15: HA-85 HA-85 HA-79 HA-165 HA-69 TROUBLE DIAGNOSES AUTO Air Mix Door Motor (Cont’d) SYSTEM DESCRIPTION Component Parts Air 1) 2) 3) 4) 5) 6) =NAHA0188 GI NAHA0188S01 mix door control system components are: Auto amp. Air mix door motor (LCU) In-vehicle sensor Ambient sensor Sunload sensor Intake sensor MA EM LC System Operation NAHA0188S02 The auto amplifier receives data from each of the sensors. The amplifier sends air mix door and mode door opening angle data to the air mix door motor LCU and mode door motor LCU. The air mix door motor and mode door motor read their respective signals according to the address signal. Opening angle indication signals received from the auto amplifier and each of the motor position sensors are compared by the LCUs in each motor with the existing decision and opening angles. Subsequently, HOT/ COLD or DEFROST/VENT operation is selected. The new selection data is returned to the auto amplifier. EC FE CL MT AT TF PD AX SU RHA872H BR ST RS BT SC EL IDX HA-103 TROUBLE DIAGNOSES AUTO Air Mix Door Motor (Cont’d) Air Mix Door Control Specification NAHA0188S03 RHA137G COMPONENT DESCRIPTION NAHA0189 The air mix door motor is attached to the heater unit. It rotates so that the air mix door is opened or closed to a position set by the auto amplifier. Motor rotation is then conveyed through a shaft and the air mix door position is then fed back to the auto amplifier by PBR built-in air mix door motor. RHA849E CONTROL LINKAGE ADJUSTMENT Air Mix Door 1. 2. 3. RHA504G 4. 5. NAHA0190 NAHA0190S01 Install air mix door motor on heater unit and connect it to main harness. Set up code No. 41 in Self-diagnosis STEP 4. Refer to HA-48 (Without navigation system, except LE grade), HA-59 (Without navigation system, LE grade) or HA-69 (With navigation system). Move air mix door lever by hand and hold it in full cold position. Attach air mix door lever to rod holder. Make sure air mix door operates properly when changing from code No. to by pushing DEF switch. Full cold HA-104 Full hot TROUBLE DIAGNOSES AUTO Intake Door Motor Intake Door Motor GI TROUBLE DIAGNOSIS PROCEDURE FOR INTAKE DOOR =NAHA0191 SYMPTOM: 쐌 Intake door does not change. 쐌 Intake door motor does not operate normally. MA EM Inspection Flow NAHA0191S01 Without Navigation System (Except LE Grade) NAHA0191S0101 LC EC FE CL MT AT TF PD AX SU BR ST RS BT SHA247F *1: *2: *3: *4: *5: HA-48 HA-155 HA-158 HA-162 HA-167 *6: STEP-BY-STEP PROCEDURE (HA-49), see No. 13. *7: HA-109 *8: HA-113 *9: HA-80 HA-105 *10: *11: *12: *13: HA-49 HA-80 HA-79 HA-165 SC EL IDX TROUBLE DIAGNOSES AUTO Intake Door Motor (Cont’d) Without Navigation System (LE Grade) NAHA0191S0103 RHA154I *1: *2: *3: *4: *5: HA-59 HA-155 HA-158 HA-162 HA-167 *6: STEP-BY-STEP PROCEDURE (HA-59), see No. 13. *7: HA-109 *8: HA-113 *9: HA-82 HA-106 *10: *11: *12: *13: HA-59 HA-82 HA-79 HA-165 TROUBLE DIAGNOSES AUTO Intake Door Motor (Cont’d) With Navigation System NAHA0191S0102 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS RHA111I *1: *2: *3: *4: *5: HA-69 HA-155 HA-158 HA-162 HA-167 *6: STEP-BY-STEP PROCEDURE (HA-69), see No. 13. *7: HA-109 *8: HA-113 *9: HA-85 *10: *11: *12: *13: HA-69 HA-85 HA-79 HA-165 BT SC EL IDX HA-107 TROUBLE DIAGNOSES AUTO Intake Door Motor (Cont’d) SYSTEM DESCRIPTION Component Parts =NAHA0192 NAHA0192S01 Intake door control system components are: 1) Auto amp. 2) Intake door motor 3) A/C LAN system (PBR built-in mode motor and air mix door motor) 4) In-vehicle sensor 5) Ambient sensor 6) Sunload sensor 7) Intake sensor System Operation NAHA0192S02 The intake door control determines intake door position based on the ambient temperature, the intake air temperature and the in-vehicle temperature. When the ECON, DEFROST, or OFF switches are pushed, the auto amplifier sets the intake door at the “Fresh” position. RHA874H Intake Door Control Specification NAHA0192S03 RHA136G HA-108 TROUBLE DIAGNOSES AUTO Intake Door Motor (Cont’d) COMPONENT DESCRIPTION NAHA0193 The intake door motor is attached to the intake unit. It rotates so that air is drawn from inlets set by the auto amplifier. Motor rotation is conveyed to a lever which activates the intake door. GI MA EM LC RHA593F DIAGNOSTIC PROCEDURE EC NAHA0194 SYMPTOM: Intake door motor does not operate normally. FE CL MT RHA502GA 1 AT CHECK BODY GROUND CIRCUIT FOR INTAKE DOOR MOTOR Does continuity exist between intake door harness connector terminal No. 1 and body ground? TF PD AX SU RHA492G BR Yes or No Yes 䊳 GO TO 2. No 䊳 Repair harness or connector. ST RS BT SC EL IDX HA-109 TROUBLE DIAGNOSES AUTO Intake Door Motor (Cont’d) 2 CHECK FOR AUTO AMP. OUTPUT Set up Self-diagnosis STEP 4. Measure voltage across auto amp. harness connector terminals and body ground. RHA821H MTBL0466 OK or NG OK 䊳 INSPECTION END NG 䊳 GO TO 3. HA-110 TROUBLE DIAGNOSES AUTO Intake Door Motor (Cont’d) 3 CHECK CIRCUIT CONTINUITY BETWEEN EACH TERMINAL ON AUTO AMP. AND ON INTAKE DOOR MOTOR GI MA EM LC EC FE CL MT AT TF PD SHA605F AX SU BR MTBL0510 ST If OK, check harness for short. OK or NG OK 䊳 GO TO 4. NG 䊳 Repair harness or connector. RS BT SC EL IDX HA-111 TROUBLE DIAGNOSES AUTO Intake Door Motor (Cont’d) 4 CHECK FOR AUTO AMP. OUTPUT Set up Self-diagnosis STEP 4. Measure voltage across auto amp. harness connector terminals and body ground. RHA823HA MTBL0468 OK or NG OK 䊳 Replace intake door motor. NG 䊳 Replace auto amp. HA-112 TROUBLE DIAGNOSES AUTO Intake Door Motor (Cont’d) CONTROL LINKAGE ADJUSTMENT Intake Door 1. 2. RHA593F 3. 4. 5. =NAHA0195 GI NAHA0195S01 Install intake door motor on intake unit and connect it to main harness. Set up code No. in Self-diagnosis STEP 4. Refer to HA-49 (Without navigation system, except LE grade), HA-59 (Without navigation system, LE grade) or HA-69 (With navigation system). Move intake door link by hand and hold it in REC position. Attach intake door lever to rod holder. Make sure intake door operates properly when changing from code No. to by pushing DEF switch. MA EM LC EC FE REC 20% FRE FRE CL MT AT TF PD AX SU BR ST RS BT SC EL IDX HA-113 TROUBLE DIAGNOSES AUTO Blower Motor Blower Motor TROUBLE DIAGNOSIS PROCEDURE FOR BLOWER MOTOR =NAHA0196 SYMPTOM: 쐌 Blower motor operation is malfunctioning. 쐌 Blower motor operation is malfunctioning under out of starting fan speed control. Inspection Flow NAHA0196S01 Without Navigation System (Except LE Grade) NAHA0196S0101 SHA691F *1: *2: *3: *4: *5: HA-48 HA-155 HA-158 HA-162 HA-167 *6: STEP-BY-STEP PROCEDURE (HA-49), see No. 13. *7: HA-118 *8: HA-118 *9: HA-49 HA-114 *10: *11: *12: *13: *14: HA-80 HA-79 HA-80 HA-165 EL-134 TROUBLE DIAGNOSES AUTO Blower Motor (Cont’d) Without Navigation System (LE Grade) NAHA0196S0103 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS RHA138I *1: *2: *3: *4: *5: HA-59 HA-155 HA-158 HA-162 HA-167 *6: STEP-BY-STEP PROCEDURE (HA-59), see No. 13. *7: HA-118 *8: HA-118 *9: HA-59 *10: *11: *12: *13: *14: HA-82 HA-79 HA-82 HA-165 EL-87 BT SC EL IDX HA-115 TROUBLE DIAGNOSES AUTO Blower Motor (Cont’d) With Navigation System NAHA0196S0102 SHA692F *1: *2: *3: *4: *5: HA-69 HA-155 HA-158 HA-162 HA-167 *6: STEP-BY-STEP PROCEDURE (HA-69), see No. 13. *7: HA-118 *8: HA-118 *9: HA-69 HA-116 *10: *11: *12: *13: *14: HA-85 HA-79 HA-85 HA-165 EL-134 TROUBLE DIAGNOSES AUTO Blower Motor (Cont’d) SYSTEM DESCRIPTION Component parts =NAHA0197 GI NAHA0197S01 Fan speed control system components are: 1) Auto amp. 2) Fan control amp. 3) A/C LAN system (PBR built-in mode door motor and air mix door motor) 4) In-vehicle sensor 5) Ambient sensor 6) Sunload sensor 7) Intake sensor MA EM LC EC System Operation NAHA0197S02 FE CL MT AT TF PD SHA006FF Automatic Mode NAHA0197S03 In the automatic mode, the blower motor speed is calculated by the automatic amplifier based on inputs from the PBR, in-vehicle sensor, sunload sensor, intake sensor and ambient sensor. The blower motor applied voltage ranges from approximately 5 volts (lowest speed) to 12 volts (highest speed). The control blower speed (in the range of 5 to 12V), the automatic amplifier supplies a gate voltage to the fan control amplifier. Based on this voltage, the fan control amplifier controls the voltage supplied to the blower motor. Starting Fan Speed Control NAHA0197S04 Start Up From “COLD SOAK” Condition (Automatic mode) NAHA0197S0401 In a cold start up condition where the engine coolant temperature is below 55°C (131°F), the blower will not operate for a short period of time (up to 150 seconds). The exact start delay time varies depending on the ambient and engine coolant temperature. In the most extreme case (very low ambient) the blower starting delay will be 150 seconds as described above. After this delay, the blower will operate at low speed until the engine coolant temperature rises above 55°C (131°F), at which time the blower speed will increase to the objective speed. Start Up From Normal or “HOT SOAK” Condition (Automatic mode) NAHA0197S0402 The blower will begin operation momentarily after the AUTO button is pushed. The blower speed will gradually rise to the objective speed over a time period of 3 seconds or less (actual time depends on the objective blower speed). AX SU BR ST RS BT SC EL IDX HA-117 TROUBLE DIAGNOSES AUTO Blower Motor (Cont’d) Blower Speed Compensation NAHA0197S05 Sunload NAHA0197S0501 When the in-vehicle temperature and the set temperature are very close, the blower will be operating at low speed. The low speed will vary depending on the sunload. During conditions of high sunload, the blower low speed is “usual” low speed (approx. 6V). During low or no sunload conditions, the low speed will drop to “low” low speed (approx. 5V). Fan Speed Control Specification NAHA0197S06 RHA138G COMPONENT DESCRIPTION Fan Control Amplifier NAHA0198 NAHA0198S01 The fan control amplifier is located on the cooling unit. The fan control amp. receives a gate voltage from the auto amp. to steplessly maintain the blower fan motor voltage in the 5 to 12 volt range (approx.). RHA648F DIAGNOSTIC PROCEDURE NAHA0199 SYMPTOM: Blower motor operation is malfunctioning under Starting Fan Speed Control. RHA467G HA-118 TROUBLE DIAGNOSES AUTO Blower Motor (Cont’d) 1 GI CHECK POWER SUPPLY FOR FAN CONTROL AMP. Disconnect fan control amp. harness connector. Do approx. 12 volts exist between fan control amp. harness connector terminal No. 3 and body ground? MA EM LC EC RHA480G Yes or No Yes 䊳 GO TO 2. No 䊳 GO TO 8. 2 FE CL CHECK BODY GROUND CIRCUIT FOR FAN CONTROL AMP. MT Does continuity exist between fan control amp. harness connector terminal No. 1 and body ground? AT TF PD AX RHA089G Yes or No Yes 䊳 Reconnect fan control amp. harness connector. And GO TO 3. No 䊳 Repair harness or connector. SU BR ST RS BT SC EL IDX HA-119 TROUBLE DIAGNOSES AUTO Blower Motor (Cont’d) 3 CHECK VOLTAGE FOR FAN CONTROL AMP. Set up Self-diagnosis STEP 4. Measure voltage across fan control amp. harness connector terminal No. 2 and body ground. RHA481GC MTBL0465 OK or NG OK 䊳 GO TO 5. NG 䊳 쐌 The voltage is less than 2.5V. Replace fan control amp. 쐌 The voltage is more than 3.0V. GO TO 4. 4 CHECK FAN CONTROL AMP. Refer to HA-124 OK or NG OK 䊳 GO TO 5. NG 䊳 1. Replace fan control amp. 2. Go to “STEP-BY-STEP PROCEDURE”, HA-49 (Without navigation system, except LE grade), HA-59 (Without navigation system, LE grade) or HA-69 (With navigation system) and perform self-diagnosis STEP 4. Confirm that blower motor operation is usual. HA-120 TROUBLE DIAGNOSES AUTO Blower Motor (Cont’d) 5 GI CHECK FAN CONTROL AMP. CIRCUIT BETWEEN FAN CONTROL AMP. AND AUTO AMP. (LCU) 1. Disconnect auto amp. (LCU) and fan control amp. harness connector. 2. Check circuit continuity between auto amp. (LCU) harness connector terminal No. 35 and fan control amp. harness connector terminal No. 2. MA EM LC EC RHA824H Continuity should exist. If OK, check harness for short. FE CL OK or NG OK 䊳 GO TO 6. NG 䊳 Repair harness or connector. 6 MT AT CHECK POWER SUPPLY FOR AUTO AMP. Reconnect auto amp. (LCU) harness connector. Do approx. 12 volts exist between auto amp. (LCU) harness connector terminal No. 33 and body ground? TF PD AX SU RHA825H BR Yes or No Yes 䊳 GO TO 7. No 䊳 Check power supply circuit and 15A fuses [Nos. 1 and 2, located in the fuse block — junction box (J/B)]. Refer to EL-12, “Wiring Diagram — POWER —”. 쐌 If OK, check for open circuit in wiring harness. Repair or replace as necessary. 쐌 If NG, replace fuse and check wiring harness for short circuit. Repair or replace as necessary. ST RS BT SC EL IDX HA-121 TROUBLE DIAGNOSES AUTO Blower Motor (Cont’d) 7 CHECK FAN FEED BACK CIRCUIT Do approx. 12 volts exist between auto amp. harness connector terminal No. 34 and body ground? RHA826H Yes or No Yes 䊳 1. Replace auto amp. 2. Go to self-diagnosis step-by-step procedure HA-49 (Without navigation system, except LE grade), HA-59 (Without navigation system, LE grade) or HA-69 (With navigation system) and perform self-diagnosis STEP-4. Confirm that blower motor operation is usual. No 䊳 GO TO 10. 8 CHECK POWER SUPPLY FOR BLOWER MOTOR Disconnect blower motor harness connector. Do approx. 12 volts exist between blower motor harness connector terminal No. 1 and body ground? RHA091G Yes or No Yes 䊳 GO TO 9. No 䊳 Check power supply circuit and 15A fuses [Nos. 1 and 2, located in the fuse block — junction box (J/B)]. 쐌 If OK, check for open circuit in wiring harness. Repair or replace as necessary. 쐌 If NG, replace fuse and check wiring harness for short circuit. Repair or replace as necessary. HA-122 TROUBLE DIAGNOSES AUTO Blower Motor (Cont’d) 9 GI CHECK CIRCUIT CONTINUITY BETWEEN BLOWER MOTOR AND FAN CONTROL AMP. Disconnect blower motor connector and auto amp. (LCU) connector. Check circuit continuity between blower motor harness connector terminal No. 2 and fan control amp. harness connector terminal No. 3. MA EM LC EC RHA472G FE OK or NG OK NG 10 䊳 䊳 Check blower motor. (Refer to HA-123.) 1. If NG, replace blower motor. 2. Go to self-diagnosis step-by-step procedure HA-49 (Without navigation system, except LE grade), HA-59 (Without navigation system, LE grade) or HA-69 (With navigation system) and perform self-diagnosis STEP-4. Confirm that blower motor operation is usual. Repair harness or connector. CL MT AT CHECK BLOWER MOTOR CIRCUIT BETWEEN BLOWER MOTOR AND AUTO AMP. (LCU) Check circuit continuity between blower motor harness connector terminal No. 2 and auto amp. (LCU) harness connector terminal No. 34. TF PD AX SU BR RHA827H Continuity should exist. ST OK or NG OK 䊳 Check harness for short. NG 䊳 Repair harness or connector. RS BT COMPONENT INSPECTION Blower Motor NAHA0200 NAHA0200S01 Confirm smooth rotation of the blower motor. 쐌 Ensure that there are no foreign particles inside the intake unit. SC EL IDX RHA941F HA-123 TROUBLE DIAGNOSES AUTO Blower Motor (Cont’d) Fan Control Amp. NAHA0200S02 Check continuity between terminals. Ohmmeter terminal Continuity (+) (–) Terminal Nos. Yes 2 RHA828H HA-124 1 TROUBLE DIAGNOSES AUTO Magnet Clutch Magnet Clutch GI TROUBLE DIAGNOSIS PROCEDURE FOR MAGNET CLUTCH =NAHA0201 SYMPTOM: 쐌 Magnet clutch does not engage. MA Inspection Flow NAHA0201S01 Without Navigation System (Except LE Grade) EM NAHA0201S0101 LC EC FE CL MT AT TF PD AX SU BR ST RS BT SHA249FA SC *1: STEP-BY-STEP PROCEDURE (HA-48) *2: HA-155 *3: HA-158 *4: HA-162 *5: HA-167 *6: STEP-BY-STEP PROCEDURE (HA-49), see No. 13. *7: HA-128 *8: HA-175 *9: HA-138 *10: HA-80 HA-125 *11: *12: *13: *14: HA-49 HA-80 HA-79 HA-165 EL IDX TROUBLE DIAGNOSES AUTO Magnet Clutch (Cont’d) Without Navigation System (LE Grade) NAHA0201S0103 RHA155I *1: STEP-BY-STEP PROCEDURE (HA-59) *2: HA-155 *3: HA-158 *4: HA-162 *5: HA-167 *6: STEP-BY-STEP PROCEDURE (HA-59), see No. 13. *7: HA-128 *9: HA-138 HA-126 *10: *11: *12: *13: *14: HA-82 HA-59 HA-82 HA-79 HA-165 TROUBLE DIAGNOSES AUTO Magnet Clutch (Cont’d) With Navigation System NAHA0201S0102 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS RHA113I *1: STEP-BY-STEP PROCEDURE (HA-69) *2: HA-155 *3: HA-158 *4: HA-162 *5: HA-167 *6: STEP-BY-STEP PROCEDURE (HA-69), see No. 13. *7: HA-128 *8: HA-175 *9: HA-138 *10: HA-85 *11: *12: *13: *14: HA-69 HA-85 HA-79 HA-165 BT SC EL IDX HA-127 TROUBLE DIAGNOSES AUTO Magnet Clutch (Cont’d) SYSTEM DESCRIPTION =NAHA0202 Auto amplifier controls compressor operation by ambient temperature and signal from ECM. Low Temperature Protection Control NAHA0202S01 Auto amplifier will turn the compressor “ON” or “OFF” as determined by a signal detected by ambient sensor. When ambient temperatures are greater than −2°C (28°F), the compressor turns “ON”. The compressor turns “OFF” when ambient temperatures are less than −5°C (23°F). RHA094GB DIAGNOSTIC PROCEDURE NAHA0203 SYMPTOM: Magnet clutch does not engage when AUTO switch is ON. RHA199I 1 CHECK POWER SUPPLY FOR COMPRESSOR Disconnect compressor harness connector. Do approx. 12 volts exist between compressor harness connector terminal No. 1 and body ground? RHA096G Yes or No Yes 䊳 Check magnet clutch coil. 1. If NG, replace magnet clutch. Refer to HA-175. 2. Go to self-diagnosis step-by-step procedure HA-49 (Without navigation system, except LE grade), HA-59 (Without navigation system, LE grade) or HA-69 (With navigation system) and perform self-diagnosis STEP-4. Confirm that magnet clutch operation is usual. No 䊳 Disconnect A/C relay. And GO TO 2. HA-128 TROUBLE DIAGNOSES AUTO Magnet Clutch (Cont’d) 2 GI CHECK CIRCUIT CONTINUITY BETWEEN A/C RELAY AND COMPRESSOR Check circuit continuity between A/C relay harness connector E26 terminal No. 5 (B/W) and compressor harness connector F202 terminal No. 1 (B/W). MA EM LC EC SHA476F Continuity should exist. If OK, check harness for short. CL OK or NG OK 䊳 GO TO 3. NG 䊳 Repair harness or connector. 3 FE MT CHECK POWER SUPPLY FOR A/C RELAY AT Disconnect A/C relay. Do approx. 12 volts exist between A/C relay harness connector E26 terminal Nos. 1 (G/W), 3 (G/W) and body ground? TF PD AX SU SHA477F Yes or No Yes 䊳 GO TO 4. No 䊳 Check power supply circuit and 7.5A (No. 6) fuse at fuse block — junction box (J/B). Refer to EL-12, “Wiring Diagram — POWER —”. 쐌 If OK, check for open circuit in wiring harness. Repair or replace as necessary. 쐌 If NG, replace fuse and check wiring harness for short circuit. Repair or replace as necessary. BR ST RS BT 4 CHECK A/C RELAY AFTER DISCONNECTING IT Refer to HA-132. OK or NG OK 䊳 Reconnect A/C relay. And GO TO 5. SC NG 䊳 1. Replace A/C relay. 2. Go to self-diagnosis step-by-step procedure HA-49 (Without navigation system, except LE grade), HA-59 (Without navigation system, LE grade) or HA-69 (With navigation system) and perform self-diagnosis STEP-4. Confirm that magnet clutch operation is usual. EL HA-129 IDX TROUBLE DIAGNOSES AUTO Magnet Clutch (Cont’d) 5 CHECK COIL SIDE CIRCUIT OF A/C RELAY Do approx. 12 volts exist between ECM harness connector terminal No. 105 and body ground? RHA200I Yes or No Yes 䊳 GO TO 6. No 䊳 Disconnect A/C relay. Disconnect ECM harness connector. GO TO 9. 6 CHECK VOLTAGE FOR ECM Do approx. 5 volts exist between ECM harness connector terminal No. 110 and body ground? RHA201I Yes or No Yes 䊳 Disconnect ECM harness connector. Disconnect auto amp. harness connector. GO TO 7. No 䊳 Check ECM. Refer to EC-149, “ECM Terminals and Reference Value”. HA-130 TROUBLE DIAGNOSES AUTO Magnet Clutch (Cont’d) 7 GI CHECK CIRCUIT CONTINUITY BETWEEN ECM AND AUTO AMP. Check circuit continuity between ECM harness connector terminal No. 110 and auto amp. harness connector terminal No. 22. MA EM LC EC RHA202I Continuity should exist. If OK, check harness for short. CL OK or NG OK 䊳 GO TO 8. NG 䊳 1. Repair harness or connector. 2. Go to “SETP-BY-STEP PROCEDURE”, “Self-diagnosis”, HA-49 (Without navigation system, except LE grade), HA-59 (Without navigation system, LE grade) or HA-69 (With navigation system) and perform self-diagnosis STEP-4. Confirm that magnet clutch operation is usual. 8 FE MT AT TF CHECK REFRIGERANT PRESSURE SENSOR Refer to HA-132. PD OK or NG OK 䊳 GO TO 9. NG 䊳 Replace refrigerant pressure sensor. 9 AX SU CHECK CIRCUIT CONTINUITY BETWEEN A/C RELAY AND ECM Check circuit continuity between A/C relay harness connector E26 terminal No. 2 (G/R) and ECM harness connector F203 terminal No. 105 (LG). BR ST RS BT RHA203I Continuity should exist. OK or NG OK 䊳 Check harness for short. NG 䊳 Repair harness or connector. SC EL IDX HA-131 TROUBLE DIAGNOSES AUTO Magnet Clutch (Cont’d) COMPONENT INSPECTION A/C Relay NAHA0204 NAHA0204S01 Check continuity between terminal Nos. 3 and 5. Conditions Continuity 12V direct current supply between terminal Nos. 1 and 2 Yes No current supply No If NG, replace relay. SHA479F Refrigeralt Pressure Sensor NAHA0204S02 Make sure that higher A/C refrigerant-pressure results in higher refrigerant-pressure sensor output voltage. Check voltage between ECM harness terminal No. 70 and body ground. Refer to EC-772, “Diagnostic Procedure”. RHA070I SHA315F HA-132 TROUBLE DIAGNOSES AUTO Insufficient Cooling Insufficient Cooling GI TROUBLE DIAGNOSIS PROCEDURE FOR INSUFFICIENT COOLING =NAHA0205 SYMPTOM: 쐌 Insufficient cooling MA Inspection Flow NAHA0205S01 Without Navigation System (Except LE Grade) EM NAHA0205S0101 LC EC FE CL MT AT TF PD AX SU BR ST RS BT SHA648F SC *1: *2: *3: *4: *5: HA-48 HA-104 HA-138 HA-57 STEP-BY-STEP PROCEDURE (HA-49), see No. 13. *6: *7: *8: *9: *10: *11: *12: *13: *14: *15: HA-95 HA-108 HA-117 HA-128 HA-136 HA-133 HA-80 HA-49 HA-3 MA-14 LC-22 EL IDX TROUBLE DIAGNOSES AUTO Insufficient Cooling (Cont’d) Without Navigation System (LE Grade) NAHA0205S0103 RHA241I *1: *2: *3: *4: *5: HA-59 HA-103 HA-138 HA-67 STEP-BY-STEP PROCEDURE (HA-59), see No. 13. *6: *7: *8: *9: *10: *11: *12: *13: *14: *15: HA-96 HA-109 HA-118 HA-128 HA-136 HA-134 HA-82 HA-59 HA-3 MA-14 LC-22 TROUBLE DIAGNOSES AUTO Insufficient Cooling (Cont’d) With Navigation System NAHA0205S0102 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS SHA649F *1: *2: *3: *4: *5: HA-69 HA-100 HA-138 HA-78 STEP-BY-STEP PROCEDURE (HA-69), see No. 13. *6: *7: *8: *9: *10: *11: *12: *13: *14: *15: HA-96 HA-107 HA-116 HA-127 HA-136 HA-85 HA-69 HA-3 MA-14 LC-22 BT SC EL IDX HA-135 TROUBLE DIAGNOSES AUTO Insufficient Cooling (Cont’d) PERFORMANCE TEST DIAGNOSES NAHA0206 SHA333F *1: HA-138 *2: HA-138 *3: HA-138 *4: HA-104 *5: HA-3 HA-136 TROUBLE DIAGNOSES AUTO Insufficient Cooling (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SHA329F *1: HA-175 *2: HA-114 *3: MA-14 SC EL IDX HA-137 TROUBLE DIAGNOSES AUTO Insufficient Cooling (Cont’d) PERFORMANCE CHART Test Condition NAHA0207 NAHA0207S01 Testing must be performed as follows: Vehicle location Indoors or in the shade (in a well-ventilated place) Doors Closed Door windows Open Hood Open TEMP. Max. COLD Mode switch (Ventilation) set (Recirculation) set REC switch (blower) speed Max. speed set Engine speed Idle speed Operate the air conditioning system for 10 minutes before taking measurements. Test Reading NAHA0207S02 Recirculating-to-discharge Air Temperature Table NAHA0207S0201 Inside air (Recirculating air) at blower assembly inlet Relative humidity % Discharge air temperature at center ventilator °C (°F) Air temperature °C (°F) 25 (77) 6.0 - 9.0 (43 - 48) 30 (86) 10.0 - 13.6 (50 - 56) 35 (95) 15.2 - 19.5 (59 - 67) 40 (104) 22.5 - 27.1 (73 - 81) 25 (77) 9.0 - 12.2 (48 - 54) 30 (86) 13.6 - 17.2 (56 - 63) 35 (95) 19.5 - 23.7 (67 - 75) 40 (104) 27.1 - 32.3 (81 - 90) 50 - 60 60 - 70 Ambient Air Temperature-to-operating Pressure Table NAHA0207S0202 Ambient air Relative humidity % High-pressure (Discharge side) kPa (kg/cm2, psi) Low-pressure (Suction side) kPa (kg/cm2, psi) 25 (77) 1,226 - 1,638 (12.5 - 16.7, 178 - 237) 172 - 250 (1.75 - 2.55, 25 - 36) 30 (86) 1,422 - 1,883 (14.5 - 19.2, 206 - 273) 196 - 275 (2.0 - 2.8, 28 - 40) 35 (95) 1,657 - 2,187 (16.9 - 22.3, 240 - 317) 231 - 309 (2.35 - 3.15, 33 - 45) 40 (104) 1,922 - 2,501 (19.6 - 25.5, 279 - 363) 280 - 373 (2.85 - 3.8, 41 - 54) Air temperature °C (°F) 50 - 70 TROUBLE DIAGNOSES FOR UNUSUAL PRESSURE NAHA0208 Whenever system’s high and/or low side pressure is unusual, diagnose using a manifold gauge. The marker above the gauge scale in the following tables indicates the standard (usual) pressure range. Since the standard (usual) pressure, however, differs from vehicle to vehicle, refer to HA-138 (“Ambient air temperature-tooperating pressure table”). HA-138 TROUBLE DIAGNOSES AUTO Insufficient Cooling (Cont’d) Both High and Low-pressure Sides are Too High. Gauge indication NAHA0208S01 Refrigerant cycle Both high and low-pressure sides are too high. Probable cause Corrective action 쐌 Pressure is reduced soon after water is splashed on condenser. Excessive refrigerant charge in refrigeration cycle Air suction by cooling fan is insufficient. Insufficient condenser cooling 쐌 Clean condenser. performance 쐌 Check and repair cooling " fan as necessary. 1. Condenser fins are clogged. 2. Improper fan rotation of cooling fan 쐌 Low-pressure pipe is not cold. 쐌 When compressor is stopped high-pressure AC359A value quickly drops by approximately 196 kPa (2 kg/cm2, 28 psi). It then decreases gradually thereafter. Engine tends to overheat. 쐌 An area of the low-pressure pipe is colder than areas near the evaporator outlet. 쐌 Plates are sometimes covered with frost. Poor heat exchange in condenser (After compressor operation stops, high pressure decreases too slowly.) " Air in refrigeration cycle High-pressure side is too high and low-pressure side is too low. Reduce refrigerant until specified pressure is obtained. Evacuate repeatedly and recharge system. MA EM LC EC FE CL MT Engine cooling systems malfunction. Check and repair each engine cooling system. 쐌 Excessive liquid refrigerant on low-pressure side 쐌 Excessive refrigerant discharge flow 쐌 Expansion valve is open a little compared with the specification. " 1. Improper expansion valve installation 2. Improper expansion valve adjustment Replace expansion valve. High-pressure Side is Too High and Low-pressure Side is Too Low. Gauge indication GI Refrigerant cycle Probable cause Upper side of condenser and high-pressure side are hot, however, liquid tank is not so hot. High-pressure tube or parts located between compressor and condenser are clogged or crushed. AT TF PD AX SU NAHA0208S02 Corrective action 쐌 Check and repair or replace malfunctioning parts. 쐌 Check lubricant for contamination. BR ST RS BT SC AC360A EL IDX HA-139 TROUBLE DIAGNOSES AUTO Insufficient Cooling (Cont’d) High-pressure Side is Too Low and Low-pressure Side is Too High. Gauge indication High-pressure side is too low and low-pressure side is too high. NAHA0208S03 Refrigerant cycle Probable cause High and low-pressure sides become equal soon after compressor operation stops. Compressor pressure operation is improper. " Damaged inside compressor packings Replace compressor. No temperature difference between high and low-pressure sides Compressor pressure operation is improper. " Damaged inside compressor packings. Replace compressor. AC356A HA-140 Corrective action TROUBLE DIAGNOSES AUTO Insufficient Cooling (Cont’d) Both High- and Low-pressure Sides are Too Low. Gauge indication Refrigerant cycle Both high- and low-pressure sides are too low. 쐌 There is a big temperature difference between receiver drier outlet and inlet. Outlet temperature is extremely low. 쐌 Liquid tank inlet and expansion valve are frosted. 쐌 Temperature of expansion valve inlet is extremely low as compared with areas near liquid tank. 쐌 Expansion valve inlet may be frosted. 쐌 Temperature difference AC353A occurs somewhere in highpressure side 쐌 Expansion valve and liquid tank are warm or only cool when touched. NAHA0208S04 Probable cause GI Corrective action Compressor discharge capac- 쐌 Replace liquid tank. ity does not change. (Com쐌 Check lubricant for conpressor stroke is set at maxitamination. mum.) MA EM LC High-pressure pipe located between receiver drier and expansion valve is clogged. 쐌 Check and repair malfunctioning parts. 쐌 Check lubricant for contamination. EC FE CL Low refrigerant charge " Leaking fittings or components Check refrigerant for leaks. Refer to “Checking Refrigerant Leaks”, HA-180. There is a big temperature Expansion valve closes a little 쐌 Remove foreign particles difference between expansion compared with the specificaby using compressed air. valve inlet and outlet while tion. 쐌 Check lubricant for conthe valve itself is frosted. " tamination. 1. Improper expansion valve adjustment 2. Malfunctioning expansion valve 3. Outlet and inlet may be clogged. An area of the low-pressure Low-pressure pipe is clogged pipe is colder than areas near or crushed. the evaporator outlet. 쐌 Check and repair malfunctioning parts. 쐌 Check lubricant for contamination. Air flow volume is not enough Evaporator is frozen. 쐌 Check intake sensor circuit. or is too low. " 쐌 Replace compressor. Compressor discharge capacity does not change. (Compressor stroke is set at maximum length.) MT AT TF PD AX SU BR ST RS BT SC EL IDX HA-141 TROUBLE DIAGNOSES AUTO Insufficient Cooling (Cont’d) Low-pressure Side Sometimes Becomes Negative. Gauge indication Refrigerant cycle 쐌 Air conditioning system does not function and does not cyclically cool the compartment air. 쐌 The system constantly functions for a certain period of time after compressor is stopped and restarted. Low-pressure side sometimes becomes negative. NAHA0208S05 Probable cause Refrigerant does not discharge cyclically. " Moisture is frozen at expansion valve outlet and inlet. " Water is mixed with refrigerant. Corrective action 쐌 Drain water from refrigerant or replace refrigerant. 쐌 Replace liquid tank. AC354A Low-pressure Side Becomes Negative. Gauge indication Low-pressure side becomes negative. NAHA0208S06 Refrigerant cycle Probable cause Corrective action Liquid tank or front/rear side of expansion valve’s pipe is frosted or dewed. High-pressure side is closed and refrigerant does not flow. " Expansion valve or liquid tank is frosted. Leave the system at rest until no frost is present. Start it again to check whether or not the problem is caused by water or foreign particles. 쐌 If water is the cause, initially cooling is okay. Then the water freezes causing a blockage. Drain water from refrigerant or replace refrigerant. 쐌 If due to foreign particles, remove expansion valve and remove the particles with dry and compressed air (not shop air). 쐌 If either of the above methods cannot correct the problem, replace expansion valve. 쐌 Replace liquid tank. 쐌 Check lubricant for contamination. AC362A HA-142 TROUBLE DIAGNOSES AUTO Insufficient Heating Insufficient Heating GI TROUBLE DIAGNOSIS PROCEDURE FOR INSUFFICIENT HEATING =NAHA0209 SYMPTOM: 쐌 Insufficient heating MA Inspection Flow NAHA0209S01 Without Navigation System (Except LE Grade) EM NAHA0209S0101 LC EC FE CL MT AT TF PD AX SU BR ST RS BT RHA242I SC *1: *2: *3: *4: *5: HA-80 HA-48 HA-49 HA-49 HA-104 *6: STEP-BY-STEP PROCEDURE (HA-49), see No. 13. *7: HA-96 *8: HA-109 *9: HA-118 HA-143 *10: *11: *12: *13: HA-100 MA-15 LC-12 LC-18 EL IDX TROUBLE DIAGNOSES AUTO Insufficient Heating (Cont’d) Without Navigation System (LE Grade) NAHA0209S0103 RHA157IB *1: *2: *3: *4: *5: HA-82 HA-59 HA-59 HA-59 HA-103 *6: STEP-BY-STEP PROCEDURE (HA-59), see No. 13. *7: HA-96 *8: HA-109 *9: HA-118 HA-144 *10: *11: *12: *13: HA-96 MA-15 LC-12 LC-18 TROUBLE DIAGNOSES AUTO Insufficient Heating (Cont’d) With Navigation System NAHA0209S0102 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS RHA243I *1: *2: *3: *4: *5: HA-85 HA-69 HA-69 HA-69 HA-104 *6: STEP-BY-STEP PROCEDURE (HA-69), see No. 13. *7: HA-96 *8: HA-107 *9: HA-116 *10: *11: *12: *13: HA-100 MA-15 LC-12 LC-18 BT SC EL IDX HA-145 TROUBLE DIAGNOSES AUTO Noise Noise TROUBLE DIAGNOSIS PROCEDURE FOR NOISE =NAHA0210 SYMPTOM: 쐌 Noise RHA883H *1: HA-175 *2: HA-177 *3: HA-172 *4: HA-80 *5: MA-14 *6: MA-15 HA-146 TROUBLE DIAGNOSES AUTO Self-diagnosis Self-diagnosis GI TROUBLE DIAGNOSIS PROCEDURE FOR SELF-DIAGNOSIS =NAHA0211 SYMPTOM: 쐌 Self-diagnosis cannot be performed. MA Inspection Flow NAHA0211S01 Without Navigation System (Except LE Grade) EM NAHA0211S0101 LC EC FE CL MT AT TF PD AX SU BR SHA250F *1: HA-89 *2: HA-155 *3: HA-158 *7: HA-80 *8: HA-79 *9: HA-80 *4: HA-162 *5: HA-165 *6: HA-167 ST RS BT SC EL IDX HA-147 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) Without Navigation System (LE Grade) NAHA0211S0103 RHA158I *1: HA-90 *2: HA-155 *3: HA-158 *7: HA-82 *8: HA-79 *9: HA-82 *4: HA-162 *5: HA-165 *6: HA-167 HA-148 TROUBLE DIAGNOSES AUTO Self-diagnosis (Cont’d) With Navigation System NAHA0211S0102 GI MA EM LC EC FE CL MT AT TF PD AX SU BR RHA116I ST *1: HA-89 *2: HA-155 *3: HA-158 *7: HA-85 *8: HA-79 *10: HA-168 *4: HA-162 *5: HA-165 *6: HA-167 RS BT SC EL IDX HA-149 TROUBLE DIAGNOSES AUTO Memory Function Memory Function TROUBLE DIAGNOSIS PROCEDURE FOR MEMORY FUNCTION =NAHA0212 SYMPTOM: 쐌 Memory function does not operate. Inspection Flow NAHA0212S01 Without Navigation System (Except LE Grade) NAHA0212S0101 RHA244I *1: HA-89 *2: HA-80 *3: HA-49 HA-150 TROUBLE DIAGNOSES AUTO Memory Function (Cont’d) Without Navigation System (LE Grade) NAHA0212S0103 GI MA EM LC EC FE CL MT AT TF RHA159IA *1: HA-90 *2: HA-82 PD *3: HA-59 AX SU BR ST RS BT SC EL IDX HA-151 TROUBLE DIAGNOSES AUTO Memory Function (Cont’d) With Navigation System NAHA0212S0102 RHA245I *1: HA-89 *2: HA-85 *3: HA-69 HA-152 TROUBLE DIAGNOSES AUTO ECON (ECONOMY) Mode ECON (ECONOMY) Mode TROUBLE DIAGNOSIS PROCEDURE FOR ECON (ECONOMY) MODE GI =NAHA0213 SYMPTOM: 쐌 ECON mode does not operate. MA Inspection Flow NAHA0213S01 Without Navigation System (Except LE Grade) EM NAHA0213S0101 LC EC FE CL MT AT TF PD AX SHA920EA *1: HA-89 *2: HA-80 *3: HA-49 SU BR ST RS BT SC EL IDX HA-153 TROUBLE DIAGNOSES AUTO ECON (ECONOMY) Mode (Cont’d) Without Navigation System (LE Grade) NAHA0213S0103 RHA160I *1: HA-90 *2: HA-82 *3: HA-59 HA-154 TROUBLE DIAGNOSES AUTO ECON (ECONOMY) Mode (Cont’d) With Navigation System NAHA0213S0102 GI MA EM LC EC FE CL MT AT TF RHA118I *1: HA-89 *2: HA-85 PD *3: HA-69 AX SU Ambient Sensor Circuit COMPONENT DESCRIPTION NAHA0214 The ambient sensor is located on the hood lock stay. It detects ambient temperature and converts it into a resistance value which is then input into the auto amplifier. BR ST RS BT RHA050G AMBIENT TEMPERATURE INPUT PROCESS NAHA0215 The automatic amplifier includes a “processing circuit” for the ambient sensor input. However, when the temperature detected by the ambient sensor increases quickly, the processing circuit retards the auto amp. function. It only allows the auto amp. to recognize an ambient temperature increase of 0.33°C (0.6°F) per 100 seconds. As an example, consider stopping for a cup of coffee after high speed driving. Although the actual ambient temperature has not changed, the temperature detected by the ambient sensor will increase. This is because the heat from the engine compartment can radiate to the front grille area, location of the ambient sensor. HA-155 SC EL IDX TROUBLE DIAGNOSES AUTO Ambient Sensor Circuit (Cont’d) DIAGNOSTIC PROCEDURE NAHA0216 SYMPTOM: Ambient sensor circuit is open or shorted. ( or is indicated on the display as a result of conducting Self− diagnosis STEP 2.) RHA051GE 1 CHECK VOLTAGE BETWEEN AMBIENT SENSOR HARNESS CONNECTOR AND BODY GROUND Disconnect ambient sensor harness connector. Do approx. 5 volts exist between ambient sensor harness connector terminal No. 1 and body ground? RHA052G Yes or No Yes 䊳 GO TO 2. No 䊳 GO TO 4. 2 CHECK AMBIENT SENSOR CIRCUIT BETWEEN AMBIENT SENSOR AND AUTO AMP. (LCU) 1. Disconnect auto amp. (LCU) harness connector. 2. Check circuit continuity between ambient sensor harness connector terminal No. 2 and auto amp. (LCU) harness connector terminal No. 9 or 11. RHA829H Continuity should exist. If OK, check harness for short. OK or NG OK 䊳 GO TO 3. NG 䊳 Repair harness or connector. HA-156 TROUBLE DIAGNOSES AUTO Ambient Sensor Circuit (Cont’d) 3 GI CHECK AMBIENT SENSOR Refer to HA-158. MA OK or NG OK NG 4 䊳 䊳 1. Replace auto amp. (LCU). 2. Go to self-diagnosis step-by-step procedure HA-49 (Without navigation system, except LE grade), HA-59 (Without navigation system, LE grade) or HA-69 (With navigation system) and perform self-diagnosis STEP-2. Confirm that code No. 20 is displayed. EM LC Replace ambient sensor. EC CHECK AMBIENT SENSOR CIRCUIT BETWEEN AMBIENT SENSOR AND AUTO AMP. (LCU) 1. Disconnect auto amp. (LCU) harness connector. 2. Check circuit continuity between ambient sensor harness connector terminal No. 1 and auto amp. (LCU) harness connector terminal No. 2. FE CL MT AT TF RHA830H Continuity should exist. If OK, check harness for short. PD OK or NG OK NG 䊳 䊳 1. Replace auto amp. (LCU). 2. Go to self-diagnosis step-by-step procedure HA-49 (Without navigation system, except LE grade), HA-59 (Without navigation system, LE grade) or HA-69 (With navigation system) and perform self-diagnosis STEP-2. Confirm that code No. 20 is displayed. AX SU Repair harness or connector. BR ST RS BT SC EL IDX HA-157 TROUBLE DIAGNOSES AUTO Ambient Sensor Circuit (Cont’d) COMPONENT INSPECTION Ambient Sensor NAHA0217 NAHA0217S01 After disconnecting ambient sensor harness connector, measure resistance between terminals 2 and 1 at sensor harness side, using the table below. SHA304F Temperature °C (°F) Resistance kΩ −15 (5) 12.73 −10 (14) 9.92 −5 (23) 7.80 0 (32) 6.19 5 (41) 4.95 10 (50) 3.99 15 (59) 3.24 20 (68) 2.65 25 (77) 2.19 30 (86) 1.81 35 (95) 1.51 40 (104) 1.27 45 (113) 1.07 If NG, replace ambient sensor. In-vehicle Sensor Circuit COMPONENT DESCRIPTION In-vehicle sensor NAHA0218 NAHA0218S01 The in-vehicle sensor is located on instrument lower panel. It converts variations in temperature of compartment air drawn from the aspirator into a resistance value. It is then input into the auto amplifier. RHA103G HA-158 TROUBLE DIAGNOSES AUTO In-vehicle Sensor Circuit (Cont’d) Aspirator NAHA0218S02 The aspirator is located in front of heater unit. It produces vacuum pressure due to air discharged from the heater unit, continuously taking compartment air in the aspirator. GI MA EM LC RHA636F EC FE CL MT RHA482A DIAGNOSTIC PROCEDURE AT NAHA0219 SYMPTOM: In-vehicle sensor circuit is open or shorted. ( or − is indicated on the display as a result of conducting Selfdiagnosis STEP 2.) TF PD AX SU RHA056GH 1 CHECK IN-VEHICLE SENSOR CIRCUIT BETWEEN IN-VEHICLE SENSOR AND BODY GROUND BR Disconnect in-vehicle sensor harness connector. Do approx. 5 volts exist between in-vehicle sensor harness connector terminal No. 1 and body ground? ST RS BT RHA579H Yes or No Yes 䊳 GO TO 2. No 䊳 GO TO 4. SC EL IDX HA-159 TROUBLE DIAGNOSES AUTO In-vehicle Sensor Circuit (Cont’d) 2 CHECK IN-VEHICLE SENSOR CIRCUIT BETWEEN IN-VEHICLE SENSOR AND AUTO AMP. (LCU) 1. Disconnect auto amp. (LCU) harness connector. 2. Check circuit continuity between in-vehicle sensor harness connector terminal No. 2 and auto amp. (LCU) harness connector terminal No. 11 or 9. RHA831H Continuity should exist. If OK, check harness for short. OK or NG OK 䊳 GO TO 3. NG 䊳 Repair harness or connector. 3 CHECK IN-VEHICLE SENSOR Refer to HA-161. OK or NG OK 䊳 1. Replace auto amp. 2. Go to self-diagnosis step-by-step procedure HA-49 (Without navigation system, except LE grade), HA-59 (Without navigation system, LE grade) or HA-69 (With navigation system) and perform self-diagnosis STEP-2. Confirm that code No. 20 is displayed. NG 䊳 1. Replace in-vehicle sensor. 2. Go to self-diagnosis step-by-step procedure HA-49 (Without navigation system, except LE grade), HA-59 (Without navigation system, LE grade) or HA-69 (With navigation system) and perform self-diagnosis STEP-2. Confirm that code No. 20 is displayed. HA-160 TROUBLE DIAGNOSES AUTO In-vehicle Sensor Circuit (Cont’d) CHECK IN-VEHICLE SENSOR CIRCUIT BETWEEN IN-VEHICLE SENSOR AND AUTO AMP. (LCU) GI 1. Disconnect auto amp. (LCU) harness connector. 2. Check circuit continuity between in-vehicle sensor harness connector terminal No. 1 and auto amp. (LCU) harness connector terminal No. 3. MA 4 EM LC EC RHA832H Continuity should exist. If OK, check harness for short. FE CL OK or NG OK NG 䊳 䊳 1. Replace auto amp. (LCU). 2. Go to self-diagnosis step-by-step procedure HA-49 (Without navigation system, except LE grade), HA-67 (Without navigation system, LE grade) or HA-69 (With navigation system) and perform self-diagnosis STEP-2. Confirm that code No. 20 is displayed. MT AT Repair harness or connector. TF PD AX SU COMPONENT INSPECTION In-vehicle Sensor NAHA0220 NAHA0220S01 After disconnecting in-vehicle sensor harness connector, measure resistance between terminals 1 and 2 at sensor harness side, using the table below. Temperature °C (°F) Resistance kΩ −15 (5) 12.73 −10 (14) 9.92 −5 (23) 7.80 0 (32) 6.19 5 (41) 4.95 10 (50) 3.99 15 (59) 3.24 20 (68) 2.65 25 (77) 2.19 30 (86) 1.81 RHA905H HA-161 BR ST RS BT SC EL IDX TROUBLE DIAGNOSES AUTO In-vehicle Sensor Circuit (Cont’d) Temperature °C (°F) Resistance kΩ 35 (95) 1.51 40 (104) 1.27 45 (113) 1.07 If NG, replace in-vehicle sensor. Sunload Sensor Circuit COMPONENT DESCRIPTION NAHA0221 The sunload sensor is located on the right defroster grille. It detects sunload entering through windshield by means of a photo diode. The sensor converts the sunload into a current value which is then input into the auto amplifier. RHA639F SUNLOAD INPUT PROCESS NAHA0222 The auto amp. also includes a processing circuit which “average” the variations in detected sunload over a period of time. This prevents drastic swings in the A/C system operation due to small or quick variations in detected sunload. For example, consider driving along a road bordered by an occasional group of large trees. The sunload detected by the sunload sensor will vary whenever the trees obstruct the sunlight. The processing circuit averages the detected sunload over a period of time, so that the (insignificant) effect of the trees momentarily obstructing the sunlight does not cause any change in the A/C system operation. On the other hand, shortly after entering a long tunnel, the system will recognize the change in sunload, and the system will react accordingly. DIAGNOSTIC PROCEDURE NAHA0223 SYMPTOM: Sunload sensor circuit is open or shorted. ( or − is indicated on the display as a result of conducting Selfdiagnosis STEP 2.) RHA084I HA-162 TROUBLE DIAGNOSES AUTO Sunload Sensor Circuit (Cont’d) 1 GI CHECK SUNLOAD SENSOR CIRCUIT BETWEEN SUNLOAD SENSOR AND BODY GROUND Disconnect sunload sensor harness connector. Do approx. 5 volts exist between sunload sensor harness connector terminal No. 1 and body ground? MA EM LC EC RHA062G FE Yes or No Yes 䊳 GO TO 2. No 䊳 GO TO 4. CL MT 2 CHECK SUNLOAD SENSOR CIRCUIT BETWEEN SUNLOAD SENSOR AND AUTO AMP. (LCU) 1. Disconnect auto amp. (LCU) harness connector. 2. Check circuit continuity between sunload sensor harness connector terminal No. 2 and auto amp. (LCU) harness connector terminal No. 11 or 9. AT TF PD AX SU RHA833H Continuity should exist. If OK, check harness for short. BR OK or NG ST OK 䊳 GO TO 3. NG 䊳 Repair harness or connector. RS 3 CHECK SUNLOAD SENSOR Refer to HA-164. BT OK or NG OK NG 䊳 䊳 1. Replace auto amp. (LCU). 2. Go to self-diagnosis step-by-step procedure HA-49 (Without navigation system, except LE grade), HA-59 (Without navigation system, LE grade) or HA-69 (With navigation system) and perform self-diagnosis STEP-2. Confirm that code No. 20 is displayed. 1. Replace sunload sensor. 2. Go to self-diagnosis step-by-step procedure HA-49 (Without navigation system, except LE grade), HA-59 (Without navigation system, LE grade) or HA-69 (With navigation system) and perform self-diagnosis STEP-2. Confirm that code No. 20 is displayed. HA-163 SC EL IDX TROUBLE DIAGNOSES AUTO Sunload Sensor Circuit (Cont’d) 4 CHECK SUNLOAD SENSOR CIRCUIT BETWEEN SUNLOAD SENSOR AND AUTO AMP. (LCU) 1. Disconnect auto amp. (LCU) harness connector. 2. Check circuit continuity between sunload sensor harness connector terminal No. 1 and auto amp. (LCU) harness connector terminal No. 12 or 10. RHA834H Continuity should exist. If OK, check harness for short. OK or NG OK 䊳 1. Replace auto amp. 2. Go to self-diagnosis step-by-step procedure HA-49 (Without navigation system, except LE grade), HA-59 (Without navigation system, LE grade) or HA-69 (With navigation system) and perform self-diagnosis STEP-2. Confirm that code No. 20 is displayed. NG 䊳 Repair harness or connector. COMPONENT INSPECTION Sunload Sensor NAHA0224 NAHA0224S01 Measure voltage between auto amp. terminal No. 12 (10) and body ground. If NG, replace sunload sensor. 쐌 When checking sunload sensor, select a place where sun shines directly on it. RHA835H HA-164 TROUBLE DIAGNOSES AUTO Sunload Sensor Circuit (Cont’d) GI MA EM LC EC FE CL SHA930E MT AT Intake Sensor Circuit COMPONENT DESCRIPTION Intake Sensor NAHA0225 The intake sensor is located on the cooling unit. It converts temperature of air after it passes through the evaporator into a resistance value which is then input to the auto amp. After disconnecting intake sensor harness connector, measure resistance between terminals 1 and 2 at sensor harness side, using the table below. RHA584E TF NAHA0225S01 Temperature °C (°F) Resistance kΩ −15 (5) 12.34 −10 (14) 9.62 −5 (23) 7.56 0 (32) 6.00 5 (41) 4.80 10 (50) 3.87 15 (59) 3.15 20 (68) 2.57 25 (77) 2.12 30 (86) 1.76 35 (95) 1.47 40 (104) 1.23 45 (113) 1.04 PD AX SU BR ST RS BT SC EL If NG, replace intake sensor. IDX HA-165 TROUBLE DIAGNOSES AUTO Intake Sensor Circuit (Cont’d) DIAGNOSTIC PROCEDURE NAHA0226 SYMPTOM: Intake sensor circuit is open or shorted. ( or is indicated on the display as a result of conducting − Self-diagnosis STEP 2.) RHA056GI 1 CHECK INTAKE SENSOR CIRCUIT BETWEEN INTAKE SENSOR AND BODY GROUND Disconnect intake sensor harness connector. Do approx. 5 volts exist between intake sensor harness connector terminal No. 1 and body ground? RHA071I Yes or No Yes 䊳 GO TO 2. No 䊳 GO TO 4. 2 CHECK INTAKE SENSOR CIRCUIT BETWEEN INTAKE SENSOR AND AUTO AMP. (LCU) 1. Disconnect auto amp. (LCU) harness connector. 2. Check circuit continuity between intake sensor harness connector terminal No. 2 and auto amp. (LCU) harness connector terminal No. 11 or 9. RHA836H Continuity should exist. If OK, check harness for short. OK or NG OK 䊳 GO TO 3. NG 䊳 Repair harness or connector. HA-166 TROUBLE DIAGNOSES AUTO Intake Sensor Circuit (Cont’d) 3 GI CHECK INTAKE SENSOR Refer to HA-165. MA OK or NG OK NG 䊳 䊳 1. Replace auto amp. 2. Go to self-diagnosis step-by-step procedure HA-49 (Without navigation system, except LE grade), HA-59 (Without navigation system, LE grade) or HA-69 (With navigation system) and perform self-diagnosis STEP-2. Confirm that code No. 20 is displayed. 1. Replace intake sensor. 2. Go to self-diagnosis step-by-step procedure HA-49 (Without navigation system, except LE grade), HA-59 (Without navigation system, LE grade) or HA-69 (With navigation system) and perform self-diagnosis STEP-2. Confirm that code No. 20 is displayed. EM LC EC FE 4 CHECK INTAKE SENSOR CIRCUIT BETWEEN INTAKE SENSOR AND AUTO AMP. (LCU) 1. Disconnect auto amp. (LCU) harness connector. 2. Check circuit continuity between intake sensor harness connector terminal No. 1 and auto amp. (LCU) harness connector terminal No. 1. CL MT AT TF PD RHA837H Continuity should exist. If OK, check harness for short. AX OK or NG OK NG 䊳 䊳 1. Replace auto amp. 2. Go to self-diagnosis step-by-step procedure HA-49 (Without navigation system, except LE grade), HA-59 (Without navigation system, LE grade) or HA-69 (With navigation system) and perform self-diagnosis STEP-2. Confirm that code No. 20 is displayed. SU BR ST Repair harness or connector. RS BT Air Mix Door Motor PBR Circuit DIAGNOSTIC PROCEDURE NAHA0227 For description of mode door motor and air mix door motor circuit, refer to HA-103. SYMPTOM: If PBR circuit is open or shorted. (− or is indicated on the display as a result of conducting Self-diagnosis STEP 2.) Perform diagnostic procedure for mode door motor and air mix door motor. Refer to HA-96. SC EL IDX HA-167 TROUBLE DIAGNOSES AUTO Multiplex Communication Circuit Multiplex Communication Circuit DIAGNOSTIC PROCEDURE NAHA0259 SYMPTOM: 쐌 A/C system does not come on. 쐌 A/C system cannot controlled. RHA888H 1 CHECK CIRCUIT CONTINUITY BETWEEN DISPLAY & NAVI CONTROL UNIT AND AUTO AMP. Check circuit continuity between each terminal on Display & Navigation control unit and on auto amp. RHA889H Continuity should exist. If OK, check harness for short. OK or NG OK 䊳 GO TO 2. NG 䊳 1. Repair harness or connector. 2. Go to “OPERATIONAL CHECK”, HA-85. Confirm that A/C system is in good order. 2 CHECK MULTI-PLEX COMMUNICATION SIGNAL Do approx. 3.5 volts exist between Display & NAVI control unit harness connector terminal Nos. 37, 38 and body ground? RHA890H Yes or No Yes 䊳 GO TO 3. No 䊳 1. Replace auto amp. 2. Go to “OPERATIONAL CHECK”, HA-85. Confirm that A/C system is in good order. HA-168 TROUBLE DIAGNOSES AUTO Multiplex Communication Circuit (Cont’d) 3 GI CHECK MULTIPLEX COMMUNICATION SIGNAL Do approx. 3.5 volts exist between auto amp. harness connector terminal No. 40 and body ground? MA EM LC EC RHA891H Yes or No Yes 䊳 INSPECTION END. No 䊳 1. Replace Display & NAVI control unit. 2. Go to “OPERATIONAL CHECK”, HA-85. Confirm that A/C system is in good order. FE CL MT AT TF PD AX SU BR ST RS BT SC EL IDX HA-169 SERVICE PROCEDURE AUTO HFC-134a (R-134a) Service Procedure HFC-134a (R-134a) Service Procedure SETTING OF SERVICE TOOLS AND EQUIPMENT Discharging Refrigerant NAHA0228 NAHA0228S01 NAHA0228S0101 WARNING: Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Remove HFC-134a (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 information may be obtained from refrigerant and lubricant manufacturers. SHA179FC Evacuating System and Charging Refrigerant NAHA0228S0102 SHA180FC HA-170 SERVICE PROCEDURE AUTO HFC-134a (R-134a) Service Procedure (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SHA251FA *1: HA-172 *2: HA-180 *3: HA-181 *4: HA-136 *5: HA-3 SC EL IDX HA-171 SERVICE PROCEDURE AUTO Maintenance of Lubricant Quantity in Compressor Maintenance of Lubricant Quantity in Compressor NAHA0229 The lubricant in the compressor circulates through the system with the refrigerant. Add lubricant to compressor when replacing any component or after a large gas leakage occurred. It is important to maintain the specified amount. If lubricant quantity is not maintained properly, the following malfunctions may result: 쐌 Lack of lubricant: May lead to a seized compressor 쐌 Excessive lubricant: Inadequate cooling (thermal exchange interference) LUBRICANT NAHA0229S01 Name: Nissan A/C System Oil Type S Part number: KLH00-PAGS0 CHECKING AND ADJUSTING NAHA0229S02 Adjust the lubricant quantity according to the test group shown below. 1 CHECK LUBRICANT RETURN OPERATION Can lubricant return operation be performed? 쐌 A/C system works properly. 쐌 There is no evidence of a large amount of lubricant leakage. Yes or No Yes 䊳 GO TO 2. No 䊳 GO TO 3. 2 PERFORM LUBRICANT RETURN OPERATION, PROCEEDING AS FOLLOWS: 1. Start engine, and set the following conditions: 쐌 Test condition Engine speed: Idling to 1,200 rpm AUTO switch: ON Blower speed: Max. position Temp. control: Optional [Set so that intake air temperature is 25 to 30°C (77 to 86°F).] 2. Next item is for V-6 compressor. Connect the manifold gauge, and check that the high pressure side pressure is 588 kPa (6 kg/cm2, 85 psi) or higher. If less than the reference level, attach a cover to the front face of the condenser to raise the pressure. 3. Perform lubricant return operation for about 10 minutes. 4. Stop engine. CAUTION: If excessive lubricant leakage is noted, do not perform the lubricant return operation. OK 3 䊳 GO TO 3. CHECK COMPRESSOR Should the compressor be replaced? Yes or No Yes 䊳 Go to “Lubricant Adjustment Procedure for Compressor Replacement”, (HA-173). No 䊳 GO TO 4. HA-172 SERVICE PROCEDURE AUTO Maintenance of Lubricant Quantity in Compressor (Cont’d) 4 GI CHECK ANY PART Is there any part to be replaced? (Evaporator, condenser, liquid tank or in case there is evidence of a large amount of lubricant leakage.) MA Yes or No Yes 䊳 Go to “Lubricant Adjusting Procedure for Components Replacement Except Compressor”, (HA-173). No 䊳 Carry out the A/C performance test. EM Lubricant Adjusting Procedure for Components Replacement Except Compressor LC NAHA0229S0201 After replacing any of the following major components, add the correct amount of lubricant to the system. Amount of lubricant to be added EC FE Lubricant to be added to system Part replaced Remarks CL MT Amount of lubricant m
(US fl oz, Imp fl oz) Evaporator 75 (2.5, 2.6) — Condenser 75 (2.5, 2.6) — Liquid tank 5 (0.2, 0.2) Add if compressor is not replaced. *1 In case of refrigerant leak 30 (1.0, 1.1) Large leak — Small leak *2 *1: *2: If compressor is replaced, addition of lubricant is included in the table. If refrigerant leak is small, no addition of lubricant is needed. Lubricant Adjusting Procedure for Compressor Replacement 1. 2. 3. 4. 5. 6. 7. 8. 9. TF PD AX NAHA0229S0202 Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If NG, recover refrigerant from equipment lines. Connect ACR4 to vehicle. Confirm refrigerant purity in supply tank using ACR4 and refrigerant identifier. If NG, refer to “CONTAMINATED REFRIGERANT”, HA-3. Confirm refrigerant purity in vehicle A/C system using ACR4 and refrigerant identifier. If NG, refer to “CONTAMINATED REFRIGERANT”, HA-3. Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure lubricant discharged into the recovery/ recycling equipment. Remove the drain plug of the “old” (removed) compressor. Drain the lubricant into a graduated container and record the amount of drained lubricant. Remove the drain plug and drain the lubricant from the “new” compressor into a separate, clean container. Measure an amount of new lubricant installed equal to amount drained from “old” compressor. Add this lubricant to “new” compressor through the suction port opening. Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant to “new” compressor through the suction port opening. Torque the drain plug. 18 - 19 N·m (1.8 - 1.9 kg-m, 13 - 14 ft-lb) HA-173 AT SU BR ST RS BT SC EL IDX SERVICE PROCEDURE AUTO Maintenance of Lubricant Quantity in Compressor (Cont’d) 10. If the liquid tank also needs to be replaced, add an additional 5 m
(0.2 US fl oz, 0.2 Imp fl oz) of lubricant at this time. Do not add this 5 m
(0.2 US fl oz, 0.2 Imp fl oz) of lubricant if only replacing the compressor. RHA065DD HA-174 SERVICE PROCEDURE AUTO Compressor Compressor REMOVAL AND INSTALLATION GI NAHA0230 MA EM LC EC FE CL MT RHA650F AT Compressor Clutch OVERHAUL NAHA0231 TF PD AX SU BR ST RS RHA122F REMOVAL 쐌 BT NAHA0232 When removing center bolt, hold clutch disc with clutch disc wrench. SC EL IDX RHA136EB HA-175 SERVICE PROCEDURE AUTO Compressor Clutch (Cont’d) RHA399F 쐌 Remove the clutch disc using the clutch disc puller. Insert the holder’s three pins into the holes in the clutch disc. Rotate the holder clockwise to hook it onto the plate. Then, tighten the center bolt to remove the clutch disc. After removing the clutch disc, remove the shims from either the drive shaft or the clutch disc. 쐌 Remove the snap ring using external snap ring pliers. 쐌 Pulley removal Position the center pulley puller on the end of the drive shaft, and remove the pulley assembly using any commercially available pulley puller. To prevent the pulley groove from being deformed, the puller claws should be positioned onto the edge of the pulley assembly. 쐌 Remove the field coil harness clip using a pair of pliers. RHA124F RHA138E RHA139E RHA125F HA-176 SERVICE PROCEDURE AUTO Compressor Clutch (Cont’d) 쐌 Remove the snap ring using external snap ring pliers. GI MA EM LC RHA145E INSPECTION Clutch Disc EC NAHA0233 NAHA0233S01 If the contact surface shows signs of damage due to excessive heat, replace clutch disc and pulley. Pulley NAHA0233S02 Check the appearance of the pulley assembly. If the contact surface of pulley shows signs of excessive grooving, replace clutch disc and pulley. The contact surfaces of the pulley assembly should be cleaned with a suitable solvent before reinstallation. RHA126F Coil NAHA0233S03 Check coil for loose connection or cracked insulation. FE CL MT AT TF PD AX SU INSTALLATION 쐌 쐌 NAHA0234 Install the field coil. Be sure to align the coil’s pin with the hole in the compressor’s front head. Install the field coil harness clip using a screwdriver. BR ST RS BT RHA142E 쐌 Install the pulley assembly using the installer and a hand press, and then install the snap ring using snap ring pliers. SC EL IDX RHA143EA HA-177 SERVICE PROCEDURE AUTO Compressor Clutch (Cont’d) 쐌 Install the clutch disc on the drive shaft, together with the original shim(s). Press the clutch disc down by hand. 쐌 Using the holder to prevent clutch disc rotation, tighten the bolt to 14 N·m (1.4 kg-m, 10 ft-lb) torque. After tightening the bolt, check that the pulley rotates smoothly. 쐌 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 spacer and readjust. RHA127F RHA086E RHA087E Break-in Operation NAHA0234S01 When replacing compressor clutch assembly, always carry out the break-in operation. This is done by engaging and disengaging the clutch about thirty times. Break-in operation raises the level of transmitted torque. HA-178 SERVICE PROCEDURE AUTO Refrigerant Lines Refrigerant Lines REMOVAL AND INSTALLATION 쐌 GI =NAHA0235 Refer to page HA-5 regarding “Precautions for Refrigerant Connection”. MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SC RHA072I EL IDX HA-179 SERVICE PROCEDURE AUTO Checking for Refrigerant Leaks Checking for Refrigerant Leaks PRELIMINARY CHECK 쐌 =NAHA0236 NAHA0236S04 Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant leakage, damage and corrosion. A/C lubricant leakage may indicate an area of refrigerant leakage. Allow extra inspection time in these areas when using either an electronic refrigerant leak detector or fluorescent dye leak detector. 쐌 If dye is observed, confirm the leak with an electronic refrigerant leak detector. It is possible a prior leak was repaired and not properly cleaned. 쐌 When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all system components and connections. 쐌 When searching for refrigerant leaks using an electronic leak detector, move the probe along the suspected leak area at 25 to 50 mm (1 to 2 in) per second and no further than 1/4 inch from the component. NOTE: Moving the electronic leak detector probe slower and closer to the suspected leak area will improve the chances of finding a leak. Electronic Refrigerant Leak Detector NAHA0250 PRECAUTIONS FOR HANDLING LEAK DETECTORNAHA0250S01 SHA196FA When performing a refrigerant leak check, use a J-41995 A/C 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. 쐌 Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the surfaces to be checked are clean. Clean with a dry cloth or blow off with shop air. 쐌 Do not allow the sensor tip of the detector to contact with any substance. This can also cause false readings and may damage the detector. 1. Position probe approximately 5 mm (3/16 in) away from point to be checked. SHA707EA HA-180 SERVICE PROCEDURE AUTO Electronic Refrigerant Leak Detector (Cont’d) 2. When testing, circle each fitting completely with probe. GI MA EM LC SHA706E 3. Move probe along component approximately 25 to 50 mm (1 to 2 in)/sec. EC FE CL MT SHA708EA CHECKING PROCEDURE AT NAHA0250S02 To prevent inaccurate or false readings, make sure there is no refrigerant vapor, shop chemicals, or cigarette 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 (3.52 kg/cm2, 50 psi) above 16°C (61°F). If less than specification, recover/evacuate and recharge the system with the specified amount of refrigerant. NOTE: At temperatures below 16°C (61°F), leaks may not be detected since the system may not reach 345 kPa (3.52 kg/cm2, 50 psi). 4. Conduct the leak test from the high side (compressor discharge a to evaporator inlet f) to the low side (evaporator drain hose g to shaft seal k). Refer to HA-179. 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. 쐌 Compressor Check the fitting of high and low pressure hoses, relief valve and shaft seal. 쐌 Liquid tank Check the tube fitting. 쐌 Service valves Check all around the service valves. Ensure service valve caps 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. HA-181 TF PD AX SU BR ST RS BT SC EL IDX SERVICE PROCEDURE AUTO Electronic Refrigerant Leak Detector (Cont’d) 쐌 Cooling unit (Evaporator) With engine OFF, turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in the cooling unit. Wait a minimum of 10 minutes accumulation time (refer to the manufacturer’s recommended procedure for actual wait time) before inserting the leak detector probe into the drain hose. Keep the probe inserted for at least ten seconds. Use caution not to contaminate the probe tip with water or dirt that may be in the drain hose. 5. If a leak detector detects a leak, verify at least once by blowing compressed air into area of suspected leak, then repeat check as outlined above. 6. Do not stop when one leak is found. Continue to check for additional leaks at all system components. If no leaks are found, perform steps 7 - 10. 7. Start engine. 8. Set the heater A/C control as follows: 1) A/C switch ON. 2) Face mode 3) Recirculation switch ON 4) Max cold temperature 5) Fan speed high 9. Run engine at 1,500 rpm for at least 2 minutes. 10. Turn engine off and perform leak check again following steps 4 through 6 above. Refrigerant leaks should be checked immediately after stopping the engine. Begin with the leak detector at the compressor. The pressure on the high pressure side will gradually drop after refrigerant circulation stops and pressure on the low pressure side will gradually rise, as shown in the graph. Some leaks are more easily detected when pressure is high. SHA839E 11. Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If pressure is displayed, recover refrigerant from equipment lines and then check refrigerant purity. 12. Confirm refrigerant purity in supply tank using ACR4 and refrigerant identifier. 13. Confirm refrigerant purity in vehicle A/C system using ACR4 and refrigerant identifier. 14. Discharge A/C system using approved refrigerant recovery equipment. Repair the leaking fitting or component as necessary. HA-182 SERVICE PROCEDURE AUTO Electronic Refrigerant Leak Detector (Cont’d) 15. Evacuate and recharge A/C system and perform the leak test to confirm no refrigerant leaks. 16. Conduct A/C performance test to ensure system works properly. GI MA EM LC EC Fluorescent Dye Leak Detector PRECAUTIONS FOR FLUORESCENT DYE LEAK DETECTION 쐌 쐌 쐌 CHECKING SYSTEM FOR LEAKS USING THE FLUORESCENT LEAK DETECTOR 1. 2. 3. 4. 5. NAHA0263 The fluorescent dye leak detector is not a replacement for an electronic refrigerant leak detector. The fluorescent dye leak detector should be used in conjunction with an electronic refrigerant leak detector (J-41995) to pinpoint refrigerant leaks. For your safety and your customer’s satisfaction, read and follow all manufacturer’s operating instructions and precautions prior to performing the work. Refer to “Precautions for Leak Detection Dye”, HA-4. NAHA0264 Check A/C system for leaks using the UV lamp and safety glasses (J-42220) in a low sunlight area (area without windows preferable). Illuminate all components, fittings and lines. The dye will appear as a bright green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain opening indicates an evaporator core assembly (tubes, core or expansion valve) leak. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or cloth, then check the cloth with the UV lamp for dye residue. Confirm any suspected leaks with an approved electronic refrigerant leak detector. After the leak is repaired, remove any residual dye using dye cleaner (J-43872) to prevent future misdiagnosis. Perform a system performance check and verify the leak repair with an approved electronic refrigerant leak detector. DYE INJECTION CL MT AT TF PD AX SU BR ST RS NAHA0265 (This procedure is only necessary when re-charging the system or when the compressor has seized and was replaced.) Refer to “Precautions for Leak Detection Dye”, HA-4. 1. Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.52 kg/cm2, 50 psi). 2. Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye into the injector tool (J-41459). 3. Connect the injector tool to the A/C LOW PRESSURE side service fitting. 4. Start engine and switch A/C ON. 5. With the A/C operating (compressor running), inject one bottle (1/4 ounce / 7.4 cc) of fluorescent dye through the low-pressure service valve using dye injector tool J-41459 (refer to the manufacturer’s operating instructions). HA-183 FE BT SC EL IDX SERVICE PROCEDURE AUTO Fluorescent Dye Leak Detector (Cont’d) 6. With the engine still running, disconnect the injector tool from the service fitting. CAUTION: Be careful not to allow dye to spray or drip when disconnecting the injector from the system. NOTE: If repairing the A/C system or replacing a component, pour the dye directly into the open system connection and proceed with the service procedures. 7. Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the leak size, operating conditions and location of the leak, it may take from minutes to days for the dye to penetrate a leak and become visible. Belt TENSION ADJUSTMENT 쐌 NAHA0237 Refer to MA-14, “Checking Drive Belts”. In-cabin Microfilter FUNCTION NAHA0271 Air inside passenger compartment is kept clean at either recirculation or fresh mode by installing In-cabin microfilter into cooling unit. NOTE: To replace In-cabin microfilter, refer to MA-9, MA-11, “Periodic Maintenance”. Caution label is fixed inside the glove box. RHA042GB REPLACEMENT PROCEDURE 1. 2. 3. Remove glove box. Remove instrument lower panel from instrument panel. Remove In-cabin microfilter fixed clip. SHA252F HA-184 NAHA0272 SERVICE PROCEDURE AUTO In-cabin Microfilter (Cont’d) 4. 5. 6. 7. Take out the lower side In-cabin microfilter from cooling unit. Then slide upper side filter to the bottom position and take off the In-cabin microfilter from the cooling unit. Replace with new one and reinstall on cooling unit. Reinstall clip, instrument lower panel and glove box. GI MA EM LC SHA253F EC FE CL MT AT TF PD AX SU BR ST RS BT SC EL IDX HA-185 SERVICE DATA AND SPECIFICATIONS (SDS) AUTO Auto Auto COMPRESSOR NAHA0241 Model Calsonic Kansei make V-6 Type V-6 variable displacement Displacement cm3 (cu in)/rev. Max. 184 (11.228) Min. 14.5 (0.885) Cylinder bore x stroke mm (in) 37 (1.46) x [2.3 - 28.6 (0.091 - 1.126)] Direction of rotation Clockwise (viewed from drive end) Drive belt Poly V LUBRICANT NAHA0242 Model Calsonic Kansei make V-6 Name Nissan A/C System Oil Type S Part number* Capacity m
(US fl oz, Imp fl oz) KLH00-PAGS0 Total in system 180 (6.1, 6.3) Compressor (Service part) charging amount 180 (6.1, 6.3) *: Always check with the Parts Department for the latest parts information. REFRIGERANT NAHA0243 Type HFC-134a (R-134a) Capacity kg (lb) 0.45 (0.99) ENGINE IDLING SPEED (WHEN A/C IS ON) 쐌 BELT TENSION 쐌 NAHA0244 Refer to EC-792, “Idle Speed and Ignition Timing”. NAHA0245 Refer to MA-14, “Checking Drive Belts”. HA-186 PRECAUTIONS MANUAL Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” GI NAHA0060 The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS composition which is available to NISSAN MODEL R50 is as follows: 쐌 For a frontal collision The Supplemental Restraint System consists of driver air bag module (located in the center of the steering wheel), front passenger air bag module (located on the instrument panel on passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. 쐌 For a side collision The Supplemental Restraint System consists of side air bag module (located in the outer side of front seat), side curtain air bag module (locating in the headlining side of front and rear seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision). WARNING: 쐌 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. 쐌 Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connector (and by yellow harness protector or yellow insulation tape before the harness connectors). Precautions for Working with HFC-134a (R-134a) NAHA0061 WARNING: 쐌 CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. If the refrigerants are mixed and compressor malfunction is likely to occur, refer to “CONTAMINATED REFRIGERANT” below. To determine the purity of HFC-134a (R-134a) in the vehicle and recovery tank, use Refrigerant Recovery/Recycling Recharging equipment (ACR4) (J-39500-NI) and Refrigerant Identifier. 쐌 Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components. If lubricant other than that specified is used, compressor malfunction is likely to occur. 쐌 The specified HFC-134a (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 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 A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Remove HFC-134a (R-134a) from the A/C system, using certified service equipment meeting requirements of SAE J2210 HFC-134a (R-134a) recycling equipment, or J2209 HFC-134a (R-134a) recovery equipment. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers. e) Do not allow lubricant (Nissan A/C System Oil Type S) to come in contact with styrofoam parts. Damage may result. CONTAMINATED REFRIGERANT MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SC NAHA0061S01 If a refrigerant other than pure HFC-134a (R-134a) is identified in a vehicle, your options are: 쐌 Explain to the customer that environmental regulations prohibit the release of contaminated refrigerant into the atmosphere. 쐌 Explain that recovery of the contaminated refrigerant could damage your service equipment and refrigerant supply. HA-187 EL IDX PRECAUTIONS MANUAL Precautions for Working with HFC-134a (R-134a) (Cont’d) 쐌 쐌 쐌 Suggest the customer return the vehicle to the location of previous service where the contamination may have occurred. If you choose to perform the repair, recover the refrigerant using only dedicated equipment and containers. Do not recover contaminated refrigerant into your existing service equipment. If your facility does not have dedicated recovery equipment, you may contact a local refrigerant product retailer for available service. This refrigerant must be disposed of in accordance with all federal and local regulations. In addition, replacement of all refrigerant system components on the vehicle is recommended. If the vehicle is within the warranty period, the air conditioner warranty is void. Please contact Nissan Customer Affairs for further assistance. General Refrigerant Precautions NAHA0062 WARNING: 쐌 Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the refrigerant every time an air conditioning system is discharged. 쐌 Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or air conditioning system. 쐌 Do not store or heat refrigerant containers above 52°C (125°F). 쐌 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. 쐌 Do not intentionally drop, puncture, or incinerate refrigerant containers. 쐌 Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns. 쐌 Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent suffocation. 쐌 Do not pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air conditioning systems with compressed air during repair. Some mixtures of air and HFC-134a (R-134a) have been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury or property damage. Additional health and safety information may be obtained from refrigerant manufacturers. Precautions for Leak Detection Dye 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 NAHA0251 The A/C system contains a fluorescent leak detection dye used for locating refrigerant leaks. An ultraviolet (UV) lamp is required to illuminate the dye when inspecting for leaks. Always wear fluorescence enhancing UV safety glasses to protect your eyes and enhance the visibility of the fluorescent dye. A compressor shaft seal should not be repaired because of dye seepage. The compressor shaft seal should only be repaired after confirming the leak with an electronic refrigerant leak detector (J-41995). Always remove any dye from the leak area after repairs are complete to avoid a misdiagnosis during a future service. Do not allow dye to come into contact with painted body panels or interior components. If dye is spilled, clean immediately with the approved dye cleaner. Fluorescent dye left on a surface for an extended period of time cannot be removed. Do not spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.). Do not use more than one refrigerant dye bottle (1/4 ounce / 7.4 cc) per A/C system. Leak detection dyes for HFC-134a (R-134a) and CFC-12 (R-12) A/C systems are different. Do not use HFC-134a (R-134a) leak detection dye in CFC-12 (R-12) A/C system or CFC-12 (R-12) leak detection dye in HFC-134a (R-134a) A/C systems or A/C system damage may result. The fluorescent properties of the dye will remain for over three (3) years unless a compressor malfunction occurs. HA-188 PRECAUTIONS MANUAL Precaution for Identification Label on Vehicle Precaution for Identification Label on Vehicle 쐌 쐌 쐌 NAHA0252 Vehicles with factory installed fluorescent dye have this identification label on the under side of hood. Vehicles with factory installed fluorescent dye have a green label. Vehicles without factory installed fluorescent dye have a blue label. GI MA EM LC SHA436FA Precautions for Refrigerant Connection EC NAHA0063 A new type refrigerant connection has been introduced to all refrigerant lines except the following portion. 쐌 Expansion valve to evaporator FEATURES OF NEW TYPE REFRIGERANT CONNECTION 쐌 쐌 FE NAHA0063S01 The O-ring has been relocated. It has also been provided with a groove for proper installation. This eliminates the chance of the O-ring being caught in, or damaged by, the mating part. The sealing direction of the O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing characteristics. The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby facilitating piping connections. CL MT AT TF PD AX SU BR ST SHA815E RS BT SC EL IDX HA-189 PRECAUTIONS MANUAL Precautions for Refrigerant Connection (Cont’d) O-RING AND REFRIGERANT CONNECTION NAHA0063S02 RHA068I CAUTION: The new and former refrigerant connections use different O-ring configurations. Do not confuse O-rings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or around, the connection. O-Ring Part Numbers and Specifications NAHA0063S0201 Connection type O-ring size New Part number D mm (in) W mm (in) 92471 N8210 6.8 (0.268) 1.85 (0.0728) 92470 N8200 6.07 (0.2390) 1.78 (0.0701) 92472 N8210 10.9 (0.429) 2.43 (0.0957) 92475 71L00 11.0 (0.433) 2.4 (0.094) 92473 N8210 13.6 (0.535) 2.43 (0.0957) 92475 72L00 14.3 (0.563) 2.3 (0.0906) 92474 N8210 16.5 (0.650) 2.43 (0.0957) 92477 N8200 17.12 (0.6740) 1.78 (0.0701) 8 Former New 12 Former New 16 Former SHA814E New 19 Former 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. HA-190 PRECAUTIONS MANUAL Precautions for Refrigerant Connection (Cont’d) CAUTION: When replacing or cleaning refrigerant cycle components, observe the following. 쐌 When the compressor is removed, store it in the same position as it is when mounted on the car. Failure to do so will cause lubricant to enter the low pressure chamber. 쐌 When connecting tubes, always use a torque wrench and a back-up wrench. 쐌 After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture. 쐌 When installing an air conditioner in the vehicle, connect the pipes as the final stage of the operation. Do not remove the seal caps of pipes and other components until just before required for connection. 쐌 Allow components stored in cool areas to warm to working area temperature before removing seal caps. This prevents condensation from forming inside A/C components. 쐌 Thoroughly remove moisture from the refrigeration system before charging the refrigerant. 쐌 Always replace used O-rings. 쐌 When connecting tube, apply lubricant to circle of the O-rings shown in illustration. Be careful not to apply lubricant to threaded portion. Lubricant name: Nissan A/C System Oil Type S Part number: KLH00-PAGS0 쐌 O-ring must be closely attached to dented portion of tube. 쐌 When replacing the O-ring, be careful not to damage O-ring and tube. 쐌 Connect tube until you hear it click, then tighten the nut or bolt by hand until snug. Make sure that the O-ring is installed to tube correctly. 쐌 After connecting line, conduct leak test and make sure that there is no leakage from connections. When the gas leaking point is found, disconnect that line and replace the O-ring. Then tighten connections of seal seat to the specified torque. GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS RHA861F Precautions for Servicing Compressor 쐌 쐌 쐌 쐌 쐌 쐌 BT NAHA0064 Plug all openings to prevent moisture and foreign matter from entering. When the compressor is removed, store it in the same position as it is when mounted on the car. When replacing or repairing compressor, follow “Maintenance of Lubricant Quantity in Compressor” exactly. Refer to HA-255. Keep friction surfaces between clutch and pulley clean. If the surface is contaminated, with lubricant, 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. HA-191 SC EL IDX PRECAUTIONS MANUAL Precautions for Service Equipment Precautions for Service Equipment RECOVERY/RECYCLING EQUIPMENT NAHA0065 NAHA0065S01 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 NAHA0065S02 Follow the manufacture’s instructions for tester operation and tester maintenance. VACUUM PUMP NAHA0065S03 The lubricant contained inside the vacuum pump is not compatible with the specified lubricant for HFC-134a (R-134a) A/C systems. The vent side of the vacuum pump is exposed to atmospheric pressure. So the vacuum pump lubricant may migrate out of the pump into the service hose. This is possible when the pump is switched off after evacuation (vacuuming) and hose is connected to it. To prevent this migration, use a manual valve situated near the hose-to-pump connection, as follows. 쐌 Usually vacuum pumps have a manual isolator valve as part of the pump. Close this valve to isolate the service hose from the pump. 쐌 For pumps without an isolator, use a hose equipped with a manual shut-off valve near the pump end. Close the valve to isolate the hose from the pump. 쐌 If the hose has an automatic shut off valve, disconnect the 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 NAHA0065S04 Be certain that the gauge face indicates R-134a or 134a. Make sure the gauge set has 1/2″-16 ACME threaded connections for service hoses. Confirm the set has been used only with refrigerant HFC-134a (R-134a) along with specified lubricant. SHA533D SERVICE HOSES NAHA0065S05 Be certain that the service hoses display the markings described (colored hose with black stripe). All hoses must include positive shut off devices (either manual or automatic) near the end of the hoses opposite the manifold gauge. RHA272D HA-192 PRECAUTIONS MANUAL Precautions for Service Equipment (Cont’d) SERVICE COUPLERS NAHA0065S06 Never attempt to connect HFC-134a (R-134a) service couplers to an CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers will not properly connect to the CFC-12 (R-12) system. However, if an improper connection is attempted, discharging and contamination may occur. Shut-off valve rotation A/C service valve Clockwise Open Counterclockwise Close GI MA EM LC RHA273D REFRIGERANT WEIGHT SCALE EC NAHA0065S07 Verify that no refrigerant other than HFC-134a (R-134a) and specified lubricants have been used with the scale. If the scale controls refrigerant flow electronically, the hose fitting must be 1/2″-16 ACME. FE CL MT RHA274D CALIBRATING ACR4 WEIGHT SCALE AT NAHA0065S09 Calibrate the scale every three months. To calibrate the weight scale on the ACR4 (J-39500-NI): 1. Press Shift/Reset and Enter at the same time. 2. Press 8787. “A1” will be displayed. 3. Remove all weight from the scale. 4. Press 0, then press Enter. “0.00” will be displayed and change to “A2”. 5. Place a known weight (dumbbell or similar weight), between 4.5 and 8.6 kg (10 and 19 lb) on the center of the weight scale. 6. Enter the known weight using four digits. (Example 10 lb = 10.00, 10.5 lb = 10.50) 7. Press Enter — the display returns to the vacuum mode. 8. Press Shift/Reset and Enter at the same time. 9. Press 6 — the known weight on the scale is displayed. 10. Remove the known weight from the scale. “0.00” will be displayed. 11. Press Shift/Reset to return the ACR4 to the program mode. TF PD AX SU BR ST RS BT CHARGING CYLINDER NAHA0065S08 Using a charging cylinder is not recommended. Refrigerant may be vented into air from cylinder’s top valve when filling the cylinder with refrigerant. Also, the accuracy of the cylinder is generally less than that of an electronic scale or of quality recycle/recharge equipment. SC EL IDX HA-193 PRECAUTIONS MANUAL Wiring Diagrams and Trouble Diagnoses Wiring Diagrams and Trouble Diagnoses NAHA0066 When you read wiring diagrams, refer to the following: 쐌 GI-11, “HOW TO READ WIRING DIAGRAMS” 쐌 EL-12, “Wiring Diagram — POWER —” When you perform trouble diagnoses, refer to the following: 쐌 GI-34, “HOW TO FOLLOW TROUBLE DIAGNOSES” 쐌 GI-24, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT” HA-194 PREPARATION MANUAL Special Service Tools Special Service Tools NAHA0067 GI The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name MA Description KV99106100 (J-41260) Clutch disc wrench Removing center bolt EM LC EC NT232 FE CL MT AT TF PD NT378 KV99232340 (J-38874) or KV992T0001 ( — ) Clutch disc puller Removing clutch disc AX SU BR NT376 KV99106200 (J-41261) Pulley installer Installing pulley ST RS NT235 BT SC EL IDX HA-195 PREPARATION MANUAL HFC-134a (R-134a) Service Tools and Equipment HFC-134a (R-134a) Service Tools and Equipment =NAHA0068 Never mix HFC-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 HFC-134a (R-134a). This is to avoid mixed use of the refrigerants/lubricant. Adapters that convert one size fitting to another must never be used: refrigerant/lubricant contamination will occur and compressor malfunction will result. Tool number (Kent-Moore No.) Tool name Description HFC-134a (R-134a) refrigerant Container color: Light blue Container marking: HFC-134a (R-134a) Fitting size: Thread size 쐌 Large container 1/2″-16 ACME NT196 KLH00-PAGS0 ( — ) Nissan A/C System Oil Type S Type: Poly alkylene glycol oil (PAG), type S Application: HFC-134a (R-134a) swash plate (piston) compressors (Nissan only) Lubricity: 40 m
(1.4 US fl oz, 1.4 Imp fl oz) NT197 (J-39500-NI) Recovery/Recycling Recharging equipment (ACR4) Function: Refrigerant Recovery and Recycling and Recharging NT195 (J-41995) Electrical leak detector Power supply: 쐌 DC 12V (Cigarette lighter) AHA281A HA-196 PREPARATION MANUAL HFC-134a (R-134a) Service Tools and Equipment (Cont’d) Tool number (Kent-Moore No.) Tool name GI Description (J-43926) Refrigerant dye leak detection kit Kit includes: (J-42220) UV lamp and UV safety glasses (J-41459) Refrigerant dye injector (J-41447) qty. 24 R-134a refrigerant dye (J-43872) Refrigerant dye cleaner Power supply: DC 12V (Battery terminal) MA EM LC EC FE ZHA200H (J-42220) Fluorescent dye leak detector UV lamp UV safety glasses Power supply: DC12V (Battery terminal) For checking refrigerant leak when fluorescent dye is installed in A/C system. Includes: UV lamp and UV safety glasses CL MT SHA438F (J-41447) R134a Fluorescent Leak Detection Dye (Box of 24, 1/4 ounce bottles) AT Dye Application: For R-134a PAG oil Container: 1/4 ounce (7.4 cc) bottle (Includes self-adhesive dye identification labels for affixing to vehicle after charging system with dye.) TF PD SHA439F (J-41459) R134a Dye Injector Use with J-41447, 1/4 ounce bottle AX Dye injector For injecting 1/4 ounce of Fluorescent Leak Detection Dye into A/C system. SU BR SHA440F (J-43872) Dye cleaner For cleaning dye spills. ST RS BT SHA441F (J-39183) Manifold gauge set (with hoses and couplers) Identification: 쐌 The gauge face indicates R-134a. Fitting size: Thread size 쐌 1/2″-16 ACME SC EL NT199 IDX HA-197 PREPARATION MANUAL HFC-134a (R-134a) Service Tools and Equipment (Cont’d) Tool number (Kent-Moore No.) Tool name Description Service hoses 쐌 High side hose (J-39501-72) 쐌 Low side hose (J-39502-72) 쐌 Utility hose (J-39476-72) Hose color: 쐌 Low hose: Blue with black stripe 쐌 High hose: Red with black stripe 쐌 Utility hose: Yellow with black stripe or green with black stripe Hose fitting to gauge: 쐌 1/2″-16 ACME NT201 Service couplers 쐌 High side coupler (J-39500-20) 쐌 Low side coupler (J-39500-24) Hose fitting to service hose: 쐌 M14 x 1.5 fitting is optional or permanently attached. NT202 (J-39650) Refrigerant weight scale For measuring of refrigerant Fitting size: Thread size 쐌 1/2″-16 ACME NT200 (J-39649) Vacuum pump (Including the isolator valve) Capacity: 쐌 Air displacement: 4 CFM 쐌 Micron rating: 20 microns 쐌 Oil capacity: 482 g (17 oz) Fitting size: Thread size 쐌 1/2″-16 ACME NT203 COMMERCIAL SERVICE TOOL Tool name NAHA0068S01 Description Refrigerant identifier equipment For checking refrigerant purity and for system contamination NT765 HA-198 PREPARATION MANUAL HFC-134a (R-134a) Service Tools and Equipment (Cont’d) Tool name GI Description Power tool Loosening bolts and nuts MA EM LC PBIC0190E EC FE CL MT AT TF PD AX SU BR ST RS BT SC EL IDX HA-199 DESCRIPTION MANUAL Refrigeration System Refrigeration System REFRIGERATION CYCLE Refrigerant Flow NAHA0069 NAHA0069S01 The refrigerant flows in the standard pattern, that is, through the compressor, the condenser, the liquid tank, through the evaporator, and back to the compressor. The refrigerant evaporation through the evaporator coil is controlled by an externally equalized expansion valve, located inside the evaporator case. Freeze Protection NAHA0069S02 Under usual operating conditions, when the A/C is switched on, the compressor runs continuously, and the evaporator pressure, and therefore temperature, is controlled by the V-6 variable displacement compressor to prevent freeze up. Refrigerant System Protection NAHA0069S03 Refrigerant Pressure Sensor NAHA0069S0301 The refrigerant system is protected against excessively high or low pressures by the refrigerant pressure sensor, located on the condenser. If the system pressure rises above, or falls below the specifications, the refrigerant pressure sensor detects the pressure inside the refrigerant line and sends the voltage signal to the ECM. ECM makes the A/C relay go OFF and stops the compressor when pressure on the high pressure side detected by refrigerant pressure sensor is over about 2,746 kPa (28 kg/cm2, 398 psi) or below about 177 kPa (1.8 kg/cm2, 26 psi). Pressure Relief Valve NAHA0069S0302 The refrigerant system is also protected by a pressure relief valve, located in the rear head of the compressor. When the pressure of refrigerant in the system increases to an unusual level [more than 3,727 kPa (38 kg/cm2, 540 psi)], the release port on the pressure relief valve automatically opens and releases refrigerant into the atmosphere. RHA031I HA-200 DESCRIPTION MANUAL V-6 Variable Displacement Compressor V-6 Variable Displacement Compressor GENERAL INFORMATION GI =NAHA0070 1. The V-6 variable compressor differs from previous units. The vent temperatures of the V-6 variable compress do not drop too far below 5°C (41°F) when: 쐌 evaporator intake air temperature is less than 20°C (68°F) 쐌 engine is running at speeds less than 1,500 rpm. This is because the V-6 compressor provides a means of “capacity” control. 2. The V-6 variable compressor provides refrigerant control under varying conditions. During cold winters, it may not produce high refrigerant pressure discharge (compared to previous units) when used with air conditioning systems. 3. A “clanking” sound may occasionally be heard during refrigerant charge. The sound indicates that the tilt angle of the swash plate has changed and is not a problem. 4. For air conditioning systems with the V-6 compressor, the clutch remains engaged unless: the system main switch, fan switch or ignition switch is turned OFF. When ambient (outside) temperatures are low or when the amount of refrigerant is insufficient, the clutch is disengaged to protect the compressor. 5. A constant range of suction pressure is maintained when engine speed is greater than a certain value. It normally ranges from 147 to 177 kPa (1.5 to 1.8 kg/cm2, 21 to 26 psi) under varying conditions. In previous compressors, however, suction pressure was reduced with increases in engine speed. MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SC EL IDX HA-201 DESCRIPTION MANUAL V-6 Variable Displacement Compressor (Cont’d) DESCRIPTION General =NAHA0132 NAHA0132S01 The variable compressor is basically a swash plate type that changes piston stroke in response to the required cooling capacity. The tilt of the swash plate allows the piston’s stroke to change so that refrigerant discharge can be continuously changed from 14.5 to 184 cm3 (0.885 to 11.228 cu in). RHA037DB HA-202 DESCRIPTION MANUAL V-6 Variable Displacement Compressor (Cont’d) Operation =NAHA0132S02 1. Operation Control Valve NAHA0132S0201 Operation control valve is located in the suction port (low-pressure) side, and opens or closes in response to changes in refrigerant suction pressure. Operation of the valve controls the internal pressure of the crankcase. The angle of the swash plate is controlled between the crankcase’s internal pressure and the piston cylinder pressure. 2. Maximum Cooling NAHA0132S0202 Refrigerant pressure on the low-pressure side increases with an increase in heat loads. When this occurs, the control valve’s bellows compress to open the low-pressure side valve and close the high-pressure side valve. This causes the following pressure changes: 쐌 the crankcase’s internal pressure to equal the pressure on the low-pressure side; 쐌 the cylinder’s internal pressure to be greater than the crankcase’s internal pressure. Under this condition, the swash plate is set to the maximum stroke position. GI MA EM LC EC FE CL MT AT TF PD AX RHA473C SU BR ST RS BT SC EL IDX HA-203 DESCRIPTION MANUAL V-6 Variable Displacement Compressor (Cont’d) 3. Capacity Control =NAHA0132S0203 쐌 Refrigerant pressure on suction side is low during high speed driving or when ambient or interior temperature is low. 쐌 The bellows expands when refrigerant pressure on the suction pressure side drops below approximately 177 kPa (1.8 kg/cm2, 26 psi). Since suction pressure is low, it makes the suction port close and the discharge port open. Thus, crankcase pressure becomes high as high pressure enters the crankcase. 쐌 The force acts around the journal pin near the swash plate, and is generated by the pressure difference before and behind the piston. The drive lug and journal pin are located where the piston generates the highest pressure. Piston pressure is between suction pressure Ps and discharge pressure Pd, which is near suction pressure Ps. If crankcase pressure Pc rises due to capacity control, the force around the journal pin makes the swash plate angle decrease and also the piston stroke decrease. In other words, crankcase pressure increase triggers pressure difference between the piston and the crankcase. The pressure difference changes the angle of the swash plate. RHA474C HA-204 DESCRIPTION MANUAL Component Layout Component Layout NAHA0071 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SC EL RHA573F HA-205 IDX DESCRIPTION MANUAL Control Operation Control Operation NAHA0072 RHA073I FAN CONTROL KNOB NAHA0072S01 This knob turns the fan ON and OFF, and controls fan speed. MODE CONTROL KNOB NAHA0072S02 This knob controls the outlet air flow. In “DEF” or “D/F” mode, the intake door is set to “FRESH”. TEMPERATURE CONTROL KNOB NAHA0072S03 This knob allows adjustment of the temperature of the outlet air. RECIRCULATION (REC) SWITCH NAHA0072S04 OFF position: Outside air is drawn into the passenger compartment. ON position: Interior air is recirculated inside the vehicle. The indicator lamp will also light. AIR CONDITIONER SWITCH NAHA0072S05 The air conditioner switch controls the A/C system. When the switch is depressed with the fan ON, the compressor will turn ON. The indicator lamp will also light. The air conditioner cooling function operates only when the engine is running. MAX A/C POSITION NAHA0072S06 The A/C system operates at maximum performance when the REC switch and A/C switch are both ON. HA-206 DESCRIPTION MANUAL Discharge Air Flow Discharge Air Flow NAHA0073 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SC EL SHA963E HA-207 IDX DESCRIPTION MANUAL System Description System Description NAHA0074 SWITCHES AND THEIR CONTROL FUNCTIONS NAHA0074S01 Knob/Switch position Knob/Switch Air outlet Intake air Compressor — — ON*1 VENT — — B/L — — FOOT — — D/F FRE — DEF FRE — — REC*2 — A/C A/C 쎻 쎻 Mode 쎻 쎻 쎻 쎻 쎻 *1: Compressor is operated by ECM. *2: In DEF and D/F modes, REC switch is canceled. HA-208 TROUBLE DIAGNOSES MANUAL Component Location Component Location ENGINE COMPARTMENT NAHA0085 GI NAHA0085S01 MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SC EL RHA074I HA-209 IDX TROUBLE DIAGNOSES MANUAL Component Location (Cont’d) PASSENGER COMPARTMENT NAHA0085S02 RHA204I HA-210 TROUBLE DIAGNOSES MANUAL Wiring Diagram — HEATER — Wiring Diagram — HEATER — NAHA0086 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SC EL MHA197B HA-211 IDX TROUBLE DIAGNOSES MANUAL Circuit Diagram — Air Conditioner Circuit Diagram — Air Conditioner NAHA0087 MHA198B HA-212 TROUBLE DIAGNOSES MANUAL Wiring Diagram — A/C, M — Wiring Diagram — A/C, M — NAHA0088 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SC EL MHA199B HA-213 IDX TROUBLE DIAGNOSES MANUAL Wiring Diagram — A/C, M — (Cont’d) MHA200B HA-214 TROUBLE DIAGNOSES MANUAL Wiring Diagram — A/C, M — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SC EL MHA201B IDX HA-215 TROUBLE DIAGNOSES MANUAL How to Perform Trouble Diagnoses for Quick and Accurate Repair How to Perform Trouble Diagnoses for Quick and Accurate Repair NAHA0075 WORK FLOW NAHA0075S01 SHA900E *1: HA-217 SYMPTOM TABLE NAHA0075S02 Symptom Reference page 쐌 Intake door does not change in VENT, B/L or FOOT mode. 쐌 Go to Trouble Diagnosis Procedure for Intake Door. HA-219 쐌 Blower motor does not rotate at all. 쐌 Go to Trouble Diagnosis Procedure for Blower Motor. HA-226 쐌 Insufficient cooling. 쐌 Go to Trouble Diagnosis Procedure for Insufficient cool- HA-233 ing. 쐌 Insufficient heating. 쐌 Go to Trouble Diagnosis Procedure for Insufficient heat- HA-241 ing. 쐌 Air outlet does not change. 쐌 Go to Trouble Diagnosis Procedure for Air Outlet. HA-243 쐌 Magnet clutch does not engage when A/C switch and 쐌 Go to Trouble Diagnosis Procedure for Magnet Clutch. fan switch are ON. HA-245 쐌 Noise HA-252 쐌 Go to Trouble Diagnosis Procedure for Noise. HA-216 TROUBLE DIAGNOSES MANUAL Operational Check Operational Check =NAHA0076 GI The purpose of the operational check is to confirm that the system operates as it should. The systems which are checked are the blower, mode (discharge air), intake air, temperature decrease, temperature increase. MA CONDITIONS: EM NAHA0076S01 Engine running at normal operating temperature. LC PROCEDURE: 1. Check Blower 1. 2. 3. 4. EC NAHA0076S02 NAHA0076S0201 Turn fan control knob to 1-speed. Blower should operate on 1-speed. Then turn fan control knob to 2-speed. Continue checking blower speed until all four speeds are checked. Leave blower on 4-speed. RHA652F 2. Check Discharge Air 1. FE CL MT AT NAHA0076S0202 Turn mode control knob. TF PD AX SU RHA653F 2. Confirm that discharge air comes out according to the air distribution table at left. Refer to “Discharge Air Flow” in “DESCRIPTION” (HA-207). BR ST RS BT SC EL IDX RHA654F HA-217 TROUBLE DIAGNOSES MANUAL Operational Check (Cont’d) 3. Check Recirculation NAHA0076S0203 1. Press recirculation switch. Recirculation indicator should light. 2. Listen for intake door position change (you should hear blower sound change slightly). NOTE: Confirm that the RECIRCULATION (REC) switch is canceled in the ) and D/F ( ) mode. DEF ( RHA655F 4. Check Temperature Decrease 1. 2. NAHA0076S0204 Turn temperature control knob to full cold. Check for cold air at discharge air outlets. RHA656F 5. Check Temperature Increase 1. 2. NAHA0076S0205 Turn temperature control knob to full hot. Check for hot air at discharge air outlets. RHA657F 6. Check Air Conditioner Switch NAHA0076S0206 Turn fan control knob to the desired (1 to 4-speed) position and push the air conditioner switch to turn ON the air conditioner. The indicator light should come on when air conditioner is ON. RHA658F HA-218 TROUBLE DIAGNOSES MANUAL Intake Door Intake Door GI TROUBLE DIAGNOSIS PROCEDURE FOR INTAKE DOOR =NAHA0135 Symptom: 쐌 Intake door does not change in VENT, B/L or FOOT mode. Inspection Flow MA EM LC EC FE CL MT AT TF PD AX SU SHA260F *1: HA-221 *2: HA-217 BR *3: HA-216 ST RS BT SC EL IDX HA-219 TROUBLE DIAGNOSES MANUAL Intake Door (Cont’d) SYSTEM DESCRIPTION Intake Door Motor NAHA0136 NAHA0136S01 The intake door motor is installed on the intake unit. Using a link it opens and closes the intake door. When RECIRCULATION switch is at REC (except DEF and D/F modes), the ground line of the motor is switched from intake door motor terminal 3 to 2. This starts the motor because the position switch contacts built into it make current flow. When RECIRCULATION switch is at FRE (except DEF and D/F modes), the ground line is switched from intake door motor terminal 2 to 3. The contacts turn along with the motor. When they reach the non-current flow position, the motor will stop. The motor always turns in the same direction. RECIRCULATION switch is canceled by MODE switch in DEF and D/F modes. RHA771F ELECTRICAL COMPONENTS INSPECTION Mode Switch NAHA0137 NAHA0137S01 Check continuity between terminals at each switch position. Terminal No. Mode switch (+) Recirculation switch connector (−) 1 1 2 Mode control knob condition Continuity VENT, B/L, FOOT Yes D/F, DEF No VENT, B/L, FOOT No D/F, DEF Yes 1 2 2 All Yes 3 3 All Yes 4 4 All Yes RHA770F Recirculation Switch NAHA0137S02 Check continuity between terminals at each switch position. Terminal No. (+) (−) 1 4 2 RHA768F HA-220 Recirculation switch condition Continuity REC Yes FRE No REC No FRE Yes 4 TROUBLE DIAGNOSES MANUAL Intake Door (Cont’d) INTAKE DOOR MOTOR CIRCUIT =NAHA0090 SYMPTOM: 쐌 Intake door does not change in VENT, B/L or FOOT mode. 1 CHECK POWER SUPPLY FOR INTAKE DOOR MOTOR Disconnect intake door motor harness connector. Do approx. 12 volts exist between intake door motor harness connector terminal No. 1 and body ground? GI MA EM LC EC FE RHA350FC CL Yes or No Yes 䊳 GO TO 2. No 䊳 Check 7.5A (No. 11) fuse at fuse block. (Refer to EL-12, “Wiring Diagram — POWER —”.) MT AT TF PD AX SU BR ST RS BT SC EL IDX HA-221 TROUBLE DIAGNOSES MANUAL Intake Door (Cont’d) 2 CHECK GROUND CIRCUIT FOR INTAKE DOOR MOTOR Check continuity between intake door motor harness connector terminals and body ground. RHA580FA MTBL0033 OK or NG OK 䊳 GO TO 3. NG 䊳 Disconnect mode switch harness connector. GO TO 4. 3 CHECK INTAKE DOOR LINKAGE Refer to Control Linkage Adjustment. (HA-225) OK or NG OK 䊳 Replace intake door motor. NG 䊳 Repair or adjust. HA-222 TROUBLE DIAGNOSES MANUAL Intake Door (Cont’d) 4 GI CHECK CONTINUITY BETWEEN MODE SWITCH AND INTAKE DOOR MOTOR Check circuit continuity between mode switch harness connector terminal No. 1 (2) and intake door motor harness connector terminal No. 2 (3). MA EM LC EC FE CL MT AT RHA581FB TF Continuity should exist. If OK, check harness for short. OK or NG OK 䊳 GO TO 5. NG 䊳 Repair harness or connector. 5 PD AX SU CHECK MODE SWITCH (Refer to Electrical Components Inspection.) (HA-220) BR OK or NG OK 䊳 GO TO 6. NG 䊳 Replace mode switch. ST RS BT SC EL IDX HA-223 TROUBLE DIAGNOSES MANUAL Intake Door (Cont’d) 6 CHECK CIRCUIT CONTINUITY BETWEEN MODE SWITCH AND RECIRCULATION SWITCH Check circuit continuity between mode switch harness connector terminal No. 4 and recirculation switch harness connector terminal No. 4. RHA769FB Continuity should exist. If OK, check harness for short. OK or NG OK 䊳 GO TO 7. NG 䊳 Replace mode switch. 7 CHECK GROUND CIRCUIT FOR MODE SWITCH Check circuit continuity between mode switch harness connector terminal No. 4 and body ground. RHA582F Continuity should exist. If OK, check harness for short. OK or NG OK 䊳 GO TO 8. NG 䊳 Repair harness or connector. 8 CHECK RECIRCULATION SWITCH (Refer to Electrical Components Inspection.) (HA-220) OK or NG OK 䊳 INSPECTION END NG 䊳 Replace recirculation switch. HA-224 TROUBLE DIAGNOSES MANUAL Intake Door (Cont’d) CONTROL LINKAGE ADJUSTMENT Intake Door Motor 1. 2. 3. 4. NAHA0093 GI NAHA0093S04 Install intake door motor on intake unit. Ensure that the intake door motor lever is fitted into the slit portion of intake door link. Connect the intake door motor harness connector. Turn ignition switch to ON. Check that intake door operates properly when RECIRCULATION switch is turned ON and OFF. MA EM LC RHA593F EC FE CL MT AT TF PD AX SU BR ST RS BT SC EL IDX HA-225 TROUBLE DIAGNOSES MANUAL Blower Motor Blower Motor TROUBLE DIAGNOSIS PROCEDURE FOR BLOWER MOTOR =NAHA0138 Symptom: 쐌 Blower motor does not rotate at all. Inspection Flow SHA261F *1: HA-228 *2: HA-217 *3: HA-216 HA-226 TROUBLE DIAGNOSES MANUAL Blower Motor (Cont’d) ELECTRICAL COMPONENTS INSPECTION Fan Switch =NAHA0139 NAHA0139S01 Check continuity between terminals at each switch position. KNOB POSITION Continuity between terminals OFF No continuity 1 5—1—6 2 4—1—6 3 3—1—6 4 2—1—6 RHA589F GI MA EM LC EC FE CL MT AT Blower Motor NAHA0139S02 Confirm smooth rotation of the blower motor. 쐌 Ensure that there are no foreign particles inside the intake unit. TF PD AX SU Blower Resistor NAHA0139S03 Check resistance between terminals. BR Terminal No. Resistance (+) 3 4 2 ST (−) Approx. 1.4 - 1.6Ω 1 Approx. 2.5 - 2.8Ω RS Approx. 0.5 - 0.6Ω BT RHA651F SC EL IDX HA-227 TROUBLE DIAGNOSES MANUAL Blower Motor (Cont’d) BLOWER MOTOR CIRCUIT =NAHA0089 SYMPTOM: 쐌 Blower motor does not rotate. Test group No. 1 INCIDENT 1 Fan fails to rotate. 2 Fan does not rotate at 1-speed. 3 Fan does not rotate at 2-speed. 4 Fan does not rotate at 3-speed. 5 Fan does not rotate at 4-speed. DIAGNOSTIC PROCEDURE Check if blower motor rotates properly at each fan speed. Conduct checks as per table at above. 1 䊳 GO TO 2. 2, 3, 4 䊳 GO TO 8. 5 䊳 GO TO 10. 2 CHECK POWER SUPPLY FOR BLOWER MOTOR 1. Disconnect blower motor harness connector. 2. Do approx. 12 volts exist between blower motor harness connector terminal No. 1 and body ground? RHA343FA Yes or No Yes 䊳 GO TO 3. No 䊳 Check 15A (Nos. 1 and No. 2) fuses at fuse block. (Refer to EL-12, “Wiring Diagram — POWER”.) HA-228 TROUBLE DIAGNOSES MANUAL Blower Motor (Cont’d) 3 GI CHECK CIRCUIT CONTINUITY FOR BLOWER MOTOR 1. Turn fan control knob to any position except OFF. 2. Check circuit continuity between blower motor harness connector terminal No. 2 and body ground. MA EM LC EC RHA344FA FE Continuity should exist. OK or NG OK 䊳 GO TO 4. NG 䊳 Reconnect blower motor harness connector. GO TO 5. 4 CL MT CHECK BLOWER MOTOR AT (Refer to Electrical Components Inspection.) (HA-227) TF OK or NG OK 䊳 INSPECTION END NG 䊳 Replace blower motor. 5 PD CHECK BLOWER MOTOR CIRCUIT BETWEEN BLOWER MOTOR AND RESISTOR AX Do approx. 12 volts exist between resistor harness connector terminal No. 1 and body ground? SU BR ST RS RHA575F Yes or No Yes 䊳 Disconnect fan switch harness connector. GO TO 7. No 䊳 Disconnect blower motor and resistor harness connectors. GO TO 6. BT SC EL IDX HA-229 TROUBLE DIAGNOSES MANUAL Blower Motor (Cont’d) 6 CHECK CIRCUIT CONTINUITY BETWEEN BLOWER MOTOR AND RESISTOR Check circuit continuity between blower motor harness terminal No. 2 and resistor harness connector terminal No. 1. RHA576F Continuity should exist. OK or NG OK 䊳 Check harness for short. NG 䊳 Repair harness or connector. 7 CHECK GROUND CIRCUIT FOR FAN SWITCH Check circuit continuity between fan switch harness connector terminal No. 6 and body ground. RHA577F OK or NG OK 䊳 GO TO 8. NG 䊳 Repair harness or connector. 8 CHECK RESISTOR AFTER DISCONNECTING IT (Refer to Electrical Components Inspection.) (HA-227) OK or NG OK 䊳 GO TO 9. NG 䊳 Replace resistor. 9 CHECK RESISTOR HARNESS CONNECTOR Reconnect resistor harness connector. OK or NG 1 䊳 GO TO 12. 2, 3, 4 䊳 GO TO 10. HA-230 TROUBLE DIAGNOSES MANUAL Blower Motor (Cont’d) 10 GI CHECK FAN SWITCH CIRCUIT Do approx. 12 volts exist between each fan switch harness connector terminal and body ground? MA EM LC EC RHA578F FE CL MT MTBL0310 AT Yes or No Yes 䊳 GO TO 12. No 䊳 GO TO 11. TF PD AX SU BR ST RS BT SC EL IDX HA-231 TROUBLE DIAGNOSES MANUAL Blower Motor (Cont’d) 11 CHECK CIRCUIT CONTINUITY BETWEEN FAN SWITCH AND RESISTOR Check circuit continuity between fan switch harness terminal and resistor harness connector terminal. RHA579F MTBL0032 Continuity should exist. OK or NG OK 䊳 Check harness for short. NG 䊳 Repair harness or connector. 12 CHECK FAN SWITCH AFTER DISCONNECTING IT (Refer to Electrical Components Inspection.) (HA-227) OK or NG OK 䊳 INSPECTION END NG 䊳 Replace fan switch. HA-232 TROUBLE DIAGNOSES MANUAL Insufficient Cooling Insufficient Cooling GI TROUBLE DIAGNOSIS PROCEDURE FOR INSUFFICIENT COOLING =NAHA0150 Symptom: 쐌 Insufficient Cooling. Inspection Flow MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SHA650F *1: HA-242 *2: HA-236 *3: HA-234 *7: HA-187 *8: MA-14 *9: LC-22 *4: HA-217 *5: HA-216 *6: HA-258 SC EL IDX HA-233 TROUBLE DIAGNOSES MANUAL Insufficient Cooling (Cont’d) PERFORMANCE TEST DIAGNOSES NAHA0082 SHA333F *1: HA-236 *2: HA-236 *3: HA-236 *4: HA-242 *5: HA-187 HA-234 TROUBLE DIAGNOSES MANUAL Insufficient Cooling (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SHA329F *1: HA-260 *2: HA-226 *3: MA-14 SC EL IDX HA-235 TROUBLE DIAGNOSES MANUAL Insufficient Cooling (Cont’d) PERFORMANCE CHART Test Condition =NAHA0083 NAHA0083S01 Testing must be performed as follows: Vehicle location Indoors or in the shade (in a well-ventilated place) Doors Closed Door windows Open Hood Open TEMP. Max. COLD Discharge Air Face (Ventilation) set REC switch (Recirculation) set FAN speed High speed Engine speed Idle speed Operate the air conditioning system for 10 minutes before taking measurements. Test Reading NAHA0083S02 Recirculating-to-discharge Air Temperature Table NAHA0083S0201 Inside air (Recirculating air) at blower assembly inlet Discharge air temperature at center ventilator °C (°F) Relative humidity % Air temperature °C (°F) 25 (77) 6.0 - 9.0 (43 - 48) 30 (86) 10.0 - 13.6 (50 - 56) 35 (95) 15.2 - 19.5 (59 - 67) 40 (104) 22.5 - 27.1 (73 - 81) 25 (77) 9.0 - 12.2 (48 - 54) 30 (86) 13.6 - 17.2 (56 - 63) 35 (95) 19.5 - 23.7 (67 - 75) 40 (104) 27.1 - 32.3 (81 - 90) 50 - 60 60 - 70 Ambient Air Temperature-to-operating Pressure Table NAHA0083S0202 Ambient air Relative humidity % High-pressure (Discharge side) kPa (kg/cm2, psi) Low-pressure (Suction side) kPa (kg/cm2, psi) 25 (77) 1,226 - 1,638 (12.5 - 16.7, 178 - 237) 172 - 250 (1.75 - 2.55, 25 - 36) 30 (86) 1,422 - 1,883 (14.5 - 19.2, 206 - 273) 196 - 275 (2.0 - 2.8, 28 - 40) 35 (95) 1,657 - 2,187 (16.9 - 22.3, 240 - 317) 231 - 309 (2.35 - 3.15, 33 - 45) 40 (104) 1,922 - 2,501 (19.6 - 25.5, 279 - 363) 280 - 373 (2.85 - 3.8, 41 - 54) Air temperature °C (°F) 50 - 70 TROUBLE DIAGNOSES FOR UNUSUAL PRESSURE NAHA0084 Whenever system’s high and/or low side pressure is unusual, diagnose using a manifold gauge. The marker above the gauge scale in the following tables indicates the standard (usual) pressure range. Since the standard (usual) pressure, however, differs from vehicle to vehicle, refer to HA-236 (“Ambient air temperature-tooperating pressure table”). HA-236 TROUBLE DIAGNOSES MANUAL Insufficient Cooling (Cont’d) Both High and Low-pressure Sides are Too High. Gauge indication NAHA0084S01 Refrigerant cycle Both high and low-pressure sides are too high. Probable cause Excessive refrigerant charge in refrigeration cycle Air suction by cooling fan is insufficient. Insufficient condenser cooling 쐌 Clean condenser. performance 쐌 Check and repair cooling " fan as necessary. 1. Condenser fins are clogged. 2. Improper fan rotation of cooling fan Engine tends to overheat. 쐌 An area of the low-pressure pipe is colder than areas near the evaporator outlet. 쐌 Plates are sometimes covered with frost. Poor heat exchange in condenser (After compressor operation stops, high pressure decreases too slowly.) " Air in refrigeration cycle High-pressure side is too high and low-pressure side is too low. Reduce refrigerant until specified pressure is obtained. Evacuate repeatedly and recharge system. MA EM LC EC FE CL MT Engine cooling systems malfunction. Check and repair each engine cooling system. 쐌 Excessive liquid refrigerant on low-pressure side 쐌 Excessive refrigerant discharge flow 쐌 Expansion valve is open a little compared with the specification. " 1. Improper expansion valve installation 2. Improper expansion valve adjustment Replace expansion valve. High-pressure Side is Too High and Low-pressure Side is Too Low. Gauge indication Corrective action 쐌 Pressure is reduced soon after water is splashed on condenser. 쐌 Low-pressure pipe is not cold. 쐌 When compressor is stopped high-pressure AC359A value quickly drops by approximately 196 kPa (2 kg/cm2, 28 psi). It then decreases gradually thereafter. GI Refrigerant cycle Probable cause Upper side of condenser and high-pressure side are hot, however, liquid tank is not so hot. High-pressure tube or parts located between compressor and condenser are clogged or crushed. AT TF PD AX SU NAHA0084S02 Corrective action 쐌 Check and repair or replace malfunctioning parts. 쐌 Check lubricant for contamination. BR ST RS BT SC AC360A EL IDX HA-237 TROUBLE DIAGNOSES MANUAL Insufficient Cooling (Cont’d) High-pressure Side is Too Low and Low-pressure Side is Too High. Gauge indication High-pressure side is too low and low-pressure side is too high. NAHA0084S03 Refrigerant cycle Probable cause High and low-pressure sides become equal soon after compressor operation stops. Compressor pressure operation is improper. " Damaged inside compressor packings Replace compressor. No temperature difference between high and low-pressure sides Compressor pressure operation is improper. " Damaged inside compressor packings. Replace compressor. AC356A HA-238 Corrective action TROUBLE DIAGNOSES MANUAL Insufficient Cooling (Cont’d) Both High- and Low-pressure Sides are Too Low. Gauge indication Refrigerant cycle Both high- and low-pressure sides are too low. 쐌 There is a big temperature difference between receiver drier outlet and inlet. Outlet temperature is extremely low. 쐌 Liquid tank inlet and expansion valve are frosted. NAHA0084S04 Probable cause Corrective action Compressor discharge capac- 쐌 Replace liquid tank. ity does not change. (Com쐌 Check lubricant for conpressor stroke is set at maxitamination. mum.) MA EM LC 쐌 Temperature of expansion High-pressure pipe located valve inlet is extremely low between receiver drier and expansion valve is clogged. as compared with areas near liquid tank. 쐌 Expansion valve inlet may be frosted. 쐌 Temperature difference AC353A occurs somewhere in highpressure side 쐌 Expansion valve and liquid tank are warm or only cool when touched. GI Low refrigerant charge " Leaking fittings or components 쐌 Check and repair malfunctioning parts. 쐌 Check lubricant for contamination. FE CL Check refrigerant for leaks. Refer to “Checking Refrigerant Leaks”, HA-263. There is a big temperature Expansion valve closes a 쐌 Remove foreign particles difference between expansion little compared with the speciby using compressed air. valve inlet and outlet while fication. 쐌 Check lubricant for conthe valve itself is frosted. " tamination. 1. Improper expansion valve adjustment 2. Malfunctioning expansion valve 3. Outlet and inlet may be clogged. An area of the low-pressure Low-pressure pipe is clogged pipe is colder than areas near or crushed. the evaporator outlet. EC 쐌 Check and repair malfunctioning parts. 쐌 Check lubricant for contamination. Air flow volume is not enough Evaporator is frozen. 쐌 Check intake sensor ciror is too low. " cuit. Compressor discharge capac- 쐌 Replace compressor. ity does not change. (Compressor stroke is set at maximum length.) MT AT TF PD AX SU BR ST RS BT SC EL IDX HA-239 TROUBLE DIAGNOSES MANUAL Insufficient Cooling (Cont’d) Low-pressure Side Sometimes Becomes Negative. Gauge indication Refrigerant cycle 쐌 Air conditioning system does not function and does not cyclically cool the compartment air. 쐌 The system constantly functions for a certain period of time after compressor is stopped and restarted. Low-pressure side sometimes becomes negative. NAHA0084S05 Probable cause Refrigerant does not discharge cyclically. " Moisture is frozen at expansion valve outlet and inlet. " Water is mixed with refrigerant. Corrective action 쐌 Drain water from refrigerant or replace refrigerant. 쐌 Replace liquid tank. AC354A Low-pressure Side Becomes Negative. Gauge indication Low-pressure side becomes negative. NAHA0084S06 Refrigerant cycle Probable cause Corrective action Liquid tank or front/rear side of expansion valve’s pipe is frosted or dewed. High-pressure side is closed and refrigerant does not flow. " Expansion valve or liquid tank is frosted. Leave the system at rest until no frost is present. Start it again to check whether or not the problem is caused by water or foreign particles. 쐌 If water is the cause, initially cooling is okay. Then the water freezes causing a blockage. Drain water from refrigerant or replace refrigerant. 쐌 If due to foreign particles, remove expansion valve and remove particles with dry and compressed air (not shop air). 쐌 If either of the above methods cannot correct the problem, replace expansion valve. 쐌 Replace liquid tank. 쐌 Check lubricant for contamination. AC362A HA-240 TROUBLE DIAGNOSES MANUAL Insufficient Heating Insufficient Heating GI TROUBLE DIAGNOSIS PROCEDURE FOR INSUFFICIENT HEATING =NAHA0140 Symptom: 쐌 Insufficient Heating. Inspection Flow MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT RHA075I *1: HA-242 *2: HA-217 *3: HA-216 *4: MA-15 *5: LC-12 *6: LC-18 *7: MA-15 SC EL IDX HA-241 TROUBLE DIAGNOSES MANUAL Insufficient Heating (Cont’d) CONTROL LINKAGE ADJUSTMENT Temperature Control Cable 1. 2. 3. NAHA0141 NAHA0141S02 Move the temperature control knob to the full hot position. Set the air mix door lever in the full hot position. Pull on the cable cover in the direction of the arrow, then clamp it. After positioning control cable, check that it operates properly. RHA632EA HA-242 TROUBLE DIAGNOSES MANUAL Air Outlet Air Outlet GI TROUBLE DIAGNOSIS PROCEDURE FOR AIR OUTLET =NAHA0142 Symptom: 쐌 Air outlet does not change. Inspection Flow MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SHA263F *1: HA-244 *2: HA-217 *3: HA-216 *4: HA-207 SC EL IDX HA-243 TROUBLE DIAGNOSES MANUAL Air Outlet (Cont’d) CONTROL LINKAGE ADJUSTMENT Mode Control Cable 1. 2. 3. NAHA0151 NAHA0151S01 Turn the mode control knob to the DEF position. Set the side link in the DEF position by hand. Pull on the cable cover in the direction of the arrow, then clamp it. After positioning control cable, check that it operates properly. RHA630EA HA-244 TROUBLE DIAGNOSES MANUAL Magnet Clutch Magnet Clutch GI TROUBLE DIAGNOSIS PROCEDURE FOR MAGNET CLUTCH =NAHA0119 Symptom: 쐌 Magnet clutch does not operate when A/C switch and fan switch are ON. Inspection Flow MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SHA264FA *1: HA-263 *2: HA-246 *3: HA-217 *4: HA-216 *5: MA-14 SC EL IDX HA-245 TROUBLE DIAGNOSES MANUAL Magnet Clutch (Cont’d) MAGNET CLUTCH CIRCUIT =NAHA0091 SYMPTOM: 쐌 Magnet clutch does not engage when A/C switch and fan switch are ON. 1 CHECK POWER SUPPLY FOR COMPRESSOR Disconnect compressor harness connector. Do approx. 12 volts exist between compressor harness connector terminal No. 1 and body ground? RHA747FA Yes or No Yes 䊳 GO TO 2. No 䊳 Disconnect A/C relay. GO TO 3. 2 CHECK MAGNET CLUTCH COIL OK or NG NG 3 䊳 Replace magnet clutch. Refer to HA-258. CHECK CIRCUIT CONTINUITY BETWEEN A/C RELAY AND COMPRESSOR Check circuit continuity between A/C relay harness connector E26 terminal No. 5 (B/W) and compressor harness connector F202 terminal No. 1 (B/W). SHA480F Continuity should exist. If OK, check harness for short. OK or NG OK 䊳 GO TO 4. NG 䊳 Repair harness or connector. HA-246 TROUBLE DIAGNOSES MANUAL Magnet Clutch (Cont’d) 4 GI CHECK POWER SUPPLY FOR A/C RELAY Disconnect A/C relay. Do approx. 12 volts exist between A/C relay harness connector E26 terminal Nos. 1 (G/W), 3 (G/W) and body ground? MA EM LC EC SHA481F FE Yes or No Yes 䊳 GO TO 5. No 䊳 Check power supply circuit and 7.5A (No. 6) fuse at fuse block. Refer to EL-12, “Wiring Diagram — POWER —”. CL MT 5 CHECK A/C RELAY AFTER DISCONNECTING IT AT Refer to HA-251. OK or NG OK 䊳 Reconnect A/C relay. GO TO 6. NG 䊳 Replace A/C relay. TF PD 6 CHECK COIL SIDE CIRCUIT OF A/C RELAY Do approx. 12 volts exist between ECM harness connector terminal No. 105 and body ground? AX SU BR ST RHA200I Yes or No Yes 䊳 GO TO 8. No 䊳 Disconnect A/C relay. Disconnect ECM harness connector. GO TO 7. RS BT SC EL IDX HA-247 TROUBLE DIAGNOSES MANUAL Magnet Clutch (Cont’d) 7 CHECK CIRCUIT CONTINUITY BETWEEN A/C RELAY AND ECM Check circuit continuity between A/C relay harness connector F203 terminal No. 2 (GR) and ECM harness connector F203 terminal No. 105 (LG). RHA203I Continuity should exist. OK or NG OK 䊳 Check harness for short. NG 䊳 Repair harness or connector. 8 CHECK VOLTAGE FOR ECM Do approx. 5 volts exist between ECM harness connector terminal No. 110 and body ground? RHA201I Yes or No Yes 䊳 GO TO 9. No 䊳 Check ECM. Refer to EC-149, “ECM Terminals and Reference Value”. 9 CHECK REFRIGERANT PRESSURE SENSOR Refer to HA-251. OK or NG OK 䊳 Disconnect A/C switch harness connector. GO TO 10. NG 䊳 Replace refrigerant pressure sensor. HA-248 TROUBLE DIAGNOSES MANUAL Magnet Clutch (Cont’d) 10 GI CHECK CIRCUIT CONTINUITY BETWEEN ECM AND A/C SWITCH Check circuit continuity between ECM harness connector terminal No. 110 and A/C switch harness connector terminal No. 2. MA EM LC EC RHA205I Continuity should exist. If OK, check harness for short. CL OK or NG OK 䊳 GO TO 11. NG 䊳 Repair harness or connector. 11 FE MT CHECK A/C SWITCH AT Refer to HA-251. OK or NG OK 䊳 Disconnect fan switch harness connector. GO TO 12. NG 䊳 Replace A/C switch. 12 TF PD CHECK CIRCUIT CONTINUITY BETWEEN A/C SWITCH AND FAN SWITCH Check circuit continuity between A/C switch harness connector terminal No. 1 and fan switch harness connector terminal No. 1. AX SU BR ST RS RHA617F Continuity should exist. If OK, check harness for short. BT OK or NG OK 䊳 GO TO 13. NG 䊳 Repair harness or connector. SC EL IDX HA-249 TROUBLE DIAGNOSES MANUAL Magnet Clutch (Cont’d) 13 CHECK BODY GROUND CIRCUIT FOR FAN SWITCH Does continuity exist between fan switch harness connector terminal No. 6 and body ground? RHA588F Yes or No Yes 䊳 GO TO 14. No 䊳 Repair harness or connector. 14 CHECK FAN SWITCH Refer to HA-227. OK or NG OK 䊳 INSPECTION END NG 䊳 Replace fan switch. HA-250 TROUBLE DIAGNOSES MANUAL Magnet Clutch (Cont’d) ELECTRICAL COMPONENTS INSPECTION A/C Switch =NAHA0092 NAHA0092S04 Check continuity between terminals at each switch position. Switch condition GI MA Terminal No. Continuity A/C (+) (−) EM ON Yes 2 1 OFF No LC RHA590F EC A/C Relay NAHA0092S07 Check continuity between terminal Nos. 3 and 5. Conditions Continuity 12V direct current supply between terminal Nos. 1 and 2 Yes No current supply No FE CL MT If NG, replace relay. SHA479F Refrigerant Pressure Sensor AT NAHA0092S08 Make sure that higher A/C refrigerant pressure results in higher refrigerant-pressure sensor output voltage. Check voltage between ECM harness terminal No. 70 and body ground. Refer to EC-772, “Diagnostic Procedure”. TF PD AX SU RHA070I BR ST RS BT SHA315F SC EL IDX HA-251 TROUBLE DIAGNOSES MANUAL Noise Noise TROUBLE DIAGNOSIS PROCEDURE FOR NOISE =NAHA0080 Symptom: 쐌 Noise Inspection Flow RHA586H *1: HA-260 *2: HA-260 *3: HA-255 *4: MA-14 HA-252 SERVICE PROCEDURE MANUAL HFC-134a (R-134a) Service Procedure HFC-134a (R-134a) Service Procedure SETTING OF SERVICE TOOLS AND EQUIPMENT Discharging Refrigerant NAHA0094 GI NAHA0094S01 NAHA0094S0101 WARNING: Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Remove HFC-134a (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 information may be obtained from refrigerant and lubricant manufacturers. MA EM LC EC FE CL MT AT TF Evacuating System and Charging Refrigerant SHA179FB PD NAHA0094S0102 AX SU BR ST RS BT SHA180FB SC EL IDX HA-253 SERVICE PROCEDURE MANUAL HFC-134a (R-134a) Service Procedure (Cont’d) SHA193FA *1: HA-255 *2: HA-263 *3: HA-264 *4: HA-234 *5: HA-187 HA-254 SERVICE PROCEDURE MANUAL Maintenance of Lubricant Quantity in Compressor Maintenance of Lubricant Quantity in Compressor GI NAHA0095 The lubricant in the compressor circulates through the system with the refrigerant. Add lubricant to compressor when replacing any component or after a large gas leakage occurred. It is important to maintain the specified amount. If lubricant quantity is not maintained properly, the following malfunctions may result: 쐌 Lack of lubricant: May lead to a seized compressor 쐌 Excessive lubricant: Inadequate cooling (thermal exchange interference) LUBRICANT LC EC FE NAHA0095S02 Adjust the lubricant quantity according to the test group shown below. 1 EM NAHA0095S01 Name: Nissan A/C System Oil Type S Part number: KLH00-PAGS0 CHECKING AND ADJUSTING MA LUBRICANT RETURN OPERATION Can lubricant return operation be performed? 쐌 A/C system works properly. 쐌 There is no evidence of a large amount of lubricant leakage. CL MT AT Yes or No Yes 䊳 GO TO 2. No 䊳 GO TO 3. 2 TF PERFORM LUBRICANT RETURN OPERATION, PROCEEDING AS FOLLOWS 1. Start engine, and set the following conditions: 쐌 Test condition Engine speed: Idling to 1,200 rpm A/C switch: ON Blower speed: Max. position Temp. control: Optional [Set so that intake air temperature is 25 to 30°C (77 to 86°F).] 2. Next item is for V-6 compressor. Connect the manifold gauge, and check that the high pressure side pressure is 588 kPa (6 kg/cm2, 85 psi) or higher. If less than the reference level, attach a cover to the front face of the condenser to raise the pressure. 3. Perform lubricant return operation for about 10 minutes. 4. Stop engine. CAUTION: If excessive lubricant leakage is noted, do not perform the lubricant return operation. PD AX SU BR ST RS 䊳 GO TO 3. BT 3 CHECK COMPRESSOR Should the compressor be replaced? Yes or No Yes 䊳 GO TO HA-256. No 䊳 GO TO 4. SC EL IDX HA-255 SERVICE PROCEDURE MANUAL Maintenance of Lubricant Quantity in Compressor (Cont’d) 4 CHECK ANY PART Is there any part to be replaced? (Evaporator, condenser, liquid tank or in case there is evidence of a large amount of lubricant leakage.) Yes or No Yes 䊳 GO TO HA-256. No 䊳 Carry out the A/C performance test. Lubricant Adjusting Procedure for Components Replacement Except Compressor NAHA0095S0201 After replacing any of the following major components, add the correct amount of lubricant to the system. Amount of lubricant to be added Lubricant to be added to system Part replaced Remarks Amount of lubricant m
(US fl oz, Imp fl oz) Evaporator 75 (2.5, 2.6) — Condenser 75 (2.5, 2.6) — Liquid tank 5 (0.2, 0.2) Add if compressor is not replaced. *1 In case of refrigerant leak 30 (1.0, 1.1) Large leak — Small leak *2 *1: *2: If compressor is replaced, addition of lubricant is included in the table. If refrigerant leak is small, no addition of lubricant is needed. Lubricant Adjustment Procedure for Compressor Replacement NAHA0095S0202 1. 2. 3. 4. 5. 6. 7. 8. 9. Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If OK, recover refrigerant from equipment lines. Confirm refrigerant purity in supply tank using ACR4 and refrigerant identifier. If NG, refer to “CONTAMINATED REFRIGERANT”, HA-187. Connect ACR4 to vehicle. Confirm refrigerant purity in vehicle A/C system using ACR4 and refrigerant identifier. If NG, refer to “CONTAMINATED REFRIGERANT”, HA-187. Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure lubricant discharged into the recovery/ recycling equipment. Remove the drain plug of the “old” (removed) compressor. Drain the lubricant into a graduated container and record the amount of drained lubricant. Remove the drain plug and drain the lubricant from the “new” compressor into a separate, clean container. Measure an amount of new lubricant installed equal to amount drained from “old” compressor. Add this lubricant to “new” compressor through the suction port opening. Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant to “new” compressor through the suction port opening. Torque the drain plug. V-6 compressor: 18 - 19 N·m (1.8 - 1.9 kg-m, 13 - 14 ft-lb) HA-256 SERVICE PROCEDURE MANUAL Maintenance of Lubricant Quantity in Compressor (Cont’d) 10. If the liquid tank also needs to be replaced, add an additional 5 m
(0.2 US fl oz, 0.2 Imp fl oz) of lubricant at this time. Do not add this 5 m
(0.2 US fl oz, 0.2 Imp fl oz) of lubricant if only replacing the compressor. GI MA EM LC EC FE CL MT AT TF PD AX RHA065DD SU BR ST RS BT SC EL IDX HA-257 SERVICE PROCEDURE MANUAL Compressor Compressor REMOVAL AND INSTALLATION NAHA0096 RHA650F Compressor Clutch OVERHAUL NAHA0097 RHA122F REMOVAL 쐌 NAHA0098 When removing center bolt, hold clutch disc with clutch disc wrench. RHA136EB HA-258 SERVICE PROCEDURE MANUAL Compressor Clutch (Cont’d) GI MA EM LC RHA399F 쐌 Remove the clutch disc using the clutch disc puller. Insert the holder’s three pins into the holes in the clutch disc. Rotate the holder clockwise to hook it onto the plate. Then, tighten the center bolt to remove the clutch disc. After removing the clutch disc, remove the shims from either the drive shaft or the clutch disc. EC FE CL MT RHA124F 쐌 Remove the snap ring using external snap ring pliers. AT TF PD AX SU RHA138E 쐌 Pulley removal Position the center pulley puller on the end of the drive shaft, and remove the pulley assembly using any commercially available pulley puller. To prevent the pulley groove from being deformed, the puller claws should be positioned onto the edge of the pulley assembly. BR ST RS BT RHA139E 쐌 Remove the field coil harness clip using a pair of pliers. SC EL IDX RHA125F HA-259 SERVICE PROCEDURE MANUAL Compressor Clutch (Cont’d) 쐌 Remove the snap ring using external snap ring pliers. RHA145E INSPECTION Clutch Disc NAHA0099 NAHA0099S01 If the contact surface shows signs of damage due to excessive heat, replace clutch disc and pulley. Pulley NAHA0099S02 Check the appearance of the pulley assembly. If the contact surface of pulley shows signs of excessive grooving, replace clutch disc and pulley. The contact surfaces of the pulley assembly should be cleaned with a suitable solvent before reinstallation. RHA126F Coil NAHA0099S03 Check coil for loose connection or cracked insulation. INSTALLATION 쐌 쐌 NAHA0100 Install the field coil. Be sure to align the coil’s pin with the hole in the compressor’s front head. Install the field coil harness clip using a screwdriver. RHA142E 쐌 Install the pulley assembly using the installer and a hand press, and then install the snap ring using snap ring pliers. RHA143EA HA-260 SERVICE PROCEDURE MANUAL Compressor Clutch (Cont’d) 쐌 Install the clutch disc on the drive shaft, together with the original shim(s). Press the clutch disc down by hand. GI MA EM LC RHA127F 쐌 Using the holder to prevent clutch disc rotation, tighten the bolt to 14 N·m (1.4 kg-m, 10 ft-lb) torque. After tightening the bolt, check that the pulley rotates smoothly. EC FE CL MT RHA086E 쐌 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 spacer and readjust. AT TF PD AX SU RHA087E Break-in Operation NAHA0100S01 When replacing compressor clutch assembly, always carry out the break-in operation. This is done by engaging and disengaging the clutch about thirty times. Break-in operation raises the level of transmitted torque. BR ST RS BT SC EL IDX HA-261 SERVICE PROCEDURE MANUAL Refrigerant Lines Refrigerant Lines REMOVAL AND INSTALLATION 쐌 =NAHA0101 Refer to page HA-189 regarding “Precautions for Refrigerant Connection”. RHA072I HA-262 SERVICE PROCEDURE MANUAL Checking for Refrigerant Leaks Checking for Refrigerant Leaks PRELIMINARY CHECK 쐌 =NAHA0102 NAHA0102S04 Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant leakage, damage and corrosion. A/C lubricant leakage may indicate an area of refrigerant leakage. Allow extra inspection time in these areas when using either an electronic refrigerant leak detector or fluorescent dye leak detector. 쐌 If dye is observed, confirm the leak with an electronic refrigerant leak detector. It is possible a prior leak was repaired and not properly cleaned. 쐌 When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all system components and connections. 쐌 When searching for refrigerant leaks using an electronic leak detector, move the probe along the suspected leak area at 25 to 50 mm (1 to 2 in) per second and no further than 1/4 inch from the component. NOTE: Moving the electronic leak detector probe slower and closer to the suspected leak area will improve the chances of finding a leak. Electronic Refrigerant Leak Detector MA EM LC EC FE CL MT AT NAHA0254 PRECAUTIONS FOR HANDLING LEAK DETECTORNAHA0254S01 SHA196FA GI When performing a refrigerant leak check, use a J-41995 A/C 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. 쐌 Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the surfaces to be checked are clean. Clean with a dry cloth or blow off with shop air. 쐌 Do not allow the sensor tip of the detector to contact with any substance. This can also cause false readings and may damage the detector. TF PD AX SU BR ST RS BT 1. Position probe approximately 5 mm (3/16 in) away from point to be checked. SC EL IDX SHA707EA HA-263 SERVICE PROCEDURE MANUAL Electronic Refrigerant Leak Detector (Cont’d) 2. When testing, circle each fitting completely with probe. 3. Move probe along component approximately 25 to 50 mm (1 to 2 in)/sec. SHA706E SHA708EA CHECKING PROCEDURE NAHA0254S02 To prevent inaccurate or false readings, make sure there is no refrigerant vapor, shop chemicals, or cigarette 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 (3.52 kg/cm2, 50 psi) above 16°C (61°F). If less than specification, recover/evacuate and recharge the system with the specified amount of refrigerant. NOTE: At temperatures below 16°C (61°F), leaks may not be detected since the system may not reach 345 kPa (3.52 kg/cm2, 50 psi). 4. Conduct the leak test from the high side (compressor discharge a to evaporator inlet f) to the low side (evaporator drain hose g to shaft seal k). Refer to HA-262. 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. 쐌 Compressor Check the fitting of high and low pressure hoses, relief valve and shaft seal. 쐌 Liquid tank Check the tube fitting. 쐌 Service valves Check all around the service valves. Ensure service valve caps 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. HA-264 SERVICE PROCEDURE MANUAL Electronic Refrigerant Leak Detector (Cont’d) 쐌 Cooling unit (Evaporator) With engine OFF, turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in the cooling unit. Wait a minimum of 10 minutes accumulation time (refer to the manufacturer’s recommended procedure for actual wait time) before inserting the leak detector probe into the drain hose. Keep the probe inserted for at least ten seconds. Use caution not to contaminate the ptobe tip with water or dirt that may be in the drain hose. 5. If a leak detector detects a leak, verify at least once by blowing compressed air into area of suspected leak, then repeat check as outlined above. 6. Do not stop when one leak is found. Continue to check for additional leaks at all system components. If no leaks are found, perform steps 7 - 10. 7. Start engine. 8. Set the heater A/C control as follows: 1) A/C switch ON. 2) Face mode 3) Recirculation switch ON 4) Max cold temperature 5) Fan speed high 9. Run engine at 1,500 rpm for at least 2 minutes. 10. Turn engine off and perform leak check again following steps 4 through 6 above. GI MA EM LC EC FE CL MT AT TF PD AX SU Refrigerant leaks should be checked immediately after stopping the engine. Begin with the leak detector at the compressor. The pressure on the high pressure side will gradually drop after refrigerant circulation stops and pressure on the low pressure side will gradually rise, as shown in the graph. Some leaks are more easily detected when pressure is high. BR ST RS BT SHA839E 11. Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If pressure is displayed, recover refrigerant from equipment lines and then check refrigerant purity. 12. Confirm refrigerant purity in supply tank using ACR4 and refrigerant identifier. 13. Confirm refrigerant purity in vehicle A/C system using ACR4 and refrigerant identifier. 14. Discharge A/C system using approved refrigerant recovery equipment. Repair the leaking fitting or component as necessary. HA-265 SC EL IDX SERVICE PROCEDURE MANUAL Electronic Refrigerant Leak Detector (Cont’d) 15. Evacuate and recharge A/C system and perform the leak test to confirm no refrigerant leaks. 16. Conduct A/C performance test to ensure system works properly. Fluorescent Dye Leak Detector PRECAUTIONS FOR FLUORESCENT DYE LEAK DETECTION 쐌 쐌 쐌 CHECKING SYSTEM FOR LEAKS USING THE FLUORESCENT LEAK DETECTOR 1. 2. 3. 4. 5. NAHA0266 The fluorescent dye leak detector is not a replacement for an electronic refrigerant leak detector. The fluorescent dye leak detector should be used in conjunction with an electronic refrigerant leak detector (J-41995) to pinpoint refrigerant leaks. For your safety and your customer’s satisfaction, read and follow all manufacturer’s operating instructions and precautions prior to performing the work. Refer to “Precautions for Leak Detection Dye”, HA-188. NAHA0267 Check A/C system for leaks using the UV lamp and safety glasses (J-42220) in a low sunlight area (area without windows preferable). Illuminate all components, fittings and lines. The dye will appear as a bright green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain opening indicates an evaporator core assembly (tubes, core or TXV) leak. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or cloth, then check the cloth with the UV lamp for dye residue. Confirm any suspected leaks with an approved electronic refrigerant leak detector. After the leak is repaired, remove any residual dye using dye cleaner (J-43872) to prevent future misdiagnosis. Perform a system performance check and verify the leak repair with an approved electronic refrigerant leak detector. DYE INJECTION NAHA0268 (This procedure is only necessary when re-charging the system or when the compressor has seized and was replaced.) Refer to “Precautions for Leak Detection Dye”, HA-188. 1. Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.52 kg/cm2, 50 psi). 2. Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye into the injector tool (J-41459). 3. Connect the injector tool to the A/C LOW PRESSURE side service fitting. 4. Start engine and switch A/C ON. 5. With the A/C operating (compressor running), inject one bottle (1/4 ounce / 7.4 cc) of fluorescent dye through the low-pressure service valve using dye injector tool J-41459 (refer to the manufacturer’s operating instructions). HA-266 SERVICE PROCEDURE MANUAL Fluorescent Dye Leak Detector (Cont’d) 6. With the engine still running, disconnect the injector tool from the service fitting. CAUTION: Be careful not to allow dye to spray or drip when disconnecting the injector from the system. NOTE: If repairing the A/C system or replacing a component, pour the dye directly into the open system connection and proceed with the service procedures. 7. Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the leak size, operating conditions and location of the leak, it may take from minutes to days for the dye to penetrate a leak and become visible. GI MA EM LC EC FE CL MT AT Belt TENSION ADJUSTMENT 쐌 NAHA0103 Refer to MA-14, “Checking Drive Belts”. TF PD AX SU In-cabin Microfilter FUNCTION NAHA0273 Air inside passenger compartment is kept clean at either recirculation or fresh mode by installing In-cabin microfilter into cooling unit. NOTE: To replace In-cabin microfilter, refer to MA-9, MA-11, “Periodic Maintenance”. Caution label is fixed inside the glove box. BR ST RS BT RHA042GB REPLACEMENT PROCEDURE 1. 2. 3. Remove glove box. Remove instrument lower panel from instrument panel. Remove In-cabin microfilter fixed clip. NAHA0274 SC EL IDX SHA252F HA-267 SERVICE PROCEDURE MANUAL In-cabin Microfilter (Cont’d) 4. 5. 6. 7. Take out the lower side In-cabin microfilter from cooling unit. Then slide upper side filter to the bottom position and take off the In-cabin microfilter from the cooling unit. Replace with new one and reinstall on cooling unit. Reinstall clip, instrument lower panel and glove box. SHA253F HA-268 SERVICE DATA AND SPECIFICATIONS (SDS) MANUAL Manual Manual GI COMPRESSOR NAHA0105 Model Calsonic Kansei make V-6 Type V-6 variable displacement Displacement cm3 (cu in)/rev. Max. 184 (11.228) Min. 14.5 (0.885) Cylinder bore x stroke mm (in) EM LC 37 (1.46) x [2.3 - 28.6 (0.091 - 1.126)] Direction of rotation Clockwise (viewed from drive end) Drive belt EC Poly V LUBRICANT NAHA0106 Model Calsonic Kansei make V-6 Name Nissan A/C System Oil Type S Part number* Capacity m
(US fl oz, Imp fl oz) MA CL KLH00-PAGS0 Total in system 180 (6.1, 6.3) Compressor (Service part) charging amount 180 (6.1, 6.3) MT AT *: Always check with the Parts Department for the latest parts information. REFRIGERANT NAHA0107 Type PD 0.45 (0.99) ENGINE IDLING SPEED (WHEN A/C IS ON) NAHA0108 AX NAHA0109 SU Refer to EC-792, “Idle Speed and Ignition Timing”. BELT TENSION 쐌 TF HFC-134a (R-134a) Capacity kg (lb) 쐌 FE Refer to MA-14, “Checking Drive Belts”. BR ST RS BT SC EL IDX HA-269 NOTES MANUAL TRANSMISSION SECTION MT GI MA EM LC EC FE CONTENTS PREPARATION ...............................................................2 Special Service Tools ..................................................2 Commercial Service Tool.............................................3 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING .....................................................4 NVH Troubleshooting Chart.........................................4 MANUAL TRANSMISSION..........................................4 ON-VEHICLE SERVICE ..................................................5 Position Switch Check .................................................5 DESCRIPTION .................................................................6 Cross-sectional View ...................................................6 REMOVAL AND INSTALLATION ...................................7 Removal.......................................................................7 Installation....................................................................8 OVERHAUL ...................................................................10 Case Components .....................................................10 Gear Components .....................................................11 Shift Control Components .........................................13 DISASSEMBLY..............................................................14 Case Components .....................................................14 DISASSEMBLY ........................................................14 Shift Control Components .........................................15 DISASSEMBLY ........................................................15 Gear Components .....................................................16 DISASSEMBLY ........................................................16 INSPECTION..................................................................20 Shift Control Components .........................................20 INSPECTION ...........................................................20 Gear Components .....................................................20 INSPECTION ...........................................................20 ASSEMBLY....................................................................22 Gear Components .....................................................22 ASSEMBLY .............................................................22 Shift Control Components .........................................30 ASSEMBLY .............................................................30 Case Components .....................................................30 ASSEMBLY .............................................................30 SERVICE DATA AND SPECIFICATIONS (SDS) .........33 General Specifications...............................................33 Gear End Play ...........................................................33 Clearance Between Baulk Ring and Gear ................33 2ND AND 3RD BAULK RING ....................................34 Distance Between Rear Surface of Reverse Cone and Reverse Baulk Ring..................................34 Available Snap Ring ..................................................34 MAIN DRIVE GEAR SNAP RING ..............................34 MAINSHAFT FRONT SNAP RING .............................34 COUNTER GEAR REAR SNAP RING .......................35 Available C-ring .........................................................35 MAINSHAFT C-RING ...............................................35 Available Shim and Washer ......................................36 TABLE FOR SELECTING PROPER COUNTER GEAR FRONT BEARING THRUST WASHER ............36 REVERSE IDLER REAR THRUST WASHER .............36 CL AT TF PD AX SU BR ST RS BT HA SC EL IDX PREPARATION Special Service Tools Special Service Tools NAMT0001 The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name Description ST23540000 (J25689-A) Pin punch Removing and installing retaining pin a: 2.3 mm (0.091 in) dia. b: 4 mm (0.16 in) dia. NT442 ST30031000 (J22912-01) Puller Removing 1st & 2nd synchronizer assembly Removing counter gear rear thrust bearing Removing main drive bearing a: 90 mm (3.54 in) dia. b: 50 mm (1.97 in) dia. NT411 ST33230000 ( — Drift Removing mainshaft and counter gear a: 51 mm (2.01 in) dia. b: 28.5 mm (1.122 in) dia. ) NT084 ST22350000 (J25678-01) Drift Removing counter gear front bearing (Use with KV38100300) a: 34 mm (1.34 in) dia. b: 28 mm (1.10 in) dia. NT065 KV38100300 (J25523) Drift Removing counter gear front bearing (Use with ST22350000) Installing counter gear rear bearing a: 54 mm (2.13 in) dia. b: 32 mm (1.26 in) dia. NT065 ST30720000 1 (J34286) 2 (J34331) Drift 1 Removing mainshaft front bearing 2 Installing mainshaft front bearing a: 77 mm (3.03 in) dia. b: 55.5 mm (2.185 in) dia. NT115 ST33210000 1 (J25523) 2 (J25803-01) Drift 1 Installing counter gear front bearing 2 Installing front cover oil seal a: 44 mm (1.73 in) dia. b: 24.5 mm (0.965 in) dia. NT084 ST30613000 (J25742-3) Drift Installing main drive gear bearing a: 72 mm (2.83 in) dia. b: 48 mm (1.89 in) dia. NT073 MT-2 PREPARATION Special Service Tools (Cont’d) Tool number (Kent-Moore No.) Tool name GI Description ST37750000 1 (J34286) 2 (J34332) 3 (J34334) 4 (J25679-01) Drift 1 Removing counter gear rear bearing 2 Installing OD gear bushing 2 Removing and installing mainshaft rear bearing 2 Installing reverse cone 3 Installing reverse counter gear 4 Installing counter gear rear end bearing a: 40 mm (1.57 in) dia. b: 31 mm (1.22 in) dia. NT065 ST22452000 (J34337) Drift MA EM LC EC Installing reverse hub a: 45 mm (1.77 in) dia. b: 36 mm (1.42 in) dia. FE NT065 (J26349-3) Puller leg Installing mainshaft and counter gear (Use with J34328) CL Installing mainshaft and counter gear (Use with J26349-3) AT NT078 (J34328) Puller TF NT079 (J26092) Drift PD Installing sub-gear snap ring a: 44.5 mm (1.752 in) dia. b: 38.5 mm (1.516 in) dia. AX NT065 (J34342) Drift SU Installing OD main gear Installing reverse gear bushing a: 44.5 mm (1.752 in) dia. b: 40.5 mm (1.594 in) dia. BR NT065 ST33220000 (J25804-01) Drift ST Installing mainshaft rear bearing a: 37 mm (1.46 in) dia. b: 22 mm (0.87 in) dia. RS BT NT084 Commercial Service Tool Tool name NAMT0002 HA Description Puller Removing counter gear rear end bearing Removing reverse synchronizer hub Removing reverse counter gear SC EL NT077 IDX MT-3 NAMT0023 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting Chart NVH Troubleshooting Chart NAMT0023S01 Use the chart below to help you find the cause of the problem. The numbers indicate the order of the inspection. If necessary, repair or replace these parts. MANUAL TRANSMISSION MT-13 MT-11 MT-11 MT-11 MT-11 GEAR (Worn or damaged) BEARING (Worn or damaged) BAULK RING (Worn or damaged) INSERT SPRING (Damaged) 1 SHIFT FORK (Worn) 1 MT-13 Hard to shift or will not shift CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged) 1 MT-13 3 O-RING (Worn or damaged) Oil leakage MT-10 2 OIL SEAL (Worn or damaged) 1 MT-10 OIL (Wrong) Noise OIL (Level low) SUSPECTED PARTS (Possible cause) GASKET (Damaged) Reference page OIL (Level too high) Refer to MA-22, “Checking M/T Oil”. NAMT0023S0101 3 3 2 2 2 2 2 Symptom Jumps out of gear 1 MT-4 2 2 ON-VEHICLE SERVICE Position Switch Check Position Switch Check Switch NAMT0024 Gear position Continuity Reverse Yes Except reverse No Neutral Yes Except neutral No GI MA Back-up lamp switch EM PNP switch LC EC FE CL SMT820CA AT TF PD AX SU BR ST RS BT HA SC EL IDX MT-5 NAMT0005 DESCRIPTION Cross-sectional View Cross-sectional View NAMT0005S02 SMT990D MT-6 NAMT0006 REMOVAL AND INSTALLATION Removal Removal NAMT0006S01 CAUTION: When removing the M/T assembly from engine, first remove the crankshaft position sensor (OBD) from the M/T assembly. Be careful not to damage sensor edge. GI MA EM LC EC FE CL AT SMT815CB TF PD AX SU 1. 2. 3. 4. 5. 6. 7. I I 8. a. SMT006E Remove battery negative terminal. Remove shift lever from transmission and control lever from transfer. Remove crankshaft position sensor (OBD) from lower side of transmission case. Remove clutch operating cylinder from transmission. Tighten clutch operating cylinder to the specified torque. Refer to CL-5, “CLUTCH SYSTEM”. Lower the transmission out of the body with the speed sensor and other harnesses still connected. The harnesses are attached to the body in four places. Remove starter motor from transmission. : 41 - 52 N·m (4.2 - 5.3 kg-m, 30 - 38 ft-lb) Remove front and rear propeller shafts. Refer to PD-8, “Removal and Installation”. 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. Remove clutch withdrawal lever and release bearing following the procedures below. Remove the dust cover on the withdrawal lever hole from the transmission case. MT-7 BR ST RS BT HA SC EL IDX REMOVAL AND INSTALLATION Removal (Cont’d) b. Pull out snap pin on the withdrawal shaft, and then pull out withdrawal shaft to remove withdrawal lever and release bearing. 9. Remove exhaust tube mounting bracket from transmission. Refer to FE-9, “EXHAUST SYSTEM”. 10. Support manual transmission with a jack. 11. Remove rear mounting member. Tighten rear mounting member to the specified torque. Refer to EM-61, “Removal and Installation”. 12. Remove bolt securing engine to manual transmission to separate engine from the transmission. 13. Lower manual transmission as much as possible. WARNING: Support Manual Transmission together with transfer, while removing it. Installation 1. 2. I NAMT0006S02 Set withdrawal shaft, washer and snap pin to withdrawal lever and release bearing. Install the manual transmission in reverse order of removal. Apply sealant as below SMT007E MT-8 REMOVAL AND INSTALLATION Installation (Cont’d) GI MA EM LC EC FE CL AT TF PD SMT156EA AX SU I Tighten bolt securing transmission. Bolt No. Tightening torque N·m (kg-m, ft-lb)  mm (in) 1 70 - 79 (7.1 - 8.1, 52 - 58) 65 (2.56) 2 70 - 79 (7.1 - 8.1, 52 - 58) 55 (2.17) 3 29 - 39 (3.0 - 4.0, 22 - 28) 40 (1.57) BR ST RS BT SMT984D HA SC EL IDX MT-9 NAMT0007 OVERHAUL Case Components Case Components NAMT0007S01 SMT159EA MT-10 OVERHAUL Gear Components Gear Components NAMT0007S02 GI MA EM LC EC FE CL AT TF PD AX SU BR ST RS BT HA SC EL SMT049E MT-11 IDX OVERHAUL Gear Components (Cont’d) SMT111EA MT-12 OVERHAUL Shift Control Components Shift Control Components NAMT0007S03 GI MA EM LC EC FE CL AT TF PD AX SU BR ST RS BT HA SC EL SMT160EA MT-13 IDX DISASSEMBLY Case Components Case Components DISASSEMBLY 1. NAMT0008 I Remove check ball plug, check spring and check ball. Then remove interlock stopper. If interlock assembly is removed as a unit, the check ball can fall into transmission case. Be careful not to lose check ball. 2. I Remove control housing, return spring and check ball. Be careful not to lose check ball. 3. Drive out retaining pin from striking arm. 4. Remove OD gear case together with striking arm by tapping lightly. 5. Remove front cover and gasket. I SMT988D SMT438B SMT158E SMT440B SMT370A MT-14 DISASSEMBLY Case Components (Cont’d) 6. Remove stopper ring and main drive bearing snap ring. GI MA EM LC SMT371A 7. EC Remove transmission case by tapping lightly. FE CL SMT372A 8. AT Remove front cover oil seal. TF PD AX SU SMT392A Shift Control Components DISASSEMBLY 1. 2. NAMT0009 Mount adapter plate on vise. Remove OD & reverse fork rod. BR ST RS BT SMT373A 3. 4. Drive out retaining pin from striking lever. While pulling out striking rod, remove striking lever and striking interlock. Then remove 1st & 2nd, 3rd & 4th and reverse shift fork. HA SC EL IDX SMT374A MT-15 DISASSEMBLY Shift Control Components (Cont’d) 5. 6. Drive out retaining pin from OD shift fork. Pull out OD fork rod and then remove OD shift fork. SMT375A Gear Components DISASSEMBLY 1. I NAMT0010 Before removing gears and shafts, measure each gear end play. Gear end play: Refer to SDS, MT-33. If not within specification, disassemble and check contact surface of gear to hub, washer, bushing, needle bearing and shaft. SMT376A 2. a. Remove rear side components on mainshaft and counter gear. Remove reverse coupling sleeve. b. Remove mainshaft rear snap ring and counter gear rear snap ring. Remove C-ring holder and mainshaft C-rings from mainshaft. Use punch and hammer to remove C-rings. SMT463A c. SMT377A d. e. Pull out counter gear rear end bearing. Remove reverse idler gear and reverse idler thrust washers. SMT378A MT-16 DISASSEMBLY Gear Components (Cont’d) f. Pull out reverse main gear together with mainshaft spacer and reverse synchronizer hub. Then remove reverse gear needle bearings. GI MA EM LC SMT380A g. h. Pull out reverse counter gear. Remove OD coupling sleeve together with OD baulk ring, reverse baulk ring and spring inserts. EC FE CL SMT773A i. Pull out reverse gear bushing. AT TF PD AX SU SMT770A j. Pull out OD counter gear together with reverse cone. BR ST RS BT SMT771A 3. Press out mainshaft and counter gear alternately. HA SC EL IDX MT-17 DISASSEMBLY Gear Components (Cont’d) SMT772A 4. a. b. I Remove front side components on mainshaft. Remove 1st gear washer and steel ball. Remove 1st main gear and 1st gear needle bearing. Be careful not to lose steel ball. c. Press out 2nd main gear together with 1st gear bushing and 1st & 2nd synchronizer assembly. Remove mainshaft front snap ring. SMT383A d. SMT482C e. Press out 3rd main gear together with 3rd & 4th synchronizer assembly and 3rd gear needle bearing. SMT385A MT-18 DISASSEMBLY Gear Components (Cont’d) 5. a. Remove front side components on counter gear. Remove counter gear rear thrust bearing. GI MA EM LC SMT404A b. EC Remove sub-gear components. FE CL SMT470A 6. a. b. AT Remove main drive gear bearing. Remove main drive gear snap ring. Press out main drive gear bearing. TF PD AX SU SMT420A 7. Remove bearings from case components. BR ST RS BT HA SC EL SMT206DA IDX MT-19 INSPECTION Shift Control Components Shift Control Components INSPECTION I NAMT0011 Check contact surface and sliding surface for wear, scratches, projections or other damage. SMT398A Gear Components INSPECTION Gears and Shafts I I NAMT0012 NAMT0012S01 Check shafts for cracks, wear or bending. Check gears for excessive wear, chips or cracks. SMT386A SMT423A Synchronizers I I I I NAMT0012S02 Check spline portion of coupling sleeves, hubs, and gears for wear or cracks. Check baulk rings for cracks or deformation. Check shifting inserts for wear or deformation. Check insert springs for deformation. SMT427C I I Measure wear of main drive, 1st and OD baulk rings. Clearance between baulk ring and gear: Refer to SDS, MT-33. If the clearance is smaller than the wear limit, replace baulk ring. SMT140 MT-20 INSPECTION Gear Components (Cont’d) I a) b) SMT041BF I Measure wear of 2nd and 3rd baulk rings. Place baulk rings in position on synchronizer cone. While holding baulk rings against synchronizer cone as far as it will go, measure dimensions “A” and “B”. Standard: A 0.7 - 0.9 mm (0.028 - 0.035 in) B 0.6 - 1.1 mm (0.024 - 0.043 in) Wear limit: 0.2 mm (0.008 in) If dimension “A” or “B” is smaller than the wear limit, replace outer baulk ring, inner baulk ring and synchronizer cone as a set. GI MA EM LC EC FE CL SMT042BC I a) b) c) Measure wear of reverse baulk ring. Place baulk ring in position on reverse cone. While holding baulk ring against reverse cone as far as it will go, measure dimension “A” with dial indicator. Dimension “A”: Standard −0.45 to 1.05 mm (−0.0177 to 0.0413 in) Wear limit 0.7 mm (0.028 in) If dimension “A” is larger than the wear limit, replace baulk ring. AT TF PD AX SU SMT424A Bearings I NAMT0012S03 Make sure bearings roll freely and are free from noise, crack, pitting or wear. BR ST RS BT SMT418A HA SC EL IDX MT-21 ASSEMBLY Gear Components Gear Components ASSEMBLY NAMT0013 SMT207DA 1. 2. a. Install bearings into case components. Install main drive gear bearing. Press main drive gear bearing. b. Select proper main drive gear snap ring to minimize clearance of groove. Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 in) Main drive gear snap ring: Refer to SDS, MT-34. Install selected snap ring on main drive gear. SMT425A c. SMT426A 3. a. I Install components on counter gear. Install sub-gear components. When installing sub-gear snap ring, tap sub-gear snap ring into position on counter gear. SMT577A MT-22 ASSEMBLY Gear Components (Cont’d) b. Install counter gear rear thrust bearing. GI MA EM LC SMT405A 4. a. Install front side components on mainshaft. Assemble 1st & 2nd synchronizer. EC FE CL SMT614B b. Assemble 3rd & 4th synchronizer. AT TF PD AX SU SMT615B c. I Press on 3rd & 4th synchronizer assembly together with 3rd main gear and 3rd gear needle bearing. Pay attention to direction of synchronizer assembly. BR ST RS BT SMT399A d. e. Select proper snap ring to minimize clearance of groove. Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 in) Mainshaft front snap ring: Refer to SDS, MT-34. Install selected snap ring on mainshaft. HA SC EL IDX SMT400A MT-23 ASSEMBLY Gear Components (Cont’d) f. Press on 1st & 2nd synchronizer assembly together with 2nd main gear and 2nd gear needle bearing. g. h. Press on 1st gear bushing using 1st gear washer. Install 1st main gear and needle bearing. i. I Install steel ball and 1st gear washer. Apply multi-purpose grease to steel ball and 1st gear washer before installing. 5. Select proper counter gear front bearing thrust washer when replacing transmission case, counter gear, counter gear rear thrust bearing or sub-gear components. Install counter gear with sub-gear components, counter gear front and rear bearing thrust washer on adapter plate. Remove counter gear front bearing thrust washer from transmission case. Place adapter plate and counter gear assembly in transmission case (case inverted). SMT401A SMT402A SMT403A a. b. c. SMT427AA MT-24 ASSEMBLY Gear Components (Cont’d) d. e. f. g. Tighten adapter plate to transmission case using 2 bolts. Place dial indicator on rear end of counter gear. Move counter gear up and down and measure dial indicator deflection. Select proper thrust washer using table below as a guide. Counter gear end play: 0.10 - 0.25 mm (0.0039 - 0.0098 in) Table for selecting proper counter gear front bearing thrust washer: Refer to SDS, MT-36. GI MA EM LC EC FE CL SMT578A 6. a. I Select proper reverse idler rear thrust washer when replacing OD gear case, reverse idler gear (with sub-gear components), reverse idler shaft. Install reverse idler gear (with sub-gear components), reverse idler needle bearings and reverse idler shaft into OD gear case. When replacing reverse idler rear thrust washer, install either A or B. Reverse idler rear thrust washer: Refer to SDS, MT-36. AT TF PD AX SU BR ST RS BT SMT112E HA SC EL IDX MT-25 ASSEMBLY Gear Components (Cont’d) b. c. d. e. Place dial indicator on front end of reverse idler shaft. Put straightedge on front surface of rear extension (or OD gear case) as a stopper of reverse idler shaft. Move reverse idler shaft up and down and measure reverse idler gear end play. Reverse idler gear end play: 0.30 - 0.53 mm (0.0118 - 0.0209 in) If not within specification, replace reverse idler rear thrust washer with the other (A or B) and check again. SMT433A 7. a. Install mainshaft and counter gear on adapter plate and main drive gear on mainshaft. Mount adapter plate on vise and apply multi-purpose grease to counter gear rear bearing. SMT438A b. I Install mainshaft a little on mainshaft front bearing. To allow for installation of counter gear, do not install mainshaft completely. c. Install counter gear on counter gear rear bearing and install main drive gear, pilot bearing and spacer on mainshaft. SMT440A SMT441A MT-26 ASSEMBLY Gear Components (Cont’d) I When installing counter gear into counter gear rear bearing, push up on upper roller of counter gear rear bearing with screwdriver. GI MA EM LC SMT442A d. e. Install Tools (J26349-3) onto adapter plate and C-ring and C-ring holder on mainshaft. Install Tool (J34328) on mainshaft. EC FE CL SMT064C f. Install mainshaft and counter gear completely by extending length of (J26349-3). AT TF PD AX SU SMT579A 8. a. Install rear side components on mainshaft and counter gear. Install OD gear bushing while pushing on the front of counter gear. BR ST RS BT SMT444A b. I c. d. Install OD main gear. Pay attention to direction of OD main gear. (B is wider than A as shown at left.) Install adapter plate with gear assembly onto transmission case. Install OD gear needle bearing and then install OD counter gear and reverse idler shaft. HA SC EL IDX SMT580AA MT-27 ASSEMBLY Gear Components (Cont’d) e. Install reverse cone. f. Install insert springs and reverse baulk ring on OD coupling sleeve. Then install them and OD baulk ring on OD counter gear. Pay attention to direction of OD coupling sleeve. SMT582A I SMT571AA SMT583A g. h. Install reverse counter gear. Install reverse gear needle bearing and then install reverse main gear, reverse idler gear and reverse idler thrust washers. i. I Install reverse hub. Pay attention to its direction. SMT584A SMT585A MT-28 ASSEMBLY Gear Components (Cont’d) j. k. Install counter gear rear end bearing. Separate adapter plate from transmission case and mount adapter plate on vice again. GI MA EM LC SMT485C l. Select proper mainshaft C-ring to minimize clearance of groove. Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 in) Mainshaft C-ring: Refer to SDS, MT-35. SMT452A m. Install selected C-ring, C-ring holder and mainshaft rear snap ring. EC FE CL AT TF PD AX SU SMT454A n. o. Select proper counter gear rear snap ring to minimize clearance of groove. Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 in) Counter gear rear snap ring: Refer to SDS, MT-35. Install selected counter gear rear snap ring. BR ST RS BT SMT453A HA SC EL IDX SMT455A MT-29 ASSEMBLY Gear Components (Cont’d) p. I q. Install reverse coupling sleeve. Pay attention to its direction. Measure each gear end play as a final check. Refer to “DISASSEMBLY”, MT-16. SMT456A Shift Control Components ASSEMBLY 1. 2. NAMT0014 Install OD fork rod and OD shift fork. Then install retaining pin into OD shift fork. Install 1st & 2nd, 3rd & 4th and reverse shift fork onto coupling sleeve. SMT457A 3. I Install striking rod into hole of shift forks, striking lever and interlock and then install retaining pin into striking lever. Make sure that striking rod moves smoothly. SMT374A Case Components ASSEMBLY 1. I 2. NAMT0015 I 3. Install front cover oil seal. Apply multi-purpose grease to seal lip. Install selected counter gear front bearing shim onto transmission case. Apply multi-purpose grease. Apply sealant to mating surface of transmission case. 4. 5. I Install gear assembly onto transmission case. Install check spring and check ball into interlock stopper. Apply multi-purpose grease to check ball. SMT393A SMT588A MT-30 ASSEMBLY Case Components (Cont’d) 6. I Install interlock stopper assembly and then tighten check ball plug. Apply genuine thread sealant to thread of check ball plug. Refer to Shift Control Components, MT-13. GI MA EM LC SMT109E 7. Install stopper ring and main drive bearing snap ring. EC FE CL SMT371A 8. I 9. Install front cover and gasket. Apply genuine thread sealant to thread of 3 bolts shown left. Refer to Case Components, MT-10. Apply sealant to mating surface of adapter plate. AT TF PD AX SU SMT110E 10. Install OD gear case together with striking arm. BR ST RS BT SMT444B 11. Install retaining pin into striking arm. HA SC EL IDX SMT439B MT-31 ASSEMBLY Case Components (Cont’d) 12. Install return spring and check ball and then install control housing. I Apply sealant to mating surface of OD gear case. Refer to Case Components, MT-10. SMT445B 13. Tighten control housing bolts. Bolt head size: A bolts 12 mm (0.47 in) B bolts 13 mm (0.51 in) SMT446BA MT-32 SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications General Specifications Applied model NAMT0016 GI VQ35DE MA 4WD Transmission FS5R30A Model code number EM 4W120 Number of speed 5 LC EC Shift pattern MT-SDS-2 Synchromesh type FE Warner Number of teeth CL Gear ratio Mainshaft Countershaft — 22 32 1st 3.580 32 13 2nd 2.077 30 21 3rd 1.360 29 31 4th 1.000 — — OD 0.811 24 43 Reverse 3.636 30 12 Drive Reverse idler gear TF PD 22 Oil capacity  (US pt, Imp pt)* Remarks AT 5.1 (10-3/4, 9) AX 2nd & 3rd double baulk ring type synchronizer *: Refer to MA-12, “Fluids and Lubricants”. SU Gear End Play NAMT0017 Unit: mm (in) Gear End play 1st main gear 0.23 - 0.33 (0.0091 - 0.0130) 2nd main gear 0.23 - 0.33 (0.0091 - 0.0130) 3rd main gear 0.06 - 0.16 (0.0024 - 0.0063) OD counter gear 0.23 - 0.33 (0.0091 - 0.0130) Reverse main gear 0.33 - 0.43 (0.0130 - 0.0169) Counter gear 0.10 - 0.25 (0.0039 - 0.0098) Reverse idler gear 0.30 - 0.53 (0.0118 - 0.0209) ST RS BT HA Clearance Between Baulk Ring and Gear NAMT0018 Unit: mm (in) Standard 1st 1.05 - 1.3 (0.0413 - 0.0512) Main drive 1.05 - 1.3 (0.0413 - 0.0512) OD 1.05 - 1.3 (0.0413 - 0.0512) MT-33 BR SC Wear limit EL 0.7 (0.028) IDX SERVICE DATA AND SPECIFICATIONS (SDS) Clearance Between Baulk Ring and Gear (Cont’d) 2ND AND 3RD BAULK RING NAMT0018S01 Unit: mm (in) SMT742C Dimension Standard Wear limit A 0.7 - 0.9 (0.028 - 0.035) B 0.6 - 1.1 (0.024 - 0.043) 0.2 (0.008) Distance Between Rear Surface of Reverse Cone and Reverse Baulk Ring NAMT0019 Unit: mm (in) SMT428C Dimension “A” Standard Wear limit 0.3 to 0.75 (0.012 to 0.0295) 1.1 (0.043) Available Snap Ring NAMT0020 MAIN DRIVE GEAR SNAP RING NAMT0020S01 Unit: mm (in) Allowable clearance 0 - 0.1 (0 - 0.004) Thickness Part number* Thickness Part number* 1.89 (0.0744) 32204-01G60 2.03 (0.0799) 32204-01G63 1.95 (0.0768) 32204-01G61 2.07 (0.0815) 32204-01G64 1.99 (0.0783) 32204-01G62 2.11 (0.0831) 32204-01G65 *: Always check with the Parts Department for the latest parts information. MAINSHAFT FRONT SNAP RING NAMT0020S02 Unit: mm (in) Allowable clearance 0 - 0.1 (0 - 0.004) Thickness Part number* Thickness Part number* 1.99 (0.0783) 32204-01G62 2.11 (0.0831) 32204-01G65 2.03 (0.0799) 32204-01G63 2.15 (0.0846) 32204-01G66 2.07 (0.0815) 32204-01G64 2.19 (0.0862) 32204-01G67 *: Always check with the Parts Department for the latest parts information. MT-34 SERVICE DATA AND SPECIFICATIONS (SDS) Available Snap Ring (Cont’d) COUNTER GEAR REAR SNAP RING NAMT0020S03 GI Unit: mm (in) Allowable clearance 0 - 0.11 (0 - 0.0043) MA Thickness Part number* Thickness Part number* 1.32 (0.0520) 32236-01G00 1.56 (0.0614) 32236-01G04 1.38 (0.0543) 32236-01G01 1.62 (0.0638) 32236-01G05 1.44 (0.0567) 32236-01G02 1.68 (0.0661) 32236-01G06 1.50 (0.0591) 32236-01G03 1.74 (0.0685) 32236-01G07 EM LC *: Always check with the Parts Department for the latest parts information. EC Available C-ring NAMT0021 MAINSHAFT C-RING NAMT0021S01 Unit: mm (in) Allowable clearance 0 - 0.1 (0 - 0.004) CL Thickness Part number* Thickness Part number* 2.63 (0.1035) 32348-01G15 3.19 (0.1256) 32348-01G07 2.70 (0.1063) 32348-01G00 3.26 (0.1283) 32348-01G08 2.77 (0.1091) 32348-01G01 3.33 (0.1311) 32348-01G09 2.84 (0.1118) 32348-01G02 3.40 (0.1339) 32348-01G10 2.91 (0.1146) 32348-01G03 3.47 (0.1366) 32348-01G11 2.98 (0.1173) 32348-01G04 3.54 (0.1394) 32348-01G12 3.05 (0.1201) 32348-01G05 3.61 (0.1421) 32348-01G13 3.12 (0.1228) 32348-01G06 3.68 (0.1449) 32348-01G14 *: Always check with the Parts Department for the latest parts information. FE AT TF PD AX SU BR ST RS BT HA SC EL IDX MT-35 SERVICE DATA AND SPECIFICATIONS (SDS) Available Shim and Washer Available Shim and Washer =NAMT0022 TABLE FOR SELECTING PROPER COUNTER GEAR FRONT BEARING THRUST WASHER NAMT0022S01 Unit: mm (in) Dial indicator deflection Thickness of proper washer Part number* 0.93 - 1.02 (0.0366 - 0.0402) 0.80 (0.0315) 32218-01G00 1.01 - 1.10 (0.0398 - 0.0433) 0.88 (0.0346) 32218-01G11 1.09 - 1.18 (0.0429 - 0.0465) 0.96 (0.0378) 32218-01G12 1.17 - 1.26 (0.0461 - 0.0496) 1.04 (0.0409) 32218-01G13 1.25 - 1.34 (0.0492 - 0.0528) 1.12 (0.0441) 32218-01G14 1.33 - 1.42 (0.0524 - 0.0559) 1.20 (0.0472) 32218-01G04 1.41 - 1.50 (0.0555 - 0.0591) 1.28 (0.0504) 32218-01G15 1.49 - 1.58 (0.0587 - 0.0622) 1.36 (0.0535) 32218-01G16 1.57 - 1.66 (0.0618 - 0.0654) 1.44 (0.0567) 32218-01G17 *: Always check with the Parts Department for the latest parts information. REVERSE IDLER REAR THRUST WASHER NAMT0022S02 Unit: mm (in) Thickness Part number* A 1.97 (0.0776) 32284-01G10 B 2.07 (0.0815) 32284-01G11 *: Always check with the Parts Department for the latest parts information. MT-36 RESTRAINT SYSTEM SECTION RS GI MA EM LC EC FE CONTENTS SEAT BELTS ...................................................................3 Precautions ..................................................................3 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ″AIR BAG″ AND ″SEAT BELT PRE-TENSIONER″ ........3 PRECAUTION FOR SEAT BELT SERVICE ..................3 Front Seat Belt.............................................................5 REMOVAL AND INSTALLATION .................................5 Rear Seat Belt .............................................................6 REMOVAL AND INSTALLATION .................................6 Seat Belt Inspection.....................................................8 AFTER A COLLISION .................................................8 PRELIMINARY CHECKS ............................................8 SEAT BELT RETRACTOR ON-VEHICLE CHECK .........9 SEAT BELT RETRACTOR OFF-VEHICLE CHECK .......9 Tether Anchor Plate ...................................................10 REMOVAL AND INSTALLATION ...............................10 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) .........11 Precautions ................................................................11 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ″AIR BAG″ AND ″SEAT BELT PRE-TENSIONER″ ......11 PRECAUTIONS FOR SRS ″AIR BAG″ AND ″SEAT BELT PRE-TENSIONER″ SERVICE...........................11 WIRING DIAGRAMS AND TROUBLE DIAGNOSIS .....11 Preparation ................................................................12 SPECIAL SERVICE TOOLS ......................................12 COMMERCIAL SERVICE TOOL ................................13 Description .................................................................14 Seat Belt Pre-tensioner with Load Limiter.................15 Side Air Bag...............................................................15 Side Curtain Air Bag ..................................................15 SRS Component Parts Location ...............................16 Diagnosis Sensor Unit ...............................................16 REMOVAL AND INSTALLATION ...............................16 Seat Belt Pre-tensioner .............................................17 REMOVAL AND INSTALLATION ...............................17 Satellite Sensor..........................................................17 REMOVAL AND INSTALLATION ...............................17 Driver Air Bag Module and Spiral Cable ...................18 REMOVAL AND INSTALLATION ...............................18 REMOVAL ...............................................................18 INSTALLATION........................................................20 Front Passenger Air Bag Module ..............................20 REMOVAL ...............................................................20 INSTALLATION........................................................22 Side Air Bag Module..................................................22 REMOVAL ...............................................................22 INSTALLATION........................................................23 Side Curtain Air Bag Module .....................................24 REMOVAL AND INSTALLATION ...............................24 Disposal of Air Bag Module and Seat Belt Pretensioner ....................................................................25 CHECKING DEPLOYMENT TOOL .............................26 DEPLOYMENT PROCEDURES FOR AIR BAG MODULE (OUTSIDE OF VEHICLE) ...........................26 DEPLOYMENT PROCEDURES FOR SIDE CURTAIN AIR BAG MODULE (OUTSIDE OF VEHICLE)................................................................29 DEPLOYMENT PROCEDURES FOR SEAT BELT PRE-TENSIONER (OUTSIDE OF VEHICLE) ..............30 DEPLOYMENT OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER WHILE MOUNTED IN VEHICLE .................................................................31 DISPOSING OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER ...........................................31 Trouble Diagnoses Introduction.................................32 DIAGNOSIS FUNCTION ...........................................32 DIAGNOSIS MODE FOR CONSULT-II .......................32 HOW TO CHANGE SELF-DIAGNOSIS MODE WITH CONSULT-II ...................................................33 HOW TO CHANGE SELF-DIAGNOSIS MODE WITHOUT CONSULT-II ............................................33 HOW TO ERASE SELF-DIAGNOSIS RESULTS .........33 How to Perform Trouble Diagnoses for Quick and Accurate Repair ..................................................35 INFORMATION FROM CUSTOMER ..........................35 PRELIMINARY CHECK ............................................35 WORK FLOW ..........................................................36 Schematic ..................................................................37 Wiring Diagram - SRS -.............................................38 SRS Operation Check ...............................................41 DIAGNOSTIC PROCEDURE 1 ..................................41 CL MT AT TF PD AX SU BR ST BT HA SC EL IDX CONTENTS Trouble Diagnoses with CONSULT-II...................42 DIAGNOSTIC PROCEDURE 2 ..................................42 DIAGNOSTIC PROCEDURE 3 ..................................46 DIAGNOSTIC PROCEDURE 4 (CONTINUED FROM DIAGNOSTIC PROCEDURE 2) ......................47 DIAGNOSTIC PROCEDURE 5 ..................................48 Trouble Diagnoses without CONSULT-II..............52 DIAGNOSTIC PROCEDURE 6 ..................................52 DIAGNOSTIC PROCEDURE 7 ..................................58 DIAGNOSTIC PROCEDURE 8 (CONTINUED FROM DIAGNOSTIC PROCEDURE 6) ......................59 RS-2 (Cont’d) Trouble Diagnoses: ″AIR BAG″ Warning Lamp Does Not Turn Off .....................................................60 DIAGNOSTIC PROCEDURE 9 ..................................60 Trouble Diagnoses: ″AIR BAG″ Warning Lamp Does Not Turn On .....................................................62 DIAGNOSTIC PROCEDURE 10 ................................62 Collision Diagnosis ....................................................63 FOR FRONTAL COLLISION .....................................63 FOR SIDE COLLISION .............................................65 SEAT BELTS Precautions Precautions SUPPLEMENTAL RESTRAINT SYSTEM (SRS) “AIR BAG” AND “SEAT BELT PRE-TENSIONER” GI NARS0001 The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS composition which is available to NISSAN MODEL R50 is as follows: I For a frontal collision The Supplemental Restraint System consists of driver air bag module (located in the center of the steering wheel), front passenger air bag module (located on the instrument panel on passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. I For a side collision The Supplemental Restraint System consists of side air bag module (located in the outer side of front seat), side curtain air bag module (locating in the headlining side of front and rear seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision). WARNING: I 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. I Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connector (and by yellow harness protector or yellow insulation tape before the harness connectors). PRECAUTION FOR SEAT BELT SERVICE NARS0002 CAUTION: I Before removing the seat belt pre-tensioner assembly, turn the ignition switch off, disconnect both battery cables and wait at least 3 minutes. I Do not use electrical test equipment for seat belt pre-tensioner connector. I After replacing or reinstalling seat belt pre-tensioner assembly, or reconnecting seat belt pre-tensioner connector, check the system function. Refer to “SRS Operation Check” (RS-41) for details. I Do not use disassemble buckle or seat belt assembly. I Replace anchor bolts if they are deformed or worn out. I Never oil tongue and buckle. I If any component of seat belt assembly is questionable, do not repair. Replace the whole seat belt assembly. I If webbing is cut, frayed, or damaged, replace seat belt assembly. I When replacing seat belt assembly, use a genuine seat belt assembly. After A Collision MA EM LC EC FE CL MT AT TF PD AX SU BR ST NARS0002S01 WARNING: Inspect all seat belt assemblies including retractors and attaching hardware after any collision. NISSAN recommends that all seat belt assemblies in use during a collision be replaced unless the collision was minor and the belts show no damage and continue to operate properly. Failure to do so could result in serious personal injury in an accident. Seat belt assemblies not in use during a collision should also be replaced if either damage or improper operation is noted. Seat belt pre-tensioner should be replaced even if the seat belts are not in use during a frontal collision in which the air bags are deployed. Replace any seat belt assembly (including anchor bolts) if: I The seat belt was in use at the time of a collision (except for minor collisions and the belts, retractors and buckles show no damage and continue to operate properly). I The seat belt was damaged in an accident. (i.e. torn webbing, bent retractor or guide, etc.) I The seat belt attaching point was damaged in an accident. Inspect the seat belt attaching area for damage or distortion and repair as necessary before installing a new seat belt assembly. I Anchor bolts are deformed or worn out. I The seat belt pre-tensioner should be replaced even if the seat belts are not in use during the collision in RS-3 BT HA SC EL IDX SEAT BELTS Precautions (Cont’d) which the air bags are deployed. RS-4 SEAT BELTS Front Seat Belt Front Seat Belt REMOVAL AND INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. GI =NARS0003 Slide the seat all the way forward and tilt the seatback toward the front. Remove adjuster cover. Remove floor anchor bolt. Remove shoulder anchor bolt. Remove center pillar upper and lower garnish. Refer to BT-29, “SIDE AND FLOOR TRIM” for details. Disconnect seat belt pre-tensioner connector. Remove the bolt securing seat belt retractor, then remove seat belt and seat belt retractor. Remove bolts securing seat belt adjuster, then remove seat belt adjuster. MA EM LC EC FE CL MT AT TF PD AX SU BR ST BT HA SC SRS873-A EL IDX RS-5 SEAT BELTS Rear Seat Belt Rear Seat Belt REMOVAL AND INSTALLATION =NARS0004 1. 2. 3. 4. 5. Raise up rear seat cushion. Remove outer anchor bolt. Remove rear side upper and lower garnish. Refer to BT-29, “SIDE AND FLOOR TRIM” for details. Remove anchor through-bolt. Remove anchor bolt and bolt securing rear seat belt retractor, then remove seat belt and seat belt retractor. 6. Remove each anchor bolt. SRS654-A RS-6 SEAT BELTS Rear Seat Belt (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST BT HA SRS781-C SC EL IDX RS-7 SEAT BELTS Seat Belt Inspection Seat Belt Inspection AFTER A COLLISION =NARS0029 NARS0029S01 WARNING: Inspect all seat belt assemblies including retractors and attaching hardware after any collision. NISSAN recommends that all seat belt assemblies in use during a collision be replaced unless the collision was minor and the belts show no damage and continue to operate properly. Failure to do so could result in serious personal injury in an accident. Seat belt assemblies not in use during a collision should also be replaced if either damage or improper operation is noted. Seat belt pre-tensioner should be replaced even if the seat belts are not in use during a frontal collision in which the air bags are deployed. Replace any seat belt assembly (including anchor bolts) if: I The seat belt was in use at the time of a collision (except for minor collisions and the belts, retractors and buckles show no damage and continue to operate properly). I The seat belt was damaged in an accident. (i.e. torn webbing, bent retractor or guide, etc.) I The seat belt attaching point was damaged in an accident. Inspect the seat belt attaching area for damage or distortion and repair as necessary before installing a new seat belt assembly. I Anchor bolts are deformed or worn out. I The seat belt pre-tensioner should be replaced even if the seat belts are not in use during the collision in which the air bags are deployed. PRELIMINARY CHECKS NARS0029S02 1. Check the seat belt warning lamp/chime for proper operation as follows: a. Switch ignition ON. The seat belt warning lamp should illuminate. Also, the seat belt warning chime should sound for about seven seconds. b. Fasten driver’s seat belt. The seat belt warning lamp should go out and the chime (if sounding) should stop. 2. If the air bag warning lamp is blinking, conduct self-diagnosis using CONSULT-II, and air bag warning lamp. Refer to “SRS Operation Check”, RS-41. 3. Check that the seat belt retractor, seat belt anchor and buckle bolts are securely attached. 4. Check the shoulder seat belt guide and shoulder belt height adjuster for front seats. Ensure guide swivels freely and that belt lays flat and does not bind in guide. Ensure height adjuster operates properly and holds securely. 5. Check retractor operation: a. Fully extend the seat belt webbing and check for twists, tears or other damage. b. Allow the seat belt to retract. Ensure that belt returns smoothly and completely into the retractor. If the seat belt does not returns smoothly, the cause may be an accumulation of dust or dirt. Use the “SEAT BELT TAPE SET” and perform the following steps. Inspect the front seat belt through-anchor. i. Pull the seat belt out to a length of 500 mm (19.69 in) or more. ii. Use a clip or other device to fix the seat belt at the center pillar belt opening. iii. Pass a thin wire through the through-anchor belt opening. Hold both ends of the wire and pull taut while moving it up and down several times along the belt opening surface to move matter stuck there. iv. Any dirt that cannot be removed with the wire can be removed by cleaning the opening with a clean cloth. v. Apply tape at the point where the belt contacts the through-anchor belt opening. NOTE: Apply the tape so that there is no looseness or wrinkling. vi. Remove the clip fixing the seat belt and check that the belt returns smoothly. c. Fasten the seat belt. Pull firmly on belt and buckle to ensure belt remains latched. Unfasten seat belt. Ensure belt releases freely and buckle button returns to original position. 6. For center (non-retractable) seat belts, check that the seat belt are accessible. Check seat belt webbing for twists, tears or other damage. Fasten the seat belt. Pull firmly on belt and buckle to ensure belt remains latched. Unfasten seat belts. Ensure belt releases freely and buckle button returns to original position. 7. Repeat steps above as necessary to check the other seat belts. RS-8 SEAT BELTS Seat Belt Inspection (Cont’d) SEAT BELT RETRACTOR ON-VEHICLE CHECK Emergency Locking Retractors (ELR) and Automatic Locking Retractors (ALR) NARS0029S03 NARS0029S0301 NOTE: All seat belt retractors are of the Emergency Locking Retractors (ELR) type. In an emergency (sudden stop) the retractor will lock and prevent the belt from extending any further. All 3-point type seat belt retractors except the driver’s seat belt also have an Automatic Locking Retractors (ALR) mode. The ALR mode (also called child restraint mode) is used when installing child seats. The ALR mode is activated when the seat belt is fully extended. When the belt is then retracted partially, the ALR mode automatically locks the seat belt in a specific position so the belt cannot be extended any further. To cancel the ALR mode, allow the seat belt to fully wind back into the retractor. Check the seat belt retractors using the following test(s) to determine if a retractor assembly is operating properly. ELR Function Stationary Check GI MA EM LC EC NARS0029S0302 Grasp the shoulder belt and pull forward quickly. The retractor should lock and prevent the belt from extending further. ALR Function Stationary Check NARS0029S0304 1. Pull out entire length of seat belt from retractor until a click is heard. 2. Retract the belt partially. A clicking noise should be heard as the belt retracts indicating that the retractor is in the Automatic Locking Retractors (ALR) mode. 3. Grasp the seat belt and try to pull out the retractor. The belt must lock and not extend any further. If NG, replace the retractor assembly. 4. Allow the entire length of the belt to retract to cancel the automatic locking mode. ELR Function Moving Check NARS0029S0303 FE CL MT AT WARNING: Perform the following test in a safe, open area clear of other vehicles and obstructions (for example, a large, empty parking lot). Road surface must be paved and dry. DO NOT perform the following test on wet or gravel roads or on public streets and highways. This could result in an accident and serious personal injury. The driver and passenger must be prepared to brace themselves in the event the retractor does not lock. 1. Fasten driver’s seat belt. Buckle a passenger into the seat for the belt that is to be tested. 2. Proceed to the designated safe area. 3. Drive the vehicle at approximately 16 km/h (10 MPH). Notify any passengers of a pending sudden stop and the driver and passenger must be prepared to brace themselves in the event the retractor does not lock, apply brakes firmly and make a very hard stop. During stop, seat belts should lock and not be extended. If the seat belt retractor assembly does not lock, perform the retractor off-vehicle check. TF SEAT BELT RETRACTOR OFF-VEHICLE CHECK ST NARS0029S04 1. Remove the seat belt retractor assembly. 2. Slowly pull out belt while tilting the retractor assembly forward from the mounted position without twisting the retractor assembly as shown in the illustration. 15 degrees or less tilt: Belt can be pulled out. 35 degrees or more tilt: Belt locks and cannot be pulled out. PD AX SU BR BT HA SC EL IDX RS-9 SEAT BELTS Seat Belt Inspection (Cont’d) SRS361 If NG, replace the retractor assembly. Tether Anchor Plate REMOVAL AND INSTALLATION CAUTION: Replace anchor bolt if they are deformed or worn out. SRS916 RS-10 NARS0050 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Precautions Precautions SUPPLEMENTAL RESTRAINT SYSTEM (SRS) “AIR BAG” AND “SEAT BELT PRE-TENSIONER” GI NARS0005 The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS composition which is available to NISSAN MODEL R50 is as follows: I For a frontal collision The Supplemental Restraint System consists of driver air bag module (located in the center of the steering wheel), front passenger air bag module (located on the instrument panel on passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. I For a side collision The Supplemental Restraint System consists of side air bag module (located in the outer side of front seat), side curtain air bag module (locating in the headlining side of front and rear seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision). WARNING: I 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. I Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connector (and by yellow harness protector or yellow insulation tape before the harness connectors). PRECAUTIONS FOR SRS “AIR BAG” AND “SEAT BELT PRE-TENSIONER” SERVICE I I I I I I I NARS0006 Do not use electrical test equipment to check SRS circuits unless instructed to in this Service Manual. 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 and seat belt pre-tensioner to deploy. Therefore, do not work on any SRS connectors or wires until at least 3 minutes have passed. Diagnosis sensor unit must always be installed with their arrow marks “g” pointing towards the front of the vehicle for proper operation. Also check diagnosis sensor unit for cracks, deformities or rust before installation and replace as required. 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 driver and passenger air bag modules with the pad side facing upward and side air bag module standing with the stud bolt side setting bottom. Conduct self-diagnosis to check entire SRS for proper function after replacing any components. After air bag inflates, the front instrument panel assembly should be replaced if damaged. WIRING DIAGRAMS AND TROUBLE DIAGNOSIS When you read wiring diagrams, refer to the following: I GI-11, “HOW TO READ WIRING DIAGRAMS” I EL-11, “POWER SUPPLY ROUTING” for power distribution circuit When you perform trouble diagnosis, refer to the following: I GI-35, “HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES” I GI-24, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT” MA EM LC EC FE CL MT AT TF PD AX SU BR ST NARS0007 BT HA SC EL IDX RS-11 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Preparation Preparation SPECIAL SERVICE TOOLS =NARS0008 The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name Description KV99106400 (J38381) Deployment tool Disposing of air bag module NT357 KV99105300 (J41246) Air bag module bracket Anchoring air bag module NT354 HT61961000 and HT62152000 combined (J38219) *Special torx bit Use for special bolts [TAMPER RESISTANT TORX (Size T50)] a: 3.5 (0.138) dia. b: 8.5 - 8.6 (0.335 - 0.339) dia. c: approx. 10 (0.39) sq. Unit: mm (in) NT361 KV99109000 (J44230) Deployment tool adapter for side air bags NT837 (J38381-80) Deployment tool adapter for seat belt pre-tensioner (Yellow connector) and side curtain air bag (Yellow and orange connectors) PHIA0184E RS-12 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Preparation (Cont’d) GI Tool number (Kent-Moore No.) Tool name Description (J-44615) Air bag master key set Removing and installing accessory air bag locking bolts MA EM LC EC FE LRS194 CL *: Special tool or commercial equivalent COMMERCIAL SERVICE TOOL Tool name NARS0051 MT Description Tamper resistant torx socket Size: T30 AT TF PD NT757 AX SU BR ST BT HA SC EL IDX RS-13 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Description Description =NARS0009 SRS018A The air bag deploys if the diagnosis sensor unit activates while the ignition switch is in the “ON” or “START” position. The collision modes for which supplemental restraint systems are activated are different among the SRS systems. For example, the driver air bag module and passenger air bag module are activated in a frontal collision but not in a side collision. SRS configurations which are activated for some collision modes are as follows; SRS configuration Frontal collision Left side collision Right side collision Driver air bag module X — — Passenger air bag module X — — Front LH seat belt pre-tensioner X — — Front RH seat belt pre-tensioner X — — Front LH side air bag module (LH) — X — Front RH side air bag module (RH) — — X LH side curtain air bag module — X — RH side curtain air bag module — — X RS-14 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Seat Belt Pre-tensioner with Load Limiter Seat Belt Pre-tensioner with Load Limiter SRS444 NARS0032 The seat belt pre-tensioner system with load limiter is installed to both the driver’s seat and the front passenger’s seat. It operates simultaneously with the SRS air bag system in the event of a frontal collision with an impact exceeding a specified level. When the frontal collision with an impact exceeding a specified level occurs, seat belt slack resulting from clothing or other factors is immediately taken up by the pre-tensioner. Vehicle passengers are securely restrained. When passengers in a vehicle are thrown forward in a collision and the restraining force of the seat belt exceeds a specified level, the load limiter permits the specified extension of the seat belt by the twisting of the ELR shaft, and a relaxation of the chest-area seat belt web tension while maintaining force. GI MA EM LC EC FE CL MT Side Air Bag AT NARS0033 Front side air bag is built-in type. The front seatbacks with built-in type side air bag have the labels shown in figures at left. TF PD AX SU SRS560-B Side Curtain Air Bag NARS0053 The side curtain air bag have the labels shown in figure at left. BR ST BT BF-2006D HA SC EL IDX RS-15 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) SRS Component Parts Location SRS Component Parts Location NARS0010 SRS019A Diagnosis Sensor Unit REMOVAL AND INSTALLATION NARS0012 CAUTION: I Before servicing SRS, turn the ignition switch off, disconnect both battery cables and wait for at least 3 minutes. I Do not use old bolts after removal; replace with new ones. I Check diagnosis sensor unit for proper installation. I Check diagnosis sensor unit to ensure it is free of deformities, dents, cracks or rust. If they show any visible signs of damage, replace them with new ones. I Check diagnosis sensor unit brackets to ensure they are free of deformities or rust. I Replace diagnosis sensor unit if it has been dropped or sustained an impact. I After replacement of diagnosis sensor unit, perform selfdiagnosis for SRS. Refer to “SRS Operation Check” for details (RS-41). RS-16 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Diagnosis Sensor Unit (Cont’d) 1. SRS636-A Disconnect connectors for driver and passenger air bag modules and seat belt pre-tensioner. 2. Remove console box. Refer to BT-22, “INSTRUMENT PANEL ASSEMBLY”. 3. Disconnect diagnosis sensor unit connector. 4. Remove ground bolt and diagnostic sensor unit fixing bolts. Use TAMPER RESISTANT TORX (Size T50) to remove special bolts. Then remove the diagnosis sensor unit. NOTE: I To install, reverse the removal procedure sequence. GI Seat Belt Pre-tensioner EC REMOVAL AND INSTALLATION NARS0034 CAUTION: I Before servicing SRS, turn the ignition switch off, disconnect both battery cables and wait at least 3 minutes. I Check seat belt pre-tensioner with load limiter for proper installation. I After replacement of seat belt pre-tensioner, check SRS function and perform self-diagnosis for SRS. Refer to “SRS Operation Check” for details. (RS-41) I Do not attempt to disassemble seat belt pre-tensioner with load limiter. I Replace seat belt pre-tensioner if it has been dropped or sustained an impact. I Do not expose seat belt pre-tensioner to temperatures exceeding 80°C (176°F). For removal of seat belt pre-tensioner, refer to “Front Seat Belt” for details. (RS-5) NOTE: I To install, reverse the removal procedure sequence. MA EM LC FE CL MT AT TF PD AX SU Satellite Sensor REMOVAL AND INSTALLATION NARS0035 CAUTION: I Before servicing SRS, turn the ignition switch off, disconnect both battery cables and wait at least 3 minutes. I Do not use old bolts coated with bonding agent after removal; replace with new ones. I Check satellite sensor for proper installation. I Check satellite sensor to ensure they are free of deformities, dents, cracks or rust. If it shows any visible signs of damage, replace it with new one. I After replacement of satellite sensor, check SRS function and perform self-diagnosis for SRS. Refer to “SRS Operation Check” for details. (RS-41) I Do not attempt to disassemble satellite sensor. I Replace satellite sensor if it has been dropped or sustained an impact. BR ST BT HA SC EL IDX RS-17 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Satellite Sensor (Cont’d) 1. Remove seat belt pre-tensioner. Refer to “Front Seat Belt” for details. (RS-5) 2. Disconnect satellite sensor connector. 3. Remove satellite sensor fixing nuts. Then remove the satellite sensor. NOTE: I To install, reverse the removal procedure sequence. SRS979 Driver Air Bag Module and Spiral Cable REMOVAL AND INSTALLATION NARS0013 SRS020A REMOVAL NARS0014 CAUTION: I Before servicing SRS, turn the ignition switch off, disconnect both battery cables and wait at least 3 minutes. I Always work from the side of air bag module. 1. Remove lower lid from steering wheel, and disconnect air bag module connector. SRS566 2. 3. Remove audio and ASCD steering switches. Using the TAMPER RESISTANT TORX (Size T30), remove left and right special bolts. Remove air bag module, and then disconnect horn connector. SRS021A RS-18 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Driver Air Bag Module and Spiral Cable (Cont’d) CAUTION: I Always place air bag module with pad side facing upward. I Do not attempt to disassemble air bag module. I The special bolts are coated with bonding agent. Do not use old bolts after removal; replace with new ones. I Do not insert any foreign objects (screwdriver, etc.) into air bag module connector. GI MA EM LC SRS443 I I I Replace air bag module if it has been dropped or sustained an impact. Do not expose the air bag module to temperatures exceeding 90°C (194°F). Do not allow oil, grease or water to come in contact with the air bag module. EC FE CL MT SBF814E 4. 5. 6. Set steering wheel in the neutral position. Remove nuts. Using steering wheel puller, remove steering wheel. Be careful not to over-tighten puller bolt on steering wheel. CAUTION: I Do not tap or bump the steering wheel. 7. Remove steering column cover. AT TF PD AX SU SRS676 8. Unlock the spiral cable connector. Then disconnect connectors and remove the four screws. The spiral cable can then be removed. CAUTION: I Do not attempt to disassemble spiral cable. I Do not apply lubricant to the spiral cable. BR ST BT SRS384 HA SC EL IDX RS-19 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Driver Air Bag Module and Spiral Cable (Cont’d) INSTALLATION NARS0015 1. 2. Set the front wheels in the straight-ahead position. Make sure that the spiral cable is in the neutral position. The neutral position is detected by turning left about 2.5 revolutions from the right end position. Align the two marks ( ). CAUTION: I The spiral cable may snap due to steering operation if the cable is installed in an improper position. I Also, with the steering linkage disconnected, the cable may snap by turning the steering wheel beyond the limited number of turns. The spiral cable can be turned to the left about 2.5 turns from the right end position. 3. Connect spiral cable connector and tighten with screws. Install steering column cover. 4. Install steering wheel, aligning with spiral cable pin guides, and pull spiral cable through. 5. Connect horn connector and steering switch connector engage spiral cable with pawls in steering wheel. Move air bag module connector away from steering wheel lower lid opening. 6. Tighten nut. : 30 - 39 N·m (3.0 - 4.0 kg-m, 22 - 28 ft-lb) SRS276 7. 8. 9. SRS021A Position air bag module and tighten with new special bolts. Connect air bag module connector. Conduct self-diagnosis to ensure entire SRS operates properly. (Use CONSULT-II or warning lamp check.) Before performing self-diagnosis, connect both battery cables. 10. Turn steering wheel to the left end and then to the right end fully to make sure that spiral cable is set in the neutral position. If air bag warning lamp blinks or stays ON (at the user mode), it shows the spiral cable may be snapped due to its improper position. Perform self-diagnosis again (use CONSULT-II or warning lamp). If a malfunction is detected, replace the spiral cable with a new one. 11. Perform self-diagnosis again to check that no malfunction is detected. Front Passenger Air Bag Module REMOVAL NARS0016 CAUTION: I Before servicing SRS, turn the ignition switch off, disconnect both battery cables and wait for at least 3 minutes. I Always work from the side of or under air bag module. 1. Remove glove box assembly. Refer to BT-22, “INSTRUMENT PANEL ASSEMBLY” for details. 2. Disconnect front passenger air bag module connector from air bag harness connector. SRS162 RS-20 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Front Passenger Air Bag Module (Cont’d) 3. Remove instrument lower panel on passenger side. Refer to BT-22, “INSTRUMENT PANEL ASSEMBLY” for details. GI MA EM LC 4. 5. I Remove front passenger fixing bolts. Use the TAMPER RESISTANT TORX (SIZE T50) to remove special bolts from front passenger air bag module. Take out the air bag module from the instrument panel. The air bag module is heavy and should be supported using both hands during removal. EC FE CL MT SRS948 AT TF PD AX SU SRS949 CAUTION: I Always place air bag module with pad side facing upward. I Do not attempt to disassemble air bag module. I Do not use old bolts after removal; replace with new bolts. I Do not insert any foreign objects (screwdriver, etc.) into air bag module connector. BR ST BT SRS164 I I I I Replace air bag module if it has been dropped or sustained an impact. Do not expose the air bag module to temperatures exceeding 90°C (194°F). Do not allow oil, grease or water to come in contact with the air bag module. After air bag inflates, the front instrument panel assembly should be replaced if damaged. HA SC EL IDX SBF814E RS-21 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Front Passenger Air Bag Module (Cont’d) INSTALLATION NARS0017 CAUTION: I Always work from the side of or under air bag module. 1. Install front passenger air bag module to instrument panel. I Ensure harness is not caught between rear of air bag module and steering member. 2. Install front passenger air bag module to steering member. SRS948 SRS949 3. 4. 5. 6. 7. Install instrument lower panel on passenger side. Connect air bag module connector to air bag harness connector. Install glove box assembly. Connect both battery cables. Conduct self-diagnosis to ensure entire SRS operates properly. (Use CONSULT-II or warning lamp check.) SRS162 Side Air Bag Module REMOVAL SRS682 NARS0036 CAUTION: I Before servicing SRS, turn the ignition switch OFF, disconnect both battery cables and wait at least 3 minutes. I Always work from the rear of the air bag module. 1. Remove seatback board. I When using a clip removal tool to remove the seatback board, take care not to damage the air bag harness. 2. Disconnect side air bag module connector by sliding tab. 3. 4. 5. Pull up the seatback trim. Remove the nuts securing the inner cloth with seatback frame. Then pull up the inner cloth. Remove seatback trim. Refer to BT-43, “FRONT SEAT” for details. SRS683-A RS-22 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Side Air Bag Module (Cont’d) 6. 7. Remove the torx nuts coated with bonding agent from the side air bag module. Remove side air bag connector. Side air bag module can then be removed. GI MA EM LC SRS684-A CAUTION: I Always place the air bag module stading with the stud bolt side setting bottom. I Do not attempt to disassemble air bag module. I The torx nuts are coated with bonding agent. Do not use old nuts after removal; replace with new coated nuts. I Do not insert any foreign objects (screwdriver, etc.) into air bag module connector. EC FE CL MT SRS623 I I I I Replace air bag module if it has been dropped or sustained an impact. Do not expose the air bag module to temperatures exceeding 90°C (194°F). Do not allow oil, grease or water to come in contact with the air bag module. After air bag inflates, all parts of front seatback (including front seatback frame) should be replaced. AT TF PD AX SU SBF814E INSTALLATION 1. 2. 3. NARS0037 Install side air bag module on seatback frame with new torx nuts coated with bonding agent. Install side air bag connector. Install seatback trim. Refer to BT-43, “FRONT SEAT” for details. BR ST BT SRS684-A 4. Secure the inner cloth which covers the side air bag module with nuts. HA SC EL IDX SRS683-A RS-23 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Side Air Bag Module (Cont’d) 5. 6. 7. 8. Connect side air bag module connector. Install seatback board with new clips. Connect both battery cables. Go to “SRS Operation Check”, RS-41 and perform self-diagnosis to ensure entire SRS operates properly. (Use CONSULT-II or air bag warning lamp.) SRS725 Side Curtain Air Bag Module REMOVAL AND INSTALLATION NARS0052 SRS022A Removal NARS0052S01 CAUTION: I Before servicing SRS, turn the ignition switch off, disconnect both battery cables and wait at least 3 minutes. I Always work from the side of the side curtain air bag module. 1. Remove headliner. Refer to BT-34, “ROOF TRIM” for details. 2. Disconnect side curtain air bag connector. 3. Remove side curtain air bag module fixing bolts, and remove the side curtain air bag module. RS-24 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Side Curtain Air Bag Module (Cont’d) CAUTION: I Always place the side curtain air bag module with the warning label facing upward. I Do not attempt to disassemble side curtain air bag module. I Do not insert any foreign objects (screwdriver, etc.) into air bag module connector. GI MA EM LC SRS023A I I I Replace side curtain air bag module if it has been dropped or sustained an impact. Do not expose the air bag module to temperatures exceeding 90°C (194°F). Do not allow oil, grease or water to come in contact with the side curtain air bag module. EC FE CL MT SBF814E Disposal of Air Bag Module and Seat Belt Pretensioner I I I I I I I I I I I I NARS0018 Before disposing of air bag module and seat belt pre-tensioner, or vehicles equipped with such systems, deploy the systems. If such systems have already been deployed due to an accident, dispose of them as indicated in “DISPOSING OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER” (RS-31). When deploying the air bag module and seat belt pretensioner, always use the Special Service Tool; Deployment tool KV99106400 (Kent-Moore No. J38381). When deploying the air bag module and seat belt pretensioner, stand at least 5 m (16 ft) away from the deployment component. When deploying air bag module and seat belt pre-tensioner, a fairly loud noise is made, followed by smoke being released. The smoke is not poisonous, however, be careful not to inhale smoke since it irritates the throat and can cause choking. Always activate one air bag module at a time. Due to heat, leave air bag module unattended for more than 30 minutes after deployment. Also leave seat belt pre-tensioner unattended for move than 10 minutes after deployment. Be sure to wear gloves when handling a deployed air bag module and seat belt pre-tensioner. Never apply water to the deployed air bag module and seat belt pre-tensioner. Wash your hands clean after finishing work. Place the vehicle outdoors with an open space of at least 6 m (20 ft) on all sides when deploying air bag module and seat belt pre-tensioner while mounted in vehicle. Use a voltmeter to make sure the vehicle battery is fully charged. Do not dispose of the air bag module and seat belt pre-tensioner un-deployed. RS-25 AT TF PD AX SU BR ST BT HA SC EL IDX SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Disposal of Air Bag Module and Seat Belt Pre-tensioner (Cont’d) CHECKING DEPLOYMENT TOOL Connecting to Battery SRS019 NARS0018S01 NARS0018S0101 CAUTION: The battery must show voltage of 9.6V or more. Remove the battery from the vehicle and place it on dry wood blocks approximately 5 m (16 ft) away from the vehicle. I Wait 3 minutes after the vehicle battery is disconnected before proceeding. I Connect red clip of deployment tool to battery positive terminal and black clip to negative terminal. Make sure the polarity is correct. The right side lamp in the tool, marked “deployment tool power”, should glow with a green light. If the right side lamp glows red, reverse the connections to the battery. Deployment Tool Check NARS0018S0102 Press the deployment tool switch to the “ON” position. The left side lamp in the tool, marked “air bag connector voltage” should illuminate. If it does not illuminate, replace the tool. Air Bag Deployment Tool Lamp Illumination Chart (Battery connected) NARS0018S0103 SBF266H Switch operation Left side lamp, green* “AIR BAG CONNECTOR VOLTAGE” Right side lamp, green* “DEPLOYMENT TOOL POWER” OFF OFF ON ON ON ON *: If this lamp glows red, the tool is connected to the battery incorrectly. Reverse the connections and make sure the lamp glows green. DEPLOYMENT PROCEDURES FOR AIR BAG MODULE (OUTSIDE OF VEHICLE) NARS0018S02 Unless the vehicle is being scrapped, deploying the air bag in the vehicle is not recommended. This may cause damage to the vehicle interior. Anchor air bag module bracket [KV99105300 (J41246)] in a vise secured to a firm foundation during deployment. RS-26 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Disposal of Air Bag Module and Seat Belt Pre-tensioner (Cont’d) Deployment of Driver Air Bag Module (Outside of GI vehicle) NARS0018S0201 1. Using wire, secure air bag module to air bag module bracket [SST: KV99105300 (J41246)] at two places. CAUTION: Use wire of at least 1 mm (0.04 in) diameter. 2. Firmly secure air bag module bracket [SST: KV99105300 (J41246)] with air bag module attached, in a vise. MA EM LC SRS233 3. Connect deployment tool [SST: KV99106400 (J38381)] to air bag module connector. EC FE CL MT SRS234-F 4. Connect red clip of deployment tool to battery positive terminal 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. CAUTION: When deploying the air bag module, stand at least 5 m (16 ft) away from the air bag module. AT TF PD AX SU SRS020-B Deployment of Passenger Air Bag Module (Outside of vehicle) NARS0018S0202 1. Make an 8.5 mm (0.335 in) diameter hole in air bag module bracket [SST: KV99105300 (J41246)] at the position shown in figure at left. BR ST BT SRS141-G 2. Firmly secure air bag module bracket [SST: KV99105300 (J41246)] in a vise. HA SC EL IDX SRS145-C RS-27 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Disposal of Air Bag Module and Seat Belt Pre-tensioner (Cont’d) 3. Match the two holes in air bag module bracket (held in vise) and passenger air bag module and fix them with two bolts [M8 × 25 - 30 mm (0.98 - 1.18 in)]. CAUTION: If a gap exists between passenger air bag module and air bag module bracket, use a piece of wood inserted in the gap to stabilize the air bag module. SRS146-C 4. 5. 6. 7. Connect deployment tool adapter [SST: KV991065S0 (J3838130)] to deployment tool [SST: KV99106400 (J38381)] connector and air bag module connector. Connect red clip of deployment tool to battery positive terminal and black clip to negative terminal. The lamp on the right side of the tool, marked “deployment tool power”, should glow green, not red. 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. SRS147-A CAUTION: I When deploying the air bag module, do not stand on the deploying side. I Stand at least 5 m (16 ft) away from the air bag module. SRS020-B Deployment of Side Air Bag Module (Outside of vehicle) 1. NARS0018S0203 Make 6.5 mm (0.256 in) diameter holes in air bag module bracket [SST: KV99105300 (J41246)] at the position shown in figure at left. SRS490-A 2. Firmly secure air bag module bracket [SST: KV99105300 (J41246)] in a vise. 3. Insert the stud bolts of side air bag module (built-in type) into the two holes in air bag module bracket (held in vise) and fix them with two M6 nuts. CAUTION: Side air bag module should be secured to air bag module bracket [SST: KV99105300 (J41246)] in a vise with metal portion facing down. SRS628 RS-28 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Disposal of Air Bag Module and Seat Belt Pre-tensioner (Cont’d) 4. Connect deployment tool adapter [SST: KV99109000 (J44230)] to deployment tool [SST: KV99106400 (J38381)] connector and connector on air bag module. GI MA EM LC SRS688 5. Connect red clip of deployment tool to battery positive terminal 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 the air bag module will deploy. CAUTION: When deploying the air bag module, stand at least 5 m (16 ft) away from the air bag module. SRS020-B DEPLOYMENT PROCEDURES FOR SIDE CURTAIN AIR BAG MODULE (OUTSIDE OF VEHICLE) NARS0018S06 1. Cut the inflator from side curtain air bag module. EC FE CL MT AT TF PD AX SU PHIA0196E 2. Connect deployment tool [SST: J38381-80] and deployment tool adapter (J38381-80) to the inflator. LH side curtain air bag module: Yellow connector RH side curtain air bag module: Orange connector BR ST BT PHIA0197E 3. Put the inflator connected with the deployment tool [SST: KV99106400 (J38381)] into a tire without a wheel. HA SC EL IDX SHIA0201E RS-29 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Disposal of Air Bag Module and Seat Belt Pre-tensioner (Cont’d) 4. WHIA0048E Put the tire with the inflator onto another tire without wheel. Add an additional tire without a wheel and then a tire mounted on a wheel on top. CAUTION: Tie all tires together with a strap in order keep them standing. 5. Connect red clip of deployment tool to battery positive terminal 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 the air bag module will deploy. CAUTION: When deploying the side curtain air bag module, stand at least 5 m (16 ft) away from the side curtain air bag module. DEPLOYMENT PROCEDURES FOR SEAT BELT PRETENSIONER (OUTSIDE OF VEHICLE) NARS0018S05 1. Firmly grip pre-tensioner in a vise and cut the webbing off. 2. Connect deployment tool adapter (J38381-80) to deployment tool [SST: KV99106400 (J38381)] connector and seat belt pretensioner. SRS984 PHIA0221E 3. Connect red clip of deployment tool to battery positive terminal and black clip to negative terminal. 4. The lamp on the right side of the tool, marked “deployment tool power”, should glow green, not red. 5. Press the button on the deployment tool. The left side lamp on the tool, marked “seat belt pre-tensioner connector voltage”, will illuminate and the seat belt pre-tensioner will deploy. CAUTION: When deploying the seat belt pre-tensioner, stand at least 5 m (16 ft) away from the seat belt pre-tensioner. SRS242 RS-30 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Disposal of Air Bag Module and Seat Belt Pre-tensioner (Cont’d) DEPLOYMENT OF AIR BAG MODULE AND SEAT BELT GI PRE-TENSIONER WHILE MOUNTED IN VEHICLE NARS0018S03 When disposing of a vehicle, deploy air bag module and seat belt pre-tensioners while they are mounted in vehicle. CAUTION: When deploying air bag module or seat belt pre-tensioner, ensure vehicle is empty. 1. Disconnect both the vehicle battery cables and wait 3 minutes. 2. Disconnect air bag module and seat belt pre-tensioner connector. 3. Connect deployment tool [SST: KV99106400 (J38381)] to air bag module or seat belt pre-tensioner. For front passenger air bag module, attach deployment tool adapter [SST: KV991065S0 (J38381-30)] to the tool connector. For side air bag module, attach deployment tool adapter [SST: KV99109000 (J44230)] to the tool connector. For seat belt pre-tensioner, attach deployment tool adapter (SST: J3838180) to the tool connector. For side curtain air bag module, attach deployment tool adapter (SST: J38381-80) to the tool connector. 4. 5. 6. Connect red clip of deployment tool to battery positive terminal and black clip to negative terminal. The lamp on the right side of the tool, marked “deployment tool power”, should glow green, not red. 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. MA EM LC EC FE CL MT AT TF PD AX SU SRS006-C DISPOSING OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER NARS0018S04 SBF276H Deployed air bag module and seat belt pre-tensioner are very hot. Before disposing of air bag module, and seat belt pre-tensioner wait at least 30 minutes, and 10 minutes, respectively. Seal them in a plastic bag before disposal. CAUTION: I Never apply water to a deployed air bag module and seat belt pre-tensioner. I Be sure to wear gloves when handling a deployed air bag module and seat belt pre-tensioner. I No poisonous gas is produced upon air bag module deployment. However, be careful not to inhale gas since it irritates throat and can cause choking. I Do not attempt to disassemble air bag module and seat belt pre-tensioner. I Air bag module and seat belt pre-tensioner cannot be reused. I Wash your hands clean after finishing work. BR ST BT HA SC EL IDX RS-31 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses Introduction Trouble Diagnoses Introduction =NARS0040 CAUTION: I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow harness connector (and with yellow harness protector or yellow insulation tape before the harness connectors). I Do not attempt to repair, splice or modify the SRS wiring harness. If the harness is damaged, replace it with a new one. I Keep ground portion clean. DIAGNOSIS FUNCTION NARS0040S01 The SRS self-diagnosis results can be read by using “AIR BAG” warning lamp and/or CONSULT-II. The reading 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-II are as follows: User mode Diagnosis mode Display type “AIR BAG” warning lamp X X ON-OFF operation CONSULT-II — X Monitoring NOTE: Seat belt pre-tensioner malfunction is indicated by “AIR BAG” warning lamp. DIAGNOSIS MODE FOR CONSULT-II NARS0040S02 I “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-II screen in real time. This refers to a malfunctioning part requiring repairs. I “SELF-DIAG [PAST]” Diagnosis results previously stored in the memory are displayed on the CONSULT-II screen. The stored results are not erased until memory erasing is executed. I “TROUBLE DIAG RECORD” With TROUBLE DIAG RECORD, diagnosis results previously erased by a reset operation can be displayed on the CONSULT-II screen. I “ECU DISCRIMINATED NO.” The diagnosis sensor unit for each vehicle model is assigned with its own, individual classification number. This number will be displayed on the CONSULT-II screen, as shown below. When replacing the diagnosis sensor unit, refer to the part number for the compatibility. After installation, replacement with a correct unit can be checked by confirming this classification number on the CONSULT-II screen. For NISSAN MODEL R50, the diagnosis sensor unit classification numbers assigned is AA2F (Models with side air bag) and AA2E (Models without side air bag). RS-32 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses Introduction (Cont’d) HOW TO CHANGE SELF-DIAGNOSIS MODE WITH CONSULT-II From User Mode to Diagnosis Mode =NARS0040S03 GI NARS0040S0301 After selecting “AIR BAG” on the “SELECT SYSTEM” screen, User mode automatically changes to Diagnosis mode. MA EM LC EC SRS803 From Diagnosis Mode to User Mode NARS0040S0302 To return to User mode from Diagnosis mode, touch “BACK” key of CONSULT-II until “SELECT SYSTEM” appears, Diagnosis mode automatically changes to User mode. FE CL MT AT TF PD SRS804 HOW TO CHANGE SELF-DIAGNOSIS MODE WITHOUT CONSULT-II From User Mode to Diagnosis Mode AX NARS0040S04 NARS0040S0401 Diagnosis mode activates only when a malfunction is detected, by turning ignition switch as follows: 1) Turn ignition switch “ON”. 2) After “AIR BAG” warning lamp lights for 7 seconds, turn ignition switch “OFF” within 1 second. 3) Wait more than 3 seconds. 4) Repeat steps 1 to 3 twice (Perform 3 times in total). 5) Turn ignition switch “ON”. SRS will not enter Diagnosis mode, if no malfunction is detected. From Diagnosis Mode to User Mode BR ST NARS0040S0402 After a malfunction is repaired, switch the ignition “OFF” for at least one second, then back “ON”. Diagnosis mode is returned to User mode. If switching Diagnosis mode to User mode is required while malfunction is being detected, by turning ignition switch as follows: 1) Turn ignition switch “ON”. 2) After “AIR BAG” warning lamp lights for 7 seconds, turn ignition switch “OFF” within 1 second. 3) Wait more than 3 seconds. 4) Repeat steps 1 to 3 twice (Perform 3 times in total). 5) Turn ignition switch “ON”. HOW TO ERASE SELF-DIAGNOSIS RESULTS With CONSULT-II I SU “SELF-DIAG [CURRENT]” A current Self-diagnosis result is displayed on the CONSULT-II screen in real time. RS-33 NARS0040S05 BT HA SC EL NARS0040S0501 IDX SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses Introduction (Cont’d) After the malfunction is repaired completely, no malfunction is detected on “SELF-DIAG [CURRENT]”. “SELF-DIAG [PAST]” Return to the “SELF-DIAG [CURRENT]” CONSULT-II screen by pushing “BACK” key of CONSULT-II and select “SELF-DIAG [CURRENT]” in SELECT DIAG MODE. Touch “ERASE” in “SELF-DIAG [CURRENT]” mode. NOTE: If the memory of the malfunction in “SELF-DIAG [PAST]” is not erased, the User mode shows the system malfunction by the operation of the warning lamp even if the malfunction is repaired completely. I SRS701 I “TROUBLE DIAG RECORD” The memory of “TROUBLE DIAG RECORD” cannot be erased. Without CONSULT-II NARS0040S0502 After a malfunction is repaired, switch the ignition “OFF” for at least one second, then back “ON”. Diagnosis mode returns to the User mode. At that time, the self-diagnostic result is cleared. RS-34 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) How to Perform Trouble Diagnoses for Quick and Accurate Repair How to Perform Trouble Diagnoses for Quick and Accurate Repair GI =NARS0041 A good understanding of the malfunction conditions can make troubleshooting faster and more accurate. In general, each customer feels differently about a malfunction. It is important to fully understand the symptoms or conditions for a customer complaint. MA INFORMATION FROM CUSTOMER EM NARS0041S01 WHAT ..... Vehicle model WHEN ..... Date, Frequencies WHERE ..... Road conditions HOW ..... Operating conditions, Symptoms LC PRELIMINARY CHECK NARS0041S02 Check that the following parts are in good order. I Battery [Refer to SC-4, “BATTERY”.] I Fuse [Refer to EL-11, “Fuse”, “POWER SUPPLY ROUTING”.] I System component-to-harness connections EC FE CL MT AT TF PD AX SU BR ST BT HA SC EL IDX RS-35 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) How to Perform Trouble Diagnoses for Quick and Accurate Repair (Cont’d) WORK FLOW =NARS0041S03 NOTE: Seat belt pre-tensioner malfunction is indicated by “AIR BAG” warning lamp. SRS799 *1: RS-35 *2: RS-41 *3: RS-42 *4: RS-52 *5: RS-46 *6: RS-58 RS-36 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Schematic Schematic NARS0042 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST BT HA SC EL MRS451A RS-37 IDX SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Wiring Diagram — SRS — Wiring Diagram — SRS — NARS0043 MRS452A RS-38 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Wiring Diagram — SRS — (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST BT HA SC EL MRS453A IDX RS-39 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Wiring Diagram — SRS — (Cont’d) MRS454A RS-40 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) SRS Operation Check SRS Operation Check NARS0044 GI DIAGNOSTIC PROCEDURE 1 NARS0044S01 Checking Air Bag Operation by Using “AIR BAG” MA Warning Lamp — User Mode NARS0044S0101 1. 2. After turning ignition switch from “OFF” to “ON”, “AIR BAG” warning lamp operates. Compare “AIR BAG” warning lamp operation to the chart below. EM LC SRS800 EC “AIR BAG” warning lamp operation — User mode — SRS condition No malfunction is detected. No further action is necessary. Reference item FE — CL MRS095A The system is malfunction- Go to DIAGNOSTIC PROing and needs to be CEDURE 2 or 6 (RS-42 or repaired as indicated. RS-52). MT AT TF MRS096A Air bag is deployed. Seat belt pre-tensioner is deployed. Air bag fuse, diagnosis sensor unit or harness is malfunctioning and needs MRS097A to be repaired. Go to COLLISION DIAGNOSIS (RS-63). Go to DIAGNOSTIC PROCEDURE 9 (RS-60). One of the following has Go to DIAGNOSTIC PROoccurred and needs to be CEDURE 10 (RS-62). repaired. I Meter fuse is blown. I “AIR BAG” warning lamp circuit has open or short. MRS098A I Diagnosis sensor unit is malfunctioning. PD AX SU BR ST BT HA SC EL IDX RS-41 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses with CONSULT-II Trouble Diagnoses with CONSULT-II DIAGNOSTIC PROCEDURE 2 =NARS0045 NARS0045S01 Inspecting SRS malfunctioning parts by using CONSULT-II — Diagnosis mode 1. Turn ignition switch “OFF”. 2. Connect CONSULT-II to data link connector. SRS844 3. 4. Turn ignition switch “ON”. Touch “START”. 5. Touch “AIR BAG”. 6. Touch “SELF-DIAG [CURRENT]”. 7. Diagnostic codes are displayed on “SELF-DIAG [CURRENT]”. SRS695 SRS771 SRS697 SHIA0203E RS-42 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses with CONSULT-II (Cont’d) If no malfunction is detected on “SELF-DIAG [CURRENT]” even though malfunction is detected in “SRS Operation Check”, check the battery voltage. If the battery voltage is less than 9V, charge the battery. Then go to DIAGNOSTIC PROCEDURE 3, page RS-46. If the battery voltage is OK, go to DIAGNOSTIC PROCEDURE 4, page RS-47, to diagnose the following cases: I Self-diagnostic result “SELF-DIAG [PAST]” (previously stored in the memory) might not be erased after repair. I The SRS system malfunctions intermittently. GI 8. 9. EC MA EM LC SRS701 10. 11. 12. 13. Touch “PRINT”. Compare diagnostic codes to “CONSULT-II Diagnostic Code Chart”, page RS-43. Touch “BACK” key of CONSULT-II until “SELECT SYSTEM” appears in order to return to User mode from Diagnosis mode. Turn ignition switch “OFF”, then turn off and disconnect CONSULT-II, and disconnect both battery cables. Repair the system as outlined by the “Repair order” in “CONSULT-II Diagnostic Code Chart”, that corresponds to the selfdiagnostic result. For replacement procedure of component parts, refer to RS-16. After repairing the system, go to DIAGNOSTIC PROCEDURE 3, page RS-46 for final checking. FE CL MT AT CONSULT-II Diagnostic Code Chart (“SELF-DIAG TF [CURRENT]”) NARS0045S0101 Diagnostic item NO DTC IS DETECTED. DRIVER AIRBAG MODULE [OPEN] Explanation When malfunction is indicated by the “AIR BAG” warning lamp in User mode Repair order “Recheck SRS at each replacement.” I Low battery voltage (Less than 9V) I Go to DIAGNOSTIC PROCEDURE 3 (RS-46) after charging battery. I Self-diagnostic result “SELF-DIAG [PAST]” (previously stored in the memory) might not be erased after repair. I Intermittent malfunction has been detected in the past. I Go to DIAGNOSTIC PROCEDURE 4 (RS-47). PD AX SU BR I No malfunction is detected. I Go to DIAGNOSTIC PROCEDURE 3 (RS-46). I Driver air bag module circuit is open. (including the spiral cable) 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace driver air bag module. (Before disposal, it must be deployed.) 4. Replace the spiral cable. 5. Replace the diagnosis sensor unit. 6. Replace the related harness. ST BT HA SC EL IDX RS-43 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses with CONSULT-II (Cont’d) Diagnostic item Explanation Repair order “Recheck SRS at each replacement.” DRIVER AIRBAG MODULE [VB-SHORT] I Driver air bag module circuit is shorted to a power supply circuit. (including the spiral cable) DRIVER AIRBAG MODULE [GND-SHORT] I Driver air bag module circuit is shorted to ground. (including the spiral cable) DRIVER AIRBAG MODULE [SHORT] I Driver air bag module circuit is shorted between lines. ASSIST A/B MODULE [VB-SHORT] I Front passenger air bag module circuit is shorted to some power supply circuit. ASSIST A/B MODULE [OPEN] I Front passenger air bag module circuit is open. ASSIST A/B MODULE [GND-SHORT] I Front passenger air bag module circuit is shorted to ground. ASSIST A/B MODULE [SHORT] I Front passenger air bag module circuit is shorted between lines. SIDE MODULE LH [OPEN] I Front LH side air bag module circuit is open. SIDE MODULE LH [VB-SHORT] I Front LH side supply circuit. SIDE MODULE LH [GND-SHORT] I Front LH side SIDE MODULE LH [SHORT] I Front LH side SIDE MODULE RH [OPEN] I Front RH side air bag module circuit is open. SIDE MODULE RH [VB-SHORT] I Front RH side air bag module circuit is shorted to a power supply circuit. SIDE MODULE RH [GND-SHORT] I Front RH side air bag module circuit is shorted to ground. SIDE MODULE RH [SHORT] I Front RH side air bag module circuit is shorted between lines. SATELLITE SENS LH [UNIT FAIL] SATELLITE SENS LH [COMM FAIL] I LH side air bag (Satellite) sensor 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace the LH side air bag (satellite) sensor. 4. Replace the diagnosis sensor unit. 5. Replace the related harness. SATELLITE SENS RH [UNIT FAIL] SATELLITE SENS RH [COMM FAIL] I RH side air bag (Satellite) sensor 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace the RH side air bag (satellite) sensor. 4. Replace the diagnosis sensor unit. 5. Replace the related harness. 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace the spiral cable. 4. Replace driver air bag module. (Before disposal, it must be deployed.) 5. Replace the diagnosis sensor unit. 6. Replace the related harness. 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace front passenger air bag module. (Before disposal, it must be deployed.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness. 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible air bag module circuit is shorted to a power damage. 3. Replace the front LH side air bag module. air bag module circuit is shorted to ground. (Before disposal, it must be deployed.) air bag module circuit is shorted between lines. 4. Replace the diagnosis sensor unit. 5. Replace the related harness. RS-44 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace the front RH side air bag module. (Before disposal, it must be deployed.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness. SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses with CONSULT-II (Cont’d) Diagnostic item Explanation PRE-TEN FRONT LH [OPEN] I Front LH seat belt pre-tensioner circuit is open. PRE-TEN FRONT LH [VB-SHORT] I Front LH seat belt pre-tensioner circuit is shorted to a power supply circuit. PRE-TEN FRONT LH [GND-SHORT] I Front LH seat belt pre-tensioner circuit is shorted to ground. PRE-TEN FRONT LH [SHORT] I Front LH pre-tensioner circuit is shorted between lines. PRE-TEN FRONT RH [OPEN] I Front RH seat belt pre-tensioner circuit is open. PRE-TEN FRONT RH [VB-SHORT] I Front RH seat belt pre-tensioner circuit is shorted to a power supply circuit. PRE-TEN FRONT RH [GND-SHORT] I Front RH seat belt pre-tensioner circuit is shorted to ground. PRE-TEN FRONT RH [SHORT] I Front RH pre-tensioner circuit is shorted between lines. CURTAIN MODULE LH I LH side curtain air bag module circuit is open. [OPEN] CURTAIN MODULE LH I LH side curtain air bag module circuit is shorted to a power [VB-SHORT] supply circuit. CURTAIN MODULE LH I LH side curtain air bag module circuit is shorted to ground. [GND-SHORT] CURTAIN MODULE LH I LH side curtain air bag module circuit is shorted between [SHORT] lines. CURTAIN MODULE RH [OPEN] I RH side curtain air bag module circuit is open. CURTAIN MODULE RH [VB-SHORT] I RH side curtain air bag module circuit is shorted to a power supply circuit. CURTAIN MODULE RH [SHORT] I RH side curtain air bag module circuit is shorted between lines. CURTAIN MODULE RH [GND-SHORT] I RH side curtain air bag module circuit is shorted to ground. CONTROL UNIT I Diagnosis sensor unit is malfunctioning. Repair order “Recheck SRS at each replacement.” 1. Visually check the wiring harness connections. 2. Replace the harness if it has visible damage. 3. Replace front LH seat belt. (Before disposal, it must be deactivated.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness. 1. Visually check the wiring harness connections. 2. Replace the harness if it has visible damage. 3. Replace front RH seat belt. (Before disposal, it must be deactivated.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness. 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace LH side curtain air bag module. (Before disposal, it must be deployed.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness. 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace RH side curtain air bag module. (Before disposal, it must be deployed.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness. 1. Visually check the wiring harness connection. 2. Replace the diagnosis sensor unit. * Follow the procedures in numerical order when repairing malfunctioning parts. Confirm whether malfunction is eliminated using the air bag warning lamp or CONSULT-II 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. GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST BT HA SC EL IDX RS-45 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses with CONSULT-II (Cont’d) DIAGNOSTIC PROCEDURE 3 NARS0045S02 Final checking after repairing SRS by using CONSULT-II — Diagnosis mode 1. After repairing SRS, connect both battery cables. 2. Connect CONSULT-II to Data link connector. 3. Turn ignition switch from “OFF” to “ON”. SRS844 4. Touch “START”. 5. Touch “AIR BAG”. 6. Touch “SELF-DIAG [CURRENT]”. 7. If no malfunction is detected on “SELF-DIAG [CURRENT]”, repair of SRS is completed. Go to step 8. If any malfunction is displayed on “SELF-DIAG [CURRENT]”, the malfunctioning part is not repaired completely or another malfunctioning part is detected. Go to DIAGNOSTIC PROCEDURE 2, page RS-42, and repair malfunctioning part completely. SRS695 SRS771 SRS697 SRS701 RS-46 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses with CONSULT-II (Cont’d) 8. Touch “ERASE”. NOTE: Touch “ERASE” to clear the memory of the malfunction (“SELF-DIAG [PAST]”). If the memory of the malfunction in “SELF-DIAG [PAST]” is not erased, the User mode shows the system malfunction by the operation of the warning lamp even if the malfunction is repaired completely. GI MA EM LC SHIA0180E 9. Touch “BACK” key of CONSULT-II to “SELECT SYSTEM” screen. Touch “SELF-DIAG [PAST]”. EC FE CL MT SRS697 10. Check that no malfunction is detected on “SELF-DIAG [PAST]”. AT TF PD AX SU SRS702 11. Touch “BACK” key of CONSULT-II until “SELECT SYSTEM” appears in order to return to User mode from Diagnosis mode. 12. Turn ignition switch “OFF”, then turn off and disconnect CONSULT-II. 13. Go to “SRS Operation Check”, page RS-41 to check SRS operation by using “AIR BAG” warning lamp with User mode. BR ST DIAGNOSTIC PROCEDURE 4 (CONTINUED FROM DIAGNOSTIC PROCEDURE 2) NARS0045S03 Inspecting SRS malfunctioning record 1 CONSIDER POSSIBILITY OF NOT ERASING SELF-DIAGNOSTIC RESULT AFTER REPAIRING BT Is it the first time for maintenance of SRS? Yes or No Yes © Go to DIAGNOSTIC PROCEDURE 5 (RS-48). No © Self-diagnostic result “SELF-DIAG [PAST]” (previously stored in the memory) might not be erased after repair. Go to DIAGNOSTIC PROCEDURE 3, step 8 (RS-46). HA SC EL IDX RS-47 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses with CONSULT-II (Cont’d) DIAGNOSTIC PROCEDURE 5 NARS0045S04 Inspecting SRS intermittent malfunction by using CONSULT-II — Diagnosis mode 1. Turn ignition switch “OFF”. 2. Connect CONSULT-II to data link connector. SRS844 3. 4. Turn ignition switch “ON”. Touch “START”. 5. Touch “AIR BAG”. 6. Touch “SELF-DIAG [PAST]”. 7. If diagnostic codes are displayed on “SELF-DIAG [PAST]”, go to step 10. SRS695 SRS771 SRS697 SHIA0181E RS-48 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses with CONSULT-II (Cont’d) If no malfunction is detected on “SELF-DIAG [PAST]”, touch “BACK” and go back to “SELECT DIAG MODE”. GI MA EM LC SRS702 8. Touch “TROUBLE DIAG RECORD”. NOTE: With “TROUBLE DIAG RECORD”, diagnosis results previously erased by a reset operation can be displayed. EC FE CL MT SRS697 9. Diagnostic code is displayed on “TROUBLE DIAG RECORD”. AT TF PD AX SU SHIA0182E 10. Touch “PRINT”. 11. Compare diagnostic codes to “Intermittent Malfunction Diagnostic Code Chart”, page RS-50. 12. Touch “BACK” key of CONSULT-II until “SELECT SYSTEM” appears. 13. Turn ignition switch “OFF”, then turn off and disconnect CONSULT-II, and disconnect both battery cables. 14. Repair the system as outlined by the “Repair order” in “Intermittent Malfunction Diagnostic Code Chart”, that corresponds to the self-diagnostic result. For replacement procedure of component parts, refer to RS-16. 15. Go to DIAGNOSTIC PROCEDURE 3, page RS-46, for final checking. BR ST BT HA SC EL IDX RS-49 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses with CONSULT-II (Cont’d) Intermittent Malfunction Diagnostic Code Chart (“SELFDIAG [PAST]” or “TROUBLE DIAG RECORD”) NARS0045S0401 Diagnostic item NO DTC IS DETECTED. Explanation When malfunction is indicated by the “AIR BAG” warning lamp in User mode I Low battery voltage (Less than 9V) Repair order I Go to DIAGNOSTIC PROCEDURE 3 (RS-46) after charging battery. I No malfunction is detected. I Go to DIAGNOSTIC PROCEDURE 3 (RS-46). DRIVER AIRBAG MODULE [OPEN] I Driver air bag module circuit is open. (including the spiral cable) DRIVER AIRBAG MODULE [VB-SHORT] I Driver air bag module circuit is shorted to a power supply circuit. (including the spiral cable) DRIVER AIRBAG MODULE [GND-SHORT] I Driver air bag module circuit is shorted to ground. (including the spiral cable) 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. If the harness check result is OK, replace driver air bag module (Before disposal, it must be deployed.), diagnosis sensor unit and spiral cable. DRIVER AIRBAG MODULE [SHORT] I Driver air bag module circuit is shorted between lines. ASSIST A/B MODULE [VB-SHORT] I Front passenger air bag module circuit is shorted to a power supply circuit. ASSIST A/B MODULE [OPEN] I Front passenger air bag module circuit is open. ASSIST A/B MODULE [GND-SHORT] I Front passenger air bag module circuit is shorted to ground. ASSIST A/B MODULE [SHORT] I Front passenger air bag module circuit is shorted between lines. SIDE MODULE LH [OPEN] I Front LH side air bag module circuit is open. SIDE MODULE LH [VB-SHORT] I Front LH side supply circuit. SIDE MODULE LH [GND-SHORT] I Front LH side SIDE MODULE LH [SHORT] I Front LH side SIDE MODULE RH [OPEN] I Front RH side air bag module circuit is open. SIDE MODULE RH [VB-SHORT] I Front RH side air bag module circuit is shorted to a power supply circuit. SIDE MODULE RH [GND-SHORT] I Front RH side air bag module circuit is shorted to ground. SIDE MODULE RH [SHORT] I Front RH side air bag module circuit is shorted between lines. SATELLITE SENS LH [UNIT FAIL] SATELLITE SENS LH [COMM FAIL] I LH side air bag (Satellite) sensor 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. If the harness check result is OK, replace front passenger air bag module (Before disposal, it must be deployed.), and diagnosis sensor unit. 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible air bag module circuit is shorted to a power damage. 3. If the harness check is OK, replace the diagnosis sensor unit and front air bag module circuit is shorted to ground. LH side air bag module. (Before disposing of the front LH side air bag module, it must be deployed.) air bag module circuit is shorted between lines. RS-50 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. If the harness check is OK, replace the diagnosis sensor unit and front RH side air bag module. (Before disposing of the front RH side air bag module, it must be deployed.) 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. If the harness check is OK, replace the diagnosis sensor unit and LH side air bag (Satellite) sensor. SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses with CONSULT-II (Cont’d) Diagnostic item SATELLITE SENS RH [UNIT FAIL] SATELLITE SENS RH [COMM FAIL] Explanation I RH side air bag (Satellite) sensor PRE-TEN FRONT LH [OPEN] I Front LH seat belt pre-tensioner circuit is open. PRE-TEN FRONT LH [VB-SHORT] I Front LH seat belt pre-tensioner circuit is shorted to a power supply circuit. PRE-TEN FRONT LH [GND-SHORT] I Front LH seat belt pre-tensioner circuit is shorted to ground. PRE-TEN FRONT LH [SHORT] I Front LH pre-tensioner circuit is shorted to between lines. PRE-TEN FRONT RH [OPEN/VB-SHORT] I Front RH seat belt pre-tensioner circuit is open. PRE-TEN FRONT RH [VB-SHORT] I Front RH seat belt pre-tensioner circuit is shorted to a power supply circuit. PRE-TEN FRONT RH [SHORT] I Front RH pre-tensioner circuit is shorted between lines. PRE-TEN FRONT RH [GND-SHORT] I Front RH pre-tensioner circuit is shorted to ground. CURTAIN MODULE LH I LH side curtain air bag module circuit is open. [OPEN] CURTAIN MODULE LH I LH side curtain air bag module circuit is shorted to a power [VB-SHORT] supply circuit. CURTAIN MODULE LH I LH side curtain air bag module circuit is shorted to ground. [GND-SHORT] CURTAIN MODULE LH I LH side curtain air bag module circuit is shorted between [SHORT] lines. CURTAIN MODULE RH [OPEN] I RH side curtain air bag module circuit is open. CURTAIN MODULE RH [VB-SHORT] I RH side curtain air bag module circuit is shorted to a power supply circuit. CURTAIN MODULE RH [SHORT] I RH side curtain air bag module circuit is shorted between lines. CURTAIN MODULE RH [GND-SHORT] I RH side curtain air bag module circuit is shorted to ground. CONTROL UNIT I Diagnosis sensor unit is malfunctioning. Repair order 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. If the harness check is OK, replace the diagnosis sensor unit and RH side air bag (Satellite) sensor. 1. Visually check the wiring harness connections. 2. Replace the harness if it has visible damage. 3. If the harness check is OK, replace the diagnosis sensor unit and front LH seat belt. (Before disposing of the front LH seat belt pre-tensioner, it must be deployed.) 1. Visually check the wiring harness connections. 2. Replace the harness if it has visible damage. 3. If the harness check is OK, replace the diagnosis sensor unit and front RH seat belt. (Before disposing of the front RH seat belt pre-tensioner, it must be deployed.) 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. If the harness check is OK, replace the diagnosis sensor unit and LH side curtain air bag module. (Before disposing of the LH side curtain air bag module, it must be deployed.) 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. If the harness check is OK, replace the diagnosis sensor unit and RH side curtain air bag module. (Before disposing of the RH side curtain air bag module, it must be deployed.) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST BT HA 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. If the harness check is OK, replace the diagnosis sensor unit. * Follow the procedures in numerical order when repairing malfunctioning parts, then make the final system check. RS-51 SC EL IDX SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses without CONSULT-II Trouble Diagnoses without CONSULT-II DIAGNOSTIC PROCEDURE 6 SRS800 NARS0046 NARS0046S01 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. Turn ignition switch “ON”. 2. After “AIR BAG” warning lamp lights for 7 seconds, turn ignition switch “OFF” within 1 second. 3. Wait more than 3 seconds. 4. Repeat steps 1 to 3 twice (Perform 3 times in total). 5. Turn ignition switch “ON”. SRS is now in Diagnosis mode. 6. “AIR BAG” warning lamp operates in Diagnosis mode as follows: NOTE: If SRS does not enter Diagnosis mode even though malfunction is detected in User mode, check the battery voltage. If the battery voltage is less than 9V, charge the battery. Then go to DIAGNOSTIC PROCEDURE 7, page RS-58. If the battery voltage is OK, replace the diagnosis sensor unit. RS-52 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses without CONSULT-II (Cont’d) No. “AIR BAG” warning lamp flash pattern — Diagnosis mode — a through b are repeated. 1 SRS333 a through d are repeated. b — Driver and passenger air bag and seat belt pre-tensioner marker (For identifying driver air bag, passenger air bag and/or seat belt pre-tensioners malfunctioning) d — Indicates malfunctioning part. The number of flash varSRS341 ies with malfunctioning part (0.5 sec. ON and 0.5 sec. OFF is counted as one flash.) 2 SRS condition I Diagnosis results (previously stored in the memory) might not be erased after repair. I Intermittent malfunction has been detected in the past. Go to DIAGNOSTIC PROCEDURE 8 (RS-59). The system is malfunctioning and needs to be repaired. a through f are repeated. b, c, d — Side air bag marker (For identifying side air bag malfunctioning) f — Indicates malfunctioning part. The number of flash varies with malfunctioning part (0.5 sec. ON and 0.5 sec. SRS342-A OFF is counted as one flash.) 3 7. Malfunctioning part is indicated by the number of flashes (part d or f). Compare the number of flashes to “Air Bag Warning Lamp Flash Code Chart”, page RS-54, and locate malfunctioning part. 8. Turn ignition switch “OFF”, and disconnect both battery cables. 9. Repair the system as outlined by the “Repair order” in “Warning Lamp Flash Code Chart” that corresponds to the flash code. For replacement procedure of component parts, refer to RS-16. 10. After repairing the system, go to DIAGNOSTIC PROCEDURE 7, page RS-58. GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST BT HA SC EL IDX RS-53 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses without CONSULT-II (Cont’d) Air Bag Warning Lamp Flash Code Chart (Diagnosis mode) NARS0046S0101 Flash pattern a through b are repeated. I Diagnosis results (previously stored in the memory) might not be erased after repair. I Intermittent malfunction has been detected in the past. SRS333 Repair order I Go to DIAGNOSTIC PROCEDURE 8 (RS-59). Flash pattern a through d are repeated. d — One flash indicates malfunctioning front RH seat belt pre-tensioner circuit. Front RH seat belt pretensioner circuit is malfunctioning. (d: 1 flash) SRS801 Repair order (“Recheck SRS at each replacement”). 1. Visually check the wiring harness connections. 2. Replace the harness if it has visible damage. 3. Replace front RH seat belt pre-tensioner. (Before disposal, it must be deactivated.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness. Flash pattern a through d are repeated. d — Two flashes indicate malfunctioning driver’s air bag module circuit. Driver air bag module circuit is malfunctioning. (d: 2 flashes) SRS334 Repair order (“Recheck SRS at each replacement.”) 1. 2. 3. 4. Visually check the wiring harness connection. Replace the harness if it has visible damage. Replace the spiral cable. Replace driver air bag module. (Before disposal, it must be deployed.) 5. Replace the diagnosis sensor unit. 6. Replace the related harness. RS-54 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses without CONSULT-II (Cont’d) GI Flash pattern a through d are repeated. d — Three flashes indicate malfunctioning front LH seat belt pre-tensioner circuit. Front LH seat belt pretensioner circuit is malfunctioning. (d: 3 flashes) MA EM LC SRS802 EC Repair order (“Recheck SRS at each replacement”). 1. Visually check the wiring harness connections. 2. Replace the harness if it has visible damage. 3. Replace front LH seat belt pre-tensioner. (Before disposal, it must be deactivated.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness. FE CL MT Flash pattern a through d are repeated. d — Seven flashes indicate malfunctioning diagnosis sensor unit. Diagnosis sensor unit is malfunctioning. (d: 7 flashes) SRS335 AT TF PD Repair order (“Recheck SRS at each replacement.”) 1. 2. 3. 4. Visually check the wiring harness connections. Replace the harness if it has visible damage. Replace the diagnosis sensor unit. Replace the related harness. AX SU Flash pattern Front passenger air bag module circuit is malfunctioning. (d: 8 flashes) a through d are repeated. d — Eight flashes indicate malfunctioning front passenger air bag module circuit. BR ST SRS336 Repair order (“Recheck SRS at each replacement.”) 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace front passenger air bag module. (Before disposal, it must be deployed.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness. BT HA SC EL IDX RS-55 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses without CONSULT-II (Cont’d) Flash pattern a through f are repeated. f — One flash indicates malfunctioning front RH side air bag module circuit. Front RH side air bag module circuit is malfunctioning. (f: 1 flash) SRS338 Repair order (“Recheck SRS at each replacement.”) 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace front RH side air bag module. (Before disposal, it must be deployed.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness. Flash pattern a through f are repeated. f — Two flashes indicate malfunctioning front LH side air bag module circuit. Front LH side air bag module circuit is malfunctioning. (f: 2 flashes) SRS337 Repair order (“Recheck SRS at each replacement.”) 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace front LH side air bag module. (Before disposal, it must be deployed.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness. Flash pattern a through f are repeated. f — Three flashes indicate malfunctioning RH side air bag (Satellite) sensor circuit. RH side air bag (Satellite) sensor is malfunctioning. (f: 3 flashes) SRS340 Repair order (“Recheck SRS at each replacement.”) 1. 2. 3. 4. 5. Visually check the wiring harness connection. Replace the harness if it has visible damage. Replace the RH side air bag (Satellite) sensor. Replace the diagnosis sensor unit. Replace the related harness. RS-56 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses without CONSULT-II (Cont’d) GI Flash pattern a through f are repeated. f — Four flashes indicate malfunctioning LH side air bag (Satellite) sensor circuit. LH side air bag (Satellite) sensor is malfunctioning. (f: 4 flashes) MA EM LC SRS339-A Repair order (“Recheck SRS at each replacement.”) 1. 2. 3. 4. 5. EC Visually check the wiring harness connection. Replace the harness if it has visible damage. Replace the LH side air bag (Satellite) sensor. Replace the diagnosis sensor unit. Replace the related harness. FE Flash pattern CL a through f are repeated. f — Five flashes indicate malfunctioning RH side curtain air bag module circuit. MT AT Side curtain air bag module (RH) circuit is malfunctioning. (f: 5 flashes) TF SRS024A Repair order (“Recheck SRS at each replacement.”) PD 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace RH side curtain air bag module. (Before disposal, it must be deployed.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness. AX SU Flash pattern a through f are repeated. f — Six flashes indicate malfunctioning LH side curtain air bag module circuit. LH side curtain air bag module circuit is malfunctioning. (f: 6 flashes) BR ST SRS025A Repair order (“Recheck SRS at each replacement.”) 1. 2. 3. 4. 5. Visually check the wiring harness connection. Replace the harness if it has visible damage. Replace LH side curtain air bag module. Replace the diagnosis sensor unit. Replace the related harness. * Follow the procedures in numerical order when repairing malfunctioning parts. Confirm whether malfunction is eliminated using the air bag warning lamp or CONSULT-II 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. BT HA SC EL IDX RS-57 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses without CONSULT-II (Cont’d) DIAGNOSTIC PROCEDURE 7 NARS0046S02 Final checking after repairing SRS by using “AIR BAG” warning lamp — Diagnosis mode and User mode 1. After repairing SRS connect both battery cables. 2. Turn ignition switch from “OFF” to “ON”. 3. “AIR BAG” warning lamp operates in Diagnosis mode as follows: SRS800 No. “AIR BAG” warning lamp flash pattern — Diagnosis mode — a through b are repeated. 1 SRS condition No malfunction is detected or repair is completed. No further action is necessary. SRS333 2 a through d are repeated. b — Driver and passenger air bag and seat belt pre-tensioner marker (For identifying driver air bag, passenger air bag and/or seat belt pre-tensioners malfunctioning) d — Indicates malfunctioning part. The number of flashes SRS341 varies with malfunctioning part (0.5 sec. ON and 0.5 sec. OFF is counted as one flash.) 3 a through f are repeated. b, c, d — Side air bag marker (For identifying side air bag malfunctioning) f — Indicates malfunctioning part. The number of flashes varies with malfunctioning part (0.5 sec. ON and 0.5 sec. OFF SRS342-A is counted as one flash.) The system is malfunctioning and needs to be repaired. NOTE: When diagnosis sensor unit is replaced with new one, “AIR BAG” warning lamp will operate in User mode. Checking “AIR BAG” warning lamp operation in Diagnosis mode is not required. Go to step 6. 4. If “AIR BAG” warning lamp operates as shown in No. 1 in chart above, turn ignition switch “OFF” to reset from Diagnosis mode to User mode and to erase the memory of the malfunction. Then go to step 6. If “AIR BAG” warning lamp operates as shown in No. 2 or No. 3 in chart above, the malfunctioning part is not repaired completely, or another malfunctioning part is detected. Go to DIAGNOSTIC PROCEDURE 6, page RS-52, and repair malfunctioning part completely. 5. Turn ignition switch “ON”. “AIR BAG” warning lamp operates in User mode. Compare “AIR BAG” warning lamp operation to the chart below. RS-58 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses without CONSULT-II (Cont’d) NOTE: If switching Diagnosis mode to User mode is required while malfunction is being detected, by turning ignition switch as follows: 1) Turn ignition switch “ON”. 2) After “AIR BAG” warning lamp lights for 7 seconds, turn ignition switch “OFF” within 1 second. 3) Wait more than 3 seconds. 4) Repeat steps 1 to 3 twice (Perform 3 times in total). 5) Turn ignition switch “ON”. SRS is now in User mode. “AIR BAG” warning lamp operation — User mode — SRS condition Reference item No malfunction is detected. No further action is necessary. — GI MA EM LC EC FE CL MRS095A The system is malfunction- Go to DIAGNOSTIC PROing and needs to be CEDURE 6 (RS-52). repaired as indicated. MT AT MRS096A Air bag is deployed. Seat belt pre-tensioner is deployed. Air bag fuse, diagnosis sensor unit or harness is malfunctioning and needs MRS097A to be repaired. Go to COLLISION DIAGNOSIS (RS-63). Go to DIAGNOSTIC PROCEDURE 9 (RS-60). One of the following has Go to DIAGNOSTIC PROoccurred and needs to be CEDURE 10 (RS-62). repaired. I Meter fuse is blown. I “AIR BAG” warning lamp circuit has open or short. MRS098A I Diagnosis sensor unit is malfunctioning. TF PD AX SU BR ST DIAGNOSTIC PROCEDURE 8 (CONTINUED FROM DIAGNOSTIC PROCEDURE 6) NARS0046S03 Inspecting SRS malfunctioning record 1 CONSIDER POSSIBILITY OF NOT ERASING SELF-DIAGNOSTIC RESULT AFTER REPAIRING BT Is it the first time for maintenance of SRS? Yes or No Yes No © © Go to DIAGNOSTIC PROCEDURE 5 (RS-48). (Further inspection cannot be performed without CONSULT-II.) Diagnosis results (previously stored in the memory) might not be erased after repair. Go to DIAGNOSTIC PROCEDURE 7, step 5 (RS-58). HA SC EL IDX RS-59 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses: “AIR BAG” Warning Lamp Does Not Turn Off Trouble Diagnoses: “AIR BAG” Warning Lamp Does Not Turn Off =NARS0047 DIAGNOSTIC PROCEDURE 9 1 NARS0047S01 SEE THE DEPLOYMENT OF AIR BAG MODULE Is air bag module deployed? Yes or No Yes © Refer to COLLISION DIAGNOSIS (RS-63). No © GO TO 2. 2 CHECK AIR BAG FUSE Is SRS “Air Bag” fuse OK? SRS577 OK or NG OK © GO TO 4. NG © GO TO 3. 3 CHECK AIR BAG FUSE AGAIN Replace “AIR BAG” fuse and turn ignition switch ON. Is “AIR BAG” fuse blown again? Yes © Repair main harness and/or replace air bag harness. No © INSPECTION END RS-60 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses: “AIR BAG” Warning Lamp Does Not Turn Off (Cont’d) 4 GI CHECK DIAGNOSIS SENSOR UNIT Connect CONSULT-II and touch “START”. I Is “AIR BAG” displayed on CONSULT-II? MA EM LC EC SRS771 Yes or No Yes © GO TO 5. No © Visually check the wiring harness connection of diagnosis sensor unit. If the harness connection check result is OK, replace diagnosis sensor unit. 5 CHECK HARNESS CONNECTION FE CL MT AT Is harness connection between warning lamp and diagnosis sensor unit OK? OK or NG OK © Replace diagnosis sensor unit. NG © Connect “AIR BAG” warning lamp and diagnosis sensor unit connector properly. If “AIR BAG” warning lamp still does not go off, replace harness. TF PD AX SU BR ST BT HA SC EL IDX RS-61 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Trouble Diagnoses: “AIR BAG” Warning Lamp Does Not Turn On Trouble Diagnoses: “AIR BAG” Warning Lamp Does Not Turn On =NARS0048 DIAGNOSTIC PROCEDURE 10 1 NARS0048S01 CHECK “METER” FUSE Is meter fuse OK? SRS852 OK or NG OK © GO TO 3. NG © GO TO 2. 2 CHECK “METER” FUSE AGAIN Replace meter fuse and turn ignition switch ON. Is meter fuse blown again? Yes © Repair main harness. No © INSPECTION END 3 CHECK HARNESS CONNECTION BETWEEN DIAGNOSIS SENSOR UNIT AND “AIR BAG” WARNING LAMP Disconnect diagnosis sensor unit connector and turn ignition switch “ON”. I Does “AIR BAG” warning lamp turn on? Yes or No Yes © Replace diagnosis sensor unit. No © Check the ground circuit of “AIR BAG” warning lamp. RS-62 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Collision Diagnosis Collision Diagnosis FOR FRONTAL COLLISION =NARS0049 NARS0049S01 To repair the SRS, perform the following steps. When SRS (except the side air bag) is activated in a collision: 1) Replace the diagnosis sensor unit. 2) Remove the air bag modules (except the side air bag module) and seat belt pre-tensioner assemblies. 3) Check the SRS components using the table shown below: I Replace any SRS components showing visible signs of damage (dents, cracks and deformation). 4) Install new air bag modules (except the side air bag module) and seat belt pre-tensioner assemblies. 5) Conduct self-diagnosis using CONSULT-II or “AIR BAG” warning lamp. Refer to “SRS Operation Check” for details (RS-41). Ensure entire SRS operation properly. When SRS is not activated in a collision: 1) Check the SRS components using the table shown below: I Replace any SRS components showing visible signs of damage (dents, cracks and deformation). 2) Conduct self-diagnosis using CONSULT-II or “AIR BAG” warning lamp. Refer to “SRS Operation Check” for details (RS-41). Ensure entire SRS operation properly. SRS Inspection (For frontal collision) Part Seat belt pre-tensioner assembly REPLACE Install seat belt pretensioner with new bolts. SRS is NOT activated 1. Remove air bag module. Check harness cover and connectors for damage, terminals for deformities, and harness for binding. 2. a. Install driver air bag module into the steering wheel to check fit and alignment with the wheel. b. Install front passenger air bag module into the instrument panel to check fit with the instrument panel. 3. No damage found, reinstall with new bolts. 4. If damaged—REPLACE. Install air bag modules with new bolts. Air bag must be deployed before disposal. EM LC EC FE CL MT AT TF PD 1. Remove seat belt pre-tensioners. Check harness cover and connectors for damage, terminals for deformities, and harness for binding. 2. Check belts for damage and anchors for loose mounting. 3. Check retractor for smooth operation. 4. If no damage is found, reinstall seat belt pre-tensioner assembly. 5. If damaged—REPLACE. Install the seat belt pre-tensioners with new bolts coated with bonding agent. Seat belt pre-tensioners must be deployed before disposal. AX 1. 2. 3. 4. ST Diagnosis sensor unit REPLACE Install with new bolts. Steering wheel 1. 2. 3. 4. 5. 6. Visually check steering wheel for deformities. Check harness (built into steering wheel) and connectors for damage, and terminals for deformities. Install air bag module to check fit or alignment with steering wheel. Check steering wheel for excessive free play. If no damage is found, reinstall with bolts. If damaged—REPLACE. 1. 2. 3. 4. 5. Visually check spiral cable and combination switch for damage. Check connectors and protective tape for damage. Check steering wheel for noise, binding or heavy operation. If no damage is found, reinstall with bolts. If damaged—REPLACE. Spiral cable MA NARS0049S0101 SRS is activated Air bag module (driver REPLACE and front passenger Install with new bolts. side) GI Check case for dents, cracks or deformities. Check connectors for damage, and terminals for deformities. If no damage is found, reinstall with new bolts and ground bolt. If damaged—REPLACE. Install diagnosis sensor unit with new bolts and ground bolt coated with bonding agent. SU BR BT HA SC EL IDX RS-63 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Collision Diagnosis (Cont’d) Part SRS is activated Harness and Connec- 1. tors 2. 3. 4. Instrument panel SRS is NOT activated Check connectors for poor connection, damage, and terminals for deformities. Check harness for binding, chafing, cuts, or deformities. If no damage is found, reinstall the harness and connectors. Damaged—REPLACE damaged section of harness. Do not attempt to repair, splice or modify any SRS harness. 1. When passenger air bag inflates, check the following points for bending, deformities or cracks. I Opening portion for passenger air bag SRS366 I Passenger air bag module brackets SRS367 I The portions securing the instrument panel SRS876 2. If no damage is found, reinstall the instrument panel. 3. If damaged—REPLACE the instrument panel with bolts. RS-64 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Collision Diagnosis (Cont’d) FOR SIDE COLLISION =NARS0049S02 To repair the SRS for a side collision, perform the following steps. When the side air bag is activated in the side collision: 1) Replace the following component: − All parts of front seatback (including front seatback frame) with side air bag module (on the side on which side air bag is activated) − Side curtain air bag module (on the side on which side curtain air bag is activated) − Diagnosis sensor unit − Side air bag (Satellite) sensor (on the side on which side air bag is activated) 2) Check the SRS components and the related parts using the table shown below. I Replace any SRS components and the related parts showing visible signs of damage (dents, cracks, deformation). 3) Conduct self-diagnosis using CONSULT-II or “AIR BAG” warning lamp. Refer to “SRS Operation Check” for details (RS-41). Ensure entire SRS operation properly. When SRS is not activated in the side collision: 1) Check the SRS components and the related parts using the table shown below. I Replace any SRS components and the related parts showing visible signs of damage (dents, cracks, deformation). 2) Conduct self-diagnosis using CONSULT-II or “AIR BAG” warning lamp. Refer to “SRS Operation Check” for details (RS-41). Ensure entire SRS operation properly. SRS Inspection (For side collision) Part (LH or RH) side curtain air bag module Side air bag is activated Replace the side curtain air bag module. (Repair the center pillar inner, etc. before installing new one if damaged.) Front (LH or RH) side REPLACE all parts of air bags module front seatback with deployed side air bag module. (LH or RH) side air bag (Satellite) sensor NARS0049S0201 REPLACE the satellite sensor on the collision side with new nuts coated with bonding agent. (Repair the center pillar inner, etc. before installing new one if damaged.) GI MA EM LC EC FE CL MT AT SRS is NOT activated 1. Check for visible signs of damage (dents, tears, deformation) of the center pillar on the collision side. 2. If damaged—Remove the side curtain air bag module. 3. Check for visible signs of damaged (tears etc.) of the side curtain air bag module. 4. Check harness and connectors for damage, and terminals for deformities. 5. If no damaged is found, reinstall the side curtain air bag module with new bolts. 6. If damaged—REPLACE the side curtain air bag module with new bolts. Air bag must be deployed before disposal. 1. Check for visible signs of damage (dents, tears, deformation) of the seatback on the collision side. 2. If damaged—REPLACE the damaged seat parts with new bolts and remove the front (LH or RH) side air bag module. 3. Check for visible signs of damaged (tears etc.) of the front (LH or RH) side air bag module. 4. Check harness and connectors for damage, and terminals for deformities. 5. If no damaged is found, reinstall the front (LH or RH) side air bag module with new torx nuts coated with bonding agent. 6. If damaged—REPLACE the front (LH or RH) side air bag module with new torx nuts coated with bonding agent. Air bag must be deployed before disposal. 1. Remove the (LH or RH) side air bag (Satellite) sensor on the collision side. Check harness connectors for damage, terminals for deformities, and harness for binding. 2. Check for visible signs of damage (dents, cracks, deformation) of the LH or RH side air bag (Satellite) sensor. 3. Install the satellite sensor to check fit. 4. If no damage is found, reinstall the (LH or RH) side air bag (Satellite) sensor with new nuts coated with bonding agent. 5. If damaged—REPLACE the (LH or RH) side air bag (Satellite) sensor with new nuts coated with bonding agent. TF PD AX SU BR ST BT HA SC EL IDX RS-65 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Collision Diagnosis (Cont’d) Part Side air bag is activated SRS is NOT activated Diagnosis sensor unit REPLACE the diagnosis sensor unit with the new bolts. 1. Check case and bracket for dents, cracks or deformities. 2. Check connectors for damage, and terminals for deformities. 3. If no damage is found, reinstall the diagnosis sensor unit with new special bolts and ground bolt. 4. If damaged—REPLACE. Install the diagnosis sensor unit with new special bolts and ground bolt. Seat belt pre-tensioner assembly 1. Check if the seat belt can be extended smoothly. If the seat belt cannot be extended smoothly. – Check for deformities of the center pillar inner. – If the center pillar inner has no damage, REPLACE the seat belt pre-tensioner assembly. 2. Remove the seat belt pre-tensioner assembly on the collision side. Check harness cover and connectors for damage, terminals for deformities, and harness for binding. 3. Check for visible signs of damage (dents, cracks, deformation) of the seat belt pre-tensioner assembly. 4. If no damage is found, reinstall the seat belt pre-tensioner assembly. 5. If damaged—REPLACE the seat belt pre-tensioner assembly with new bolts coated with bonding agent. The seat belt pre-tensioner assembly must be deployed before disposal. Seat with side air bag REPLACE all parts of 1. Visually check the seat on the collision side. front seatback (includ- 2. Remove the seat on the collision side and check the following for damage and deformities. ing front seatback I Harness, connectors and terminals frame) I Frame and recliner (for front and rear seat), and also adjuster and slides (for front seat) 3. If no damage is found, reinstall the seat. 4. If damaged—REPLACE the damaged seat parts with new bolts. Center pillar inner 1. Check the center pillar inner on the collision side for damage (dents, cracks, deformation). 2. If damaged—REPAIR the center pillar inner. Trim 1. Check for visible signs of damage (dents, cracks, deformation) of the interior trim on the collision side. 2. If damaged—REPLACE the damaged trim parts. RS-66 STARTING & CHARGING SYSTEM SECTION SC GI MA EM LC EC FE CONTENTS PRECAUTIONS ...............................................................2 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″...............2 Precautions for SRS ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″ Service...............................2 Wiring Diagrams and Trouble Diagnosis.....................2 PREPARATION ...............................................................3 Special Service Tool ....................................................3 BATTERY.........................................................................4 How to Handle Battery ................................................4 METHODS OF PREVENTING OVER-DISCHARGE ......4 CHECKING ELECTROLYTE LEVEL ............................4 SPECIFIC GRAVITY CHECK ......................................5 CHARGING THE BATTERY ........................................6 Trouble Diagnoses with Battery/Starting/Charging System Tester ..............................................................7 DIAGNOSTIC RESULT ITEM CHART ..........................9 STARTING SYSTEM .....................................................10 System Description....................................................10 WITH M/T................................................................10 WITH A/T ................................................................10 Wiring Diagram - START -/With M/T .........................11 Wiring Diagram - START -/With A/T..........................12 Trouble Diagnoses with Battery/Starting/Charging System Tester ............................................................13 DIAGNOSTIC RESULT ITEM CHART ........................14 WORK FLOW ..........................................................15 DIAGNOSTIC PROCEDURE 1 ..................................16 DIAGNOSTIC PROCEDURE 2 ..................................18 MINIMUM SPECIFICATION OF CRANKING VOLTAGE REFERENCING COOLANT TEMPERATURE ......................................................19 Construction...............................................................19 Removal and Installation ...........................................19 Pinion/Clutch Check ..................................................20 CHARGING SYSTEM ....................................................21 System Description....................................................21 Wiring Diagram - CHARGE -.....................................22 Trouble Diagnoses with Battery/Starting/Charging System Tester ............................................................23 DIAGNOSTIC RESULT ITEM CHART ........................25 WORK FLOW ..........................................................26 DIAGNOSTIC PROCEDURE 1 ..................................27 DIAGNOSTIC PROCEDURE 2 ..................................28 DIAGNOSTIC PROCEDURE 3 ..................................29 MALFUNCTION INDICATOR ....................................30 Construction...............................................................30 Removal and Installation ...........................................30 SERVICE DATA AND SPECIFICATIONS (SDS) .........31 Battery........................................................................31 Starter ........................................................................31 Alternator ...................................................................31 CL MT AT TF PD AX SU BR ST RS BT HA EL IDX PRECAUTIONS Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” NASC0001 The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS composition which is available to NISSAN MODEL R50 is as follows: I For a frontal collision The Supplemental Restraint System consists of driver air bag module (located in the center of the steering wheel), front passenger air bag module (located on the instrument panel on passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. I For a side collision The Supplemental Restraint System consists of side air bag module (located in the outer side of front seat), side curtain air bag module (locating in the headliner side of front and rear seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision). WARNING: I 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. I Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connector (and by yellow harness protector or yellow insulation tape before the harness connectors). Precautions for SRS “AIR BAG” and “SEAT BELT PRE-TENSIONER” Service I I I I I I I NASC0025 Do not use electrical test equipment to check SRS circuits unless instructed to in this Service Manual. Before servicing the SRS, turn ignition switch “OFF”, disconnect battery ground cable and wait at least 3 minutes. For approximately 3 minutes after the cables are removed, it is still possible for the air bag and seat belt pre-tensioner to deploy. Therefore, do not work on any SRS connectors or wires until at least 3 minutes have passed. Diagnosis sensor unit must always be installed with their arrow marks “g” pointing towards the front of the vehicle for proper operation. Also check diagnosis sensor unit for cracks, deformities or rust before installation and replace as required. 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 driver and passenger air bag modules with the pad side facing upward and side air bag module standing with the stud bolt side setting bottom. Conduct self-diagnosis to check entire SRS for proper function after replacing any components. After air bag inflates, the front instrument panel assembly should be replaced if damaged. Wiring Diagrams and Trouble Diagnosis When you read wiring diagrams, refer to the following: I GI-11, “HOW TO READ WIRING DIAGRAMS” I EL-11, “POWER SUPPLY ROUTING” for power distribution circuit When you perform trouble diagnosis, refer to the following: I GI-35, “HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES” I GI-24, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT” SC-2 NASC0002 PREPARATION Special Service Tool Special Service Tool Tool number Tool name Description NASC0017 GI MA J-44373 Model 620 Battery/Starting/Charging system tester EM LC EC FE CL MT SEL403X AT TF PD AX SU BR ST RS BT HA EL IDX SC-3 BATTERY How to Handle Battery How to Handle Battery NASC0003 CAUTION: I If it becomes necessary to start the engine with a booster battery and jumper cables, use a 12-volt booster battery. I After connecting battery cables, ensure that they are tightly clamped to battery terminals for good contact. I Never add distilled water through the hole used to check specific gravity. METHODS OF PREVENTING OVER-DISCHARGE NASC0003S01 The following precautions must be taken to prevent over-discharging a battery. I The battery surface (particularly its top) should always be kept clean and dry. I The terminal connections should be clean and tight. I At every routine maintenance, check the electrolyte level. This also applies to batteries designated as “low maintenance” and “maintenance-free”. MEL040F I When the vehicle is not going to be used over a long period of time, disconnect the negative battery terminal. (If the vehicle has an extended storage switch, turn it off.) I Check the charge condition of the battery. Periodically check the specific gravity of the electrolyte. Keep a close check on charge condition to prevent over-discharge. MEL041F MEL042F CHECKING ELECTROLYTE LEVEL NASC0003S02 WARNING: Do not allow battery fluid to come in contact with skin, eyes, 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. SC-4 BATTERY How to Handle Battery (Cont’d) I I Remove the cell plug using a suitable tool. Add distilled water up to the MAX level. GI MA EM LC MEL043F EC Sulphation SEL709EA NASC0003S0201 A battery will be completely discharged if it is left unattended for a long time and the specific gravity will become less than 1.100. This may result in sulphation on the cell plates. To determine if a battery has been “sulphated”, note its voltage and current when charging it. As shown in the figure, less current and higher voltage are observed in the initial stage of charging sulphated batteries. A sulphated battery may sometimes be brought back into service by means of a long, slow charge, 12 hours or more, followed by a battery capacity test. CL MT AT SPECIFIC GRAVITY CHECK 1. FE NASC0003S03 Read hydrometer and thermometer indications at eye level. TF PD AX SU MEL042FA 2. Use the chart below to correct your hydrometer reading according to electrolyte temperature. Hydrometer Temperature Correction NASC0003S0301 Battery electrolyte temperature °C (°F) Add to specific gravity reading 71 (160) 0.032 66 (150) 0.028 60 (140) 0.024 54 (130) 0.020 49 (120) 0.016 43 (110) 0.012 38 (100) 0.008 32 (90) 0.004 27 (80) 0 21 (70) −0.004 16 (60) −0.008 10 (50) −0.012 SC-5 BR ST RS BT HA EL IDX BATTERY How to Handle Battery (Cont’d) Battery electrolyte temperature °C (°F) Add to specific gravity reading 4 (40) −0.016 −1 (30) −0.020 −7 (20) −0.024 −12 (10) −0.028 −18 (0) −0.032 Corrected specific gravity Approximate charge condition 1.260 - 1.280 Fully charged 1.230 - 1.250 3/4 charged 1.200 - 1.220 1/2 charged 1.170 - 1.190 1/4 charged 1.140 - 1.160 Almost discharged 1.110 - 1.130 Completely discharged CHARGING THE BATTERY NASC0003S04 CAUTION: I Do not “quick charge” a fully discharged battery. I Keep the battery away from open flame while it is being charged. I 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. I If battery electrolyte temperature rises above 60°C (140°F), stop charging. Always charge battery at a temperature below 60°C (140°F). Charging Rates NASC0003S0401 Amps Time 50 1 hour 25 2 hours 10 5 hours 5 10 hours Do not charge at more than 50 ampere rate. NOTE: The ammeter reading on your battery charger will automatically decrease as the battery charges. This indicates that the voltage of the battery is increasing normally as the state of charge improves. The charging amps indicated above refer to initial charge rate. I If, after charging, the specific gravity of any two cells varies more than .050, the battery should be replaced. SC-6 BATTERY Trouble Diagnoses with Battery/Starting/Charging System Tester Trouble Diagnoses with Battery/Starting/Charging System Tester GI NASC0018 CAUTION: When working with batteries, always wear appropriate eye protection. NOTE: I To ensure a complete and thorough diagnosis, the battery, starter and alternator test segments must be done as a set from start to finish. I If battery surface charge is detected while testing, the tester will prompt you to turn on the headlamps to remove the surface charge. I If necessary, the tester will prompt you to determine if the battery temperature is above or below 0°C (32°F). Choose the appropriate selection by pressing the up or down arrow button, then press “ENTER” to make the selection. MA EM LC EC FE CL MT 1. SEL404X Turn off all loads on the vehicle electrical system. Clean or repair as necessary. 2. Visually inspect the battery, battery terminals and cable ends with ignition switch in “OFF” position. NOTE: The contact surface between the battery terminals, cable ends and tester leads must be clean for a valid test. A poor connection will prevent testing and a “CHECK CONNECTION” message will appear during the test procedures. If this occurs, clean the battery post and terminals, reconnect them and restart the test. 3. Connect the red tester lead clamp to the positive battery terminal, and the black to the negative terminal. AT TF PD AX SU BR ST RS BT 4. The tester will turn on automatically. Using the arrow keys, select “IN VEHICLE” on the tester and then press the “ENTER” key. HA EL IDX SEL405X SC-7 BATTERY Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d) 5. SEL406X Locate the battery type and rating stamped or written on the top case of the battery to be tested. NOTE: The battery type and rating will have either of the following. CCA: Cold Cranking Amps (490 CCA, 550 CCA, etc.) JIS: Japanese Industrial Standard. Battery is stamped with a number such as: 80D26L: 80 (rank of output), D (physical size-depth), 26 (width in cm). The last character L (post configuration) is not input into the tester. The tester requires the rating for the battery be entered exactly as it is written or stamped on the battery. Do not attempt a CCA conversion for JIS stamped batteries. JIS must be input directly. 6. Using the arrow and “ENTER” keys alternately, select the battery type and rating. NOTE: The tester lists five choices; CCA, JIS, IEC, DIN, and EN. Only use CCA or JIS. 7. Press “ENTER” to begin the test. Diagnosis results are displayed on the tester. Refer to “DIAGNOSTIC RESULT ITEM CHART” on the next page. SEL407X 8. SEL576X Press “ENTER”, then test output code is displayed. Record the test output code on the repair order. 9. Toggle back to the “DIAGNOSTIC SCREEN” for test results. NOTE: I If necessary, the tester will ask the user to determine if the battery has just been charged. Choose the appropriate selection by pressing the up or down arrow button and then press the “ENTER” button to make the selection. I When testing a battery installed in a vehicle that has recently been driven, select “BEFORE CHANGE”. I If the battery has just been slow charged due to a “CHARGE & RETEST” decision by the tester, and the tester asks the user “BEFORE CHARGE/AFTER CHARGE”, select “AFTER CHARGE”. SC-8 BATTERY Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d) DIAGNOSTIC RESULT ITEM CHART Diagnostic item NASC0018S01 GI Service procedure GOOD BATTERY Battery is OK, go to “Trouble Diagnoses”, “STARTING SYSTEM”. Refer to SC-13. MA REPLACE BATTERY Replace battery. Before replacing battery, clean the battery cable clamps and battery posts. Perform battery test again with Battery/Starting/Charging system tester. If second test result is “Replace Battery”, then do so. Perform battery test again to confirm repair. EM BAD CELL-REPLACE Replace the battery. Perform battery test again with Battery/Starting/Charging system tester to confirm repair. GOOD-RECHARGE Perform the slow battery charging procedure. (Initial rate of charge is 10A for 12 hours.) Perform battery test again with Battery/Starting/Charging system tester. CHARGE & RETEST Perform the slow battery charging. (Initial rate of charge is 10A for 12 hours.) Perform battery test again with Battery/Starting/Charging system tester to confirm repair. NOTE: If the tester asks the user “BEFORE CHARGE/AFTER CHARGE”, select “AFTER CHARGE”. LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA EL IDX SC-9 STARTING SYSTEM System Description System Description WITH M/T NASC0004 NASC0004S02 Power is supplied at all times I to ignition switch terminal 1 I through 40A fusible link (letter e, located in the fuse and fusible link box). With the ignition switch in the START position, power is supplied I through terminal 5 of the ignition switch I to clutch interlock relay terminal 3. With the ignition switch in the ON or START position, power is supplied I through 7.5A fuse [No. 11, located in the fuse block (J/B)] or 10A fuse [No. 16, located in the fuse block (J/B)] I to clutch interlock relay terminal 1. If clutch pedal is depressed, ground is supplied I to clutch interlock relay terminal 2 I through clutch interlock switch I from body grounds M111, M147, M66, M4 and M157. The clutch interlock relay is energized and power is supplied I from terminal 5 of the clutch interlock relay I to terminal 2 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 cylinder block. With power and ground supplied, cranking occurs and the engine starts. WITH A/T NASC0004S01 Power is supplied at all times I to ignition switch terminal 1 I through 40A fusible link (letter e, located in the fuse and fusible link box). With the ignition switch in the ON or START position, power is supplied I through 10A fuse [No. 18, located in the fuse block (J/B)] I to park/neutral position relay terminal 1. Also, with the ignition switch in the START position, power is supplied I from ignition switch terminal 5 I to park/neutral position relay terminal 3. With the selector lever in the P or N position, ground is supplied I to park/neutral position relay terminal 2 through the park/neutral position switch I from body grounds B55 and B75. Then park/neutral position relay is energized and power is supplied I from park/neutral position relay terminal 5 I to terminal 2 of the starter motor windings. The starter motor plunger closes and provides a closed circuit between the battery and starter motor. The starter motor is grounded to the engine block. With power and ground supplied, cranking occurs and the engine starts. SC-10 STARTING SYSTEM Wiring Diagram — START —/With M/T Wiring Diagram — START —/With M/T NASC0005 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA EL MEL409R SC-11 IDX STARTING SYSTEM Wiring Diagram — START —/With A/T Wiring Diagram — START —/With A/T NASC0021 MEL124Q SC-12 STARTING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester Trouble Diagnoses with Battery/Starting/Charging System Tester GI NASC0019 NOTE: To ensure a complete and thorough diagnosis, the battery, starter and alternator test segments must be done as a set from start to finish. MA EM LC 1. 2. 3. Turn off all loads on the vehicle electrical system. Perform battery test with Battery/Starting/Charging system tester. Refer to SC-7. Press “ENTER” to begin the starting system test. EC FE CL MT SEL408X 4. Start the engine. AT TF PD AX SU SEL409X 5. Diagnosis result is displayed on the tester. Refer to “DIAGNOSTIC RESULT ITEM CHART” on the next page. NOTE: I If the starter performs normally but the engine does not start, perform engine diagnosis. I For intermittent “NO CRANK” or “NO STARTER OPERATION” incidents, go to DIAGNOSTIC PROCEDURE 2. BR ST RS BT SEL410X HA EL IDX SC-13 STARTING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d) DIAGNOSTIC RESULT ITEM CHART Diagnostic item NASC0019S01 Service procedure CRANKING VOLTAGE NORMAL Go to “WORK FLOW”, SC-15. CRANKING VOLTAGE LOW Go to “WORK FLOW”, SC-15. CHARGE BATTERY Perform the slow battery charging procedure. (Initial rate of charge is 10A for 12 hours.) Perform battery test again with Battery/Starting/Charging system tester. Refer to SC-7. REPLACE BATTERY Before replacing battery, clean the battery cable clamps and battery posts. Perform battery test again with Battery/Starting/Charging system tester. Refer to SC-7. If second test result is “REPLACE BATTERY”, then do so. Perform battery test again to confirm repair. SC-14 STARTING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d) WORK FLOW NASC0019S02 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SEL411XA *1 *2 SC-7 SC-19 *3 SC-16 *4 SC-18 EL IDX SC-15 STARTING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d) DIAGNOSTIC PROCEDURE 1 Check “B” Terminal Circuit 1 1. 2. 3. 4. 5. NASC0019S03 NASC0019S0301 CHECK POWER SUPPLY FOR STARTER MOTOR “B” TERMINAL Remove the fuel pump fuse. Crank or start the engine (where possible) until the fuel pressure is released. Turn the ignition switch OFF. Check that the starter motor B terminal E108 terminal 1 (B/R) connection is clean and tight. Check voltage between starter motor B terminal E108 terminal 1 (B/R) and ground using a digital circuit tester. SEL961XA OK or NG OK © GO TO 2. NG © Check harness between the battery and the starter motor for open circuit. 2 CHECK BATTERY CABLE CONNECTION QUALITY (VOLTAGE DROP TEST) 1. Check voltage between starter motor B terminal E108 terminal 1 (B/R) and battery positive terminal using a digital circuit tester. SEL962XA OK or NG OK © GO TO 3. NG © Check harness between the battery and the starter motor for poor continuity. SC-16 STARTING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d) 3 GI CHECK STARTER MOTOR GROUND CIRCUIT (VOLTAGE DROP TEST) 1. Check voltage between starter motor case and battery negative terminal using a digital circuit tester. MA EM LC EC SEL666YB OK or NG OK © Starter motor “B” terminal circuit is OK. Further inspection necessary. Refer to “WORK FLOW”, SC-15. NG © Check the starter motor case and ground for poor continuity. FE CL MT AT TF PD AX SU BR ST RS BT HA EL IDX SC-17 STARTING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d) DIAGNOSTIC PROCEDURE 2 Check “S” Terminal Circuit 1 1. 2. 3. 4. 5. =NASC0019S04 NASC0019S0401 CHECK POWER SUPPLY FOR STARTER MOTOR “S” TERMINAL Remove the fuel pump fuse. Crank or start the engine (where possible) until the fuel pressure is released. Turn the ignition switch OFF. Disconnect starter motor terminal 2 connector. Check voltage between starter motor connector E147 terminal 2 (B/P) and ground using a digital circuit tester. SEL948X OK or NG OK © GO TO 2. NG © Check the following. I 40A fusible link (letter e, located in fuse and fusible link box) I Clutch interlock relay or park/neutral position relay I Harness for open or short 2 CHECK “S” TERMINAL CONNECTION QUALITY (VOLTAGE DROP TEST) 1. Connect starter motor terminal 2 connector. 2. Check voltage between starter motor connector E147 terminal 2 (B/P) and battery positive terminal using a digital circuit tester. SEL949X OK or NG OK © Starter motor “S” terminal circuit is OK. Further inspection necessary. Refer to “WORK FLOW”, SC-15. NG © Check harness between the battery and the starter motor “S” terminal for poor continuity. SC-18 STARTING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d) MINIMUM SPECIFICATION OF CRANKING VOLTAGE GI REFERENCING COOLANT TEMPERATURE =NASC0019S05 Engine coolant temperature Voltage V −30°C to −20°C (−22°F to −4°F) 8.6 −19°C to −10°C (−2°F to 14°F) 9.1 −9°C to 0°C (16°F to 32°F) 9.5 More than 1°C (More than 34°F) 9.9 Construction MA EM LC EC NASC0006 FE CL MT AT TF PD AX SU BR MEL943OA ST RS BT Removal and Installation NASC0007 HA EL IDX SEL936Y SC-19 STARTING SYSTEM Pinion/Clutch Check Pinion/Clutch Check 1. I 2. I 3. I NASC0008 Inspect pinion teeth. Replace pinion if teeth are worn or damaged. (Also check condition of ring gear teeth.) Inspect reduction gear teeth. Replace reduction gear if teeth are worn or damaged. (Also check condition of armature shaft gear teeth.) 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. SC-20 CHARGING SYSTEM System Description System Description NASC0009 The alternator 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 alternator terminal S through: I 120A fusible link (letter a, located in the fuse and fusible link box), and I 7.5A fuse (No. 65, located in the fuse and fusible link box). Terminal B supplies power to charge the battery and operate the vehicle’s electrical system. Output voltage is controlled by the IC regulator at terminal S detecting the input voltage. The charging circuit is protected by the 120A fusible link. Terminal E of the alternator supplies ground through body ground E101. With the ignition switch in the ON or START position, power is supplied I through 10A fuse [No. 8, located in the fuse block (J/B)] I to combination meter terminal 66 for the charge warning lamp. Ground is supplied to combination meter terminal 68 through alternator terminal 1 (L). With power and ground supplied, the charge warning lamp will illuminate. When the alternator is providing sufficient voltage 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 malfunction is indicated. GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA EL IDX SC-21 CHARGING SYSTEM Wiring Diagram — CHARGE — Wiring Diagram — CHARGE — NASC0010 MEL125Q SC-22 CHARGING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester Trouble Diagnoses with Battery/Starting/Charging System Tester GI NASC0020 NOTE: To ensure a complete and thorough diagnosis, the battery, starter and alternator test segments must be done as a set from start to finish. MA EM LC 1. 2. 3. 4. Turn off all loads on the vehicle electrical system. Perform battery and starting system test with Battery/Starting/ Charging system tester. Press “ENTER” to begin the charging system test. Start engine. EC FE CL MT SEL417X 5. SEL418X Press “ENTER” until “LOADS OFF REV ENGINE 5 SEC” is displayed. 6. Raise and hold the engine speed at 1,500 to 2,000 rpm for about 5 seconds, then return to the engine to idle. Once the increase in engine rpm is detected, press “ENTER” to continue. NOTE: I If after 30 seconds an increase in engine idle speed is not detected, “RPM NOT DETECTED” will display. I Some engines may have a higher idle initially after starting, particularly when the engine is cold. The tester may detect this without any other action being taken. If this occurs, continue on with the testing process. The final results will not be affected. AT TF PD AX SU BR ST RS BT 7. The tester now checks the engine at idle and performs the DIODE/RIPPLE check. 8. When complete, the tester will prompt you to turn on the following electrical loads. I Heater fun set to highest. Do not run the A/C or windshield defroster. I Headlamp high beam I Rear window defogger NOTE: Do not run the windshield wipers or any other cyclical loads. SEL419X SC-23 HA EL IDX CHARGING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d) 9. Press “ENTER” to continue. SEL420X 10. Raise and hold the engine speed at 1,500 to 2,000 rpm for about 5 seconds, then return the engine to idle. Once the increase in engine rpm is detected, press “ENTER” to continue. NOTE: If after 30 seconds an increase in engine idle speed is not detected, “RPM NOT DETECTED” will be displayed. Press “ENTER” to restart the test. SEL421X 11. Diagnostic result is displayed on the tester. Refer to the following “DIAGNOSTIC RESULT ITEM CHART” on the next page. SEL422X 12. Press “ENTER” then test output code is displayed. Record the test output code on the repair order. 13. Toggle back to the “DIAGNOSTIC SCREEN” for test results. SEL577X SC-24 CHARGING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d) DIAGNOSTIC RESULT ITEM CHART Diagnostic item NASC0020S01 GI Service procedure CHARGING SYSTEM NORMAL Charging system is normal and will also show DIODE RIPPLE test result. NO CHARGING VOLTAGE Go to “WORK FLOW”, SC-26. LOW CHARGING VOLTAGE Go to “WORK FLOW”, SC-26. HIGH CHARGING VOLTAGE Go to “WORK FLOW”, SC-26. DIODE RIPPLE NORMAL Diode ripple is OK and will also show CHARGING VOLTAGE test result. EXCESS RIPPLE DETECTED Replace the alternator. Perform “DIODE RIPPLE” test again using Battery/Starting/ Charging system tester to confirm repair. DIODE RIPPLE NOT DETECTED Go to “WORK FLOW”, SC-26. MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA EL IDX SC-25 CHARGING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d) WORK FLOW NASC0020S02 SEL423X SC-26 CHARGING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d) DIAGNOSTIC PROCEDURE 1 Check “L” Terminal Circuit 1 NASC0020S03 GI NASC0020S0301 MA CHECK “L” TERMINAL CONNECTION Check to see if “L” terminal is clean and tight. OK or NG EM OK © GO TO 2. NG © Repair “L” terminal connection. Confirm repair by performing complete Battery/Starting/ Charging system test. 2 LC EC CHECK “L” TERMINAL CIRCUIT 1. Disconnect E106 connector from alternator. 2. Apply ground to alternator connector E106 terminal 1 (Y/B) with the ignition switch in the ON position. FE CL MT AT SEL424XA TF OK or NG OK © Replace the alternator. Confirm repair by performing complete Battery/Starting/Charging system test. NG © Check the following. I 10A fuse [No. 8, located in fuse block (J/B)] I CHARGE lamp I Harness for open or short between combination meter and fuse I Harness for open or short between combination meter and alternator PD AX SU BR ST RS BT HA EL IDX SC-27 CHARGING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d) DIAGNOSTIC PROCEDURE 2 Check “B” Terminal Circuit 1 =NASC0020S04 NASC0020S0401 CHECK “B” TERMINAL CONNECTION Check to see if “B” terminal is clean and tight. OK or NG OK © GO TO 2. Confirm repair by performing complete Battery/Starting/Charging system test. NG © Repair “B” terminal connection. 2 CHECK ALTERNATOR “B” TERMINAL CIRCUIT Check voltage between alternator B terminal E107 (B/R) and ground using a digital circuit tester. SEL967XA OK or NG OK © GO TO 3. NG © Check the following. I 120A fusible link (letter a, located in fuse and fusible link box) I Harness for open or short between alternator and fusible link 3 CHECK “B” TERMINAL CONNECTION QUALITY (VOLTAGE DROP TEST) Check voltage between alternator B terminal E107 (B/R) and battery positive terminal using a digital circuit tester. SEL968XA OK or NG OK © Replace the alternator. Confirm repair by performing complete Battery/Starting/Charging system test. NG © Check harness between the battery and the alternator for poor continuity. SC-28 CHARGING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d) DIAGNOSTIC PROCEDURE 3 Check “S” Terminal Circuit 1 =NASC0020S05 GI NASC0020S0501 MA CHECK “S” TERMINAL CONNECTION Check to see if “S” terminal is clean and tight. OK or NG EM OK © GO TO 2. NG © Repair “S” terminal connection. Confirm repair by performing complete Battery/Starting/ Charging system test. 2 LC EC CHECK ALTERNATOR “S” TERMINAL CIRCUIT Check voltage between alternator connector E106 terminal 2 (L/Y) and ground using a digital circuit tester. FE CL MT AT SEL427XA OK or NG TF PD OK © GO TO 3. NG © Check the following. I 7.5A fuse (No. 65, located in fuse and fusible link box) I Harness for open or short between alternator and fuse AX 3 CHECK “S” TERMINAL CONNECTION QUALITY (VOLTAGE DROP TEST) Check voltage between alternator connector E106 terminal 2 (L/Y) and battery positive terminal using a digital circuit tester. SU BR ST RS BT SEL428XA OK or NG OK © Replace the alternator. Confirm repair by performing complete Battery/Starting/Charging system test. NG © Check harness between the battery and the alternator for poor continuity. HA EL IDX SC-29 CHARGING SYSTEM Trouble Diagnoses with Battery/Starting/Charging System Tester (Cont’d) MALFUNCTION INDICATOR =NASC0020S06 The IC regulator warning function activates to illuminate “CHARGE” warning lamp, if any of the following symptoms occur while alternator is operating: I Excessive voltage is produced. I No voltage is produced. Construction NASC0012 SEL667Y Removal and Installation MEL952LB SC-30 NASC0013 SERVICE DATA AND SPECIFICATIONS (SDS) Battery Battery Type NASC0022 80D23R Capacity MA 12V-52AH Cold cranking current (For reference value) 582A Starter EM NASC0023 M0T50571 Type MITSUBISHI make System voltage 12V Terminal voltage LC EC Reduction gear type No-load GI FE 11.0V Current Less than 90A Revolution CL More than 2,700 rpm Minimum diameter of commutator 28.8 mm (1.134 in) Minimum length of brush 7.0 mm (0.276 in) Brush spring tension MT 15.0 - 20.4 N (1.53 - 2.08 kg, 3.37 - 4.59 lb) Clearance between bearing metal and armature shaft AT Less than 0.2 mm (0.008 in) Movement “” in height of pinion assembly 0.5 - 2.0 mm (0.020 - 0.079 in) Alternator TF NASC0024 A3TB4291 PD Type MITSUBISHI make Nominal rating 12V-110A Ground polarity Negative Minimum revolution under no-load (When 13.5V is applied) Less than 1,300 rpm More than 35A/1,300 rpm More than 91A/2,500 rpm More than 110A/5,000 rpm Hot output current (When 13.5V is applied) Regulated output voltage 14.1 - 14.7V Minimum length of brush More than 5.00 mm (0.197 in) Brush spring pressure AX SU BR ST 4.8 - 6.0 N (490 - 610 g, 17.28 - 21.51 oz) Slip ring minimum outer diameter More than 22.1 mm (0.870 in) Rotor (Field coil) resistance 1.7 - 2.1Ω RS BT HA EL IDX SC-31 NOTES PROPELLER SHAFT & DIFFERENTIAL CARRIER SECTION PD GI MA EM LC EC FE CONTENTS PROPELLER SHAFT ......................................................3 Preparation ..................................................................3 SPECIAL SERVICE TOOLS ........................................3 Noise, Vibration and Harshness (NVH) Troubleshooting ...........................................................4 NVH TROUBLESHOOTING CHART ............................4 Components.................................................................5 FRONT PROPELLER SHAFT .....................................5 REAR PROPELLER SHAFT .......................................6 On-vehicle Service.......................................................8 PROPELLER SHAFT VIBRATION ...............................8 APPEARANCE CHECKING ........................................8 Removal and Installation .............................................8 Inspection.....................................................................9 Disassembly.................................................................9 CENTER BEARING - 2WD - .......................................9 JOURNAL (71H AND 80B)........................................10 Assembly ...................................................................11 CENTER BEARING - 2WD - .....................................11 JOURNAL (71H AND 80B)........................................11 Service Data and Specifications (SDS).....................12 GENERAL SPECIFICATIONS ...................................12 SERVICE DATA .......................................................13 SNAP RING (80B)....................................................13 SNAP RING (71H) ...................................................13 SNAP RING (1310) ..................................................13 R200A FRONT FINAL DRIVE ...................................................14 Preparation ................................................................14 SPECIAL SERVICE TOOLS ......................................14 Noise, Vibration and Harshness (NVH) Troubleshooting .........................................................16 On-vehicle Service.....................................................16 FRONT OIL SEAL REPLACEMENT...........................16 REAR COVER GASKET REPLACEMENT..................17 Components...............................................................18 Removal and Installation ...........................................19 REMOVAL ...............................................................19 INSTALLATION........................................................19 CL Disassembly...............................................................19 PRE-INSPECTION ...................................................19 FINAL DRIVE HOUSING ..........................................20 DIFFERENTIAL CASE ..............................................22 DIFFERENTIAL SIDE SHAFT ...................................23 Inspection...................................................................24 RING GEAR AND DRIVE PINION .............................24 DIFFERENTIAL CASE ASSEMBLY ...........................24 BEARING ................................................................24 Adjustment .................................................................25 SIDE BEARING PRELOAD .......................................25 PINION GEAR HEIGHT AND PINION BEARING PRELOAD ...............................................................26 TOOTH CONTACT ...................................................30 Assembly ...................................................................31 DIFFERENTIAL SIDE SHAFT ...................................31 DIFFERENTIAL CASE ..............................................32 FINAL DRIVE HOUSING ..........................................33 Service Data and Specifications (SDS).....................37 R200A.....................................................................37 H233B REAR FINAL DRIVE .....................................................39 Preparation ................................................................39 SPECIAL SERVICE TOOLS ......................................39 Noise, Vibration and Harshness (NVH) Troubleshooting .........................................................41 On-vehicle Service.....................................................41 FRONT OIL SEAL REPLACEMENT...........................41 Components...............................................................43 Removal and Installation ...........................................44 REMOVAL ...............................................................44 INSTALLATION........................................................44 Disassembly...............................................................44 PRE-INSPECTION ...................................................44 DIFFERENTIAL CARRIER ........................................45 DIFFERENTIAL CASE ..............................................47 Inspection...................................................................48 RING GEAR AND DRIVE PINION .............................48 DIFFERENTIAL CASE ASSEMBLY ...........................48 MT AT TF AX SU BR ST RS BT HA SC EL IDX CONTENTS BEARING ................................................................48 Limited Slip Differential..............................................48 PREPARATION FOR DISASSEMBLY ........................48 DISASSEMBLY ........................................................49 INSPECTION ...........................................................50 ADJUSTMENT .........................................................51 ASSEMBLY .............................................................52 Adjustment .................................................................54 PINION GEAR HEIGHT ............................................54 PD-2 (Cont’d) TOOTH CONTACT ...................................................57 Assembly ...................................................................58 DIFFERENTIAL CASE ..............................................58 DIFFERENTIAL CARRIER ........................................59 Service Data and Specifications (SDS).....................62 H233B.....................................................................62 PROPELLER SHAFT Preparation Preparation GI SPECIAL SERVICE TOOLS NAPD0001 The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name MA Description EM KV38108300 (J44195) Companion flange wrench Removing and installing propeller shaft lock nut, and drive pinion lock nut LC EC NT771 ST3090S000 ( — ) Drive pinion rear inner race puller set 1 ST30031000 (J22912-01) Puller 2 ST30901000 (J26010-01) Base Removing and installing drive pinion rear inner cone a: 79 mm (3.11 in) dia. b: 45 mm (1.77 in) dia. c: 35 mm (1.38 in) dia. FE CL MT AT NT527 TF AX SU BR ST RS BT HA SC EL IDX PD-3 PD-24, 48 Improper gear contact PD-30, 57 Tooth surfaces worn PD-24, 48 PD-19, 44 × × PROPELLER SHAFT — × DIFFERENTIAL — × DRIVE SHAFT AX-3 × AXLE AX-3 × SUSPENSION SU-4 × TIRES SU-4 × ROAD WHEEL SU-4 × BRAKES BR-7 × STEERING ST-6 × × × × × × × × × × × × × × × × =NAPD0049 — NAPD0049S01 × Improper gear oil × — × × Companion flange excessive runout × × Incorrect backlash PROPELLER SHAFT × Rough gear tooth × PD-8 Noise, Vibration and Harshness (NVH) Troubleshooting × Excessive runout PD-8 Noise, Vibration and Harshness (NVH) Troubleshooting × × × × × × × × × × × × Rotation imbalance — × Excessive joint angle — × Center bearing mounting (insulator) cracks, damage or deterioration — × Excessive center bearing axial end play PD-6 NVH TROUBLESHOOTING CHART Noise Shake Vibration Noise Center bearing improper installation — Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts. Reference page PROPELLER SHAFT DIFFERENTIAL Possible cause and SUSPECTED PARTS Symptom ×: Applicable PD-4 Uneven rotation torque PROPELLER SHAFT Components Components FRONT PROPELLER SHAFT NAPD0002 GI NAPD0002S01 MA EM LC EC FE CL MT AT TF SPD517A AX SU BR ST RS BT HA SC EL IDX PD-5 PROPELLER SHAFT Components (Cont’d) REAR PROPELLER SHAFT NAPD0002S02 SPD524A SPD522A PD-6 PROPELLER SHAFT Components (Cont’d) GI MA EM LC EC FE CL MT AT TF SPD469AA AX SU BR ST RS BT HA SC EL SPD468AA IDX PD-7 PROPELLER SHAFT On-vehicle Service On-vehicle Service PROPELLER SHAFT VIBRATION NAPD0003 If vibration is present at high speed, inspect propeller shaft runout first. 1. Raise rear wheels. 2. Measure propeller shaft runout at several points by rotating final drive companion flange with hands. Runout limit: 0.6 mm (0.024 in) Propeller shaft runout measuring points: Unit: mm (in) SPD356A Distance A B C 3S80B-2BJ 2WD M/T 162 (6.38) 240 (9.45) 240 (9.45) 3F80B-2BJ 2WD A/T 372.5 (14.67) 240 (9.45) 240 (9.45) 280 (11.02) 480.8 (18.93) 266.5 (10.49) 2S1310 Part-time 4WD 280 (11.02) 480 (18.90) 266.5 (10.49) 2S80B-T Full-time 4WD 280 (11.02) 463.5 (18.25) 266.5 (10.49) Part-time 4WD 179.5 (7.07) — — Full-time 4WD 173.5 (6.83) — — 2F71H SPD525A 3. 4. 5. If runout exceeds specifications, disconnect propeller shaft at final drive companion flange; then rotate companion flange 180 degrees and reconnect propeller shaft. Check runout again. If runout still exceeds specifications, replace propeller shaft assembly. Perform road test. APPEARANCE CHECKING I SPD102 I Removal and Installation I NAPD0004 Inspect propeller shaft tube surface for dents or cracks. If damaged, replace propeller shaft assembly. If center bearing is noisy or damaged, replace center bearing. NAPD0005 Put match marks on flanges and separate propeller shaft from final drive. SPD103 PD-8 PROPELLER SHAFT Removal and Installation (Cont’d) I Draw out propeller shaft from transmission and plug up rear end of transmission rear extension housing. GI MA EM LC SPD359 Inspection I EC NAPD0006 Inspect propeller shaft runout. If runout exceeds specifications, replace propeller shaft assembly. Runout limit: 0.6 mm (0.024 in) FE CL MT SPD106 I If the play exceeds specifications, replace propeller shaft assembly. Journal axial play: 0.02 mm (0.0008 in) or less AT TF AX SU SPD874 Disassembly CENTER BEARING — 2WD — 1. NAPD0007 NAPD0007S01 Put match marks on flanges, and separate 2nd tube from 1st tube. BR ST RS BT SPD109 2. Put match marks on the flange and shaft. HA SC EL IDX SPD110 PD-9 PROPELLER SHAFT Disassembly (Cont’d) 3. 4. Remove locking nut with Tool. Tool number: KV38108300 (J44195) Remove companion flange with puller. SPD475A 5. Remove center bearing with Tool and press. Tool number: ST30031000 (J22912-01) SPD113 JOURNAL (71H AND 80B) NAPD0007S02 1. Put match marks on shaft and flange or yoke. 2. Remove snap ring. 3. Remove pushed out journal bearing by lightly tapping yoke with a hammer, taking care not to damage journal and yoke hole. SPD128 SPD731 SPD732 PD-10 PROPELLER SHAFT Disassembly (Cont’d) 4. Remove bearing at opposite side in above operation. Put marks on disassembled parts so that they can be reinstalled in their original positions from which they were removed. GI MA EM LC SPD131 Assembly CENTER BEARING — 2WD — I I EC NAPD0008 NAPD0008S01 When installing center bearing, position the “F” mark on center bearing toward front of vehicle. Apply a coat of multi-purpose lithium grease containing molybdenum disulfide to the end face of the center bearing and both sides of the washer. FE CL MT SPD114 I I AT Stake the nut. Always use new one. Align match marks when assembling tubes. TF AX SU SPD117 JOURNAL (71H AND 80B) NAPD0008S02 1. Assemble journal bearing. Apply recommended multi-purpose grease on bearing inner surface. When assembling, be careful that needle bearing does not fall down. BR ST RS BT SPD133 2. Select snap ring that will provide specified play in axial direction of journal, and install them. Refer to SDS, PD-13. Select snap rings with a difference in thickness at both sides within 0.06 mm (0.0024 in). HA SC EL IDX SPD134 PD-11 PROPELLER SHAFT Assembly (Cont’d) 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 SPD732 SPD874 Service Data and Specifications (SDS) GENERAL SPECIFICATIONS 2WD Model NAPD0009 NAPD0009S01 Transmission Propeller shaft model M/T A/T 3S80B-2BJ 3F80B-2BJ Number of joints 3 Coupling method with transmission Sleeve type Type of journal bearings Distance between yokes Solid type (disassembly type — without Birfield joint —) mm (in) 80 (3.15) 1st Shaft length (Spider to spider) mm (in) Shaft outer diameter Flange type 612 (24.19) 650 (25.59) 2nd 749 (29.49) 1st 75 (2.95) 2nd 65 (2.56) mm (in) 4WD Model NAPD0009S02 Rear Front Location A/T M/T Full-time Part-time Propeller shaft model 2F71H 2S1310 Number of joints Part time 2S80B-T 2 Coupling method with transmission Flange type Type of journal bearings Distance between yokes Sleeve type Solid type (disassembly type) mm (in) Shaft length (Spider to spider) Shaft outer diameter Full time mm (in) mm (in) 71 (2.80) 553 (21.77) 80 (3.15) 565 (22.24) 50.8 (2.000) PD-12 965.1 (38.00) 76.2 (3.000) 927 (36.50) 960 (37.80) 75 and 63.5 (2.95 and 2.500) PROPELLER SHAFT Service Data and Specifications (SDS) (Cont’d) SERVICE DATA NAPD0010 GI Unit: mm (in) Propeller shaft runout limit 0.6 (0.024) Journal axial play MA 0.02 (0.0008) or less SNAP RING (80B) NAPD0011 EM 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-C9400 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 LC EC FE CL MT *: Always check with the Parts Department for the latest parts information. SNAP RING (71H) NAPD0012 AT Unit: mm (in) Thickness Color Part number* 1.99 (0.0783) White 37146-01G00 2.02 (0.0795) Yellow 37147-01G00 2.05 (0.0807) Red 37148-01G00 2.08 (0.0819) Green 37149-01G00 2.11 (0.0831) Blue 37150-01G00 2.14 (0.0843) Light brown 37151-01G00 2.17 (0.0854) Pink 37152-01G00 2.20 (0.0866) No paint 37153-01G00 TF AX SU BR *: Always check with the Parts Department for the latest parts information. SNAP RING (1310) NAPD0052 ST 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-C9400 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 RS BT HA SC EL *: Always check with the Parts Department for the latest parts information. IDX PD-13 FRONT FINAL DRIVE R200A Preparation Preparation SPECIAL SERVICE TOOLS NAPD0013 The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name ST3127S000 (See J25765-A) Preload gauge 1 GG91030000 (J25765) Torque wrench 2 HT62940000 ( — ) Socket adapter 3 HT62900000 ( — ) Socket adapter Description Measuring pinion bearing preload and total preload NT124 KV38100800 (J34310, J25604-01) Differential attachment Mounting final drive (To use, make a new hole.) a: 152 mm (5.98 in) NT119 KV38108300 (J44195) Companion flange wrench Removing and installing propeller shaft lock nut, and drive pinion lock nut NT771 ST3090S000 ( — ) Drive pinion rear inner race puller set 1 ST30031000 (J22912-01) Puller 2 ST30901000 (J26010-01) Base ST3306S001 Differential side bearing puller set 1 ST33051001 (J22888-20) Body 2 ST33061000 (J8107-2) Adapter Removing and installing drive pinion rear inner cone a: 79 mm (3.11 in) dia. b: 45 mm (1.77 in) dia. c: 35 mm (1.38 in) dia. NT527 Removing and installing differential side bearing inner cone a: 28.5 mm (1.122 in) dia. b: 38 mm (1.50 in) dia. NT072 KV38100300 (J25523) Differential side bearing drift Installing side bearing inner cone a: 54 mm (2.13 in) dia. b: 46 mm (1.81 in) dia. c: 32 mm (1.26 in) dia. NT085 PD-14 FRONT FINAL DRIVE R200A Preparation (Cont’d) Tool number (Kent-Moore No.) Tool name GI Description KV38100600 (J25267) Side bearing spacer drift Installing side bearing spacer a: 8 mm (0.31 in) b: R42.5 mm (1.673 in) NT528 ST30611000 (J25742-1) Drift Installing pinion rear bearing outer race (Use with ST30621000 or ST30613000) MA EM LC EC FE NT090 ST30621000 (J25742-5) Drift Installing pinion rear bearing outer race (Use with ST30611000) a: 79 mm (3.11 in) dia. b: 59 mm (2.32 in) dia. CL MT NT073 ST30613000 (J25742-3) Drift Installing pinion front bearing outer race (Use with ST30611000) a: 72 mm (2.83 in) dia. b: 48 mm (1.89 in) dia. AT TF NT073 KV38100500 (J25273) Gear carrier front oil seal drift Installing front oil seal a: 85 mm (3.35 in) dia. b: 60 mm (2.36 in) dia. AX NT115 KV38100200 (J26233) Gear carrier side oil seal drift Installing side oil seal SU BR ST NT120 (J34309) Differential shim selector Adjusting bearing pre-load and gear height RS BT HA NT134 (J25269-4) Side bearing discs (2 Req’d) Selecting pinion height adjusting washer SC EL NT136 IDX PD-15 FRONT FINAL DRIVE R200A Preparation (Cont’d) Tool number (Kent-Moore No.) Tool name Description (J8129) Spring gauge Measuring carrier turning torque NT127 Noise, Vibration and Harshness (NVH) Troubleshooting NAPD0050 Refer to “NVH TROUBLESHOOTING CHART”, PD-4. On-vehicle Service FRONT OIL SEAL REPLACEMENT 1. 2. Remove front propeller shaft. Loosen drive pinion nut. Tool number: KV38108300 (J44195) 3. Remove companion flange. 4. Remove front oil seal. SPD476A SPD734 SPD735 PD-16 NAPD0014 FRONT FINAL DRIVE R200A On-vehicle Service (Cont’d) 5. 6. 7. Apply multi-purpose grease to cavity at sealing lips of oil seal. Press front oil seal into carrier. Install companion flange and drive pinion nut. Install propeller shaft. Tool number: KV38100500 (J25273) GI MA EM LC SPD736 REAR COVER GASKET REPLACEMENT 1. 2. 3. 4. Drain gear oil. Remove rear cover and rear cover gasket. Install new rear cover gasket and rear cover. Fill final drive with recommended gear oil. EC NAPD0015 FE CL MT SPD740-A AT TF AX SU BR ST RS BT HA SC EL IDX PD-17 FRONT FINAL DRIVE R200A Components Components NAPD0016 SPD557A PD-18 FRONT FINAL DRIVE R200A Removal and Installation Removal and Installation REMOVAL I NAPD0017 GI NAPD0017S01 Remove front of propeller shaft. Plug front end of transfer. I Remove drive shaft. Refer to AX-12, “Removal”. I Remove front final drive mounting bolts. CAUTION: Be careful not to damage spline, sleeve yoke and front oil seal when removing propeller shaft. MA INSTALLATION EC I EM LC NAPD0017S02 Fill final drive with recommended gear oil. FE CL MT SPD123 Disassembly PRE-INSPECTION SPD664 AT NAPD0018 NAPD0018S01 Before disassembling final drive, perform the following inspection. I Total preload a) Turn drive pinion in both directions several times to set bearing rollers. b) Check total preload with Tool. Tool number: ST3127S000 (J25765-A) Total preload: P1 + [0.3 - 1.5 N·m (3 - 15 kg-cm, 2.6 - 13.0 in-lb)] P1 = Drive pinion preload TF AX SU BR ST RS BT I Ring gear to drive pinion backlash Check backlash of ring gear with a dial indicator at several points. Ring gear-to-drive pinion backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 in) HA SC EL IDX SPD513 PD-19 FRONT FINAL DRIVE R200A Disassembly (Cont’d) I I 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 “TOOTH CONTACT”, PD-30. SPD524 I Side gear to pinion mate gear backlash Using a feeler gauge, measure clearance between side gear thrust washer and differential case. Clearance between side gear thrust washer and differential case: Less than 0.15 mm (0.0059 in) SPD665 FINAL DRIVE HOUSING NAPD0018S02 1. Using three spacers [20 mm (0.79 in)], mount final drive assembly on Tool. Tool number: KV38100800 (J34310, J25604-01) 2. Remove differential side shaft assembly. 3. Remove differential side flange. SPD666 SPD644 SPD667 PD-20 FRONT FINAL DRIVE R200A Disassembly (Cont’d) 4. 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. GI MA EM LC SPD526 5. Remove side bearing caps. EC FE CL MT PD343 6. Remove differential case assembly with a pry bar. AT TF AX SU SPD668 Be careful to keep the side bearing outer races together with their respective inner cones — do not mix them up. CAUTION: Side bearing spacer is placed on either the left or right depending upon final drive gear ratio. It should be labeled so that it may be replaced correctly. BR ST RS BT SPD527 7. 8. Loosen drive pinion nut. Tool number: KV38108300 (J44195) Remove companion flange with puller. HA SC EL IDX SPD477A PD-21 FRONT FINAL DRIVE R200A Disassembly (Cont’d) 9. Take out drive pinion together with rear bearing inner cone, drive pinion bearing spacer and pinion bearing adjusting washer. 10. Remove front oil seal and pinion front bearing inner cone. SPD670 11. Remove pinion bearing outer races with a brass drift. PD349 12. Remove pinion rear bearing inner cone and drive pinion height adjusting washer. Tool number: ST30031000 (J22912-01) SPD209 DIFFERENTIAL CASE NAPD0018S03 1. Remove side bearing inner cones. To prevent damage to bearing, engage puller jaws in grooves. Tool number: A ST33051001 (J22888-20) B ST33061000 (J8107-2) SPD207A Be careful not to confuse the right and left hand parts. Keep bearing and bearing race for each side together. SPD022 PD-22 FRONT FINAL DRIVE R200A Disassembly (Cont’d) 2. Loosen ring gear bolts in a criss-cross pattern. 3. Tap ring gear off the differential case with a soft hammer. Tap evenly all around to keep ring gear from binding. GI MA EM LC SPD024 4. Punch off pinion mate shaft lock pin from ring gear side. EC FE CL MT SPD025 DIFFERENTIAL SIDE SHAFT 1. AT NAPD0018S04 Cut collar with cold chisel. Be careful not to damage differential side shaft. TF AX SU SPD236A 2. 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. BR ST RS BT HA SC EL IDX SPD672 PD-23 FRONT FINAL DRIVE R200A Disassembly (Cont’d) 3. Remove grease seal and oil seal. SPD647 SPD781 Inspection RING GEAR AND DRIVE PINION NAPD0019 NAPD0019S01 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 NAPD0019S02 Check mating surfaces of differential case, side gears, pinion mate gears, pinion mate shaft and thrust washers. SPD097AA BEARING 1. 2. NAPD0019S03 Thoroughly clean bearing. 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-24 FRONT FINAL DRIVE R200A Adjustment Adjustment NAPD0020 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 SDS, PD-38. 5. Ring and pinion gear tooth contact pattern SIDE BEARING PRELOAD GI MA EM LC EC NAPD0020S01 A selection of carrier side bearing adjusting washer 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 “DEXRONTM” type automatic transmission fluid. 2. Place the differential carrier, with side bearings and bearing races installed, into the final drive housing. FE CL MT SPD527 3. Put the side bearing spacer in place. CAUTION: Side bearing spacer is placed on either the right or left depending upon final drive gear ratio. Be sure to replace it on the correct side. AT TF AX SU SPD894 4. Using Tool, install original carrier side bearing preload shims on the carrier end, opposite the ring gear. Tool number: KV38100600 (J25267) BR ST RS BT SPD986 5. 6. Install the side bearing caps in their correct locations and torque the bearing cap retaining bolts. Specification: 88 - 98 N·m (9 - 10 kg-m, 65 - 72 ft-lb) Turn the carrier several times to seat the bearings. HA SC EL IDX SPD526 PD-25 FRONT FINAL DRIVE R200A Adjustment (Cont’d) 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 8. If the carrier turning torque is not within the specification range, increase or decrease the total thickness of the side bearing adjusting washers until the turning torque is correct. If the turning torque is less than the specified range, install washers of greater thickness; if the turning torque is greater than the specification, install thinner washers. See the SDS section for washer dimensions and part numbers. Record the total amount of washer thickness required for the correct carrier side bearing preload. SPD194A 9. SPD772 10. Remove the carrier from the final drive housing, saving the selected preload washers for later use during the assembly of the final drive unit. SPD668 PINION GEAR HEIGHT AND PINION BEARING PRELOAD 1. 2. NAPD0020S02 Make sure all parts are clean and that the bearings are well lubricated. Assemble the pinion gear bearings into the pinion pre-load shim selector Tool, J34309. SPD769 I I 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, J3430915, 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. SPD197A PD-26 FRONT FINAL DRIVE R200A Adjustment (Cont’d) 3. Place the pinion preload shim selector Tool, J34309-1, gauge screw assembly with the pinion rear bearing inner cone installed into the final drive housing. GI MA EM LC SPD893 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. EC FE CL MT SPD199A 5. Turn the assembly several times to seat the bearings. AT TF AX SU SPD770 6. Measure the turning torque at the end of the J34309-2 gauge anvil using torque wrench J25765A. Turning torque specification: 1.0 - 1.3 N·m (10 - 13 kg-cm, 8.7 - 11.3 in-lb) BR ST RS BT SPD234A 7. Place the J34309-1 “R200A” pinion height adapter onto the gauge plate and tighten it by hand. CAUTION: Make sure all machined surfaces are clean. HA SC EL IDX SPD208A PD-27 FRONT FINAL DRIVE R200A Adjustment (Cont’d) PINION BEARING PRELOAD WASHER SELECTION 8. Place the solid pinion bearing spacer, small end first, over the J34309-2 gauge anvil and seat the small end squarely against the tip of the J34309-1 gauge screw in the tool recessed portion. SPD209A SPD773 9. Select the correct thickness of pinion bearing preload adjusting washer using a standard gauge of 3.5 mm (0.138 in) and your J34309-101 feeler gauge. The exact measure you get with your gauges is the thickness of the adjusting washer required. Select the correct washer. Drive pinion bearing preload adjusting washer: Refer to SDS, PD-38. 10. Set your selected, correct pinion bearing preload adjusting washer aside for use when assembling the pinion gear and bearings into the final drive. SPD210A SPD774 PINION HEIGHT ADJUSTING WASHER SELECTION 11. Now, position the side bearing discs, J25269-4, and arbor firmly into the side bearing bores. SPD211A PD-28 FRONT FINAL DRIVE R200A Adjustment (Cont’d) 12. Install the side bearing caps and tighten the cap bolts. Specification: 88 - 98 N·m (9 - 10 kg-m, 65 - 72 ft-lb) GI MA EM LC SPD212A 13. Select the correct standard pinion height adjusting washer thickness by using a standard gauge of 3.0 mm (0.118 in) and your J34309-101 feeler gauge. Measure the gap between the J34309-11 “R200A” pinion height adapter and the arbor. EC FE CL MT SPD204A 14. Write down your exact total measurement. AT TF AX SU SPD775 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 second 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. Refer to SDS, PD-38. BR ST RS BT SPD542 HA SC EL IDX PD-29 FRONT FINAL DRIVE R200A Adjustment (Cont’d) Pinion Head Height Number Add or Remove from the 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 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. Remove the J34309 pinion preload shim selector tool from the final drive housing and disassemble to retrieve the pinion bearings. SPD205A TOOTH CONTACT NAPD0020S03 Gear tooth contact pattern check is necessary to verify correct relationship between ring gear and drive pinion. Hypoid gear sets which are not positioned properly in relation to one another 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. 2. Thoroughly clean ring gear and drive pinion teeth. Sparingly apply a mixture of powdered ferric oxide and oil or equivalent to 3 or 4 teeth of ring gear drive side. SPD357 PD-30 FRONT FINAL DRIVE R200A Adjustment (Cont’d) 3. Hold companion flange steady by hand and rotate the ring gear in both directions. GI MA EM LC SPD677 EC FE CL MT AT TF SPD007-B AX SU Assembly DIFFERENTIAL SIDE SHAFT 1. NAPD0021 NAPD0021S01 BR Install oil seal and grease seal. ST RS BT SPD782-A HA SC EL IDX SPD654-A PD-31 FRONT FINAL DRIVE R200A Assembly (Cont’d) 2. Install extension tube retainer, rear axle bearing and rear axle shaft bearing collar on differential side shaft. SPD655 DIFFERENTIAL CASE NAPD0021S02 1. Install side gears, pinion mate gears and thrust washers into differential case. 2. Fit pinion mate shaft to differential case so that it meets lock pin holes. Adjust backlash between side gear and pinion mate gear by selecting side gear thrust washer. Refer to SDS, PD-37. Backlash between side gear and pinion mate gear (Clearance between side gear thrust washer and differential case): Less than 0.15 mm (0.0059 in) SPD552 3. SPD258 4. Install pinion mate shaft lock pin with a punch. Make sure lock pin is flush with case. SPD030 5. Apply gear oil to gear tooth surfaces and thrust surfaces and check to see they turn properly. SPD322 PD-32 FRONT FINAL DRIVE R200A Assembly (Cont’d) 6. 7. Install differential case assembly on ring gear. Apply genuine medium strength thread locking sealant or equivalent. Refer to GI section, “Recommended chemical products and sealants” to ring gear bolts, and install them. After tightening, tighten by rotating 34 to 39 degress. Tighten bolts in a criss-cross pattern, lightly tapping bolt head with a hammer. GI MA EM LC SPD554 8. Press-fit side bearing inner cones on differential case with Tool. Tool number: A KV38100300 (J25523) B ST33061000 (J8107-2) EC FE CL MT PD353 FINAL DRIVE HOUSING 1. AT NAPD0021S03 Press-fit front and rear bearing outer races with Tools. Tool number: A ST30611000 (J25742-1) B ST30621000 (J25742-5) C ST30613000 (J25742-3) TF AX SU BR ST RS BT SPD679 2. 3. Select drive pinion height adjusting washer and pinion bearing adjusting washer. Refer to “PINION GEAR HEIGHT AND PINION BEARING PRELOAD”, PD-26. 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) HA SC EL IDX SPD377 PD-33 FRONT FINAL DRIVE R200A Assembly (Cont’d) 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: KV38100500 (J25273) 6. Place drive pinion bearing spacer, drive pinion bearing adjusting washer and drive pinion in final drive housing. 7. Insert companion flange into drive pinion by tapping the companion flange with a soft hammer. SPD581 SPD680 SPD658 SPD681 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: KV38108300 (J44195) SPD478A PD-34 FRONT FINAL DRIVE R200A Assembly (Cont’d) 9. Turn drive pinion in both directions several revolutions, and measure pinion bearing preload. Tool number: ST3127S000 (J25765-A) Pinion bearing preload: 1.1 - 1.4 N·m (11 - 14 kg-cm, 9.5 - 12.2 in-lb) When pinion bearing preload is outside the specifications, replace pinion bearing adjusting washer and spacer with a different thickness. GI MA EM LC SPD664 10. Select side bearing adjusting washer. Refer to “SIDE BEARING PRELOAD”, PD-25. 11. Install differential case assembly with side bearing outer races into final drive housing. EC FE CL MT SPD527 12. Insert left and right side bearing adjusting washers in place between side bearings and final drive housing. AT TF AX SU SPD558 13. Drive in side bearing spacer with Tool. Tool number: KV38100600 (J25267) BR ST RS BT SPD559 14. Align mark on bearing cap with that on final drive housing and install bearing cap on final drive housing. HA SC EL IDX SPD526 PD-35 FRONT FINAL DRIVE R200A Assembly (Cont’d) 15. Apply multi-purpose grease to cavity at sealing lips of oil seal. Install side oil seal. Tool number: KV38100200 (J26233) SPD560 16. Measure ring gear to drive pinion backlash with a dial indicator. Ring gear-to-drive pinion backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 in) I 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. SPD513 17. Check total preload with Tool. When checking preload, turn drive pinion in both directions several times to set bearing rollers. Tool number: ST3127S000 (J25765-A) Total preload: P1 + [0.3 - 1.5 N·m (3 - 15 kg-cm, 2.6 - 13.0 in-lb)] P1 = Drive pinion preload SPD664 I If preload is too great, remove the same amount of shim from each side. I 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. 18. Recheck ring gear to drive pinion backlash because increase or decrease in thickness of shims will cause change of ring gear-to-pinion backlash. SPD561 SPD524 19. Check runout of ring gear with a dial indicator. Runout limit: 0.05 mm (0.0020 in) I If backlash varies excessively in different places, the variance may have resulted from foreign matter caught between the ring gear and the differential case. I 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. 20. Check tooth contact. Refer to “TOOTH CONTACT”, PD-30. 21. Install rear cover and gasket. PD-36 FRONT FINAL DRIVE R200A Assembly (Cont’d) 22. Install differential side shaft assembly. GI MA EM LC SPD682 EC Service Data and Specifications (SDS) R200A General Specifications NAPD0022 NAPD0022S01 FE Standard Front final drive CL R200A 2-pinion Gear ratio 4.363 Number of teeth (Ring gear/drive pinion) 48/11 Oil capacity (Approx.)  (US pt, lmp pt) 1.85 (3-7/8, 3-1/4) Ring Gear Runout Ring gear runout limit AT NAPD0022S02 mm (in) NAPD0022S03 Side gear backlash (Clearance between side gear and differential case) mm (in) Thickness mm (in) 0.75 0.78 0.81 0.84 0.87 0.90 0.93 Less than 0.15 (0.0059) AX Part number* (0.0295) (0.0307) (0.0319) (0.0331) (0.0343) (0.0354) (0.0366) 38424-N3110 38424-N3111 38424-N3112 38424-N3113 38424-N3114 38424-N3115 38424-N3116 SU BR ST *: Always check with the Parts Department for the latest parts information. Side Bearing Adjustment NAPD0022S04 Differential carrier assembly turning resistance N (kg, lb) 34.3 - 39.2 (3.5 - 4.0, 7.7 - 8.8) Thickness mm (in) Available side bearing adjusting washers TF 0.05 (0.0020) Side Gear Adjustment Available side gear thrust washers MT 2.00 2.05 2.10 2.15 2.20 2.25 2.30 2.35 2.40 2.45 2.50 2.55 2.60 RS Part number* (0.0787) (0.0807) (0.0827) (0.0846) (0.0866) (0.0886) (0.0906) (0.0925) (0.0945) (0.0965) (0.0984) (0.1004) (0.1024) 38453-N3100 38453-N3101 38453-N3102 38453-N3103 38453-N3104 38453-N3105 38453-N3106 38453-N3107 38453-N3108 38453-N3109 38453-N3110 38453-N3111 38453-N3112 *: Always check with the Parts Department for the latest parts information. PD-37 BT HA SC EL IDX FRONT FINAL DRIVE R200A Service Data and Specifications (SDS) (Cont’d) Total Preload Adjustment Total preload NAPD0022S05 N·m (kg-cm, in-lb) Ring gear backlash P1 + [0.3 - 1.5 (3 - 15, 2.6 - 13.0)] mm (in) 0.10 - 0.15 (0.0039 - 0.0059) P1 = Drive pinion preload Drive Pinion Height Adjustment Available pinion height adjusting washers NAPD0022S06 Thickness mm (in) Part number* 3.09 (0.1217) 3.12 (0.1228) 3.15 (0.1240) 3.18 (0.1252) 3.21 (0.1264) 3.24 (0.1276) 3.27 (0.1287) 3.30 (0.1299) 3.33 (0.1311) 3.36 (0.1323) 3.39 (0.1335) 3.42 (0.1346) 3.45 (0.1358) 3.48 (0.1370) 3.51 (0.1382) 3.54 (0.1394) 3.57 (0.1406) 3.60 (0.1417) 3.63 (0.1429) 3.66 (0.1441) 38154-P6017 38154-P6018 38154-P6019 38154-P6020 38154-P6021 38154-P6022 38154-P6023 38154-P6024 38154-P6025 38154-P6026 38154-P6027 38154-P6028 38154-P6029 38154-P6030 38154-P6031 38154-P6032 38154-P6033 38154-P6034 38154-P6035 38154-P6036 *: Always check with the Parts Department for the latest parts information. Drive Pinion Preload Adjustment NAPD0022S07 Drive pinion bearing preload adjusting method Drive pinion preload with front oil seal Adjusting washer and spacer N·m (kg-cm, in-lb) [P1] 1.1 - 1.4 (11 - 14, 9.5 - 12.2) Thickness mm (in) Available drive pinion bearing preload adjusting washers Available drive pinion bearing preload adjusting spacers 3.81 3.83 3.85 3.87 3.89 3.91 3.93 3.95 3.97 3.99 4.01 4.03 4.05 4.07 4.09 Part number* (0.1500) (0.1508) (0.1516) (0.1524) (0.1531) (0.1539) (0.1547) (0.1555) (0.1563) (0.1571) (0.1579) (0.1587) (0.1594) (0.1602) (0.1610) 38125-61001 38126-61001 38127-61001 38128-61001 38129-61001 38130-61001 38131-61001 38132-61001 38133-61001 38134-61001 38135-61001 38136-61001 38137-61001 38138-61001 38139-61001 Length mm (in) Part number* 54.50 (2.1457) 54.80 (2.1575) 55.10 (2.1693) 55.40 (2.1811) 55.70 (2.1929) 56.00 (2.2047) 38165-B4000 38165-B4001 38165-B4002 38165-B4003 38165-B4004 38165-61001 *: Always check with the Parts Department for the latest parts information. PD-38 REAR FINAL DRIVE H233B Preparation Preparation GI SPECIAL SERVICE TOOLS NAPD0029 The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name ST3127S000 (See J25765-A) Preload gauge 1 GG91030000 (J25765) Torque wrench 2 HT62940000 ( — ) Socket adapter 3 HT62900000 ( — ) Socket adapter MA Description EM Measuring pinion bearing preload and total preload LC EC FE NT124 CL ST06340000 (J24310, J34310) Differential attachment Mounting final drive MT AT NT140 ST32580000 (J34312) Differential side bearing adjusting nut wrench Adjusting side bearing preload and backlash (ring gear-drive pinion) TF NT141 KV38108300 (J44195) Companion flange wrench Removing and installing propeller shaft lock nut, and drive pinion lock nut AX SU BR NT771 ST3090S000 ( — ) Drive pinion rear inner race puller set 1 ST30031000 (J22912-01) Puller 2 ST30901000 (J26010-01) Base ST3306S001 Differential side bearing puller set 1 ST33051001 (J22888-20) Body 2 ST33061000 (J8107-2) Adapter Removing and installing drive pinion rear inner cone a: 79 mm (3.11 in) dia. b: 45 mm (1.77 in) dia. c: 35 mm (1.38 in) dia. ST RS BT NT527 Removing and installing differential side bearing inner cone a: 28.5 mm (1.122 in) dia. b: 38 mm (1.50 in) dia. HA SC EL NT072 IDX PD-39 REAR FINAL DRIVE H233B Preparation (Cont’d) Tool number (Kent-Moore No.) Tool name Description ST33190000 (J25523) Differential side bearing drift Installing side bearing inner cone a: 52 mm (2.05 in) dia. b: 45.5 mm (1.791 in) dia. c: 34 mm (1.34 in) dia. NT085 ST33081000 ( — ) Side bearing puller adapter Installing side bearing inner cone a: 43 mm (1.69 in) dia. b: 33.5 mm (1.319 in) dia. NT431 ST30611000 (J25742-1) Drift Installing pinion rear bearing outer race (Use with ST30621000 or ST30613000) NT090 ST30621000 (J25742-5) Drift Installing pinion rear bearing outer race a: 79 mm (3.11 in) dia. b: 59 mm (2.32 in) dia. NT073 ST30613000 (J25742-3) Drift Installing pinion front bearing outer race (Use with ST30611000) a: 72 mm (2.83 in) dia. b: 48 mm (1.89 in) dia. NT073 KV381025S0 ( — ) Oil seal fitting tool 1 ST30720000 (J25405) Drift bar 2 KV38102510 ( — ) Drift Installing front oil seal a: 77 mm (3.03 in) dia. b: 55 mm (2.17 in) dia. c: 71 mm (2.80 in) dia. d: 65 mm (2.56 in) dia. NT525 (J34309) Differential shim selector Adjusting bearing pre-load and gear height NT134 PD-40 REAR FINAL DRIVE H233B Preparation (Cont’d) Tool number (Kent-Moore No.) Tool name GI Description (J25269-18) Side bearing discs (2 Req’d) MA Selecting pinion height adjusting washer EM NT135 KV381052S0 ( — ) Rear axle shaft dummy 1 KV38105210 ( — ) Torque wrench side 2 KV38105220 ( — ) Vice side Checking differential torque on limited slip differential LC EC NT142 FE KV38100500 (J25273) Gear carrier front oil seal drift Installing front oil seal a: 85 mm (3.35 in) dia. b: 60 mm (2.36 in) dia. CL MT NT115 Noise, Vibration and Harshness (NVH) Troubleshooting AT NAPD0051 Refer to “NVH TROUBLESHOOTING CHART”, PD-4. TF AX SU On-vehicle Service FRONT OIL SEAL REPLACEMENT 1. 2. Remove propeller shaft. Loosen drive pinion nut. Tool number: KV38108300 (J44195) NAPD0030 BR ST RS BT SPD479A 3. Remove companion flange. HA SC EL IDX SPD737 PD-41 REAR FINAL DRIVE H233B On-vehicle Service (Cont’d) 4. Remove front oil seal. 5. Apply multi-purpose grease to cavity at sealing lips of oil seal. Press front oil seal into carrier. Tool number: KV38100500 (J25273) Install companion flange and drive pinion nut. Install rear propeller shaft. SPD738 6. 7. SPD739 PD-42 REAR FINAL DRIVE H233B Components Components NAPD0031 GI MA EM LC EC FE CL MT AT TF AX SU BR ST RS BT HA SC EL SPD362AB PD-43 IDX REAR FINAL DRIVE H233B Removal and Installation Removal and Installation REMOVAL I NAPD0032 NAPD0032S01 Remove rear of propeller shaft. Plug front end of transfer. I Remove axle shaft. Refer to AX-20, “Removal”. I Remove rear final drive mounting bolts. CAUTION: Be careful not to damage spline, sleeve yoke and front oil seal when removing propeller shaft. INSTALLATION I Fill final drive with recommended gear oil. I Pay attention to the direction of gasket. NAPD0032S02 SPD123 SPD767 Disassembly PRE-INSPECTION SPD149 NAPD0033 NAPD0033S01 Before disassembling final drive, perform the following inspection. I Total preload a) Turn drive pinion in both directions several times to seat bearing rollers correctly. b) Check total preload with Tool. Tool number: ST3127S000 (J25765-A) Total preload: 1.2 - 2.0 N·m (12 - 20 kg-cm, 10 - 17 in-lb) I 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) SPD246 PD-44 REAR FINAL DRIVE H233B Disassembly (Cont’d) I Ring gear runout Check runout of ring gear with a dial indicator. Runout limit: 0.08 mm (0.0031 in) GI MA EM LC SPD247 I I Tooth contact Check tooth contact. Refer to “TOOTH CONTACT”, PD-57. 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 differential case: 0.10 - 0.20 mm (0.0039 - 0.0079 in) EC FE CL MT SPD004 DIFFERENTIAL CARRIER 1. AT NAPD0033S02 Mount final drive assembly on Tool. Tool number: ST06340000 (J24310, J34310) TF AX SU SPD683 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. BR ST RS BT SPD249 3. Remove side lock fingers and side bearing caps. HA SC EL IDX SPD250 PD-45 REAR FINAL DRIVE H233B Disassembly (Cont’d) 4. Remove side bearing adjuster with Tool. Tool number: ST32580000 (J34312) 5. Remove differential case assembly with a pry bar. SPD684 SPD685 Be careful to keep the side bearing outer races together with their respective inner cones — do not mix them up. SPD011 6. 7. Remove drive pinion nut with Tool. Tool number: KV38108300 (J44195) Remove companion flange with puller. SPD480A 8. Take out drive pinion together with pinion rear bearing inner cone, drive pinion bearing spacer and pinion bearing adjusting shim. SPD687 PD-46 REAR FINAL DRIVE H233B Disassembly (Cont’d) 9. Remove front oil seal and pinion front bearing inner cone. 10. Remove pinion bearing outer races with a brass drift. GI MA EM LC SPD563 11. Remove pinion rear bearing inner cone and drive pinion adjusting washer. Tool number: ST30031000 (J22912-01) EC FE CL MT SPD542A DIFFERENTIAL CASE 1. AT NAPD0033S03 Remove side bearing inner cones. To prevent damage to bearing, engage puller jaws in groove. Tool number: A ST33051001 (J22888-20) B ST33061000 (J8107-2) TF AX SU SPD207A Be careful not to confuse the left and right hand parts. Keep bearing and bearing race for each side together. BR ST RS BT SPD022 2. Loosen ring gear bolts in a criss-cross pattern. 3. Tap ring gear off differential case with a soft hammer. Tap evenly all around to keep ring gear from binding. HA SC EL IDX SPD024 PD-47 REAR FINAL DRIVE H233B Disassembly (Cont’d) 4. Drive out pinion mate shaft lock pin, with punch from ring gear side. Lock pin is calked at pin hole mouth on differential case. SPD025 Inspection RING GEAR AND DRIVE PINION NAPD0034 NAPD0034S01 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 NAPD0034S02 Check mating surfaces of differential case, side gears, pinion mate gears, pinion mate shaft, and thrust washers. SPD530-A BEARING 1. 2. NAPD0034S03 Thoroughly clean bearing. 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 Limited Slip Differential PREPARATION FOR DISASSEMBLY Checking Differential Torque SPD415 NAPD0035 NAPD0035S01 Measure differential torque with Tool. If it is not within the specifications, inspect components of limited slip differential. Differential torque: 40 - 58 N·m 4 - 6 kg-m, 29 - 43 ft-lb) Tool number: A KV38105210 ( — ) Tool number: B KV38105220 ( — ) PD-48 REAR FINAL DRIVE H233B Limited Slip Differential (Cont’d) DISASSEMBLY NAPD0036 GI MA EM LC EC FE CL MT AT TF SPD544A CAUTION: Do not run engine when one wheel (rear) is off the ground. AX SU 1. Remove side bearing inner cone with Tool. 2. Loosen ring gear bolts in a criss-cross pattern. 3. Tap ring gear off gear case with a soft hammer. Tap evenly all around to keep ring gear from binding. BR ST RS BT SPD552A 4. Remove couple bolts on differential cases A and B with a press. Tool number: ST33081000 ( — ) 5. Separate differential case A and B. Draw out component parts (discs and plates, etc.). Put marks on component parts so that they can be reinstalled in their original positions from which they were removed. HA SC EL IDX SPD363A PD-49 REAR FINAL DRIVE H233B Limited Slip Differential (Cont’d) INSPECTION Contact Surfaces 1. 2. NAPD0037 NAPD0037S01 Clean the disassembled parts in suitable solvent and blow dry with compressed air. If following surfaces are found with burrs or scratches, smooth with oil stone. 1 Differential case B 2 Differential case A 3 Side gear 4 Pinion mate gear 5 Pinion mate shaft 6 Friction plate guide SPD359A Disc and Plate 1. 2. 3. NAPD0037S02 Clean the discs, plates and spacer in suitable solvent and blow dry with compressed air. Inspect discs and plates for wear, nicks and burrs. To test if friction disc or plate is not distorted, place it on a surface plate and rotate it by hand with indicating finger of dial gauge resting against disc or plate surface. Maximum allowable warpage: 0.08 mm (0.0031 in) If it exceeds limits, replace with a new plate or disc to eliminate possibility of clutch slippage or sticking. SPD279 PD-50 REAR FINAL DRIVE H233B Limited Slip Differential (Cont’d) 4. Measure thickness of spring plate. Thickness of spring plate Standard: 1.5 mm (0.059 in) Wear limit: 1.4 mm (0.055 in) 5. Measure frictional surfaces and projected portions of friction disc, friction plate, and determine each part’s differences to see if the specified wear limit has been exceeded. If any part has worn beyond the wear limit, and deformed or fatigued, 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 A − B = Wear limit mm (in) I: Measuring points A: Projected portion B: Frictional surface GI MA EM LC EC FE CL MT SPD551A ADJUSTMENT Friction Disc and Friction Plate End Play SPD545A AT NAPD0038 NAPD0038S01 End play of friction disc and friction plate can be calculated by using following equation and should be adjusted within following range. Adjustment can be made by selecting friction disc or friction plate having three different thicknesses. End play E: (One side) 0.05 - 0.15 mm (0.0020 - 0.0059 in) E = A − (B + C) A: Length of differential case contact surface to differential case inner bottom. B: Total thickness of friction discs, friction plates, spring plate and spacer in differential case on one side. C: Length of differential case contact surface to back side of side gear. 1. Measure values of “A”. Standard length A: 49.50 - 49.55 mm (1.9488 - 1.9508 in) TF AX SU BR ST RS BT SPD417 2. Measure thickness of each disc and plate. Total thickness “B”: 18.57 - 20.43 mm (0.7311 - 0.8043 in) No. of discs and plates (One side) Friction disc: 2 Friction plate: 5 Spring plate: 2 Spacer: 1 HA SC EL IDX SPD420 PD-51 REAR FINAL DRIVE H233B Limited Slip Differential (Cont’d) 3. a. b. Measure values of “C”. Attach a dial indicator to the base plate. Place differential case B on the base plate, and install a master gauge on case B. Then adjust the dial indicator scale to zero with its tip on the master gauge. SPD418 c. SPD419 Install pinion mate gears, side gears and pinion mate shaft in differential case B. d. Set dial indicator’s tip on the rear of side gear, and read the indication. Example: 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 49.15 (D) = 19.45 (B) + 29.7 (C) E=A−D 0.37 (E) = 49.52 (A) − 49.15 (D) 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. 4. Calculate end play of differential case A with the same procedure of differential case B. ASSEMBLY NAPD0039 Prior to assembling discs and plates, properly lubricate them by dipping them in limited slip differential oil. 1. Position specified number of friction plates, friction discs and spacer on rear of side gear. Always position a friction plate first on rear of side gear. No. of discs and plates (One side) Friction disc: 2 Friction plate: 5 Spacer: 1 SPD546A PD-52 REAR FINAL DRIVE H233B Limited Slip Differential (Cont’d) 2. Install two spring plates. GI MA EM LC SPD547A 3. Install friction plate guides. Correctly align the raised portions of friction plates, and apply LSD gear oil to inner surfaces of friction plate guides to prevent them from falling. EC FE CL MT SPD385A 4. I I Install differential case B over side gear, discs, plates, spacer and friction plate guide assembly. Install differential case B while supporting friction plate guides with your middle finger inserted through oil hole in differential case. Be careful not to detach spring plate from the hexagonal part of the side gear. AT TF AX SU SPD386A 5. Install pinion mate gears and pinion mate thrust washers on pinion mate shaft, then install pinion mate shaft in differential case B. BR ST RS BT SPD426 6. Install side gear to pinion mate gears. 7. Install each disc and plate. Use same procedures as outlined in steps 1. through 4. above. HA SC EL IDX SPD387A PD-53 REAR FINAL DRIVE H233B Limited Slip Differential (Cont’d) 8. Install differential case A. Position differential cases A and B by correctly aligning marks stamped on cases. SPD388A 9. Tighten differential case couple bolts. 10. Place ring gear on differential case and tighten ring gear bolts. Tighten bolts in a criss-cross pattern. 11. Install side bearing inner cone. 12. Check differential torque. SPD364A Adjustment NAPD0040 For quiet and reliable final drive operation, the following five adjustments must be made correctly: 1. Side bearing preload 2. Pinion gear height 3. Side bearing preload 4. Ring gear-to-pinion backlash. Refer to SDS, PD-63. 5. Ring and pinion gear tooth contact pattern PINION GEAR HEIGHT 1. 2. NAPD0040S01 Make sure all parts are clean and that the bearings are well lubricated. Assemble the pinion gear bearings into the pinion pre-load shim selector tool, J34309. SPD196A I I 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 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. SPD197A PD-54 REAR FINAL DRIVE H233B Adjustment (Cont’d) 3. Place the pinion preload shim selector tool gauge screw assembly, J34309-1, with the pinion rear bearing inner cone installed, into the final drive housing. GI MA EM LC SPD216A 4. 5. 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. Turn the assembly several times to seat the bearings. EC FE CL MT SPD217A 6. Measure the turning torque at the end of the J34309-2 gauge anvil using torque wrench J25765A. Turning torque specification: 0.4 - 0.9 N·m (4 - 9 kg-cm, 3.5 - 7.8 in-lb) AT TF AX SU 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. BR ST RS BT SPD208A PINION HEIGHT ADJUSTING WASHER SELECTION 8. Position the J25269-18 side bearing discs and the arbor into the side bearing bores. HA SC EL IDX SPD286A PD-55 REAR FINAL DRIVE H233B Adjustment (Cont’d) 9. Install the bearing caps and torque the bolts. Specification: 93 - 103 N·m (9.5 - 10.5 kg-m, 69 - 76 ft-lb) SPD237A 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 your J34309-101 feeler gauge. Measure the distance between the J34309-12 “H233B” pinion height adapter and the arbor. SPD204A 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 second number is the “pinion head height number”, and it refers to the ideal pinion height from standard for the quietest operation. Use the following chart to determine the correct pinion height washer. Refer to SDS, PD-64. SPD542 PD-56 REAR FINAL DRIVE H233B Adjustment (Cont’d) Pinion Head Height Number Add or Remove from the Selected 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 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) GI MA EM LC EC FE CL MT 13. Remove the J34309 pinion preload shim selector tool from the final drive housing and disassemble to retrieve the pinion bearings. AT TF AX SU SPD220A TOOTH CONTACT NAPD0040S02 Gear tooth contact pattern check is necessary to verify correct relationship between ring gear and drive pinion. Hypoid gear sets which are not positioned properly in relation to one another 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. BR ST RS BT 1. 2. Thoroughly clean ring gear and drive pinion teeth. Sparingly apply a mixture of powdered ferric oxide and oil or equivalent to 3 or 4 teeth of ring gear drive side. HA SC EL IDX SPD005 PD-57 REAR FINAL DRIVE H233B Adjustment (Cont’d) 3. Hold companion flange steady by hand and rotate the ring gear in both directions. SPD695 SPD007-B Assembly DIFFERENTIAL CASE NAPD0041 NAPD0041S01 1. Install side gears, pinion mate gears and thrust washers into differential case. 2. Fit pinion mate shaft to differential case so that it meets lock pin holes. Adjust backlash between side gear and pinion mate gear by selecting side gear thrust washer. Refer to SDS, PD-63. Backlash between side gear and pinion mate gear (Clearance between side gear thrust washer and differential case): 0.10 - 0.20 mm (0.0039 - 0.0079 in) SPD552 3. SPD258 PD-58 REAR FINAL DRIVE H233B Assembly (Cont’d) 4. Install pinion mate shaft lock pin with a punch. Make sure lock pin is flush with case. GI MA EM LC SPD030 5. Apply gear oil to gear tooth surfaces and thrust surfaces and check to see they turn properly. 6. Install differential case assembly on ring gear. Tighten bolts in a criss-cross pattern, lightly tapping bolt head with a hammer. EC FE CL MT SPD322 7. Press-fit side bearing inner cones on differential case with Tool. Tool number: A ST33190000 (J25523) B ST33081000 ( — ) AT TF AX SU PD244 DIFFERENTIAL CARRIER 1. Press-fit front and rear bearing outer races with Tools. Tool number: A ST30611000 (J25742-1) B ST30621000 (J25742-5) C ST30613000 (J25742-3) NAPD0041S02 BR ST RS BT HA SC EL IDX SPD580 PD-59 REAR FINAL DRIVE H233B Assembly (Cont’d) 2. 3. Select drive pinion height adjusting washer. Refer to “Adjustment”, PD-54. Install drive pinion adjusting washer in drive pinion, and pressfit pinion rear bearing inner cone in it, with press and Tool. Tool number: ST30901000 (J26010-01) SPD377 4. Place pinion front bearing inner cone in gear carrier. 5. Apply multi-purpose grease to cavity at sealing lips of oil seal. Install front oil seal. Tool number: A ST30720000 (J25405) B KV38102510 ( — ) 6. Install drive pinion bearing spacer, pinion bearing adjusting shim and drive pinion in gear carrier. 7. Insert companion flange into drive pinion by tapping the companion flange with a soft hammer. SPD581 SPD291A SPD935-A SPD697 PD-60 REAR FINAL DRIVE H233B Assembly (Cont’d) 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: KV38108300 (J44195) GI MA EM LC SPD481A 9. SPD149 Turn drive pinion in both directions several times, and measure pinion bearing preload. Tool number: ST3127S000 (J25765-A) Pinion bearing preload (Without front oil seal): 0.12 - 0.20 N·m (1.2 - 2.0 kg-cm, 1.0 - 1.7 in-lb) If preload is out of specification, adjust the thickness of spacer and shim combination by replacing shim and spacer with thinner one. I Start from the combination of thickest spacer and shim. I Combine each spacer and shim thickness one by one until the correct specification are achieved. Drive pinion bearing preload adjusting spacer and shim: Refer to SDS, PD-65. 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) EC FE CL MT AT TF AX SU SPD684 12. Align mark on bearing cap with that on gear carrier and install bearing cap on gear carrier. I Do not tighten at this point to allow further tightening of side bearing adjusters. BR ST RS BT SPD265 13. Tighten both right and left side bearing adjusters alternately 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 preload can be obtained. Ring gear-to-drive pinion backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in) HA SC EL IDX SPD246 PD-61 REAR FINAL DRIVE H233B Assembly (Cont’d) I When checking preload, turn drive pinion in both directions several times to set bearing rollers. Tool number: ST3127S000 (J25765-A) Total preload: P1 + [0.3 - 0.4 N·m (3 - 4 kg-cm, 2.6 - 3.5 in-lb)] P1 = Drive pinion preload SPD149 14. Tighten side bearing cap bolts. 15. Install side lock finger in place to prevent rotation during operation. SPD698 16. Check runout of ring gear with a dial indicator. Runout limit: 0.08 mm (0.0031 in) I If backlash varies excessively in different places, the variance may have resulted from foreign matter caught between the ring gear and the differential case. I 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. 17. Check tooth contact. Refer to “TOOTH CONTACT”, PD-57. SPD247 Service Data and Specifications (SDS) H233B General Specifications NAPD0042 NAPD0042S01 2WD Model NAPD0042S0101 Applied model Standard Optional (SE grade) H233B Rear final drive 2-pinion LSD Gear ratio 4.363 Number of teeth (Ring gear/drive pinion) 48/11 Oil capacity (Approx.)  (US pt, lmp pt) 2.8 (5-7/8, 4-7/8) 4WD Model NAPD0042S0102 Applied model All Standard Rear final drive Optional H233B 2-pinion Gear ratio LSD 4.363 PD-62 REAR FINAL DRIVE H233B Service Data and Specifications (SDS) (Cont’d) Applied model GI All Number of teeth (Ring gear/drive pinion) 48/11 Oil capacity (Approx.)  (US pt, lmp pt) EM Ring Gear Runout Ring gear runout limit MA 2.8 (5-7/8, 4-7/8) NAPD0042S02 mm (in) 0.08 (0.0031) LC Side Gear Adjustment NAPD0042S03 Side gear backlash (Clearance between side gear and differential case) Available side gear thrust washers mm (in) EC 0.10 - 0.20 (0.0039 - 0.0079) Thickness mm (in) Part number* 1.75 (0.0689) 1.80 (0.0709) 1.85 (0.0728) 38424-T5000 38424-T5001 38424-T5002 FE CL *: Always check with the Parts Department for the latest parts information. Differential Torque Adjustment (LSD models) Differential torque N·m (kg-m, ft-lb) 40 - 58 (4 - 6, 29 - 43) Friction disc Total thickness 2 0.1 (0.004) mm (in) 0.08 (0.0031) mm (in) Available discs and plates TF 1 mm (in) Plate name AT 5 Spacer Allowable warpage of friction disc and plate 18.57 - 20.43 (0.7311 - 0.8043) Thickness mm (in) AX Part number* Friction disc 1.4 (0.055) 1.5 (0.059) 1.6 (0.063) 38433-C6004 (Adjusting type) 38433-C6002 (Standard type) 38433-C6003 (Adjusting type) SU Friction plate 1.4 (0.055) 1.5 (0.059) 1.6 (0.063) 38432-C6002 (Adjusting type) 38432-C6001 (Standard type) 38432-C6003 (Adjusting type) BR Spring plate 1.5 (0.059) 38435-S9200 Spacer 6.0 (0.236) 38454-S9200 ST *: Always check with the Parts Department for the latest parts information. RS Total Preload Adjustment Total preload NAPD0042S05 N·m (kg-cm, in-lb) Ring gear backlash MT 2 Number of discs, plates and spacer Friction plate (One side) Spring plate Wear limit of plate and disc NAPD0042S04 P1 + [0.3 - 0.4 (3 - 4, 2.6 - 3.5)] mm (in) BT 0.13 - 0.18 (0.0051 - 0.0071) Side bearing adjusting method Side adjuster HA P1 = Drive pinion preload SC EL IDX PD-63 REAR FINAL DRIVE H233B Service Data and Specifications (SDS) (Cont’d) Drive Pinion Height Adjustment Available pinion height adjust washers NAPD0042S06 Thickness mm (in) Part number* 2.58 (0.1016) 2.61 (0.1028) 2.64 (0.1039) 2.67 (0.1051) 2.70 (0.1063) 2.73 (0.1075) 2.76 (0.1087) 2.79 (0.1098) 2.82 (0.1110) 2.85 (0.1122) 2.88 (0.1134) 2.91 (0.1146) 2.94 (0.1157) 2.97 (0.1169) 3.00 (0.1181) 3.03 (0.1193) 3.06 (0.1205) 3.09 (0.1217) 3.12 (0.1228) 3.15 (0.1240) 3.18 (0.1252) 3.21 (0.1264) 3.24 (0.1276) 3.27 (0.1287) 3.30 (0.1299) 3.33 (0.1311) 3.36 (0.1323) 3.39 (0.1335) 3.42 (0.1346) 3.45 (0.1358) 3.48 (0.1370) 3.51 (0.1382) 3.54 (0.1394) 3.57 (0.1406) 3.60 (0.1417) 3.63 (0.1429) 3.66 (0.1441) 38151-01J00 38151-01J01 38151-01J02 38151-01J03 38151-01J04 38151-01J05 38151-01J06 38151-01J07 38151-01J08 38151-01J09 38151-01J10 38151-01J11 38151-01J12 38151-01J13 38151-01J14 38151-01J15 38151-01J16 38151-01J17 38151-01J18 38151-01J19 38151-01J60 38151-01J61 38151-01J62 38151-01J63 38151-01J64 38151-01J65 38151-01J66 38151-01J67 38151-01J68 38151-01J69 38151-01J70 38151-01J71 38151-01J72 38151-01J73 38151-01J74 38151-01J75 38151-01J76 *: Always check with the Parts Department for the latest parts information. PD-64 REAR FINAL DRIVE H233B Service Data and Specifications (SDS) (Cont’d) Drive Pinion Preload Adjustment NAPD0042S07 Drive pinion bearing preload adjusting method Drive pinion preload without front oil seal Adjusting shim and spacer N·m (kg-cm, in-lb) [P1] Thickness mm (in) Available front drive pinion bearing adjusting shims 2.31 2.33 2.35 2.37 2.39 2.41 2.43 2.45 2.47 2.49 2.51 2.53 2.55 2.57 2.59 4.50 4.75 5.00 5.25 5.50 1.2 - 2.0 (12 - 20, 10 - 17) MA Part number* (0.0909) (0.0917) (0.0925) (0.0933) (0.0941) (0.0949) (0.0957) (0.0965) (0.0972) (0.0980) (0.0988) (0.0996) (0.1004) (0.1012) (0.1020) 38125-82100 38126-82100 38127-82100 38128-82100 38129-82100 38130-82100 38131-82100 38132-82100 38133-82100 38134-82100 38135-82100 38136-82100 38137-82100 38138-82100 38139-82100 Thickness mm (in) Available drive pinion bearing adjusting spacers GI EM LC EC FE CL Part number* (0.1772) (0.1870) (0.1969) (0.2067) (0.2165) 38165-76000 38166-76000 38167-76000 38166-01J00 38166-01J10 MT AT *: Always check with the Parts Department for the latest parts information. TF AX SU BR ST RS BT HA SC EL IDX PD-65 NOTES STEERING SYSTEM SECTION ST GI MA EM LC EC FE CONTENTS PRECAUTIONS ...............................................................2 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″...............2 Precautions for SRS ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″ Service...............................2 Precautions for Steering System.................................2 PREPARATION ...............................................................3 Special Service Tools ..................................................3 Commercial Service Tools ...........................................4 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING .....................................................6 NVH Troubleshooting Chart.........................................6 ON-VEHICLE SERVICE ..................................................7 Checking Steering Wheel Play....................................7 Checking Neutral Position on Steering Wheel ............7 PRE-CHECKING ........................................................7 CHECKING ...............................................................7 Front Wheel Turning Angle..........................................7 Checking Gear Housing Movement ............................8 Adjusting Rack Retainer ..............................................8 Checking and Adjusting Drive Belts ............................8 Checking Fluid Level ...................................................8 Checking Fluid Leakage ..............................................8 Bleeding Hydraulic System..........................................9 Checking Steering Wheel Turning Force ....................9 Checking Hydraulic System.......................................10 STEERING WHEEL AND STEERING COLUMN .........11 Components...............................................................11 Removal and Installation ...........................................11 STEERING WHEEL .................................................11 STEERING COLUMN ...............................................12 Disassembly and Assembly.......................................13 Inspection...................................................................14 TILT MECHANISM ...................................................14 STEERING TRANSFER GEAR .....................................15 Removal.....................................................................15 Installation..................................................................16 Inspection...................................................................16 POWER STEERING GEAR AND LINKAGE ................17 Components...............................................................17 Removal and Installation ...........................................18 Disassembly...............................................................19 Inspection...................................................................20 BOOT .....................................................................20 RACK .....................................................................20 PINION ASSEMBLY .................................................20 GEAR HOUSING CYLINDER ....................................20 TIE-ROD OUTER AND INNER SOCKETS..................21 Assembly ...................................................................21 Adjustment .................................................................24 POWER STEERING OIL PUMP....................................27 Components...............................................................27 Pre-disassembly Inspection.......................................27 Disassembly...............................................................28 Inspection...................................................................29 Assembly ...................................................................29 SERVICE DATA AND SPECIFICATIONS (SDS) .........32 General Specifications...............................................32 Steering Wheel ..........................................................32 Steering Column ........................................................32 Steering Transfer Gear ..............................................32 Steering Gear and Linkage .......................................33 Power Steering ..........................................................33 CL MT AT TF PD AX SU BR RS BT HA SC EL IDX PRECAUTIONS Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” NAST0047 The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS composition which is available to NISSAN MODEL R50 is as follows: I For a frontal collision The Supplemental Restraint System consists of driver air bag module (located in the center of the steering wheel), front passenger air bag module (located on the instrument panel on passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. I For a side collision The Supplemental Restraint System consists of side air bag module (located in the outer side of front seat), side curtain air bag module (locating in the headliner side of front and rear seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision). WARNING: I 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. I Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connector (and by yellow harness protector or yellow insulation tape before the harness connectors). Precautions for SRS “AIR BAG” and “SEAT BELT PRE-TENSIONER” Service I I I I I I I Precautions for Steering System I I I I I I I NAST0048 Do not use electrical test equipment to check SRS circuits unless instructed to in this Service Manual. Before servicing the SRS, turn ignition switch “OFF”, disconnect battery ground cable and wait at least 3 minutes. For approximately 3 minutes after the cables are removed, it is still possible for the air bag and seat belt pre-tensioner to deploy. Therefore, do not work on any SRS connectors or wires until at least 3 minutes have passed. Diagnosis sensor unit must always be installed with their arrow marks “g” pointing towards the front of the vehicle for proper operation. Also check diagnosis sensor unit for cracks, deformities or rust before installation and replace as required. 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 driver and passenger air bag modules with the pad side facing upward and side air bag module standing with the stud bolt side setting bottom. Conduct self-diagnosis to check entire SRS for proper function after replacing any components. After air bag inflates, the front instrument panel assembly should be replaced if damaged. NAST0046 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. Place disassembled parts in order, on a parts rack, for easier and proper assembly. 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 power steering fluid* to hydraulic parts. Vaseline may be applied to O-rings and seals. Do not use any grease. Replace all gaskets, seals and O-rings. Avoid damaging O-rings, seals and gaskets during installation. Perform functional tests whenever designated. *: Genuine Nissan PSF II or equivalent. Refer to MA-12, “Fluids and Lubricants”. ST-2 PREPARATION Special Service Tools Special Service Tools NAST0003 GI The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name MA Description KV48100700 (J26364) Torque adapter Measuring pinion rotating torque EM LC NT169 ST35300000 ( — Drift Installing power steering oil pump oil seal a: 59 mm (2.32 in) dia. b: 45 mm (1.77 in) dia. ) EC FE CL NT073 ST27180001 (J25726-A) Steering wheel puller Removing steering wheel MT AT TF NT544 ST29020001 (J24319-01) Ball joint remover Removing ball joint a: 34 mm (1.34 in) b: 6.5 mm (0.256 in) c: 61.5 mm (2.421 in) PD AX SU NT694 KV48103500 (J26357 and J26357-10) Pressure gauge Measuring oil pressure BR RS NT547 KV48102500 ( — ) Pressure gauge adapter Measuring oil pressure BT HA SC NT542 EL IDX ST-3 PREPARATION Special Service Tools (Cont’d) Tool number (Kent-Moore No.) Tool name ST3127S000 (See J25765-A) 1 GG91030000 (J25765-A) Torque wrench 2 HT62940000 ( — ) Socket adapter 3 HT62900000 ( — ) Socket adapter Description Measuring turning torque NT541 KV48104400 ( — ) Rack seal ring reformer Reforming teflon ring a: 50 mm (1.97 in) dia. b: 36 mm (1.42 in) dia. c: 100 mm (3.94 in) NT550 KV48103400 ( — ) Torque adapter Measuring steering transfer gear rotating torque NT236 KV48104200 ( — ) Rear cover wrench Removing and installing gear housing end cover a: 4 mm (0.16 in) dia. b: 5 mm (0.20 in) c: 3 mm (0.12 in) dia. d: 5 mm (0.20 in) NT540 Commercial Service Tools Tool name Description Rear oil seal drift Installing rear oil seal a: 28 mm (1.10 in) dia. NT063 ST-4 NAST0004 PREPARATION Commercial Service Tools (Cont’d) Tool name GI Description Pinion oil seal drift Installing pinion oil seal a: 40 mm (1.57 in) dia. MA EM NT063 Oil pump attachment Disassembling and assembling oil pump Unit: mm (in) LC EC FE NT179 CL MT AT TF PD AX SU BR RS BT HA SC EL IDX ST-5 × Tie-rod ball joint swinging force ST-21 × Tie-rod ball joint rotating torque ST-21 × Tie-rod ball joint end play ST-21 × Steering gear fluid leakage ST-8 × Steering wheel play ST-7 × Steering gear rack sliding force ST-9 × Drive belt looseness MA-14 × Steering column deformation or damage ST-13 × Improper installation or looseness of steering column ST-13 Steering linkage looseness ST-17 × PROPELLER SHAFT PD-4 × DIFFERENTIAL PD-4 × DRIVE SHAFT AX-3 × AXLE AX-3 × SUSPENSION SU-4 × TIRES SU-4 × ROAD WHEEL SU-4 × BRAKES BR-7 × × × × × × × × × × × × × × × × × × × × × × × NAST0043 × ST-8 × — NAST0043S01 × Mounting rubber deterioration × × ST-13 × × × Improper installation or looseness or tilt lock lever × × × Improper steering wheel NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ST-9 NVH Troubleshooting Chart × Air in hydraulic system NVH Troubleshooting Chart × ST-8 Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts. Reference page Noise Shake Shimmy Judder STEERING Vibration Possible cause and SUSPECTED PARTS Symptom ×: Applicable ST-6 Fluid level ON-VEHICLE SERVICE Checking Steering Wheel Play Checking Steering Wheel Play 1. 2. SST489B NAST0005 With wheels in a straight-ahead position, check steering wheel play. Steering wheel play: 35 mm (1.38 in) or less If it is not within specification, check the following for loose or worn components. Steering gear assembly Steering column Front suspension and axle Checking Neutral Position on Steering Wheel GI MA EM LC EC NAST0006 PRE-CHECKING I I CHECKING 1. SST490BA 2. 3. NAST0006S01 Make sure that wheel alignment is correct. Wheel alignment: Refer to SU-34, “Wheel Alignment”. Verify that the steering gear is centered before removing the steering wheel. FE CL MT NAST0006S02 Check that the steering wheel is in the neutral position when driving straight ahead. If it is not in the neutral position, remove the steering wheel and reinstall it correctly. If the neutral position is between two teeth, loosen tie-rod lock nuts. Turn the tie-rods by the same amount in opposite directions on both left and right sides. AT TF PD AX SU Front Wheel Turning Angle 1. NAST0007 Rotate steering wheel all the way right and left; measure turning angle. Turning angle of full turns: Refer to SU-34, “Wheel Alignment”. BR RS BT SMA127 2. If it is not within specification, check rack stroke. Rack stroke “S”: Refer to SDS (ST-33). HA SC EL IDX SST651C ST-7 ON-VEHICLE SERVICE Checking Gear Housing Movement Checking Gear Housing Movement 1. I 2. NAST0008 Check the movement of steering gear housing during stationary steering on a dry paved surface. Apply a force of 49 N (5 kg, 11 lb) to steering wheel to check the gear housing movement. Turn off ignition key while checking. Movement of gear housing: ±2 mm (±0.08 in) or less If movement exceeds the limit, replace mount insulator after confirming proper installation of gear housing clamps. SST601C Adjusting Rack Retainer I a) b) I NAST0009 Perform this driving test on a flat road. Check whether vehicle moves in a straight line when steering wheel is released. Check whether steering wheel returns to neutral position when steering wheel is released from a slightly turned (approx. 20°) position. If any abnormality is found, correct it by resetting adjusting screw. SST602C Checking and Adjusting Drive Belts NAST0010 Refer to MA-14, “Checking Drive Belts”. Checking Fluid Level NAST0011 Check fluid level. Use the correct range of the dipstick depending on the fluid temperature. Use the “HOT” range at 50 to 80°C (122 to 176°F), or the “COLD” range at 0 to 30°C (32 to 86°F). CAUTION: I Do not overfill. I Recommended fluid is Genuine Nissan PSF II or equivalent. Refer to MA-12, “Fluids and Lubricants”. SST280BA Checking Fluid Leakage NAST0012 Check the lines for improper attachment and for leaks, cracks, damage, loose connections, chafing and deterioration. 1. Run engine between idle speed and 1,000 rpm. Make sure temperature of fluid in reservoir tank rises to 50 to 80°C (122 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. SST458C ST-8 ON-VEHICLE SERVICE Checking Fluid Leakage (Cont’d) CAUTION: Do not hold the steering wheel in a locked position for more than 15 seconds. 4. If fluid leakage at connectors is noticed, loosen flare nut and then retighten. Do not overtighten connector as this can damage O-ring, washer and connector. 5. Check rack boots for accumulation of power steering fluid. GI MA EM LC Bleeding Hydraulic System EC NAST0013 1. 2. Raise front end of vehicle until wheels are clear of the ground. Add fluid into 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. I Incomplete air bleeding will cause the following to occur. When this happens, bleed air again. a) Air bubbles in reservoir tank b) Clicking noise in oil pump c) Excessive buzzing in oil pump Fluid noise may occur in the valve or oil pump. This is common when the vehicle is stationary or while turning steering wheel slowly. This does not affect performance or durability of the system. FE CL MT AT TF PD AX SU Checking Steering Wheel Turning Force 1. 2. 3. SST491B SST090B NAST0014 Park vehicle on a level, dry surface and set parking brake. Start engine. Bring power steering fluid up to adequate operating temperature. [Make sure temperature of fluid is approximately 50 to 80°C (122 to 176°F).] Tires need to be inflated to normal pressure. 4. Check steering wheel turning force when steering wheel has been turned 360° from the neutral position. Steering wheel turning force: 39 N (4 kg, 9 lb) or less 5. If steering wheel turning force is out of specification, check rack sliding force. a. Disconnect steering column lower joint and knuckle arms from the gear. b. Start and run engine at idle to make sure steering fluid has reached normal operating temperature. c. Pull tie-rod slowly to move it from neutral position to ±11.5 mm (±0.453 in) at speed of 3.5 mm (0.138 in)/s. Check that rack sliding force is within specification. Rack sliding force: 167 - 254 N (17.0 - 25.9 kg, 37 - 57 lb) ST-9 BR RS BT HA SC EL IDX ON-VEHICLE SERVICE Checking Steering Wheel Turning Force (Cont’d) 6. 7. If rack sliding force is not within specification, overhaul steering gear assembly. If rack sliding force is OK, inspect steering column. Refer to “Inspection”, “STEERING WHEEL AND STEERING COLUMN”, ST-14. Checking Hydraulic System SST834-F NAST0015 Before starting, check belt tension, driving pulley and tire pressure. 1. Set Tool. Open shut-off valve. Then bleed air. Refer to “Bleeding Hydraulic System”, ST-9. 2. Run engine, at idle speed or 1,000 rpm. Make sure fluid temperature in reservoir tank rises to 50 to 80°C (122 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 the power steering pump increase to maximum. This will raise fluid temperature abnormally. 3. Check pressure with steering wheel fully turned to left and right positions with engine idling at 1,000 rpm. CAUTION: Do not hold the steering wheel in a locked position for more than 15 seconds. Power steering pump maximum operating pressure: 8,630 - 9,219 kPa (88 - 94 kg/cm2, 1,251 - 1,337 psi) I If pressure reaches maximum operating pressure, system is OK. I If pressure increases above maximum operating pressure, check power steering pump flow control valve. Refer to ST-28. 4. If power steering pressure is below the maximum operating pressure, slowly close shut-off valve and check pressure again. CAUTION: Do not close shut-off valve for more than 15 seconds. I If pressure increases to maximum operating pressure, gear should be damaged. Refer to “Removal and Installation”, ST-18. I If pressure remains below maximum operating pressure, pump should be damaged. Refer to “Disassembly”, ST-28. 5. After checking hydraulic system, remove Tool and add fluid as necessary. Then completely bleed air out of system. Refer to ST-9. ST-10 STEERING WHEEL AND STEERING COLUMN Components Components NAST0016 GI MA EM LC EC FE CL SST010D 1. 2. Air bag module Steering wheel 3. 4. Spiral cable Combination switch 5. 6. Steering column assembly Column cover MT AT CAUTION: I 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. Do not rotate the steering column while the steering gear is removed. I Remove the steering wheel before removing the steering lower joint to avoid damaging the SRS spiral cable. TF PD AX SU Removal and Installation STEERING WHEEL 1. NAST0017 NAST0017S01 BR Remove air bag module and spiral cable. Refer to RS-18, “Removal — Air Bag Module and Spiral Cable”. RS BT SBF812E HA SC EL IDX ST-11 STEERING WHEEL AND STEERING COLUMN Removal and Installation (Cont’d) 2. a. b. Align spiral cable correctly when installing steering wheel. Set the front wheels in the straight-ahead position. Make sure that the spiral cable is in the neutral position. The neutral position is detected by turning left about 2.5 revolutions from the right end position. Align the two marks ( ). CAUTION: I The spiral cable may snap due to steering operation if the cable is installed in an improper position. I Also, with the steering linkage disconnected, the cable may snap by turning the steering wheel beyond the limited number of turns. The spiral cable can be turned to the left about 2.5 turns from the right end position. SRS266 3. Remove steering wheel with Tool. 4. Remove key interlock cable. SST818C SST329C STEERING COLUMN I I NAST0017S02 When installing steering column, fingertighten all lower bracket and clamp retaining bolts; then tighten them securely. Do not apply undue stress to steering column. When attaching coupling joint, be sure tightening bolt faces cutout portion. SST844C ST-12 STEERING WHEEL AND STEERING COLUMN Disassembly and Assembly Disassembly and Assembly NAST0018 GI MA EM LC EC FE CL MT AT TF SST845C 1. 2. 3. Combination switch Lock nut Jacket tube assembly 4. 5. 6. Tilt lever Tilt spring Steering column shaft assembly 7. 8. 9. Band Jacket tube bracket insulator assembly Hole cover PD AX SU I I When disassembling and assembling, unlock steering lock with key. Install lock nut on steering column shaft and tighten the nut to specification. : 25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-lb) BR RS BT SST490C I a) b) Steering lock Break self-shear type screws with a drill or other appropriate tool. Install new self-shear type screws and then cut off self-shear type screw heads. HA SC EL IDX SST742A ST-13 STEERING WHEEL AND STEERING COLUMN Inspection Inspection I a) b) I SST606C NAST0019 When steering wheel does not turn smoothly, check the steering column as follows and replace damaged parts. Check column bearings for damage and unevenness. Lubricate with recommended multi-purpose grease or replace steering column as an assembly, if necessary. Check steering column lower shaft for deformation and breakage. Replace if necessary. When the vehicle comes into a light collision, check length “L1”, “L2” and “L3”. Steering column length “L1”: 716.7 - 718.7 mm (28.22 - 28.30 in) Steering column lower shaft length “L2”: 178 - 180 mm (7.01 - 7.09 in) Steering column upper joint length “L3”: 430.7 - 432.7 mm (16.96 - 17.04 in) If out of the specifications, replace steering column upper joint or steering column as an assembly. SST607C TILT MECHANISM NAST0019S01 After installing steering column, check tilt mechanism operation. SST582BE ST-14 STEERING TRANSFER GEAR Removal Removal NAST0021 GI MA EM LC EC FE CL SST846C 1. 2. Power steering gear assembly Steering column lower joint 3. Transfer gear assembly 4. Steering column upper joint MT AT TF PD AX SU 1. 2. Set wheels in the straight-ahead position. Straight-forward position is indicated by a protrusion on the power steering gear rear cover cap and matching mark on the rear housing. BR RS BT SST609C 3. 4. Remove steering column upper and lower joint from transfer gear. Remove transfer gear assembly. HA SC EL IDX SST610C ST-15 STEERING TRANSFER GEAR Installation Installation 1. 2. 3. 4. NAST0022 Set wheels in the straight-ahead position. Install transfer gear assembly. Install column lower joint while aligning groove with protrusions on the steering gear rear cover cap. Tighten bolt while aligning groove on steering gear. Before tightening bolt, ensure it is inserted correctly. SST847C 5. When attaching steering column upper and lower joint to transfer gear, it must be positioned as shown in figure at left. SST848C Inspection SST707CA NAST0024 Do not disassemble steering transfer gear assembly. I Check that steering transfer gear assembly operates smoothly. Also check for grease leakage, deformation and damage. Replace steering transfer gear assembly if necessary. I Check rotating torque at input shaft in 360° and in both directions. Rotating torque: 0.25 - 0.69 N·m (2.5 - 7.0 kg-cm, 2.2 - 6.1 in-lb) If rotating torque is out of specification, replace steering transfer gear assembly. ST-16 POWER STEERING GEAR AND LINKAGE Components Components NAST0026 GI MA EM LC EC FE CL MT AT TF PD AX SU BR RS SST618CB 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Rear cover cap Rear housing assembly Pinion seal ring Pinion assembly O-ring Shim Pinion oil seal Lock nut Adjusting screw Spring 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Retainer Gear housing assembly Rack oil seal Rack assembly Rack seal ring O-ring O-ring Rack bushing Rack oil seal Snap ring 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. End cover assembly Boot clamp Dust boot Boot clamp Lock plate Tie-rod inner socket Tie-rod Tie-rod outer socket Cotter pin Cylinder tube BT HA SC EL IDX ST-17 POWER STEERING GEAR AND LINKAGE Removal and Installation Removal and Installation NAST0027 SST011D 1. 2. Gear and linkage assembly Rack mounting insulator 3. Gear housing mounting bracket 4. Cotter pin CAUTION: I 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. Do not rotate the steering column while the steering gear is removed. I Remove the steering wheel before removing the steering lower joint to avoid damaging the SRS spiral cable. I Detach tie-rod outer sockets from knuckle arms with Tool. SFA756B I I SST615C I Install pipe connector. Observe specified tightening torque when tightening high-pressure and low-pressure pipe connectors. Excessive tightening will damage threads of connector or O-ring. Connector tightening torque: Low-pressure side “1” 30 - 35 N·m (3.1 - 3.6 kg-m, 22 - 26 ft-lb) High-pressure side “2” 30 - 35 N·m (3.1 - 3.6 kg-m, 22 - 26 ft-lb) The O-ring in low-pressure pipe connector is larger than that ST-18 POWER STEERING GEAR AND LINKAGE Removal and Installation (Cont’d) in high-pressure connector. Take care to install the proper O-ring. GI MA EM LC I Initially, tighten nut on tie-rod outer socket and knuckle arm to 64 to 69 N·m (6.5 to 7.0 kg-m, 47 to 51 ft-lb). Then tighten further to align nut groove with first pin hole so that cotter pin can be installed. CAUTION: Tightening torque must not exceed 108 N·m (11.0 kg-m, 80 ftlb). EC FE CL MT SST616C I I Before removing steering column lower joint from gear, set gear in neutral (wheels in straight-ahead position). After removing steering column lower joint, put matching mark on pinion shaft and pinion housing to record neutral position. To install, set left and right dust boots to equal deflection. Attach steering column lower joint by aligning matching marks of pinion shaft and pinion housing. AT TF PD AX SU SST819A I Tighten gear housing mounting bracket bolts in the order shown. Secure tightening torque: 157 - 186 N·m (16 - 18 kg-m, 116 - 137 ft-lb) BR RS BT SST617C Disassembly 1. SST718CA NAST0028 Prior to disassembling, measure pinion rotating torque. Record the pinion rotating torque as a reference. I Before measuring, disconnect cylinder tube and drain fluid. I Use soft jaws when holding steering gear housing. Handle gear housing carefully, as it is made of aluminum. Do not grip cylinder in a vise. 2. Remove pinion gear. Be careful not to damage pinion gear when removing pinion seal ring. ST-19 HA SC EL IDX POWER STEERING GEAR AND LINKAGE Disassembly (Cont’d) 3. 4. 5. 6. 7. Remove tie-rod outer sockets and boots. Loosen tie-rod inner socket by prying up staked portion, and remove socket. Remove retainer. Remove pinion assembly. Use a 2 to 2.5 mm (0.079 to 0.098 in) diameter drill to completely remove staked portion of gear housing end. SST051C 8. 9. 10. I Remove gear housing end cover assembly with a suitable tool. Draw out rack assembly. Remove rack seal ring. Using a heat gun, heat rack seal to approximately 40°C (104°F). I Remove rack seal ring. Be careful not to damage rack. SST652C 11. Remove rack bushing and rack oil seal using tape wrapped socket and extension bar. Do not scratch inner surfaces of pinion housing. SST644C Inspection NAST0029 Thoroughly clean all parts in cleaning solvent or Genuine Nissan PSF II or equivalent. Blow dry with compressed air, if available. BOOT I I NAST0029S01 Check condition of boot. If cracked excessively, replace it. Check boots for accumulation of power steering fluid. RACK NAST0029S02 Thoroughly examine rack gear. If damaged, cracked and worn, replace it. PINION ASSEMBLY I I NAST0029S03 Thoroughly examine pinion gear. If pinion gear is damaged, cracked and worn, replace it. Check that all bearings roll freely. Ensure that balls, rollers and races are not cracked, pitted and worn. GEAR HOUSING CYLINDER NAST0029S04 Check gear housing cylinder bore for scratches and other damage. Replace if necessary. ST-20 POWER STEERING GEAR AND LINKAGE Inspection (Cont’d) TIE-ROD OUTER AND INNER SOCKETS I I I SST468C I NAST0029S05 Check ball joints for swinging force. Tie-rod outer and inner ball joints swinging force “A”: Refer to SDS, ST-33. Check ball joint for rotating torque. Tie-rod outer ball joint rotating torque “B”: Refer to SDS, ST-33. Check ball joints for axial end play. Tie-rod outer and inner ball joints axial end play “C”: Refer to SDS, ST-33. Check condition of dust cover. If cracked excessively, replace outer tie-rod. GI MA EM LC EC FE CL MT Assembly 1. AT NAST0030 Using a heat gun, heat new teflon rack seal ring to approximately 40°C (104°F). Then place it onto rack. TF PD AX SU SST083B 2. Using Tool, compress rack seal ring securely on rack. Always insert Tool from the rack gear side. BR RS BT SBR132C 3. I I I Insert new rack oil seal. Place plastic film into rack oil seal to prevent damage by rack teeth. Do not forget to remove plastic film after rack oil seal is positioned properly. Make sure lips of rack oil seal face each other. HA SC EL IDX SST201A ST-21 POWER STEERING GEAR AND LINKAGE Assembly (Cont’d) 4. Install rack oil seal and rack bushing with rack assembly. 5. Insert rack oil seal and end cover assembly to rack. Then tighten end cover assembly. 6. Fasten cylinder end cover assembly to gear housing by staking. 7. Set rack gear in the neutral position. Rack stroke “S”: Refer to SDS, ST-33. SST645C SST653C SST654C SST651C 8. Coat seal lip of new pinion oil seal with multi-purpose grease. Install it into pinion housing of gear with a suitable tool. Make sure lip of oil seal faces up when installed. SST381A ST-22 POWER STEERING GEAR AND LINKAGE Assembly (Cont’d) 9. I Install pinion bearing adjusting shim(s). Whenever pinion assembly, gear housing and rear housing are disassembled, replace shim(s) with new ones. Always use the same number of shim(s) when replacing. GI MA EM LC SST074B 10. Install new pinion seal ring (made of Teflon) on pinion gear assembly. I Using a heat gun, heat pinion seal ring to approximately 40°C (104°F) before installing it onto pinion gear assembly. I Make sure pinion seal ring is properly settled in valve groove. EC FE CL MT SST085B 11. Apply a coat of multi-purpose grease to needle bearing roller and oil seal lip. AT TF PD AX SU SST075B 12. Install pinion assembly to rear housing. Be careful not to damage pinion oil seal. BR RS BT SST552 13. Apply a coat of multi-purpose grease to new rear oil seal lip before installing rear housing. HA SC EL IDX SST133C ST-23 POWER STEERING GEAR AND LINKAGE Assembly (Cont’d) 14. Ensure that the rack is centered. Install rear cover cap so that its protrusion is positioned as shown in figure. Be careful not to damage worm ring and oil seal. 15. Install retainer, spring and adjusting screw temporarily. SST609C 16. Install new lock plate. I Attach lock plate 2 to side rod inner socket 1. I Apply locking sealant to inner socket threads 3. Screw inner socket into rack 4 and tighten to specified torque. I Clinch two places of lock plate at rack’s groove. CAUTION: To prevent scratching the boot, remove burrs from lock plate. SST135C 17. Tighten outer socket lock nut. Tie-rod length “L”: Refer to SDS, ST-33. 18. Measure rack stroke. Rack stroke “S”: Refer to SDS, ST-33. SST655C 19. Before installing boot, coat the contact surfaces between boot and tie-rod with grease. SST967A Adjustment NAST0031 Adjust pinion rotating torque as follows: 1. Set rack to the neutral position without fluid in the gear. 2. Coat the adjusting screw with locking sealant and screw it in. 3. Lightly tighten lock nut. 4. Tighten adjusting screw to a torque of 4.9 to 5.9 N·m (50 to 60 kg-cm, 43 to 52 in-lb). 5. Loosen adjusting screw, then retighten it to 0.2 N·m (2 kg-cm, 1.7 in-lb). SST619C ST-24 POWER STEERING GEAR AND LINKAGE Adjustment (Cont’d) 6. 7. 8. 9. Move rack over its entire stroke several times. Measure pinion rotating torque within the range of 180° from neutral position. Stop the gear at the point of maximum torque. Loosen adjusting screw, then retighten it to 4.9 to 5.9 N·m (50 to 60 kg-cm, 43 to 52 in-lb). Loosen adjusting screw by 10° to 20°. GI MA EM LC SST718CA 10. Prevent adjusting screw from turning, and tighten lock nut to specified torque. EC FE CL MT SST713C SST718CA 11. Measure pinion rotating torque. Lock to lock: Average rotating torque 0.78 - 1.47 N·m (8.0 - 15.0 kg-cm, 6.9 - 13.0 in-lb) Within ±100° from the neutral position: Maximum torque variation 0.4 N·m (4 kg-cm, 3.5 in-lb) Outside the above range: Maximum force variation 0.6 N·m (6 kg-cm, 5.2 in-lb) I If pinion rotating torque is not within specifications, readjust it starting from step 4. If pinion rotating torque is still out of specifications after readjustment, replace steering gear assembly. AT TF PD AX SU BR RS BT SST090B 12. Check rack sliding force on vehicle as follows: a. Install steering gear onto vehicle, but do not connect tie-rod to knuckle arm. b. Connect all piping and fill with steering fluid. c. Start engine and bleed air completely. d. Disconnect steering column lower joint from the gear. e. Keep engine at idle and make sure steering fluid has reached normal operating temperature. f. Pull tie-rod slowly to move it from neutral position to ±11.5 mm (±0.453 in) at speed of 3.5 mm (0.138 in)/s. Check that rack sliding force is within specification. ST-25 HA SC EL IDX POWER STEERING GEAR AND LINKAGE Adjustment (Cont’d) I I Rack sliding force: 167 - 254 N (17.0 - 25.9 kg, 37 - 57 lb) If rack sliding force is not within specification, readjust by repeating adjustment procedure from the beginning. If rack sliding force is still out of specification after readjustment, gear assembly needs to be replaced. ST-26 POWER STEERING OIL PUMP Components Components NAST0032 GI MA EM LC EC FE CL MT AT TF PD AX SST924C 1. 2. 3. 4. 5. 6. 7. 8. Pulley and drive shaft Front bracket Oil seal Suction pipe O-ring Casing Flow control valve spring Flow control A valve 9. 10. 11. 12. 13. 14. 15. Dowel pin Flow control B valve assembly Side plate (Front) Cam ring Rotor Vane Snap ring 16. 17. 18. 19. 20. 21. 22. Side plate (Rear) Side plate inner seal Side plate outer seal O-ring Rear cover Power steering pump bracket Copper washer SU BR RS BT Pre-disassembly Inspection NAST0033 Disassemble the power steering oil pump only if the following items are found. I Oil leak from any point shown in the figure. I Deformed or damaged pulley. I Poor performance. HA SC EL IDX SST925C ST-27 POWER STEERING OIL PUMP Disassembly Disassembly NAST0034 CAUTION: I Parts which can be disassembled are strictly limited. Never disassemble parts other than those specified. I Disassemble in as clean a place as possible. I Clean your hands before disassembly. I Do not use rags; use nylon cloths or paper towels. I Follow the procedures and cautions in the Service Manual. I When disassembling and reassembling, do not let foreign matter enter or contact the parts. 1. Fix power steering pump to vise. CAUTION: When fixing the pump to vise, use an aluminum plate or such to avoid damaging the fitting plane of the steering pump. 2. Remove the front bracket mounting bolt, and remove the front bracket from the casing. 3. Remove the cover body mounting bolt, and remove the rear cover from the casing. 4. Remove the O-ring from the casing. 5. Remove side plate (rear side) from cam ring, then remove side plate inner/outer seals from side plate (rear side). 6. Remove rotor snap ring using snap ring pliers, and remove pulley from casing. CAUTION: Do not damage pulley shaft when removing rotor snap ring. SST926C SST928C 7. Remove the followings from casing. I Cam ring I Rotor I Vane I Side plate (front side) I Flow control A valve I Flow control valve spring I Flow control B valve assembly CAUTION: Be careful not to drop flow control valve. 8. Remove suction pipe mounting bolt, and remove suction pipe from casing. 9. Remove suction pipe O-ring from suction pipe. 10. Remove drive shaft oil seal from casing with a screwdriver. CAUTION: Do not damage casing surface with the screwdriver. ST-28 POWER STEERING OIL PUMP Inspection Inspection I I I I I NAST0035 If pulley is cracked or deformed, replace it. If an oil leak is found around drive shaft oil seal, replace the seal. Check the casing and the inside of the rear cover for damage. If damages are found in the rear cover, replace the rear cover. If the casing is damaged, replace the power steering pump as an assembly. Check the cam ring for damage. If damage is found, replace the cam ring, rotor and vane as a set. Check the side plates (front and rear) for damage. If damage is found, replace the side plates as a set (front and rear). GI MA EM LC EC FE CL MT Assembly AT NAST0036 1. Apply grease to the lip of the drive shaft oil seal, and attach the casing. CAUTION: The drive shaft oil seal cannot be reused. Always replace after every disassembly. TF PD AX SU SST934C 2. 3. When removing the dowel pin, if it is difficult to insert with your hands, insert into the casing by tapping lightly with a hammer or similar tool. Attach the flow control A valve, flow control valve spring, and the flow control B valve assembly to the locations indicated in the drawing left. BR RS BT SST928C 4. Match the dowel pin A on the flow control A valve side with the notch B of the side plate (front), and attach the side plate (front) to the casing. HA SC EL IDX SST929C ST-29 POWER STEERING OIL PUMP Assembly (Cont’d) 5. Face the cam ring side with fewer pores towards the casing, and attach the cam ring on top of the side plate (front). 6. Attach the pulley to the casing. CAUTION: Attach with care so as not to damage the drive shaft oil seal. SST930C 7. Face the side of the rotor with the punch mark towards the casing, and attach the rotor to the drive shaft. 8. Attach the vane to the rotor so that the vane’s arc touches the cam ring. SST289A SST843A 9. Use a hammer or suitable tool to insert the rotor snap ring into the drive shaft channel. CAUTION: I The rotor snap ring cannot be reused. Always replace after every disassembly. I Insert with care so as not to damage the rotor or the drive shaft. I If the rotor is damaged, replace the power steering as an assembly. SST931C 10. Match the dowel pin A on the flow control A valve side with the notch B of the side plate (rear), and attach the side plate (rear) to the cam ring. 11. Apply Genuine Nissan PSF II or equivalent to O-ring and attach to the casing. CAUTION: The O-ring cannot be reused. Always replace after every disassembly. SST932C ST-30 POWER STEERING OIL PUMP Assembly (Cont’d) SST933C 12. Attach a side plate inner seal and side plate outer seal with Genuine Nissan PSF II or equivalent applied, to the side plate (rear). CAUTION: The side plate inner seal and outer seal cannot be reused. Always replace after every disassembly. 13. Set the power steering pump on the vice. CAUTION: When securing to the vise, use an aluminum plate or other material to protect the installation surface of the power steering pump from damage. 14. Attach the rear cover to the casing, and secure the bolts (4 bolts) in a diagonal order to the specified torque. 15. Attach the front bracket to the casing, and secure the bolts (2 bolts) to the specified torque. 16. Attach the suction pipe O-ring to the grooves of the suction pipe, and attach the suction pipe to the casing with attachment bolts. CAUTION: The suction pipe O-ring cannot be reused. Always replace after every disassembly. GI MA EM LC EC FE CL MT AT TF PD AX SU BR RS BT HA SC EL IDX ST-31 SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications General Specifications NAST0037 Applied model All Steering model Power steering Steering gear type PR32K Steering overall gear ratio 17.2 Turns of steering wheel (Lock to lock) 3.09 Steering column type Collapsible, tilt Steering Wheel NAST0038 Unit: mm (in) Steering wheel axial play 0 (0) Steering wheel play 35 (1.38) or less Movement of gear housing ±2 (±0.08) or less Steering Column NAST0039 Unit: mm (in) Steering column length “L1” 716.7 - 718.7 (28.22 - 28.30) Steering column lower shaft length “L2” 178 - 180 (7.01 - 7.09) Steering column upper joint length “L3” 430.7 - 432.7 (16.96 - 17.04) SST739C Steering Transfer Gear Rotating torque NAST0041 0.25 - 0.69 N·m (2.5 - 7.0 kg-cm, 2.2 - 6.1 in-lb) ST-32 SERVICE DATA AND SPECIFICATIONS (SDS) Steering Gear and Linkage Steering Gear and Linkage Applied model GI All Steering gear type MA PR32K Swinging force at cotter pin hole: “A” Tie-rod outer ball joint NAST0040 4.9 - 47.1 N (0.5 - 4.8 kg, 1.1 - 10.6 lb) Rotating torque: “B” 0.3 - 2.9 N·m (3 - 30 kg-cm, 2.6 - 26.0 in-lb) Axial end play: “C” 0.1 mm (0.004 in) or less Swinging force*: “A” EM LC 3.9 - 32.4 N (0.4 - 3.3 kg, 0.9 - 7.3 lb) Tie-rod inner ball joint Axial end play: “C” 0.3 mm (0.012 in) or less Tie-rod standard length “L” Rack stroke “S” 72.0 mm (2.835 in) FE Lock to lock Average rotating torque Pinion gear preload without gear fluid EC 200 mm (7.87 in) 0.78 - 1.47 N·m (8.0 - 15.0 kg-cm, 6.9 - 13.0 in-lb) Within ±100° from the neutral position Maximum torque variation 0.4 N·m (4 kg-cm, 3.5 in-lb) Outside the above range Maximum torque variation 0.6 N·m (6 kg-cm, 5.2 in-lb) CL MT *: Measuring point [: 240 mm (9.45 in)] AT TF PD AX SST740C SU Power Steering Steering gear type PR32K Rack sliding force Under normal operating oil pressure BR 167 - 254 N (17.0 - 25.9 kg, 37 - 57 lb) Initial tightening torque Retainer adjustment (Adjustment screw) NAST0042 4.9 - 5.9 N·m (50 - 60 kg-cm, 43 - 52 in-lb) Retightening torque after loosening Tightening torque after gear has settled Returning angle 0.2 N·m (2 kg-cm, 1.7 in-lb) 10° - 20° Steering wheel turning force (Measured at one full turn from the neutral position) RS 4.9 - 5.9 N·m (50 - 60 kg-cm, 43 - 52 in-lb) BT 39 N (4 kg, 9 lb) or less Fluid capacity (Approximate) 0.9 (1 US qt, 3/4 Imp qt) Oil pump maximum pressure 8,630 - 9,219 kPa (88 - 94 kg/cm2, 1,251 - 1,337 psi) HA SC EL IDX ST-33 NOTES MAINTENANCE SECTION MA GI EM LC EC FE CONTENTS PRECAUTIONS ...............................................................3 Precautions for Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″ ......................................................3 PREPARATION ...............................................................4 Special Service Tool ....................................................4 Commercial Service Tool.............................................4 GENERAL MAINTENANCE ............................................5 PERIODIC MAINTENANCE ............................................7 Schedule 1...................................................................8 EMISSION CONTROL SYSTEM MAINTENANCE .........8 CHASSIS AND BODY MAINTENANCE ........................9 Schedule 2.................................................................10 EMISSION CONTROL SYSTEM MAINTENANCE .......10 CHASSIS AND BODY MAINTENANCE ......................11 RECOMMENDED FLUIDS AND LUBRICANTS...........12 Fluids and Lubricants ................................................12 SAE Viscosity Number ..............................................13 GASOLINE ENGINE OIL ..........................................13 Anti-freeze Coolant Mixture Ratio .............................13 ENGINE MAINTENANCE ..............................................14 Checking Drive Belts .................................................14 Changing Engine Coolant..........................................15 -DRAINING ENGINE COOLANT- ..............................15 -REFILLING ENGINE COOLANT-..............................16 -FLUSHING COOLING SYSTEM- ..............................16 Checking Fuel Lines ..................................................17 Changing Fuel Filter ..................................................17 WITH CONSULT-II ..............................................17 WITHOUT CONSULT-II .......................................18 Changing Air Cleaner Filter .......................................18 VISCOUS PAPER TYPE ...........................................18 Changing Engine Oil..................................................18 Changing Oil Filter.....................................................19 Changing Spark Plugs...............................................20 Checking EVAP Vapor Lines .....................................21 CHASSIS AND BODY MAINTENANCE .......................22 Checking Exhaust System.........................................22 Checking Clutch Fluid Level and Leaks....................22 Checking M/T Oil .......................................................22 Changing M/T Oil.......................................................22 Checking A/T Fluid ....................................................23 Changing A/T Fluid ....................................................23 Checking Part Time 4WD Transfer Fluid...................24 Changing Part Time 4WD Transfer Fluid ..................24 Checking All-mode 4WD Transfer Fluid ....................24 Changing All-mode 4WD Transfer Fluid....................24 Checking Propeller Shaft...........................................25 Greasing Propeller Shaft ...........................................25 Checking Differential Gear Oil...................................25 Changing Differential Gear Oil ..................................26 LIMITED-SLIP DIFFERENTIAL GEAR........................26 Balancing Wheels ......................................................26 Tire Rotation ..............................................................26 Checking Brake Fluid Level and Leaks.....................27 Checking Brake Lines and Cables ............................27 Checking Disc Brake .................................................27 ROTOR ...................................................................27 CALIPER .................................................................27 PAD ........................................................................27 Checking Drum Brake ...............................................28 WHEEL CYLINDER ..................................................28 DRUM .....................................................................28 LINING ....................................................................28 TEMPORARY METHOD FOR CHECKING LINING WEAR .....................................................................28 Checking Steering Gear, Linkage and Transfer Gear ...........................................................................28 STEERING GEAR ....................................................28 STEERING LINKAGE ...............................................28 STEERING TRANSFER GEAR..................................28 Checking Power Steering Fluid and Lines ................29 CHECKING FLUID LEVEL ........................................29 CHECKING LINES ...................................................29 Axle and Suspension Parts .......................................29 FRONT WHEEL BEARING .......................................30 Drive Shaft .................................................................30 Lubricating Locks, Hinges and Hood Latches...........30 Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters...............................................31 CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX CONTENTS SERVICE DATA AND SPECIFICATIONS (SDS) .........32 Engine Maintenance ..................................................32 DRIVE BELT DEFLECTION ......................................32 DRIVE BELT TENSION ............................................32 MA-2 (Cont’d) SPARK PLUG (PLATINUM-TIPPED TYPE) ................32 Chassis and Body Maintenance................................32 WHEEL BALANCE ...................................................32 PRECAUTIONS Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” Precautions for Supplemental Restraint System GI (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” NAMA0001 The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS composition which is available to NISSAN MODEL R50 is as follows: I For a frontal collision The Supplemental Restraint System consists of driver air bag module (located in the center of the steering wheel), front passenger air bag module (located on the instrument panel on passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. I For a side collision The Supplemental Restraint System consists of side air bag module (located in the outer side of front seat), side curtain air bag module (locating in the headlining side of front and rear seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision). WARNING: I 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. I Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connector (and by yellow harness protector or yellow insulation tape before the harness connectors). EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX MA-3 PREPARATION Special Service Tool Special Service Tool NAMA0002 The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name Description KV10115801 (J38956) Oil filter cap wrench Removing oil filter a: 64.3 mm (2.531 in) NT375 Commercial Service Tool Tool name (Kent-Moore No.) Description Belt tension gauge (BT3373-F) Checking drive belt tension AMA126 MA-4 NAMA0045 NAMA0003 GENERAL MAINTENANCE General maintenance includes those items which should be checked during the normal day-to-day operation 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. OUTSIDE THE VEHICLE GI The maintenance items listed here should be performed from time to time, unless otherwise specified. Item Tires Wheel nuts Reference page Check the pressure with a gauge, including the spare, at least once a month and always prior to a long distance trips. Adjust to the specified pressure if necessary. Check carefully for damage, cuts or excessive wear. — 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). Wheel alignment and balance If the vehicle pulls to either side while driving on a straight and level road, or if you detect uneven or abnormal tire wear, there may be a need for wheel alignment. If the steering wheel or seat vibrates at normal highway speeds, wheel balancing may be needed. Windshield wiper blades Doors and engine hood Check for cracks or wear if they do not wipe properly. Check that all doors and the engine hood operate smoothly as well as the trunk lid and back hatch. Also make sure that all latches lock securely. Lubricate if necessary. Make sure that the secondary 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. MA-26, SU-8, “Front Wheel Alignment” EC FE CL — MT MA-30 AT TF The maintenance items listed here should be checked on a regular basis, such as when performing periodic maintenance, cleaning the vehicle, etc. Lamps LC MA-26 INSIDE THE VEHICLE Item EM Reference page PD AX 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. — 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 sufficient quantity when operating the heater or air conditioning. — Steering wheel Check that it has the specified play. Be sure to check for changes in the steering condition, such as excessive play, hard steering or strange noises. Free play: Less than 35 mm (1.38 in) — 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 restrains move up and down smoothly and that the locks (if equipped) hold securely in all latched positions. Check that the latches lock securely for folding-down rear seatbacks. — HA 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 cuts, fraying, wear or damage. MA-31 RS-8, “Seat Belt Inspection” SC Clutch pedal Make sure the pedal operates smoothly and check that it has the proper free play. CL-6, “Adjusting Clutch Pedal” Brakes Check that the brake does not pull the vehicle to one side when applied. Seats MA-5 SU BR ST RS BT — EL IDX GENERAL MAINTENANCE Item Reference page Brake pedal and booster Check the pedal for smooth operation and make sure it has the proper distance under it when depressed fully. Check the brake booster function. Be sure to keep floor mats away from the pedal. Refer to BR-13, “Brake Pedal and Bracket” and “Brake Booster” Parking brake Check that the lever has the proper travel and make sure that the vehicle is held securely on a fairly steep hill when only the parking brake is applied. Refer to BR-31, “Parking Brake Control” Automatic transmission “Park” mechanism Check that the lock release button on the selector 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). Item Reference page Windshield washer fluid Check that there is adequate fluid in the tank. Engine coolant level Check the coolant level when the engine is cold. Radiator and hoses Check the front of the radiator and clean off any dirt, insects, leaves, etc., that may have accumulated. Make sure the hoses have no cracks, deformation, deterioration or loose connections. Brake and clutch fluid Make sure that the brake and clutch fluid levels are between the “MAX” and levels “MIN” lines on the reservoir. Battery Check the fluid level in each cell. It should be between the “MAX” and “MIN” lines. Vehicles operated in high temperatures or under severe conditions require frequent checks of the battery fluid level. — MA-16 — MA-22, 27 — Engine drive belts Make sure that no belt is frayed, worn, cracked or oily. MA-14 Engine oil level Check the level on the dipstick after parking the vehicle on a level spot and turning off the engine. MA-18 Power steering fluid level and lines Check the level on the dipstick with the engine off. Check the lines for improper attachment, leaks, cracks, etc. MA-29 Automatic transmission fluid level Check the level on the dipstick after putting the selector lever in “P” with the engine idling. MA-23 Exhaust system Make sure 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 and correct it. MA-22 Underbody Fluid leaks 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. — Check under the vehicle for fuel, oil, water or other fluid leaks after the vehicle has been parked for a while. Water dripping from the air conditioner after use is normal. If you should notice any leaks or gasoline fumes are evident, check for the cause and correct it immediately. — MA-6 NAMA0004 PERIODIC MAINTENANCE Two different maintenance schedules are provided, and should be used, depending upon the conditions in which the vehicle is mainly operated. After 60,000 miles (96,000 km) or 48 months, continue the periodic maintenance at the same mileage/time intervals. Schedule 1 Follow Periodic Maintenance Schedule 1 if your driving habits frequently includes one or more of the following driving conditions: I Repeated short trips of less than 5 miles (8 km). I Repeated short trips of less than 10 miles (16 km) with outside temperatures remaining below freezing. I Operating in hot weather in stop-and-go “rush hour” traffic. I Extensive idling and/or low speed driving for long distances, such as police, taxi or door-to-door delivery use. I Driving in dusty conditions. I Driving on rough, muddy, or salt spread roads. I Towing a trailer, using a camper or a car-top carrier. Emission Control System Maintenance Follow Periodic Maintenance Schedule 2 if none of the driving conditions shown in Schedule 1 apply to your driving habits. Emission Control System Maintenance MA-10 Chassis and Body Maintenance MA-11 MA-8 GI EM LC Chassis and Body Maintenance MA-9 EC FE Schedule 2 Maintenance for off-road driving ( only) Whenever you drive off-road through sand, mud or water, more frequent maintenance may be required of the following items: G Brake pads and discs G Brake lining and drums G Brake lines and hoses G Wheel bearing grease G Differential, transmission and transfer oil G Steering linkage G Propeller shaft and drive shafts G Air cleaner filter G Clutch housing CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX MA-7 Perform at number of miles, kilometers or months, whichever comes first. [ ]: At the mileage intervals only MAINTENANCE INTERVAL Miles x 1,000 (km x 1,000) Months Reference Section - Page 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 or (6) (12) (18) (24) (30) (36) (42) (48) (54) (60) (66) (72) (78) (84) (90) (96) - Content Title 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 Drive belts I* I* MA-14 [R] [R] MA-18 EVAP vapor lines I* I* MA-21 Fuel lines I* I* MA-17 Air cleaner filter NOTE (1) NOTE (2) Engine coolant NOTE (3) MA-17 R* MA-15 R R R R R R R R R R R R R R R R MA-18 Engine oil filter (Use part No. 15208-31U00 or equivalent.) R R R R R R R R R R R R R R R R MA-19 MA-8 Spark plugs (PLATINUMTIPPED type) Intake & exhaust valve clearance* Replace every 105,000 miles (169,000 km) NOTE (4) MA-20 EM-54 Schedule 1 Engine oil NOTE: (1) If operating mainly in dusty conditions, more frequent maintenance may be required. (2) When the filter becomes clogged, the vehicle speed cannot be increased as the driver wishes. In such an event, replace the filter. (3) After 60,000 miles (96,000 km) or 48 months, replace every 30,000 miles (48,000 km) or 24 months. (4) If valve noise increases, inspect valve clearance. ★ 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. PERIODIC MAINTENANCE Fuel filter* Schedule 1 MAINTENANCE OPERATION I = Inspect. Correct or replace if necessary. EMISSION CONTROL SYSTEM MAINTENANCE Abbreviations: R = Replace. NAMA0004S01 NAMA0004S0101 MAINTENANCE OPERATION Perform at number of miles, kilometers or months, whichever comes first. Reference Section - Page or - Content Title 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 (km x 1,000) (6) (12) (18) (24) (30) (36) (42) (48) (54) (60) (66) (72) (78) (84) (90) (96) Months 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 Brake lines & cables I Brake pads, rotors, drums & linings I I I I I I I I I I MA-27 I MA-27, 28 NOTE (1) I I I I MA-22, 23, 24, 25 LSD gear oil NOTE (1) I R I R MA-26 I MA-28 MA-29 Steering gear, linkage & transfer gear, axle & suspension parts Tire rotation I I I I I I I NOTE (2) MA-5 MA-9 Drive shaft boots & propeller shaft ( ) Propeller shaft NOTE (3) “Front wheel bearing grease” PERIODIC MAINTENANCE Automatic transmission, (allmode 4WD) transfer fluid, manual transmission & differential gear oil (exc. LSD) CHASSIS AND BODY MAINTENANCE Abbreviations: R = Replace. I = Inspect. Correct or replace if necessary. L = Lubricate. I I I I I I I I MA-30 MA-25 L L L L L L L L MA-25 I MA-30 R MA-30 I MA-22 4x2 I Front wheel bearing grease I Exhaust system I R I I I I I I I NOTE: (1) If towing a trailer, using a camper or a car-top carrier, or driving on rough or muddy roads, change (not just inspect) oil (exc. LSD) at every 30,000 miles (48,000 km) or 24 months, and change LSD gear oil every 15,000 miles (24,000 km) or 12 months. (2) Refer to “Tire rotation” under the “GENERAL MAINTENANCE” heading earlier in this section. (3) The propeller shaft should be re-greased after being immersed in water. Schedule 1 (Cont’d) NAMA0004S0102 GI EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX MAINTENANCE INTERVAL [ ]: At the mileage intervals only 60 (96) 48 Reference Section - Page or - Content Title I* I* MA-14 [R] [R] MA-18 EVAP vapor lines I* I* MA-21 Fuel lines I* I* MA-17 Perform at number of miles, kilometers or months, whichever comes first. Miles x 1,000 (km x 1,000) Months 7.5 (12) 6 15 (24) 12 22.5 (36) 18 Drive belts Air cleaner filter NOTE (1) Engine coolant NOTE (2) 37.5 (60) 30 45 (72) 36 52.5 (84) 42 MA-17 R* MA-15 R R R R R R R R MA-18 Engine oil filter (Use part No. 15208-31U00 or equivalent.) R R R R R R R R MA-19 MA-10 Spark plugs (PLATINUM-TIPPED type) Intake & exhaust valve clearance* Replace every 105,000 miles (169,000 km) NOTE (3) MA-20 EM-54 NOTE: (1) When the filter becomes clogged, the vehicle speed cannot be increased as the driver wishes. In such an event, replace the filter. (2) After 60,000 miles (96,000 km) or 48 months, replace every 30,000 miles (48,000 km) or 24 months. (3) If valve noise increases, inspect valve clearance. ★ 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. Schedule 2 Engine oil PERIODIC MAINTENANCE Fuel filter* 30 (48) 24 Schedule 2 MAINTENANCE OPERATION I = Inspect. Correct or replace if necessary. EMISSION CONTROL SYSTEM MAINTENANCE Abbreviations: R = Replace. NAMA0004S02 NAMA0004S0201 MAINTENANCE OPERATION I = Inspect. Correct or replace if necessary. MAINTENANCE INTERVAL Perform at number of miles, kilometers or months, whichever comes first. Miles x 1,000 (km x 1,000) Months 7.5 (12) 6 15 (24) 12 22.5 (36) 18 30 (48) 24 37.5 (60) 30 45 (72) 36 52.5 (84) 42 L = Lubricate. 60 (96) 48 Reference Section - Page or - Content Title I I I I MA-27 Brake pads, rotors, drums & linings I I I I MA-27, 28 Automatic transmission, (all-mode 4WD) transfer fluid, manual transmission & differential gear oil (exc. LSD) I I I I MA-22, 23, 24, 25 LSD gear oil I R I R MA-26 I MA-28 MA-29 Steering gear, linkage & transfer gear, axle & suspension parts Tire rotation I NOTE (1) MA-5 Drive shaft boots & propeller shaft ( ) MA-11 Propeller shaft NOTE (2) I I I I MA-30 MA-25 L L L L MA-25 I MA-30 R MA-30 I MA-22 Front wheel bearing grease (4x2) Front wheel bearing grease ( I ) I R Exhaust system I I PERIODIC MAINTENANCE Brake lines & cables CHASSIS AND BODY MAINTENANCE Abbreviations: R = Replace. NOTE: (1) Refer to “Tire rotation” under the “GENERAL MAINTENANCE” heading earlier in this section. (2) The propeller shaft should be re-greased after being immersed in water. Schedule 2 (Cont’d) NAMA0004S0202 GI EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX NAMA0005 RECOMMENDED FLUIDS AND LUBRICANTS Fluids and Lubricants Fluids and Lubricants NAMA0005S01 Capacity (Approximate) Recommended Fluids/Lubricants US measure Imp measure Liter With oil filter 5-1/4 qt 4-3/8 qt 5.0 Without oil filter 5-1/8 qt 4-1/4 qt 4.8 7-1/4 qt 6 qt 6.8 Cooling system (With reservoir) 9-3/4 qt 8-1/8 qt 9.2 Genuine NISSAN anti-freeze coolant or equivalent Manual transmission gear oil 10-3/4 pt 9 pt 5.1 API GL-4, Viscosity SAE 75W-85 Drain and refill Engine oil Dry engine (Engine overhaul) I API Certification Mark*1 I API grade SG/SH, Energy Conserving I & II or API grade SJ or SL, Energy Conserving*1 I ILSAC grade GF-I, GF-II & GF-III*1 Part time 4WD model 2-3/8 qt 2 qt 2.2 NISSAN Matic “D” (Continental U.S. and Alaska) or Canada NISSAN Automatic Transmission Fluid*2 or API GL-4, viscosity SAE 75W-90 All-mode 4WD model 3-1/8 qt 2-5/8 qt 3.0 NISSAN Matic “D” (Continental U.S. and Alaska) or Canada NISSAN Automatic Transmission Fluid*2 Front (4WD) 3-7/8 pt 3-1/4 pt 1.85 Rear 5-7/8 pt 4-7/8 pt 2.8 9 qt 7-1/2 qt 8.5 NISSAN Matic “D” (Continental U.S. and Alaska) or Canada NISSAN Automatic Transmission Fluid*2 Power steering fluid (PSF) — — — Genuine NISSAN PSF or equivalent*6 Brake and clutch fluid — — — Genuine NISSAN Brake Fluid*3 or equivalent DOT 3 (U.S. FMVSS No. 116) Propeller shaft grease — — — NLGI No. 2 (Lithium soap base) Multi-purpose grease — — — NLGI No. 2 (Lithium soap base) Transfer fluid Differential carrier gear oil Automatic transmission fluid 2WD 4WD Standard differential gear: API GL-5, viscosity SAE 80W-90*4 Limited-slip differential (LSD) gear: Use only LSD gear oil API GL-5 and SAE 80W-90*4 approved for NISSAN LSD*5. *1: For further details, see “SAE Viscosity Number”. *2: DEXRONTM III/MERCONTM 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 DEXRONTM III/MERCONTM Automatic Transmission Fluid. *3: Available in mainland USA through your NISSAN dealer. *4: For hot areas, viscosity SAE 90 is suitable for ambient temperatures above 0°C (32°F). *5: Contact a NISSAN dealer for a list of approved oils. *6: For Canada, NISSAN Automatic Transmission Fluid (ATF), DEXRONTM III/MERCONTM or equivalent ATF may also be used. MA-12 RECOMMENDED FLUIDS AND LUBRICANTS SAE Viscosity Number SAE Viscosity Number GASOLINE ENGINE OIL NAMA0005S02 GI NAMA0005S0201 SAE 5W-30 viscosity oil is preferred for all ambient temperatures. SAE 10W-30, 10W-40 viscosity oil may be used if the ambient temperature is above −18°C (0°F). EM LC EC FE CL MT MMA117AA Anti-freeze Coolant Mixture Ratio SMA947CA AT NAMA0005S03 The engine cooling system is filled at the factory with a high-quality, year-round, anti-freeze coolant solution. The anti-freeze solution contains rust and corrosion inhibitors. Therefore, additional cooling system additives are not necessary. CAUTION: When adding or replacing coolant, be sure to use only a Genuine NISSAN anti-freeze coolant or equivalent with the proper mixture ratio of 50% anti-freeze and 50% demineralized water/ distilled water. Other types of coolant solutions may damage your engine cooling system. TF PD AX SU BR ST RS BT HA SC EL IDX MA-13 ENGINE MAINTENANCE Checking Drive Belts Checking Drive Belts NAMA0049 SMA091D 1. Inspect belt for cracks, fraying, wear and oil. If necessary, replace. 2. Inspect drive belt deflection or tension at a point on the belt midway between pulleys. 3. Check belt tension using belt tension gauge (BT3373-F or equivalent). Inspect drive belt deflection or tension when engine is cold. Adjust if belt deflections exceed the limit or if belt tension is not within specifications. Belt deflection and tension Deflection adjustment Unit: mm (in) Tension adjustment *1 Used belt Unit: N (kg, lb) Used belt New belt New belt Limit After adjustment Alternator Power steering oil pump Fan 7 (0.28) 4-5 (0.16 - 0.20) 3.5 - 4.5 (0.138 - 0.177) 294 (30, 66) 730 - 818 (74.4 - 838 - 926 (85.4 83.5, 164 - 184) 94.5, 188 - 208) Air conditioner compressor 12 (0.47) 9 - 10 (0.35 - 0.39) 8-9 (0.31 - 0.35) 196 (20, 44) 348 - 436 (35.5 - 470 - 559 (47.9 44.5, 78 - 98) 57.0, 106 - 126) Applied pushing force Limit 98 N (10 kg, 22 lb) After adjustment — *1 If belt tension gauge cannot be installed at check points shown, check drive belt tension at a different location on the belt. MA-14 ENGINE MAINTENANCE Changing Engine Coolant Changing Engine Coolant NAMA0050 GI WARNING: To avoid the danger of being scalded, never change the coolant when the engine is hot. —DRAINING ENGINE COOLANT— 1. a. SMA857C b. 2. 3. I NAMA0050S01 Set air conditioning system as follows to prevent coolant from remaining in the system. Turn ignition switch “ON” and set temperature controller to maximum hot position. Wait 10 seconds before turning ignition switch “OFF”. Open radiator drain plug at the bottom of radiator. Remove radiator cap. Be careful not to allow coolant to contact drive belts. EM LC EC FE CL MT SMA858C When draining all the coolant in the system, also perform the following two steps. 1) Open drain plugs on right side of cylinder block and water pump side, then open air relief plugs to drain coolant. 2) Check drained coolant for contaminants such as rust, corrosion or discoloration. If contaminated flush engine cooling system, “Refer to FLUSHING COOLING SYSTEM”, MA-16. AT TF PD AX SU SMA092D BR ST RS BT SMA093D HA SC EL IDX SMA131D MA-15 ENGINE MAINTENANCE Changing Engine Coolant (Cont’d) —REFILLING ENGINE COOLANT— NAMA0050S02 1. 2. SMA182B SMA412B Install reservoir tank if removed, and radiator drain plug. Close and tighten cylinder block drain plugs securely if removed. I Apply sealant to the thread of cylinder block drain plugs. : 7.8 - 11.8 N·m (0.8 - 1.2 kg-m, 69 - 104 in-lb) Front side : 17.6 - 21.6 N·m (1.8 - 2.2 kg-m, 13 - 15 ft-lb) Right side Use Genuine Thread Sealant or equyivalent. Refer to GI-53. 3. Fill radiator slowly with coolant. If air relief plug was removed, fill until coolant spills from the air relief plug, then install air relief plug. 4. Fill reservoir tank if removed with coolant up to the MAX level and install radiator cap. Use Genuine NISSAN antifreeze coolant or equivalent mixed with demineralized water/distilled water. For coolant mixture ratio, refer to “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-13. Coolant capacity (Without reservoir tank): 8.6  (9-1/8 US qt, 7-5/8 Imp qt) Reservoir tank capacity (for MAX level): 0.6  (5/8 US qt, 1/2 Imp qt) Pour coolant through coolant filler neck slowly to allow air in system to escape. 5. Warm up engine to normal operating temperature with radiator cap installed. 6. Run engine at 2,500 rpm for 10 seconds and return to idle speed. I Repeat 2 or 3 times. Watch coolant temperature gauge so as not to overheat the engine. 7. Stop engine and cool it down. I Cool down using a fan to reduce the time. 8. Refill reservoir tank to Max line with coolant. 9. Repeat steps 5 through step 8 two or more times until coolant level no longer drops. 10. Check cooling system for leaks with engine running. 11. Warm up engine, and check for sound of coolant flow while running engine from idle up to 3,000 rpm with heater temperature control set at several positions between COOL and HOT. I Sound may be noticeable at heater water cock. 12. If sound is heard, bleed air from cooling system by repeating steps 5 through 8 until coolant level no longer drops. I Clean excess coolant from engine. —FLUSHING COOLING SYSTEM— 1. 2. 3. 4. 5. 6. NAMA0050S03 Open air relief plug. Fill radiator with water until water spills from the air relief holes, then close air relief plugs. Fill radiator and reservoir tank with water and reinstall radiator cap. Run engine and warm it up to normal operating temperature. Rev engine two or three times under no-load. Stop engine and wait until it cools down. Drain water. MA-16 ENGINE MAINTENANCE Changing Engine Coolant (Cont’d) 7. Repeat steps 1 through 6 until clear water begins to drain from radiator. GI EM LC Checking Fuel Lines EC NAMA0051 Inspect fuel lines and tank for improper attachment, leaks, cracks, damage, loose connections, chafing or deterioration. If necessary, repair or replace faulty parts. FE CL MT SMA803A 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 screw does not contact adjacent parts. AT TF PD AX SU MMA104A Changing Fuel Filter NAMA0052 WARNING: Before removing fuel filter, release fuel pressure from fuel line. WITH CONSULT-II 1. 2. 3. 4. SEF214Y 5. NAMA0052S01 Turn ignition switch “ON”. Perform “FUEL PRESSURE RELEASE” in “WORK SUPPORT” mode with CONSULT-II. Start engine. After engine stalls, crank engine two or three times to release all fuel pressure. Turn ignition switch “OFF”. BR ST RS BT HA SC EL IDX MA-17 ENGINE MAINTENANCE Changing Fuel Filter (Cont’d) 6. 7. I I I Loosen fuel hose clamps. Replace fuel filter. Be careful not to spill fuel over engine compartment. Place a shop towel to absorb fuel. Use a high-pressure type fuel filter. Do not use a synthetic resinous fuel filter. When tightening fuel hose clamps, refer to “Checking Fuel Lines”. SMA861C WITHOUT CONSULT-II 1. 2. 3. 4. NAMA0052S02 Remove fuel pump fuse located in fuse box. Start engine. After engine stalls, crank it two or three times to release all fuel pressure. Turn ignition switch “OFF” and install fuel pump fuse. SMA869C 5. 6. I I I Loosen fuel hose clamps. Replace fuel filter. Be careful not to spill fuel over engine compartment. Place a shop towel to absorb fuel. Use a high-pressure type fuel filter. Do not use a synthetic resinous fuel filter. When tightening fuel hose clamps, refer to “Checking Fuel Lines”. SMA861C Changing Air Cleaner Filter VISCOUS PAPER TYPE NAMA0053 NAMA0053S01 The viscous paper type filter does not need cleaning between replacement intervals. SMA095D Changing Engine Oil SMA096D NAMA0054 WARNING: I Be careful not to burn yourself, as the engine oil is hot. I 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. 1. Warm up engine, and check for oil leakage from engine components. 2. Stop engine and wait for more than 10 minutes. 3. Remove drain plug and oil filler cap. MA-18 ENGINE MAINTENANCE Changing Engine Oil (Cont’d) 4. Drain oil and refill with new engine oil. Oil specification and viscosity I API grade SG or SH, Energy Conserving I & II or API grade SJ or SL, Energy Conserving I API Certification Mark I ILSAC grade GF-I, GF-II & GF-III I See “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-12. Oil capacity (Approximately): Unit:  (US qt, Imp qt) With oil filter change 5.0 (5-1/4, 4-3/8) Without oil filter change 4.8 (5-1/8, 4-1/4) Drain and refill Dry engine (engine overhaul) GI EM LC EC 6.8 (7-1/4, 6) CAUTION: I Be sure to clean drain plug and install with new washer. Oil pan drain plug: : 29.4 - 39.2 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb) I The refill capacity depends on the oil temperature and drain time. Use these specifications for reference only. Always use the dipstick to determine when the proper amount of oil is in the engine. 5. Warm up engine and check area around drain plug and oil filter for oil leakage. 6. Stop engine and wait for more than 10 minutes. 7. Check oil level. FE CL MT AT TF PD AX SU JMA122D Changing Oil Filter NAMA0055 1. Remove oil filter with Tool. WARNING: Be careful not to burn yourself, as the engine and engine oil are hot. The filter is a full-flow cartridge type and is provided with a relief valve. Refer to LC-8, “Oil Filter”. BR ST RS BT SMA097D 2. Clean oil filter mounting surface on cylinder block. Coat rubber seal of new oil filter with engine oil. HA SC EL IDX SMA010 MA-19 ENGINE MAINTENANCE Changing Oil Filter (Cont’d) 3. Screw in the oil filter until a slight resistance is felt, then tighten an additional 2/3 turn. 4. Add engine oil. Refer to MA-18, “Changing Engine Oil”. I Clean excess oil from engine. SMA702C Changing Spark Plugs 1. 2. 3. 4. 5. 6. NAMA0056 Remove engine cover. Remove air duct with air cleaner assembly. Disconnect harness connectors and harness brackets around ignition coil sides. Remove electric throttle control actuator. (Only when removing the No. 4 cylinder spark plug) Disconnect ignition coil harness connectors. Loosen ignition coil fixing bolts and pull out coil from rocker cover. Ignition coil: : 8.5 - 10.8 N·m (0.87 - 1.1 kg-m, 76 - 95 in-lb) SMA176D 7. Check type and gap of new spark plug. Spark plug type (Platinum-tipped type): SEM294A Symbol Make Standard type PLFR5A-11 NGK Cold type PLFR6A-11 NGK Hot type PLFR4A-11 NGK Gap (Nominal): 1.1 mm (0.043 in) Spark plug: : 19.6 - 29.4 N·m (2.0 - 2.9 kg-m, 15 - 22 ft-lb) Use standard type spark plug for normal condition. The hot type spark plug is suitable when fouling may occur with the standard type spark plug such as: I frequent engine starts I low ambient temperatures The cold type spark plug is suitable when spark knock may occur with the standard type spark plug such as: I extended highway driving I frequent high engine revolution MA-20 ENGINE MAINTENANCE Changing Spark Plugs (Cont’d) I I Do not use a wire brush for cleaning. If plug tip is covered with carbon, spark plug cleaner may be used. Cleaner air pressure: Less than 588 kPa (6 kg/cm2, 85 psi) Cleaning time: Less than 20 seconds GI EM LC SMA773C I Checking and adjusting plug gap is not required between change intervals. EC FE CL MT SMA806CA Checking EVAP Vapor Lines 1. AT NAMA0057 Visually inspect EVAP vapor lines for improper attachment, cracks, damage, loose connections, chafing or deterioration. 2. Inspect vacuum relief valve of fuel tank filler cap for clogging, sticking, etc. Refer to EC-41, “EVAPORATIVE EMISSION SYSTEM”. TF PD AX SU BR ST RS BT SEC151D HA SC EL IDX MA-21 CHASSIS AND BODY MAINTENANCE Checking Exhaust System Checking Exhaust System NAMA0019 Check exhaust pipes, muffler and mounting for improper attachment, leaks, cracks, damage, loose connections, chafing or deterioration. SMA211A Checking Clutch Fluid Level and Leaks NAMA0020 If fluid level is extremely low, check clutch system for leaks. SMA956C Checking M/T Oil NAMA0021 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) SMA103 Changing M/T Oil 1. 2. NAMA0022 Drain oil from drain plug and refill with new gear oil. Check oil level. Oil grade and viscosity: API GL-4. Refer to “Fluids and Lubricants”, “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-12. Oil capacity: 5.1  (10-3/4 US pt, 9 Imp pt) Drain plug: : 25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-lb) MA-22 CHASSIS AND BODY MAINTENANCE Checking A/T Fluid Checking A/T Fluid NAMA0024 1. 2. 3. SMA121D Warm up engine. Check for fluid leakage. 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. b. Start engine and move selector lever through each gear position. Leave selector lever in “P” position. c. Check fluid level with engine idling. d. Remove dipstick and note reading. If level is at low side of either range, and fluid to the charging pipe. e. Re-insert dipstick into charging pipe as far as it will go. 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. Re-check fluid level at fluid temperatures of 50 to 80°C (122 to 176°F) using “HOT” range on dipstick. CAUTION: Securely install A/T fluid level gauge. GI SMA070D 6. I I Check fluid condition. If fluid is very dark or smells burned, refer to AT section for checking operation of A/T. Flush cooling system after repair of A/T. If A/T fluid contains frictional material (clutches, bands, etc.), replace radiator and flush cooler line using cleaning solvent and compressed air after repair of A/T. Refer to LC-21, “Radiator”. EM LC EC FE CL MT AT TF PD AX SU SMA853B Changing A/T Fluid 1. 2. 3. SMA515C 4. 5. NAMA0025 Warm up A/T fluid. Stop engine. Drain A/T fluid from drain plug and refill with new A/T fluid. Always refill same volume with drained fluid. Fluid grade: Nissan Matic “D” (Continental U.S. and Alaska) or Canada NISSAN Automatic Transmission Fluid. Refer to “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-12. Fluid capacity (With torque converter): 2WD, 4WD 8.5  (9 US qt, 7-1/2 Imp qt) Drain plug: : 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb) Run engine at idle speed for five minutes. Check fluid level and condition. Refer to MA-23, “Checking A/T Fluid”. If fluid is still dirty, repeat steps 2 through 5. BR ST RS BT HA SC EL IDX MA-23 CHASSIS AND BODY MAINTENANCE Checking Part Time 4WD Transfer Fluid Checking Part Time 4WD Transfer Fluid NAMA0026 Check for fluid leakage and fluid level. A/T fluid is used for the transfer in the factory. Never start engine while checking fluid level. Filler plug: : 25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-lb) SMA439B Changing Part Time 4WD Transfer Fluid SMA444B NAMA0027 When changing transfer fluid completely, A/T fluid may be used. Fluid grade: NISSAN Matic “D” (Continental U.S. and Alaska) or Canada NISSAN Automatic Transmission Fluid or API GL-4. Refer to “Fluids and Lubricants”, “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-12. Fluid capacity: 2.2  (2-3/8 US qt, 2 Imp qt) Drain plug: : 25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-lb) Checking All-mode 4WD Transfer Fluid NAMA0047 Check for oil leakage and fluid level. A/T fluid is used for the all-mode 4WD transfer in the factory. Never start engine while checking fluid level. Filler plug: : 10 - 20 N·m (1.0 - 2.0 kg-m, 87 - 174 in-lb) SMA439B Changing All-mode 4WD Transfer Fluid SMA444B NAMA0048 When changing all-mode 4WD transfer fluid completely, A/T fluid may be used. Fluid grade: NISSAN Matic “D” (Continental U.S. and Alaska) or Canada NISSAN Automatic Transmission Fluid Refer to “Fluids and Lubricants”, “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-12. Fluid capacity: 3.0  (3-1/8 US qt, 2-5/8 Imp qt) MA-24 CHASSIS AND BODY MAINTENANCE Changing All-mode 4WD Transfer Fluid (Cont’d) Drain plug: : 10 - 20 N·m (1.0 - 2.0 kg-m, 87 - 174 in-lb) GI EM LC Checking Propeller Shaft EC NAMA0028 Check propeller shaft for damage, looseness or grease leakage. FE CL MT SMA231-A AT TF PD AX SU SMA872CA Greasing Propeller Shaft NAMA0029 Apply specified grease to nipples provided on propeller shaft. Grease grade: Refer to “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-12. BR ST RS BT SMA123D Checking Differential Gear Oil Check for oil leakage and oil level. Filler plug: Front : 39 - 59 N·m (4 - 6 kg-m, 29 - 43 ft-lb) Rear : 59 - 118 N·m (6 - 12 kg-m, 43 - 87 ft-lb) NAMA0030 HA SC EL IDX SMA440B MA-25 CHASSIS AND BODY MAINTENANCE Changing Differential Gear Oil Changing Differential Gear Oil 1. 2. SMA632C SMA631C LIMITED-SLIP DIFFERENTIAL GEAR I I 1. 2. 3. NAMA0031 Drain oil from drain plug and refill with new gear oil. Check oil level. Oil grade and viscosity: See “RECOMMENDED FLUIDS AND LUBRICATNS”, MA-12. Oil capacity: Front 1.85 (3-7/8 US pt, 3-1/4 Imp pt) Rear 2.8 (5-7/8 US pt, 4-7/8 Imp pt) Filler plug: Front : 39 - 59 N·m (4 - 6 kg-m, 29 - 43 ft-lb) Rear : 59 - 118 N·m (6 - 12 kg-m, 43 - 87 ft-lb) Drain plug: Front : 59 - 98 N·m (6 - 10 kg-m, 43 - 72 ft-lb) Rear : 59 - 118 N·m (6 - 12 kg-m, 43 - 87 ft-lb) NAMA0031S01 Use only approved limited-slip differential gear oil. Limited-slip differential identification. Lift both rear wheels off the ground. Turn one rear wheel by hand. If both rear wheels turn in the same direction simultaneously, vehicle is equipped with limited-slip differential. Balancing Wheels NAMA0032 Adjust wheel balance using the road wheel center. Wheel balance (Maximum allowable unbalance): Refer to SDS, MA-32. Tire Rotation I I NAMA0033 After rotating the tires, adjust the tire pressure. Retighten the wheel nuts after the vehicle has been driven for the 1,000 km (600 miles). (also in cases of a flat tire, etc.) Wheel nuts: : 118 - 147 N·m (12 - 15 kg-m, 87 - 108 ft-lb) SGI991 MA-26 CHASSIS AND BODY MAINTENANCE Checking Brake Fluid Level and Leaks Checking Brake Fluid Level and Leaks NAMA0034 GI If fluid level is extremely low, check brake system for leaks. EM LC SBR451D Checking Brake Lines and Cables EC NAMA0035 Check brake fluid lines and parking brake cables for improper attachment, leaks, chafing, abrasions and deterioration. FE CL MT SBR389C Checking Disc Brake ROTOR AT NAMA0036 NAMA0036S01 Check condition, wear and damage. Standard thickness: 28 mm (1.10 in) Minimum thickness: 26 mm (1.02 in) TF PD AX SU CALIPER NAMA0036S02 Check for leakage. BR ST RS BT SMA922A PAD NAMA0036S03 Check wear or damage. Standard thickness: 11 mm (0.43 in) Minimum thickness: 2 mm (0.08 in) HA SC EL IDX BRA0010D MA-27 CHASSIS AND BODY MAINTENANCE Checking Drum Brake Checking Drum Brake WHEEL CYLINDER NAMA0037 NAMA0037S01 Check for leakage. DRUM NAMA0037S02 Check condition and inner surface. Standard inner diameter: 295 mm (11.61 in) Drum repair limit (Inner diameter): 296.5 mm (11.67 in) SMA848B LINING NAMA0037S03 Check wear or damage. Standard thickness: 6.1 mm (0.240 in) Lining wear limit (Minimum thickness): 1.5 mm (0.059 in) SMA849B TEMPORARY METHOD FOR CHECKING LINING WEAR NAMA0037S04 Remove inspection hole plug and check for lining wear. SMA870C Checking Steering Gear, Linkage and Transfer Gear NAMA0038 STEERING GEAR I I Check gear housing and boots for looseness, damage and grease leakage. Check connection with steering column for looseness. STEERING LINKAGE I SMA874CA NAMA0038S02 Check ball joint, dust cover and other component parts for looseness, wear, damage and grease leakage. STEERING TRANSFER GEAR I NAMA0038S01 NAMA0038S03 Check gear box for looseness, damage and grease leakage. MA-28 CHASSIS AND BODY MAINTENANCE Checking Power Steering Fluid and Lines Checking Power Steering Fluid and Lines CHECKING FLUID LEVEL I I SST280B NAMA0039 NAMA0039S01 Check fluid level with engine off. Check fluid level with dipstick on reservoir cap. Use “HOT” range at fluid temperatures of 50 to 80°C (122 to 176°F). Use “COLD” range at fluid temperatures of 0 to 30°C (32 to 86°F). CAUTION: I Do not overfill. I Recommended fluid is Genuine NISSAN PSF or equivalent. Refer to “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-12. CHECKING LINES I I GI EM LC EC NAMA0039S02 Check lines for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration. Check rack boots for accumulation of power steering fluid. FE CL MT SST118B Axle and Suspension Parts AT NAMA0061 Check front and rear axle and suspension parts for excessive play, cracks, wear, or other damage. I Shake each wheel to check for excessive play. I Rotate each wheel to check for abnormal noise. I Check axle and suspension nuts and bolts for looseness. I Check strut (shock absorber) for oil leakage or other damage. I Check suspension ball joint for grease leakage and ball joint dust cover for cracks or other damage. TF PD AX SU SMA525A BR ST RS BT SFA757B HA SC EL IDX SFA392B MA-29 CHASSIS AND BODY MAINTENANCE Axle and Suspension Parts (Cont’d) FRONT WHEEL BEARING NAMA0061S01 Apply multi-purpose grease sparingly to the following parts: I Threaded portion of spindle I Contact surface between wheel bearing lock washer (chamfered side) and outer wheel bearing I Grease seal lip I Wheel hub (as shown at left) — 4WD — SFA891 Drive Shaft NAMA0062 Check boot and drive shaft for cracks, wear, damage and grease leakage. SFA901 Lubricating Locks, Hinges and Hood Latches NAMA0040 SMA031D MA-30 CHASSIS AND BODY MAINTENANCE Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters GI NAMA0041 EM LC EC FE CL MT AT TF PD SMA854CD AX SU BR ST RS BT HA SC EL IDX MA-31 SERVICE DATA AND SPECIFICATIONS (SDS) Engine Maintenance Engine Maintenance DRIVE BELT DEFLECTION NAMA0058 Unit: mm (in) Used belt deflection Deflection of new belt Limit Deflection after adjustment Alternator Power steering oil pump Fan 7 (0.28) 4 - 5 (0.16 - 0.20) 3.5 - 4.5 (0.138 - 0.177) Air conditioner compressor 12 (0.47) 9 - 10 (0.35 - 0.39) 8 - 9 (0.31 - 0.35) Applied pushing force 98 N (10 kg, 22 lb) DRIVE BELT TENSION NAMA0059 Unit: N (kg, lb) Used belt New belt Limit After adjustment Generator Power steering oil pump Fan 294 (30, 66) 730 - 818 (74.4 - 83.5, 164 - 184) 838 - 926 (85.4 - 94.5, 188 - 208) Air conditioner compressor 196 (20, 44) 348 - 436 (35.5 - 44.5, 78 - 98) 470 - 559 (47.9 - 57.0, 106 - 126) SPARK PLUG (PLATINUM-TIPPED TYPE) NAMA0060 Symbol Make Standard type PLFR5A-11 NGK Cold type PLFR6A-11 NGK Hot type PLFR4A-11 NGK Plug gap (Nominal) 1.1 mm (0.043 in) Chassis and Body Maintenance WHEEL BALANCE NAMA0044 Dynamic (At rim flange) g (oz) 10 (0.35) (one side) Maximum allowable unbalance Static g (oz) 20 (0.71) MA-32 GENERAL INFORMATION SECTION GI MA EM LC EC FE CONTENTS PRECAUTIONS ...............................................................3 Precautions ..................................................................3 PRECAUTIONS FOR SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ″AIR BAG″ AND ″SEAT BELT PRE-TENSIONER″ .................................3 PRECAUTIONS FOR NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM - NATS).................................3 GENERAL PRECAUTIONS .........................................4 PRECAUTIONS FOR MULTIPORT FUEL INJECTION SYSTEM OR ENGINE CONTROL SYSTEM ...................................................................6 PRECAUTIONS FOR THREE WAY CATALYST ...........6 PRECAUTIONS FOR HOSES .....................................6 PRECAUTIONS FOR ENGINE OILS ...........................7 PRECAUTIONS FOR FUEL ........................................8 PRECAUTIONS FOR AIR CONDITIONING ..................8 HOW TO USE THIS MANUAL........................................9 HOW TO READ WIRING DIAGRAMS..........................11 Sample/Wiring Diagram - EXAMPL - ........................11 OPTIONAL SPLICE..................................................12 Description .................................................................13 CONNECTOR SYMBOLS .........................................15 HARNESS INDICATION ...........................................16 COMPONENT INDICATION ......................................16 SWITCH POSITIONS ...............................................16 DETECTABLE LINES AND NON-DETECTABLE LINES .....................................................................17 MULTIPLE SWITCH .................................................18 REFERENCE AREA .................................................19 HOW TO CHECK TERMINAL .......................................21 Connector and Terminal Pin Kit.................................21 How to Probe Connectors .........................................21 PROBING FROM HARNESS SIDE ............................21 PROBING FROM TERMINAL SIDE ...........................21 How to Check Enlarged Contact Spring of Terminal .....................................................................22 Waterproof Connector Inspection ..............................23 RUBBER SEAL INSPECTION ...................................23 WIRE SEAL INSPECTION ........................................23 Terminal Lock Inspection ...........................................23 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT ...............................24 Work Flow..................................................................24 Incident Simulation Tests...........................................25 INTRODUCTION ......................................................25 VEHICLE VIBRATION ..............................................25 HEAT SENSITIVE ....................................................26 FREEZING ..............................................................26 WATER INTRUSION ................................................27 ELECTRICAL LOAD .................................................27 COLD OR HOT START UP.......................................27 Circuit Inspection .......................................................27 INTRODUCTION ......................................................27 TESTING FOR ″OPENS″ IN THE CIRCUIT ................28 TESTING FOR ″SHORTS″ IN THE CIRCUIT ..............29 GROUND INSPECTION ...........................................30 VOLTAGE DROP TESTS ..........................................30 CONTROL UNIT CIRCUIT TEST ...............................32 HOW TO FOLLOW TROUBLE DIAGNOSES...............34 How to Follow Test Groups in Trouble Diagnoses....35 Harness Wire Color and Connector Number Indication....................................................................36 TYPE 1: HARNESS WIRE COLOR AND CONNECTOR NUMBER ARE SHOWN IN ILLUSTRATION .......................................................36 TYPE 2: HARNESS WIRE COLOR AND CONNECTOR NUMBER ARE SHOWN IN TEXT ........36 Key to Symbols Signifying Measurements or Procedures.................................................................37 CONSULT-II CHECKING SYSTEM ...............................39 Function and System Application ..............................39 Nickel Metal Hydride Battery Replacement...............40 Checking Equipment..................................................40 CONSULT-II Start Procedure ....................................41 CONSULT-II Data Link Connector (DLC) Circuit ......41 INSPECTION PROCEDURE .....................................41 IDENTIFICATION INFORMATION ................................43 Model Variation ..........................................................43 2WD .......................................................................43 4WD .......................................................................43 CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX CONTENTS PREFIX AND SUFFIX DESIGNATIONS .....................43 Identification Number.................................................44 VEHICLE IDENTIFICATION NUMBER ARRANGEMENT .....................................................44 IDENTIFICATION PLATE..........................................45 ENGINE SERIAL NUMBER.......................................45 MANUAL TRANSMISSION NUMBER.........................45 AUTOMATIC TRANSMISSION NUMBER ...................45 TRANSFER SERIAL NUMBER ..................................46 Dimensions ................................................................46 Wheels & Tires ..........................................................46 LIFTING POINTS AND TOW TRUCK TOWING ...........47 Screw Jack ................................................................47 (Cont’d) Garage Jack and Safety Stand .................................48 2-pole Lift ...................................................................49 Tow Truck Towing ......................................................49 2WD MODELS.........................................................50 PART TIME 4WD MODELS ......................................50 ALL-MODE 4WD MODELS .......................................51 VEHICLE RECOVERY ..............................................51 TIGHTENING TORQUE OF STANDARD BOLTS ........52 RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ....................................................................53 SAE J1930 TERMINOLOGY LIST ................................54 SAE J1930 Terminology List .....................................54 GI-2 PRECAUTIONS Precautions Precautions NAGI0001 Observe the following precautions to ensure safe and proper servicing. These precautions are not described in each individual section. MA EM LC EC PRECAUTIONS FOR SUPPLEMENTAL RESTRAINT SYSTEM (SRS) “AIR BAG” AND “SEAT BELT PRE-TENSIONER” NAGI0001S01 FE SGI646 The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS composition which is available to NISSAN MODEL R50 is as follows: I For a frontal collision The Supplemental Restraint System consists of driver air bag module (located in the center of the steering wheel), front passenger air bag module (located on the instrument panel on passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. I For a side collision The Supplemental Restraint System consists of side air bag module (located in the outer side of front seat), side curtain air bag module (locating in the headlining side of front and rear seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision). WARNING: I 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. I Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connector (and by yellow harness protector or yellow insulation tape before the harness connectors). PRECAUTIONS FOR NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS) MT AT TF PD AX SU BR ST RS BT HA NAGI0001S08 NVIS (NATS) will immobilize the engine if someone tries to start it without the registered key of NVIS (NATS). Both of the originally supplied ignition key IDs have been NVIS (NATS) registered. The security indicator is located on the instrument panel. The indicator blinks when the ignition switch is in “OFF” or “ACC” position. Therefore, NVIS (NATS) warns outsiders that the vehicle is equipped with the anti-theft system. GI-3 CL SC EL IDX PRECAUTIONS Precautions (Cont’d) I When NVIS (NATS) detects trouble, the security indicator lamp lights up while ignition switch is in “ON” position. This lighting up indicates that the anti-theft is not functioning, so prompt service is required. I When servicing NVIS (NATS) (trouble diagnoses, system initialization and additional registration of other NVIS (NATS) ignition key IDs), CONSULT-II hardware and CONSULT-II NVIS (NATS) software is necessary. Regarding the procedures of NVIS (NATS) initialization and NVIS (NATS) ignition key ID registration, refer to CONSULT-II operation manual, IVIS/NVIS. Therefore, CONSULT-II NVIS (NATS) software (program card and operation manual) must be kept strictly confidential to maintain the integrity of the anti-theft function. I When servicing NVIS (NATS) (trouble diagnoses, system initialization and additional registration of other NVIS (NATS) ignition key IDs), it may be necessary to re-register original key identification. Therefore, be sure to receive all keys from vehicle owner. A maximum of five key IDs can be registered into NVIS (NATS). I When failing to start the engine first time using the key of NVIS (NATS) (for example, when interference is caused by another NVIS (NATS) key, an automated full road device or automated payment device on the key ring), restart as follows. a) Leave the ignition switch in “ON” position for approximately 5 seconds. b) Turn ignition switch to “OFF” or “LOCK” position and wait approximately 5 seconds. c) Repeat step 1 and 2. d) Restart the engine while holding the device (which may have caused the interference) separate from the registered NVIS (NATS) key. If the no start condition re-occurs, NISSAN recommends placing the registered nats key on a separate key ring to avoid interference from other devices. GENERAL PRECAUTIONS NAGI0001S02 I 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, refrigerant gas, etc. When working in a pit or other enclosed area, be sure to properly ventilate the area before working with hazardous materials. Do not smoke while working on the vehicle. I 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 lifting before working 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 it. Also, do not allow it to strike adjacent parts, especially the brake tubes and master cylinder. SGI285 I SGI231 GI-4 PRECAUTIONS Precautions (Cont’d) I Before starting repairs which do not require battery power: Turn off ignition switch. Disconnect the negative battery cable. MA EM LC SEF289H I To prevent serious burns: Avoid contact with hot metal parts. Do not remove the radiator cap when the engine is hot. EC FE CL MT SGI233 I Before servicing the vehicle: Protect fenders, upholstery and carpeting with appropriate covers. Take caution that keys, buckles or buttons do not scratch paint. AT TF PD AX SU SGI234 I I I I I I I I I I I Clean all disassembled parts in the designated liquid or solvent prior to inspection or assembly. Replace oil seals, gaskets, packings, O-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 indicate 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. GI-5 BR ST RS BT HA SC EL IDX PRECAUTIONS Precautions (Cont’d) WARNING: To prevenvt ECM from storing the diagnostic trouble codes, do not carelessly disconnect the harness connectors which are related to the engine control system and TCM (Transmission Control Module) system. The connectors should be disconnected only when working according to the WORK FLOW of TROUBLE DIAGNOSES in EC and AT sections. PRECAUTIONS FOR MULTIPORT FUEL INJECTION SYSTEM OR ENGINE CONTROL SYSTEM NAGI0001S03 I I SGI787 I Before connecting or disconnecting any harness connector for the multiport fuel injection system or ECM (Engine Control Module): 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 NAGI0001S04 If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To prevent this, follow the instructions below: I Use unleaded gasoline only. Leaded gasoline will seriously damage the three way catalyst. I When checking for ignition spark or measuring engine compression, make tests quickly and only when necessary. I 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 flammable material. Keep flammable material off the exhaust pipe and the three way catalyst. PRECAUTIONS FOR HOSES Hose Removal and Installation I NAGI0001S10 NAGI0001S1001 To prevent damage to rubber hose, do not pry off rubber hose with tapered tool or screwdriver. SMA019D GI-6 PRECAUTIONS Precautions (Cont’d) I To reinstall the rubber hose securely, make sure of hose insertion length and clamp orientation. (If tube is equipped with hose stopper, insert rubber hose into tube until it butts up against hose stopper.) MA EM LC SMA020D Hose Clamping I I EC NAGI0001S1002 If old rubber hose is re-used, install hose clamp in its original position (at the indentation where the old clamp was). If there is a trace of tube bulging left on the old rubber hose, align rubber hose at that position. Discard old clamps; replace with new ones. FE CL MT SMA021D I After installing leaf spring clamps, apply force to them in the direction of the arrow, tightening rubber hose equally all around. AT TF PD AX SU SMA022D PRECAUTIONS FOR ENGINE OILS NAGI0001S05 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 I I I I I I I I ST NAGI0001S0501 Avoid prolonged and repeated contact with oils, particularly used engine oils. Wear protective clothing, including impervious gloves where practicable. Do not put oily rags in pockets. Avoid contaminating clothes, particularly underpants, with oil. Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. First Aid treatment should be obtained immediately for open cuts and wounds. 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 cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. GI-7 BR RS BT HA SC EL IDX PRECAUTIONS Precautions (Cont’d) I I I I Do not use gasoline, kerosine, diesel fuel, gas oil, thinners or solvents for cleaning skin. If skin disorders develop, obtain medical advice without delay. Where practicable, degrease components prior to handling. 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. Environmental Protection Precautions NAGI0001S0502 Burning used engine oil in small space heaters or boilers can be recommended only for units of approved design. The heating system must meet the requirements of HM Inspectorate of Pollution for small burners of less than 0.4 MW. If in doubt check with the 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 to the ground, down sewers or drains, or into water courses. The regulations concerning pollution vary between regions. PRECAUTIONS FOR FUEL NAGI0001S06 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 damage the three way catalyst. Using a fuel other than that specified could adversely affect the emission control devices and systems, and could also affect the warranty coverage validity. PRECAUTIONS FOR AIR CONDITIONING NAGI0001S07 Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to HA-170, “HFC-134a (R-134a) Service Procedure” for specific instructions. GI-8 NAGI0002 HOW TO USE THIS MANUAL I I I I I I I 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. 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. ) 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. 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 number (e.g. “BR-5”). THE LARGE ILLUSTRATIONS are exploded views (See below.) and contain tightening torques, lubrication 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. MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS SBR364AC I I I THE SMALL ILLUSTRATIONS show the important steps such as inspection, use of special tools, knacks 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. The UNITS given in this manual are primarily expressed as the SI 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. GI-9 BT HA SC EL IDX HOW TO USE THIS MANUAL I I SERVICE DATA AND SPECIFICATIONS are contained at the end of each section for quick reference of data. The following SYMBOLS AND ABBREVIATIONS are used: SYMBOL ABBREVIATION SYMBOL Tightening torque ABBREVIATION 2-Wheel Drive 2WD Should be lubricated with grease. Unless otherwise indicated, use recommended multi-purpose grease. A/C Should be lubricated with oil. P/S Power Steering Sealing point SST Special Service Tools Checking point SAE Society of Automotive Engineers, Inc. Always replace after every disassembly. ATF Automatic Transmission Fluid Apply petroleum jelly. Air Conditioner D1 q P Drive range 1st gear Apply ATF. D2 Drive range 2nd gear ★ Select with proper thickness. D3 Drive range 3rd gear ✩ Adjustment is required. D4 Drive range 4th gear Service Data and Specifications OD Overdrive LH, RH Left-Hand, Right-Hand 22 2nd range 2nd gear FR, RR Front, Rear 21 2nd range 1st gear M/T Manual Transaxle/Transmission 12 1st range 2nd gear A/T Automatic Transaxle/Transmission 11 1st range 1st gear SDS , 4-Wheel Drive 4WD GI-10 NAGI0003 HOW TO READ WIRING DIAGRAMS Sample/Wiring Diagram — EXAMPL — Sample/Wiring Diagram — EXAMPL — I NAGI0003S01 For Description, refer to GI-13. MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL SGI134A GI-11 IDX HOW TO READ WIRING DIAGRAMS Sample/Wiring Diagram — EXAMPL — (Cont’d) OPTIONAL SPLICE NAGI0003S0101 SGI942 GI-12 HOW TO READ WIRING DIAGRAMS Description Description Number Item =NAGI0003S02 Description 1 Power condition I This shows the condition when the system receives battery positive voltage (can be operated). 2 Fusible link I The double line shows that this is a fusible link. I The open circle shows current flow in, and the shaded circle shows current flow out. 3 Fusible link/fuse loca- I This shows the location of the fusible link or fuse in the fusible link or fuse box. For tion arrangement, refer to EL-12, “POWER SUPPLY ROUTING”. 4 Fuse I The single line shows that this is a fuse. I The open circle shows current flow in, and the shaded circle shows current flow out. 5 Current rating I This shows the current rating of the fusible link or fuse. Connectors I This shows that connector E3 is female and connector M1 is male. I The G/R wire is located in the 1A terminal of both connectors. I Terminal number with an alphabet (1A, 5B, etc.) indicates that the connector is SMJ connector. Refer to GI-19. 6 7 Optional splice I The open circle shows that the splice is optional depending on vehicle application. 8 Splice I The shaded circle shows that the splice is always on the vehicle. 9 Page crossing I This arrow shows that the circuit continues to an adjacent page. I The A will match with the A on the preceding or next page. 10 Common connector I The dotted lines between terminals show that these terminals are part of the same connector. 11 Option abbreviation I This shows that the circuit is optional depending on vehicle application. 12 Relay I This shows an internal representation of the relay. For details, refer to EL-9, “STANDARDIZED RELAY”. 13 Connectors I This shows that the connector is connected to the body or a terminal with bolt or nut. I This shows a code for the color of the wire. 14 Wire color B = Black W = White R = Red G = Green L = Blue Y = Yellow LG = Light Green BR = Brown OR = Orange P = Pink PU = Purple GY = Gray SB = Sky Blue 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: L/W = Blue with White Stripe 15 Option description I This shows a description of the option abbreviation used on the page. 16 Switch I 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. 17 Assembly parts I Connector terminal in component shows that it is a harness incorporated assembly. Cell code I This identifies each page of the wiring diagram by section, system and wiring diagram page number. Current flow arrow I Arrow indicates electric current flow, especially where the direction of standard flow (vertically downward or horizontally from left to right) is difficult to follow. I A double arrow “ ” shows that current can flow in either direction depending on circuit operation. 18 19 20 System branch I This shows that the system branches to another system identified by cell code (section and system). GI-13 MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX HOW TO READ WIRING DIAGRAMS Description (Cont’d) Number Item Description 21 Page crossing I This arrow shows that the circuit continues to another page identified by cell code. I The C will match with the C on another page within the system other than the next or preceding pages. 22 Shielded line I The line enclosed by broken line circle shows shield wire. 23 Component box in wave line I This shows that another part of the component is also shown on another page (indicated by wave line) within the system. 24 Component name I This shows the name of a component. 25 Connector number I This shows the connector number. I The letter shows which harness the connector is located in. I Example: M: main harness. For detail and to locate the connector, refer to EL-522, “Main Harness”. A coordinate grid is included for complex harnesses to aid in locating connectors. 26 Ground (GND) I The line spliced and grounded under wire color shows that ground line is spliced at the grounded connector. 27 Ground (GND) I This shows the ground connection. 28 Connector views I This area shows the connector faces of the components in the wiring diagram on the page. 29 Common component I Connectors enclosed in broken line show that these connectors belong to the same component. 30 Connector color I This shows a code for the color of the connector. For code meaning, refer to wire color codes, Number 14 of this chart. 31 Fusible link and fuse box I This shows the arrangement of fusible link(s) and fuse(s), used for connector views of “POWER SUPPLY ROUTING” in EL section. The open square shows current flow in, and the shaded square shows current flow out. 32 Reference area I This shows that more information on the Super Multiple Junction (SMJ) and Joint Connectors (J/C) exists on the foldout page. Refer to GI-19 for details. GI-14 HOW TO READ WIRING DIAGRAMS Description (Cont’d) CONNECTOR SYMBOLS =NAGI0003S0201 Most of connector symbols in wiring diagrams are shown from the terminal side. I Connector symbols shown from the terminal side are enclosed by a single line and followed by the direction mark. I Connector symbols shown from the harness side are enclosed by a double line and followed by the direction mark. MA EM LC EC FE CL MT SGI364 I Male and female terminals Connector guides for male terminals are shown in black and female terminals in white in wiring diagrams. AT TF PD AX SU BR ST RS BT SGI363 HA SC EL IDX GI-15 HOW TO READ WIRING DIAGRAMS Description (Cont’d) HARNESS INDICATION I I COMPONENT INDICATION I NAGI0003S0206 Letter designations next to test meter probe indicate harness (connector) wire color. Connector numbers in a single circle M33 indicate harness connectors. NAGI0003S0207 Connector numbers in a double circle F211 indicate component connectors. AGI070 SWITCH POSITIONS NAGI0003S0202 Switches are shown in wiring diagrams as if the vehicle is in the normal condition. A vehicle is in the normal condition when: I ignition switch is OFF, I doors, hood and trunk lid/back door are closed, I pedals are not depressed, and I parking brake is released. SGI860 GI-16 HOW TO READ WIRING DIAGRAMS Description (Cont’d) DETECTABLE LINES AND NON-DETECTABLE LINES NAGI0003S0203 In some wiring diagrams, two kinds of lines, representing wires, with different weight are used. I A line with regular weight (wider line) represents a “detectable line for DTC (Diagnostic Trouble Code)”. A “detectable line for DTC” is a circuit in which ECM (Engine Control Module) can detect its malfunctions with the on board diagnostic system. I A line with less weight (thinner line) represents a “non-detectable line for DTC”. A “non-detectable line for DTC” is a circuit in which ECM cannot detect its malfunctions with the on board diagnostic system. MA EM LC EC FE CL MT SGI862-A AT TF PD AX SU BR ST RS BT HA SC EL IDX GI-17 HOW TO READ WIRING DIAGRAMS Description (Cont’d) MULTIPLE SWITCH =NAGI0003S0204 The continuity of multiple switch is described in two ways as shown below. I The switch chart is used in schematic diagrams. I The switch diagram is used in wiring diagrams. SGI875 GI-18 HOW TO READ WIRING DIAGRAMS Description (Cont’d) REFERENCE AREA =NAGI0003S0208 The Reference Area of the wiring diagram contains references to additional electrical reference pages at the end of the manual. If connector numbers and titles are shown in the Reference Area of the wiring diagram, these connector symbols are not shown in the Connector Area. MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT SGI092A Super multiple junction (SMJ) In a wiring diagram, the SMJ connectors include a letter of the alphabet in the terminal number. SMJ connector numbers are shown in the Reference Area of the wiring diagram. SMJ terminal arrangement can be found on the electrical reference pages at the end of the manual. For terminal arrangement of these connectors, refer to the “SUPER MULTIPLE JUNCTION (SMJ)” electrical reference page at the end of the GI-19 HA SC EL IDX HOW TO READ WIRING DIAGRAMS Description (Cont’d) manual. Fuse block — Junction box (J/B) Fuse block — Junction box (J/B) connector number is shown in the Reference Area of the wiring diagram. For connector terminal and fuse arrangement, refer to the “FUSE BLOCK — Junction Box (J/B)” electrical reference page at the end of the manual. Fuse and fusible link box For fuse arrangement in the fuse and fusible link box, refer to the “FUSE AND FUSIBLE LINK BOX” electrical reference page at the end of the manual. Electrical units Electrical unit connector symbols are shown in the Connector Area of the wiring diagram. However, when there is not enough space to show the connector terminal arrangement in the Connector Area of the wiring diagram, the electrical unit connector number is shown in the Reference Area of the wiring diagram. For electrical unit connector terminal arrangement, refer to the “ELECTRICAL UNITS” electrical reference page at the end of the manual. Most of the electrical unit connectors on this page are shown from the harness side of the connector. Joint connector Joint connector symbols are shown in the connector area of the wiring diagram. For connector internal wiring layout and joint connector terminal arrangement, refer to the “JOINT CONNECTOR (J/C)” electrical reference page at the end of the manual. GI-20 NAGI0011 HOW TO CHECK TERMINAL Connector and Terminal Pin Kit Connector and Terminal Pin Kit NAGI0011S01 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 terminals. Tool number (Kent-Moore No.) Tool name MA EM Description LC — (J38751-95NI) Connector and terminal pin kit — (J42992-98KIT) OBD Terminal Repair Kit EC FE CL MT AGI121 How to Probe Connectors AT NAGI0011S02 Connector damage and an intermittent connection can result from improperly probing of the connector during circuit checks. The probe of a digital multimeter (DMM) may not correctly fit the connector cavity. To correctly probe the connector, follow the procedures below using a “T” pin. For the best contact grasp the “T” pin using an alligator clip. TF PD AX SU PROBING FROM HARNESS SIDE NAGI0011S0201 Standard type (not waterproof type) connector should be probed from harness side with “T” pin. I If the connector has a rear cover such as a ECM connector, remove the rear cover before probing the terminal. I Do not probe waterproof connector from harness side. Damage to the seal between wire and connector may result. BR ST RS BT SGI841 PROBING FROM TERMINAL SIDE NAGI0011S0202 Female Terminal I There is a small notch above each female terminal. Probe each terminal with the “T” pin through the notch. Do not insert any object other than the same type male terminal into female terminal. HA SC EL IDX SEL265V GI-21 HOW TO CHECK TERMINAL How to Probe Connectors (Cont’d) I Some connectors do not have a notch above each terminal. To probe each terminal, remove the connector retainer to make contact space for probing. SEL266V Male Terminal Carefully probe the contact surface of each terminal using a “T” pin. Do not bend terminal. SEL267V How to Check Enlarged Contact Spring of Terminal NAGI0011S03 An enlarged contact spring of a terminal may create intermittent signals in the circuit. If the intermittent open circuit occurs, follow the procedure below to inspect for open wires and enlarged contact spring of female terminal. 1. 2. Assemble a male terminal and approx. 10 cm (3.9 in) of wire. Use a male terminal which matches the female terminal. Disconnect the suspected faulty connector and hold it terminal side up. SEL270V 3. While holding the wire of the male terminal, try to insert the male terminal into the female terminal. Do not force the male terminal into the female terminal with your hands. SEL271V GI-22 HOW TO CHECK TERMINAL How to Check Enlarged Contact Spring of Terminal (Cont’d) 4. While moving the connector, check whether the male terminal can be easily inserted or not. MA EM LC SEL272V I If the male terminal can be easily inserted into the female terminal, replace the female terminal. EC FE CL MT SEL273V Waterproof Connector Inspection AT NAGI0011S04 If water enters the connector, it can short interior circuits. This may lead to intermittent problems. Check the following items to maintain the original waterproof characteristics. RUBBER SEAL INSPECTION I SEL275V I PD NAGI0011S0401 Most waterproof connectors are provided with a rubber seal between the male and female connectors. If the seal is missing, the waterproof performance may not meet specifications. The rubber seal may come off when connectors are disconnected. Whenever connectors are reconnected, make sure the rubber seal is properly installed on either side of male or female connector. WIRE SEAL INSPECTION TF NAGI0011S0402 The wire seal must be installed on the wire insertion area of a waterproof connector. Be sure that the seal is installed properly. AX SU BR ST RS BT Terminal Lock Inspection NAGI0011S05 Check for unlocked terminals by pulling wire at the end of connector. An unlocked terminal may create intermittent signals in the circuit. HA SC EL IDX SEL330V GI-23 NAGI0004 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Work Flow Work Flow NAGI0004S01 SGI838 STEP STEP 1 DESCRIPTION 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 incident cannot be duplicated, refer to “Incident Simulation Tests” next page. STEP 3 Get the proper diagnosis materials together including: POWER SUPPLY ROUTING System Operation Descriptions Applicable Service Manual Sections Check for any Service Bulletin. 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 the system works properly under all conditions. Make sure you have not inadvertently created a new incident during your diagnosis or repair steps. GI-24 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Incident Simulation Tests Incident Simulation Tests INTRODUCTION NAGI0004S02 NAGI0004S0201 Sometimes the symptom is not present when the vehicle is brought in for service. If possible, re-create 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. The section is broken into the six following topics: I Vehicle vibration I Heat sensitive I Freezing I Water intrusion I Electrical load I Cold or hot start up Get a thorough description of the incident from the customer. It is important for simulating the conditions of the incident. VEHICLE VIBRATION NAGI0004S0202 The incident may occur or become worse while driving on a rough road or when engine is vibrating (idle with A/C on). In such a case, you will want to check for a vibration related condition. Refer to the illustration below. Connectors & Harness Determine which connectors and wiring harness 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 to get a thin film of corrosion on the connector terminals. A visual inspection may not reveal this without disconnecting the connector. If the problem occurs intermittently, perhaps the incident is caused by corrosion. It is a good idea to disconnect, inspect and clean the terminals on related connectors in the system. 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. MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SGI839 SC EL IDX GI-25 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Incident Simulation Tests (Cont’d) Engine Compartment There are several reasons a vehicle or engine vibration could cause an electrical complaint. Some of the things to check for are: I Connectors not fully seated. I Wiring harness not long enough and is being stressed due to engine vibrations or rocking. I Wires laying across brackets or moving components. I Loose, dirty or corroded ground wires. I Wires routed too close to hot components. To inspect components under the hood, start by verifying the integrity of ground connections. (Refer to GROUND INSPECTION described later.) First make sure 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 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 aggravate 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 possible damage or pinching. HEAT SENSITIVE NAGI0004S0203 The owner’s incident may occur during hot weather or after car has sat for a short time. In such cases you will want to check for a heat sensitive condition. To determine if an electrical component is heat sensitive, heat the component with a heat gun or equivalent. Do not heat components above 60°C (140°F). If incident occurs while heating the unit, either replace or properly insulate the component. SGI842 FREEZING NAGI0004S0204 The customer may indicate the incident goes away after the car warms up (winter time). The cause could be related to water 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 outside overnight. In the morning, do a quick and thorough diagnosis of those electrical components which could be affected. SGI843 GI-26 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Incident Simulation Tests (Cont’d) The second method is to put the suspect component into a freezer long enough for any water to freeze. Reinstall the part into the car and check for the reoccurrence of the incident. If it occurs, repair or replace the component. MA EM LC WATER INTRUSION EC NAGI0004S0205 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. FE CL MT SGI844 ELECTRICAL LOAD AT NAGI0004S0206 The incident may be electrical load sensitive. Perform diagnosis with all accessories (including A/C, rear window defogger, radio, fog lamps) turned on. TF COLD OR HOT START UP PD NAGI0004S0207 On some occasions an electrical incident may occur only when the car is started cold. Or it may occur when the car is restarted hot shortly after being turned off. In these cases you may have to keep the car overnight to make a proper diagnosis. AX SU SGI845 Circuit Inspection INTRODUCTION NAGI0004S03 NAGI0004S0302 In general, testing electrical circuits is an easy task if it is approached in a logical and organized method. Before beginning it is important to have all available information on the system to be tested. Also, get a thorough understanding of system 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. OPEN A circuit is open when there is no continuity through a section of the circuit. SHORT There are two types of shorts. BR ST RS BT HA I SHORT CIRCUIT When a circuit contacts another circuit and causes the normal resistance to change. SC I SHORT TO GROUND When a circuit contacts a ground source and grounds the circuit. EL NOTE: Refer to “HOW TO CHECK TERMINAL” in GI-21 to probe or check terminal. GI-27 IDX HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d) TESTING FOR “OPENS” IN THE CIRCUIT NAGI0004S0303 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 working knowledge of the system. SGI846 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 to 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 circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite 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 the presence of 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. GI-28 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d) 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. TESTING FOR “SHORTS” IN THE CIRCUIT NAGI0004S0304 To simplify the discussion of shorts in the system please refer to the schematic below. MA EM LC EC FE CL MT SGI847 Resistance Check Method 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 fuse. 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 for continuity. 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 ground. Then, check for continuity. continuity; short is between SW1 and the relay (point B). no continuity; short is further down the circuit than the relay. 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 for continuity. continuity; short is between relay and solenoid (point C). 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 disconnected) powered through the fuse. 2) Turn the ignition key to the ON or START position. Verify battery voltage at the B + side of the fuse terminal (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 for 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 for voltage. voltage; short is between SW1 and the relay (point B). GI-29 AT TF PD AX SU BR ST RS BT HA SC EL IDX HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d) 5) no voltage; short is further down the circuit than the relay. With SW1 closed, relay contacts jumped with fused jumper wire check for voltage. voltage; short is down the circuit of the relay or between the relay and the disconnected solenoid (point C). no voltage; retrace steps and check power to fuse block. GROUND INSPECTION NAGI0004S0305 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 drastically 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 or screw. 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. SGI853 VOLTAGE DROP TESTS NAGI0004S0306 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 GI-30 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d) 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 as follows: I Undersized wiring (single strand example) I Corrosion on switch contacts I 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 the voltmeter should be closer to power and the 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 circuit. Note in the illustration that there is an excessive 4.1 volt drop between the battery and the bulb. MA EM LC EC FE CL MT AT TF PD AX SU BR SGI974 Measuring Voltage Drop — Step by Step The step by step method is most useful for isolating excessive drops in low voltage systems (such as those in “Computer Controlled Systems”). Circuits in the “Computer Controlled System” operate on very low amperage. The (Computer Controlled) system 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 corrosion. The step by step voltage drop test can identify a component or wire with too much resistance. ST RS BT HA SC EL IDX GI-31 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d) SGI854 CONTROL UNIT CIRCUIT TEST NAGI0004S0307 System Description: When the switch is ON, the control unit lights up the lamp. MGI034A Input-output voltage chart Pin No. Item Condition Voltage value V In case of high resistance such as single strand V* 1 Switch Switch ON Battery voltage Lower than battery voltage Approx. 8 (Example) Switch OFF Approx. 0 Approx. 0 Switch ON Battery voltage Approx. 0 (Inoperative lamp) Switch OFF Approx. 0 Approx. 0 2 Lamp The voltage value is based on the body ground. * : If high resistance exists in the switch side circuit (caused by a single strand), terminal 1 does not detect battery voltage. Control unit does not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not supply power to light up the lamp. GI-32 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Circuit Inspection (Cont’d) MA EM LC MGI035A EC Input-output voltage chart Pin No. Item Condition Voltage value V In case of high resistance such as single strand V* 1 Lamp Switch ON Approx. 0 Battery voltage (Inoperative lamp) Switch OFF Battery voltage Battery voltage Switch ON Approx. 0 Higher than 0 Approx. 4 (Example) Switch OFF Approx. 5 Approx. 5 2 Switch The voltage value is 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. 0V. Control unit does not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not control ground to light up the lamp. FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX GI-33 NAGI0005 HOW TO FOLLOW TROUBLE DIAGNOSES NOTICE: Trouble diagnoses indicate work procedures required to diagnose problems effectively. Observe the following instructions before diagnosing. 1) Before performing trouble diagnoses, read the “Preliminary Check”, the “Symptom Chart” or the “Work Flow”. 2) After repairs, re-check 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 need to 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 as they were. GI-34 HOW TO FOLLOW TROUBLE DIAGNOSES How to Follow Test Groups in Trouble Diagnoses How to Follow Test Groups in Trouble Diagnoses NAGI0005S01 MA EM LC EC FE CL MT AT TF PD AX SGI138A 1) 2) 3) 4) Work and diagnostic procedure Start to diagnose an incident using procedures indicated in enclosed test groups. Questions and required results. Questions and required results are indicated in bold type in test group. The meaning of are as follows: a. Battery voltage → 11 - 14V or approximately 12V b. Voltage: Approximately 0V → Less than 1V Symbol used in illustration Symbols included in illustrations refer to measurements or procedures. Before diagnosing a problem, familiarize yourself with each symbol. Refer to “CONNECTOR SYMBOLS” (GI-15) and “Key to Symbols Signifying Measurements or Procedures” (GI37). Action items Next action for each test group is indicated based on result of each question. Test group number is shown in the left upper portion of each test group. SU BR ST RS BT HA SC EL IDX GI-35 HOW TO FOLLOW TROUBLE DIAGNOSES Harness Wire Color and Connector Number Indication Harness Wire Color and Connector Number Indication NAGI0005S03 There are two types of harness wire color and connector number indication. TYPE 1: HARNESS WIRE COLOR AND CONNECTOR NUMBER ARE SHOWN IN ILLUSTRATION NAGI0005S0301 I I I Letter designations next to test meter probe indicate harness wire color. Connector numbers in a single circle (e.g. M33) indicate harness connectors. Connector numbers in a double circle (e.g. F211) indicate component connectors. AGI070 TYPE 2: HARNESS WIRE COLOR AND CONNECTOR NUMBER ARE SHOWN IN TEXT NAGI0005S0302 SGI144A GI-36 HOW TO FOLLOW TROUBLE DIAGNOSES Key to Symbols Signifying Measurements or Procedures Key to Symbols Signifying Measurements or Procedures NAGI0005S02 Symbol Symbol explanation Symbol Symbol explanation Check after disconnecting the connector to be measured. Procedure with Generic Scan Tool (GST, OBD-II scan tool) Check after connecting the connector to be measured. Procedure without CONSULT-II or GST Insert key into ignition switch. A/C switch is “OFF”. MA EM LC EC Remove key from ignition switch. A/C switch is “ON”. Turn ignition switch to “OFF” position. REC switch is “ON”. Turn ignition switch to “ON” position. REC switch is “OFF”. FE CL MT Turn ignition switch to “START” position. Fan switch is “ON”. (At any position except for “OFF” position) Turn ignition switch from “OFF” to “ACC” position. Fan switch is “OFF”. Turn ignition switch from “ACC” to “OFF” position. Apply positive voltage from battery with fuse directly to components. Turn ignition switch from “OFF” to “ON” position. Drive vehicle. AT TF PD AX SU Turn ignition switch from “ON” to “OFF” position. Disconnect battery negative cable. Do not start engine, or check with engine stopped. Depress brake pedal. Start engine, or check with engine running. Release brake pedal. Apply parking brake. Depress accelerator pedal. Release parking brake. Release accelerator pedal. BR ST RS BT HA SC EL IDX GI-37 HOW TO FOLLOW TROUBLE DIAGNOSES Key to Symbols Signifying Measurements or Procedures (Cont’d) Symbol Symbol explanation Symbol Check after engine is warmed up sufficiently. Voltage should be measured with a voltmeter. Circuit resistance should be measured with an ohmmeter. Current should be measured with an ammeter. Procedure with CONSULT-II Procedure without CONSULT-II GI-38 Symbol explanation Pin terminal check for SMJ type ECM and TCM connectors. For details regarding the terminal arrangement, refer to the “ELECTRICAL UNITS” electrical reference page at the end of the manual. NAGI0006 CONSULT-II CHECKING SYSTEM Function and System Application Function and System Application Diagnostic test mode Function ALLENGINE MODE 4WD A/T ABS ABS (Including VDC) AIR BAG NVIS (NATS)*1 NAGI0006S01 SMART ENTRANCE AIR PRESSURE MONITOR MA EM This mode enables a technician to adjust some devices faster and more accurate by following the indications on CONSULT-II. x x x — x — — x x Self-diagnos- Self-diagnostic results can tic results be read and erased quickly. x x x x x x x — x Current self-diagnostic Trouble diag- results and all trouble diagnostic record nostic records previously stored can be read. — — — — — x — — — ECU discriminated No. Classification number of a replacement ECU can be read to prevent an incorrect ECU from being installed. — — — — — x — — — MT Data monitor Input/Output data in the ECU (ECM) can be read. x x x x x — — x x AT CAN diagno- Indicates the communicasis support tion condition of CAN commonitor munication line. x x x — x — — — — TF This mode enables a technician to set operating conditions to confirm self-diagnosis status/results. — — x — — — — — — The specified values will be displayed when OK/NG Data monitor judgement is difficult for the (Spec.) DATA MONITOR items by Barchart and LIne Graph. x Work support DTC work support EC FE CL PD AX — — — — — — — — SU BR Active test Diagnostic Test Mode in which CONSULT-II drives some actuators apart from the ECMs and also shifts some parameters in a specified range. x — — x x — — x — ECU (ECM) part number ECU (ECM) part number can be read. x x x x x — — — x Control unit initialization All registered ignition key IDs in NATS components can be initialized and new IDs can be registered. — The results of SRT (System Readiness Test) and the self-diagnosis status/results can be confirmed. x SRT & DTC confirmation LC ST RS BT — — — — — x — — HA — — — — — — — — SC EL IDX GI-39 CONSULT-II CHECKING SYSTEM Function and System Application (Cont’d) Diagnostic test mode Function ALLENGINE MODE 4WD A/T ABS ABS (Including VDC) AIR BAG NVIS (NATS)*1 SMART ENTRANCE AIR PRESSURE MONITOR A maximum of four IDs (identifications) can be registered in the memory using the remote controller. These IDs can be also be confirmed and erased as required. — — — — — — — x — Conducted by CONSULT-II instead of a technician to Function test determine whether each system is “OK” or “NG” (No Good). x — x x x x — — — REMO CONT ID SET UP x: Applicable *1: NVIS (NATS) [NISSAN Vehicle Immobilizer System (Nissan Anti-Theft System)] Nickel Metal Hydride Battery Replacement NAGI0006S06 CONSULT-II contains a nickel metal hydride battery. When replacing the battery obey the following: WARNING: Replace the nickel metal hydride battery with Genuine CONSULT-II battery 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 NAGI0006S07 When ordering the below equipment, contact your NISSAN/INFINITI distributor. Tool name Description NISSAN CONSULT-II q 1 CONSULT-II unit (Tester internal soft: Resident version 3.3.0) and accessories q 2 Program card AED03E and AEN02C q 3 CONSULT-II CONVERTER q 4 “CONSULT-II Pigtail” Cable SAIA0363E NOTE: I The CONSULT-II must be used in conjunction with a program card. CONSULT-II does not require loading (Initialization) procedure. I Be sure the CONSULT-II is turned off before installing or removing a program card. CAUTION: Previous CONSULT-II “I” and “Y” DLC-I and DLC-II cables should NOT be used anymore because their DDL connector pins can be damaged during cable swapping. GI-40 CONSULT-II CHECKING SYSTEM CONSULT-II Start Procedure CONSULT-II Start Procedure NAGI0006S09 MA EM LC EC PAIA0070E 1. Turn off the ignition switch. 2. Connect CONSULT-II and CONSULT-II CONVERTER to the data link connector. FE CL MT AT TF SAIA0450E PD 3. Turn on the ignition switch. 4. Touch “START (NISSAN BASED VHCL)” or “System shortcut” (eg: Engine) on the screen. CONSULT-II Data Link Connector (DLC) Circuit AX NAGI0006S08 SU BR ST SOM801 INSPECTION PROCEDURE NAGI0006S0801 If the CONSULT-II cannot diagnose the system properly, check the following items. Symptom Check item CONSULT-II cannot access any system. I CONSULT-II DLC power supply circuit (Terminal 8) and ground circuit (Terminal 4) (For detailed circuit, refer to EC-791, “MIL & DATA LINK CONNECTORS”.) I CONSULT-II (DDL) cable and CONSULT-II CONVERTER CONSULT-II cannot access indi- I CONSULT-II program card (Check the approprite CONSULT-II program card for the system. vidual system. (Other systems Refer to “Checking Equipment” above.) can be accessed.) I Power supply and ground circuit for the control unite of the system (For detailed circuit, refer to wiring diagram for each system.) I Open or short circuit between the system and CONSULT-II DLC (For detailed circuit, refer to wiring diagram for each system.) GI-41 RS BT HA SC EL IDX CONSULT-II CHECKING SYSTEM CONSULT-II Data Link Connector (DLC) Circuit (Cont’d) NOTE: The DDL1 and DDL2 circuits from DLC pins 12, 13, 14 and 15 may be connected to more than one system. A short in a DDL circuit connected to a control unit in one system may affect CONSULT-II access to other systems. GI-42 NAGI0007 IDENTIFICATION INFORMATION Model Variation Model Variation NAGI0007S01 2WD Destination Body NAGI0007S0101 Grade Engine VQ35DE Transmission RE4R01A (Automatic) Differential carrier H233B SE U.S.A. VLJULTAR50EUA Wide 4-door LE Grade EC VQ35DE Transmission FS5R30A (Manual) Differential carrier U.S.A. Rear H233B Front R200A FE RE4R01A (Automatic) Front R200A Rear H233B SE VLJZLTFR50EUA *1 VLJZLTAR50EUA LE — *2 VLJWLVAR50EUA TLJZLRFR50ENA *1 TLJZLRAR50ENA Wide Wagon Canada XE 4-door Transfer LC NAGI0007S0102 Engine Body EM VLJULVAR50EUA 4WD Destination MA *1 SE VLJZLTFR50ENA LE — Wide VLJWLTAR50ENA CL MT AT *2 VLJWLVAR50ENA TF *1 TX10A (Part time 4WD models) *2 ATX14A (All-mode 4WD models) PREFIX AND SUFFIX DESIGNATIONS PD NAGI0007S0103 AX SU BR ST RS BT MGI037AB HA SC EL IDX GI-43 IDENTIFICATION INFORMATION Identification Number Identification Number NAGI0007S02 SGI935-A VEHICLE IDENTIFICATION NUMBER ARRANGEMENT NAGI0007S0201 SGI067AJ GI-44 IDENTIFICATION INFORMATION Identification Number (Cont’d) IDENTIFICATION PLATE NAGI0007S0202 MA EM LC EC FE CL MGI039A ENGINE SERIAL NUMBER MT AT NAGI0007S0203 TF PD AX SU SGI136A MANUAL TRANSMISSION NUMBER NAGI0007S0204 BR ST RS BT SGI185A AUTOMATIC TRANSMISSION NUMBER NAGI0007S0205 HA SC EL IDX MGI042A GI-45 IDENTIFICATION INFORMATION Identification Number (Cont’d) TRANSFER SERIAL NUMBER NAGI0007S0206 MGI043A Dimensions NAGI0007S03 Unit: mm (in) Wagon*2 Wide*3 VQ35DE Overall length*1 4,640 (182.7) Overall width 1,770 (69.7) 1,820 (71.7) Overall height 1,730 (68.1) 1,725 (67.9) Front tread 1,480 (58.3) 1,540 (60.6) Rear tread 1,485 (58.5) 1,545 (60.8) Wheelbase 2,700 (106.3) *1: On spare tire carrier equipped models, the spare tire carrier adds 240 mm (9.45 in) to the overall length. *2: XE models *3: SE models and LE wide models Wheels & Tires Road wheel/offset mm (in) NAGI0007S04 Tire Spare tire size SE 16 x 7JJ Aluminum/20 (0.79) P255/65R16 106S P255/65R16 106S 215/80R16 103S* LE 17 x 8JJ Aluminum/20 (0.79) P245/65R17 105S P245/65R17 105S 215/80R16 103S* XE 16 x 7JJ Aluminum/50 (1.97) P245/70R16 106S P245/70R16 106S SE 16 x 7JJ Aluminum/20 (0.79) P255/65R16 106S P255/65R16 106S LE 17 x 8JJ Aluminum/20 (0.79) P245/65R17 105S P245/65R17 105S 4x2 PATHFINDER 4x4 PATHFINDER *: If so equipped (US only) GI-46 NAGI0008 LIFTING POINTS AND TOW TRUCK TOWING WARNING: I 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. I Place wheel chocks at both front and back of the wheels on the ground. Screw Jack MA EM NAGI0008S01 LC EC FE CL MT AT TF SGI152A PD AX SU BR ST RS BT HA SC EL IDX GI-47 LIFTING POINTS AND TOW TRUCK TOWING Garage Jack and Safety Stand Garage Jack and Safety Stand =NAGI0008S02 CAUTION: Place a wooden or rubber block between safety stand and vehicle body when the supporting body is flat. SGI130A GI-48 LIFTING POINTS AND TOW TRUCK TOWING 2-pole Lift 2-pole Lift =NAGI0008S03 WARNING: When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear of the vehicle are well balanced. When setting the lift arm, do not allow the arm to contact the brake tubes, brake cable and fuel lines. MA EM LC EC FE CL MT AT SGI131A TF PD AX SU Tow Truck Towing SGI988 NAGI0008S04 CAUTION: I All applicable state or Provincial (in Canada) laws and local laws regarding the towing operation must be obeyed. I 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. I Always attach safety chains before towing. I When towing, make sure that the transmission, steering system and power train are in good order. If any unit is damaged, dollies must be used. I Never tow an automatic transmission model from the rear (that is backward) with four wheels on the ground as this may cause serious and expensive damage to the transmission. BR ST RS BT HA SC EL IDX GI-49 LIFTING POINTS AND TOW TRUCK TOWING Tow Truck Towing (Cont’d) 2WD MODELS NAGI0008S0401 NISSAN recommends that vehicle be towed with the driving (rear) wheels off the ground as illustrated. CAUTION: I When towing manual or automatic transmission models with the front wheels on the ground: Turn the ignition key to the OFF position and secure the steering wheel in a straightahead position 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. I When towing manual transmission models with the rear wheels on the ground or four wheels on the ground (if you do not use towing dollies): Always release the parking brake and move the transmission shift lever to the N (neutral) position. Observe the following restricted towing speeds and distances. Manual transmission models: I Speed: Below 95 km/h (59 MPH) I Distance: Less than 800 km (500 miles) If the speed or distance must necessarily be greater, remove the propeller shaft beforehand to prevent damage to the transmission. SGI989 PART TIME 4WD MODELS SGI990 NAGI0008S0402 NISSAN recommends that a dolly be used as illustrated when towing 4WD models. CAUTION: If towing with the front wheels on the ground or with the rear wheels on the ground (if you do not use towing dollies) is necessary: Move the transfer case shift lever into the 2H position. I When towing with the front wheels on the ground: On manual transmission models to move the shift lever to the N (neutral) position, turn the ignition key to the OFF position and secure the steering wheel in a straightahead position with a rope or similar device. On automatic transmission models to move the selector lever to N (neutral) position, turn the ignition key to the ACC position. After moving the selector lever to the N (neutral) position, turn the ignition key to the OFF position and secure the steering wheel in a straightahead position 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. I When towing manual transmission models with the rear wheels on the ground or four wheels on the ground: Always release the parking brake and move the transmission shift lever to the N (neutral) position. Observe the following restricted towing speeds and distances. Manual transmission models: I Speed: Below 95 km/h (59 MPH) I 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. GI-50 LIFTING POINTS AND TOW TRUCK TOWING Tow Truck Towing (Cont’d) MA EM LC EC FE CL SGI950 MT ALL-MODE 4WD MODELS NAGI0008S0404 NISSAN recommends that a dolly or a flat bed truck be used as illustrated when towing all-mode 4WD models. AT TF PD AX SU VEHICLE RECOVERY I I I SGI977 I NAGI0008S0403 Use the towing hook only, not other parts of the vehicle. Otherwise, the vehicle body will be damaged. Use the towing hook only to free a vehicle stuck in sand, snow, mud, etc. Never tow the vehicle for a long distance using only the towing hook. The towing hook is under tremendous force when used to free a stuck vehicle. Always pull the cable straight out from the front or rear of the vehicle. Never pull on the hook at a sideways angle. Stand clear of a stuck vehicle. BR ST RS BT HA SC EL IDX GI-51 NAGI0009 TIGHTENING TORQUE OF STANDARD BOLTS Grade 4T Pitch mm M6 6.0 M8 8.0 Bolt size M10 M12 7T Hexagon head bolt Hexagon flange bolt N·m kg-m ft-lb in-lb N·m kg-m ft-lb in-lb 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 — 1.0 13 1.3 9 — 16 1.6 12 — 1.5 25 2.5 18 — 29 3.0 22 — 1.25 25 2.6 19 — 30 3.1 22 — 1.75 42 4.3 31 — 51 5.2 38 — 1.25 46 4.7 34 — 56 5.7 41 — 10.0 12.0 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 — 1.25 43 4.4 32 — 51 5.2 38 — 1.75 71 7.2 52 — 84 8.6 62 — 1.25 77 7.9 57 — 92 9.4 68 — M10 M12 9T Tightening torque (Without lubricant) Bolt diameter * mm 10.0 12.0 M14 14.0 1.5 127 13.0 94 — 147 15.0 108 — M6 6.0 1.0 12 1.2 9 — 15 1.5 11 — 1.25 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 — 1.25 62 6.3 46 — 74 7.5 54 — 1.75 98 10.0 72 — 118 12.0 87 — 1.25 108 11.0 80 — 137 14.0 101 — 1.5 177 18.0 130 — 206 21.0 152 — M10 M12 M14 10.0 12.0 14.0 *: Nominal diameter 1) Special parts are excluded. 2) This standard is applicable to bolts having the following marks embossed on the bolt head. MGI044A GI-52 NAGI0012 RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS Refer to the following chart for help in selecting the appropriate chemical product or sealant. Recommended Chemical Products and Sealants Product Description 1 2 3 Purpose Rear View Mirror Adhesive Used to permanently remount rear view mirrors to windows. Anaerobic Liquid Gasket For metal-to-metal flange sealing. Can fill a 0.38 mm (0.015 inch) gap and provide instant sealing for most powertrain applications. 999MP-AM001P High Performance Thread Sealant Provides instant sealing on any threaded straight or parallel threaded fitting. (Thread sealant only, no locking ability.) I Do not use on plastic. 999MP-AM002P Gasket Maker 4 6 999MP-AM000P Nissan Canada Part No. (Canada) 99998-50505 High Temperature, High Strength Thread Locking Sealant (Red) Medium Strength Thread Locking Sealant (Blue) Threadlocker Threadlocker (service tool removable) Aftermarket Cross Reference Part Nos. MA Permatex 81844 EM LC 99998-50503 Permatex 51813 and 51817 EC FE CL 999MP-AM002P Permatex 56521 MT 999MP-AM003P (Ultra Grey) 99998-50506 (Ultra Grey) Silicone RTV Gasket Maker for Maxima/Quest 5-speed automatic transmission (RE5F22A) 5 Nissan North America Part No. (USA) — 999MP-AM004P 999MP-AM005P — 999MP-AM004P 999MP-AM005P Permatex Ultra Grey 82194; Three Bond 1207, 1215, 1216, 1217F and 1217G; Nissan RTV Part No. 999MP-A7007 Three Bond 1281B or exact equivalent in its quality AT TF PD AX Permatex 27200; Three Bond 1360, 1360N, 1305 N&P, 1307N, 1335, 1335B, 1363B, 1377C, 1386B, D&E and 1388 SU Permatex 24200, 24206, 24240, 24283 and 09178; Three Bond 1322, 1322N, 1324 D&N, 1333D, 1361C, 1364D, 1370C and 1374 ST BR RS BT HA SC EL IDX GI-53 NAGI0010 SAE J1930 TERMINOLOGY LIST SAE J1930 Terminology List SAE J1930 Terminology List NAGI0010S01 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. NEW ACRONYM / ABBREVIATION NEW TERM OLD TERM 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 Canister *** Canister Carburetor CARB 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 Clutch switch Continuous fuel injection system CFI system *** Continuous trap oxidizer system CTOX system *** Crankshaft position CKP *** Crankshaft position sensor CKPS *** Data link connector DLC *** 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 DI 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 EI system Ignition timing control Engine control EC *** Engine control module ECM ECCS control unit Engine coolant temperature ECT Engine temperature Engine coolant temperature sensor ECTS Engine temperature sensor Engine modification EM *** Engine speed RPM Engine speed Erasable programmable read only memory EPROM *** GI-54 SAE J1930 TERMINOLOGY LIST SAE J1930 Terminology List (Cont’d) NEW ACRONYM / ABBREVIATION NEW TERM OLD TERM Evaporative emission canister EVAP canister Canister Evaporative emission system EVAP system Canister control solenoid valve Exhaust gas recirculation valve EGR valve EGR valve Exhaust gas recirculation control-BPT valve EGRC-BPT valve BPT valve Exhaust gas recirculation control-solenoid valve EGRC-solenoid valve EGR control solenoid valve Exhaust gas recirculation temperature sensor EGRT sensor Exhaust gas temperature sensor MA EM LC EC FE 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 tank temperature sensor FTT Tank fuel temperature sensor Fuel trim FT *** Heated Oxygen sensor HO2S Exhaust gas sensor Idle air control system IAC 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-FICD solenoid valve IACV-FICD solenoid valve FICD solenoid valve Idle air control valve-idle up control solenoid valve IACV-idle up control solenoid valve Idle up control solenoid valve Idle speed control-FI pot ISC-FI pot FI pot Idle speed control system ISC system *** Ignition control IC *** Ignition control module ICM *** Indirect fuel injection system IFI system *** Intake air IA Air Intake air temperature sensor IAT sensor Air temperature sensor Knock *** Detonation Knock sensor KS Detonation sensor Malfunction indicator lamp MIL Check engine light Manifold absolute pressure MAP *** Manifold absolute pressure sensor MAPS *** CL MT AT TF PD AX SU BR ST GI-55 RS BT HA SC EL IDX SAE J1930 TERMINOLOGY LIST SAE J1930 Terminology List (Cont’d) NEW ACRONYM / ABBREVIATION NEW TERM OLD TERM Manifold differential pressure MDP *** Manifold differential pressure sensor MDPS *** 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 Multiport fuel injection System MFI system Fuel injection control Neutral position switch *** Neutral switch Nonvolatile random access memory NVRAM *** 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 O2S 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 multiport fuel injection system SFI system Sequential fuel injection Service reminder indicator SRI *** Simultaneous multiport fuel injection system *** Simultaneous fuel injection Smoke puff limiter system SPL system *** Supercharger SC *** GI-56 SAE J1930 TERMINOLOGY LIST SAE J1930 Terminology List (Cont’d) NEW ACRONYM / ABBREVIATION NEW TERM OLD TERM MA Supercharger bypass SCB *** System readiness test SRT *** 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 Three way + oxidation catalytic converter system TWC + OC system *** EC Throttle body TB Throttle chamber SPI body FE Throttle body fuel injection system TBI system Fuel injection control Throttle position TP Throttle position Throttle position sensor TPS Throttle sensor Throttle position switch TP switch Throttle switch Torque converter clutch solenoid valve TCC solenoid valve Lock-up cancel solenoid Lock-up solenoid Transmission control module TCM A/T control unit 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 sys- WU-OC system tem *** 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 EM LC CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX GI-57 NOTES ACCELERATOR CONTROL, FUEL & EXHAUST SYSTEMS SECTION FE GI MA EM LC EC CONTENTS PREPARATION ...............................................................2 Special Service Tool ....................................................2 Commercial Service Tools ...........................................2 ACCELERATOR CONTROL SYSTEM ...........................3 Removal and Installation .............................................3 REMOVAL .................................................................3 INSTALLATION..........................................................3 INSPECTION AFTER INSTALLATION .........................3 FUEL SYSTEM ................................................................4 Removal and Installation .............................................4 FUEL TANK ...............................................................5 FUEL PUMP AND FUEL LEVEL SENSOR UNIT ..........6 EXHAUST SYSTEM ........................................................9 Removal and Installation .............................................9 CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX PREPARATION Special Service Tool Special Service Tool NAFE0001 The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name Description KV10114400 (J38365) Heated oxygen sensor wrench Loosening or tightening rear heated oxygen sensor (For right bank) a: 22 mm (0.87 in) NT636 Commercial Service Tools Tool number (Kent-Moore No.) Tool name NAFE0007 Description Oxygen sensor thread cleaner (J-43897-18) (J-43897-12) Reconditioning the exhaust system threads before installing a new heated oxygen sensor. Use with anti-seize lubricant shown below. a: J-43897-18 (18 mm dia.) for Zirconia Heated Oxygen Sensor b: J-43897-12 (12 mm dia.) for Titania Heated Oxygen Sensor NT778 Anti-seize lubricant (PermatexTM 133AR or equivalent meeting MIL specification MIL-A-907) Lubricating heated oxygen sensor thread cleaning tool when reconditioning exhaust system threads. NT779 FE-2 ACCELERATOR CONTROL SYSTEM Removal and Installation Removal and Installation NAFE0008 CAUTION: I Check that throttle valve opens when accelerator pedal is fully depressed. Also check that it returns to idle position when pedal is released when ignition switch is in “ON” position. I Check accelerator control parts for improper contact with any adjacent parts. GI MA EM LC EC CL MT AT SFE787A TF 1. Accelerator pedal assembly PD REMOVAL NAFE0008S01 1. Remove harness connector. 2. Remove mounting nut then remove accelerator pedal assembly. CAUTION: I Do not disassemble accelerator pedal or remove/install accelerator pedal position sensor. I Do not drop or shock accelerator pedal assembly. I Keep accelerator pedal assembly from getting wet. INSTALLATION AX SU BR NAFE0008S02 Install in reverse order of removal. ST INSPECTION AFTER INSTALLATION I I I I NAFE0008S03 Check if accelerator pedal moves smoothly within its range. Check if accelerator pedal returns securely to its original position. Perform “Accelerator Pedal Released Position Learning” when removing the accelerator pedal position sensor harness connector. Refer to EC-81, “BASIC SERVICE PROCEDURE”. For electrical inspection of accelerator pedal assembly, refer to EC-731, “DTC P2138 APP SENSOR”. RS BT HA SC EL IDX FE-3 FUEL SYSTEM Removal and Installation Removal and Installation NAFE0004 WARNING: When replacing fuel line parts, be sure to observe the following: I Put a “CAUTION: INFLAMMABLE” sign in workshop. I Do not smoke while servicing fuel system. Keep open flames and sparks away from work area. I Be sure to work in a well ventilated area and furnish the workshop with a CO2 fire extinguisher. CAUTION: I Before removing fuel line parts, carry out the following procedures: a) Put drained fuel in an explosion-proof container and put lid on securely. Keep the container in safe area. b) Release fuel pressure from fuel line. Refer to MA-17, “Changing Fuel Filter”. c) Disconnect battery ground cable. I Always replace O-ring with new ones. I Do not kink or twist hose and tube when they are installed. I Do not tighten hose clamps excessively to avoid damaging hoses. I When installing fuel check valve, be careful of its designated direction. Refer to EC-41, “EVAPORATIVE EMISSION SYSTEM”. I For inspection of ORVR system parts, refer to EC-47, “ON Board Refueling Vapor Recovery (ORVR)”. I After installation, make sure there is no fuel leaks at connections in the following steps. a) Apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). Then check for fuel leaks at connections. b) Start the engine and rev it up and check for fuel leaks at connections. FE-4 FUEL SYSTEM Removal and Installation (Cont’d) GI MA EM LC EC CL MT AT TF SFE766A PD AX SU FUEL TANK 1. 2. 3. 4. I NAFE0004S01 Release fuel pressure from fuel line. Refer to MA-17, “Changing Fuel Filter”. Remove inspection hole cover located behind the rear seat. Disconnect harness connectors under inspection hole cover. Disconnect fuel hoses. Put mating marks on hoses for correct installation. BR ST RS BT SFE420A 5. Disconnect filler hose, vent hose and evaporation hose at fuel tank side. HA SC EL IDX SFE468A FE-5 FUEL SYSTEM Removal and Installation (Cont’d) 6. 7. Remove parking brake wire from fuel tank protector. Remove fuel tank protector. SFE422A 8. Remove fuel tank band mounting bolts while supporting fuel tank. 9. Remove fuel tank. Installation procedure is the reverse order of removal. SFE469A FUEL PUMP AND FUEL LEVEL SENSOR UNIT NAFE0004S02 SFE810A 1. 2. 3. I 4. Release fuel pressure from fuel line. Refer to MA-17, “Changing Fuel Filter”. Remove inspection hole cover located behind the rear seat. Disconnect harness connectors and fuel tubes from upper plate of fuel level sensor unit. Put mating marks on tubes for correct installation. Remove fuel level sensor unit retainer and fuel level sensor unit. FE-6 FUEL SYSTEM Removal and Installation (Cont’d) 5. I I Disconnect the quick connectors as follows. Hold the sides of the connector, push in tubs and pull out the tube. If the connector and the tube are stuck together, push and pull several times until they start to move. Then disconnect them by pulling. GI MA EM LC SFE544A CAUTION: I The quick connector can be removed when the tabs are completely depressed. Do not twist it more than necessary. I Do not use any tools to remove the quick connector. I Keep the resin tube away from heat. Be especially careful when welding near the tube. I Prevent acid liquid such as battery electrolyte, etc. from getting on the resin tube. I Do not bend or twist the tube during installation and removal. I Only when the quick connector is replaced, remove the remaining retainer on the fuel level sensor unit. (Feed tube) I When the fuel level sensor unit is replaced, also replace the retainer with a new one [Yellow colored retainer]. (Feed tube) EC CL MT AT TF PD AX SU KBIA1295E I Press fuel tube and fuel level sensor unit as shown in the figure. Disconnect the joint by pushing tab and pull out fuel tube. (Return tube) BR ST RS BT JFE791A I To keep the connecting portion clean and to avoid damage and foreign materials, cover them completely with plastic bags or something similar. HA SC EL IDX JFE792A FE-7 FUEL SYSTEM Removal and Installation (Cont’d) 6. Remove fuel pump with bracket while lifting the pawl of the fuel pump bracket upward. 7. I 1) 2) 3) To install, reverse the removal procedure. Connect the quick connectors as follows. Be sure that the connecting portion is clean and smooth. Align mating marks. Insert tube straight into the connector aligning each center until you hear a click. After connecting, make sure that the connection is secure by following method. Pull the tube and the connector to make sure they are securely connected. Visually confirm that the two retainer tabs are connected to the connector. SFE425A 4) a. JFE793A b. I Face fuel level sensor unit as shown in the figure, and install it with knock pin on back aligned with knock pin hole on fuel tank. SFE428A FE-8 EXHAUST SYSTEM Removal and Installation Removal and Installation NAFE0005 CAUTION: I Always replace exhaust gaskets with new ones when reassembling. I With engine running, check all tube connections for exhaust gas leaks, and entire system for unusual noises. I Check to ensure that mounting brackets and mounting insulators are installed properly and free from undue stress. Improper installation could result in excessive noise or vibration. I 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. I Before installing new heated oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 of J-43897-12 and approved anti-seize lubricant. I Do not overtorque the heated oxygen sensor. Doing so may cause damage to the heated oxygen sensor, resulting in the MIL coming on. GI MA EM LC EC CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX FE-9 EXHAUST SYSTEM Removal and Installation (Cont’d) SFE788A 1. 2. 3. 4. Heated oxygen sensor 2 (bank 1) Front tube Heated oxygen sensor 2 (bank 2) Dynamic damper 5. 6. 7. Mounting rubber Clamp Mounting bracket FE-10 8. Mounting rubber 9. Main muffler 10. Post muffler EXHAUST SYSTEM Removal and Installation (Cont’d) GI MA EM LC EC CL MT AT TF PD AX SU BR ST RS BT HA SFE789A 1. 2. 3. Heated oxygen sensor 2 (bank 1) Front tube Heated oxygen sensor 2 (bank 2) 4. 5. 6. Mounting bracket Mounting rubber Main muffler 7. 8. Post muffler Dynamic damper SC EL IDX FE-11 NOTES ENGINE LUBRICATION & COOLING SYSTEMS SECTION LC GI MA EM EC FE CONTENTS ENGINE LUBRICATION SYSTEM..................................2 Precautions ..................................................................2 LIQUID GASKET APPLICATION PROCEDURE ............2 Preparation ..................................................................2 SPECIAL SERVICE TOOLS ........................................2 COMMERCIAL SERVICE TOOL ..................................3 Lubrication Circuit ........................................................3 Oil Pressure Check......................................................5 Oil Pump ......................................................................6 REMOVAL AND INSTALLATION .................................6 DISASSEMBLY AND ASSEMBLY................................6 OIL PUMP INSPECTION ............................................7 REGULATOR VALVE INSPECTION ............................7 OIL FILTER ...............................................................8 Oil Cooler.....................................................................8 REMOVAL AND INSTALLATION .................................8 INSPECTION .............................................................9 Service Data and Specifications (SDS).......................9 OIL PRESSURE ........................................................9 REGULATOR VALVE .................................................9 OIL PUMP .................................................................9 ENGINE COOLING SYSTEM........................................10 Precautions ................................................................10 LIQUID GASKET APPLICATION PROCEDURE ..........10 Preparation ................................................................10 SPECIAL SERVICE TOOLS ......................................10 Cooling Circuit ...........................................................11 System Check............................................................12 CHECKING COOLING SYSTEM HOSES ...................12 CHECKING RADIATOR ............................................12 CHECKING RADIATOR CAP ....................................12 CHECKING COOLING SYSTEM FOR LEAKS ............13 Water Pump ...............................................................13 REMOVAL AND INSTALLATION ...............................13 REMOVAL ...............................................................14 INSPECTION ...........................................................15 INSTALLATION........................................................16 Thermostat.................................................................18 REMOVAL AND INSTALLATION ...............................18 INSPECTION ...........................................................18 Water Control Valve...................................................19 REMOVAL AND INSTALLATION ...............................19 INSPECTION ...........................................................20 Radiator .....................................................................21 REMOVAL AND INSTALLATION ...............................21 Cooling Fan (Crankshaft driven) ...............................22 REMOVAL AND INSTALLATION ...............................22 INSPECTION ...........................................................22 Refilling Engine Coolant ............................................22 Radiator (Aluminum type)..........................................23 PREPARATION .......................................................23 DISASSEMBLY ........................................................23 ASSEMBLY .............................................................24 INSPECTION ...........................................................25 Overheating Cause Analysis .....................................26 Service Data and Specifications (SDS).....................27 THERMOSTAT ........................................................27 WATER CONTROL VALVE .......................................27 RADIATOR ..............................................................27 CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX ENGINE LUBRICATION SYSTEM Precautions Precautions LIQUID GASKET APPLICATION PROCEDURE 1. 2. I SEM164F I 3. 4. 5. NALC0001 Use a scraper to remove all traces of old liquid gasket from mating surfaces and grooves. Also, completely clean any oil from these areas. Apply a continuous bead of liquid gasket to mating surfaces. (Use Genuine RTV silicone sealant or equivalent. Refer to GI-53.) For oil pan, be sure liquid gasket diameter is 4.0 to 5.0 mm (0.157 to 0.197 in). For areas except oil pan, be sure liquid gasket diameter is 2.0 to 3.0 mm (0.079 to 0.118 in). Apply liquid gasket around the inner side of bolt holes (unless otherwise specified). Assembly should be done within 5 minutes after coating. Wait at least 30 minutes before refilling engine oil and engine coolant. AEM080 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.) Tool name Description ST25051001 (J25695-1) Oil pressure gauge NT050 ST25052000 (J25695-2) Hose Adapting oil pressure gauge to upper oil pan NT559 WS39930000 ( — ) Tube pressure Pressing the tube of liquid gasket NT052 LC-2 NALC0002 ENGINE LUBRICATION SYSTEM Preparation (Cont’d) COMMERCIAL SERVICE TOOL Tool name NALC0040 GI Description MA Removing and installing oil pressure switch Deep socket 26 mm, 3/8 drive Deep socket EM NT818 EC FE CL MT Lubrication Circuit AT NALC0003 TF PD AX SU BR ST RS BT HA SLC350BD SC EL IDX LC-3 ENGINE LUBRICATION SYSTEM Lubrication Circuit (Cont’d) SLC493BA LC-4 ENGINE LUBRICATION SYSTEM Oil Pressure Check Oil Pressure Check NALC0004 WARNING: I Be careful not to burn yourself, as the engine and oil may be hot. I Oil pressure check should be done in “Neutral position” (M/T) or “Parking position” (A/T). 1. Check oil level. 2. Disconnect oil pressure switch harness connector. 3. Remove oil pressure switch using a deep socket. (Commercial service tool) 4. Install pressure gauge. 5. Start engine and warm it up to normal operating temperature. 6. Check oil pressure with engine running under no-load. SLC497B 7. a. b. Engine speed rpm Approximate discharge pressure kPa (kg/cm2, psi) Idle speed 2,000 More than 98 (1.0, 14) 294 (3.0, 43) If difference is extreme, check oil passage and oil pump for oil leaks. After the inspections, install the oil pressure switch as follows. Remove the old sealant adhering to switch and engine. Apply Genuine RTV silicone sealant or equivalent to the thread and tighten. Refer to GI-53. 13 - 17 N·m (1.25 - 1.75 kg-m, 9 - 12 ft-lb) GI MA EM EC FE CL MT AT TF PD AX SU BR ST RS BT SLC498B HA SC EL IDX SLC926 LC-5 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump REMOVAL AND INSTALLATION 1. 2. I 3. =NALC0005 Remove timing chain. Refer to EM-24, “Removal”. Remove oil pump assembly. Inspect the oil pump after removing it. Reinstall any parts removed in reverse order of removal. DISASSEMBLY AND ASSEMBLY NALC0006 SLC494B I When installing oil pump, apply engine oil to rotors. LC-6 ENGINE LUBRICATION SYSTEM Oil Pump (Cont’d) OIL PUMP INSPECTION NALC0007 I Install oil pump with the groove of the inner rotor facing the oil pump cover. Using a feeler gauge, straightedge and micrometers, check the following clearances: Unit: mm (in) SLC324B Body to outer rotor radial clearance 1 0.114 - 0.200 (0.0045 - 0.0079) Inner rotor to outer gear tip clearance 2 Below 0.18 (0.0071) Body to inner rotor axial clearance 3 0.030 - 0.070 (0.0012 - 0.0028) Body to outer rotor axial clearance 4 0.050 - 0.110 (0.0020 - 0.0043) Inner rotor to brazed portion of housing clearance 5 0.045 - 0.091 (0.0018 - 0.0036) I I If the tip clearance (2) exceeds the limit, replace rotor set. If body to rotor clearances (1, 3, 4, 5) exceed the limit, replace oil pump body assembly. GI MA EM EC FE CL MT SLC932A AT TF PD AX SU SLC933A BR ST RS BT SLC934AB REGULATOR VALVE INSPECTION 1. 2. NALC0008 Visually inspect components for wear and damage. 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. If damaged, replace regulator valve set or oil pump body. HA SC EL IDX SLC251B LC-7 ENGINE LUBRICATION SYSTEM Oil Pump (Cont’d) 4. Check regulator valve to oil pump body clearance. Clearance: 6 : 0.040 - 0.097 mm (0.0016 - 0.0038 in) If it exceeds the limit, replace oil pump body. SLC935AA OIL FILTER NALC0009 The oil filter is a small, full-flow cartridge type and is provided with a relief valve. I Use Tool specified in MA-19 for changing oil filter. ALC094 Oil Cooler REMOVAL AND INSTALLATION NALC0036 SLC353BC 1. I 2. Disconnect water hoses from oil cooler, pinching water hose to prevent coolant spill. Do not spill coolant on the drive belt. Remove oil cooler. LC-8 ENGINE LUBRICATION SYSTEM Oil Cooler (Cont’d) I Inspect the oil cooler after removing it. GI MA EM 3. I Installation is in reverse order of removal. When installing the oil cooler, align the oil cooler stopper with the stopper of the oil cooler bracket. INSPECTION Oil Cooler 1. 2. FE NALC0037 NALC0037S01 Check oil cooler for cracks. Check oil cooler for clogging by blowing through coolant inlet. If necessary, replace oil cooler assembly. Oil Pressure Relief Valve SLC333B EC CL MT NALC0037S02 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 in place by tapping it. AT TF PD AX SU Service Data and Specifications (SDS) OIL PRESSURE NALC0010 Engine speed rpm Approximate discharge pressure kPa (kg/cm2, psi) Idle speed 2,000 More than 98 (1.0, 14) 294 (3.0, 43) BR ST RS REGULATOR VALVE NALC0011 Unit: mm (in) Regulator valve to oil pump cover clearance BT 0.040 - 0.097 (0.0016 - 0.0038) OIL PUMP NALC0012 Unit: mm (in) Body to outer rotor radial clearance 0.114 - 0.200 (0.0045 - 0.0079) Inner rotor to outer rotor tip clearance Below 0.18 (0.0071) Body to inner rotor axial clearance 0.030 - 0.070 (0.0012 - 0.0028) Body to outer rotor axial clearance 0.050 - 0.110 (0.0020 - 0.0043) Inner rotor to brazed portion of housing clearance 0.045 - 0.091 (0.0018 - 0.0036) LC-9 HA SC EL IDX ENGINE COOLING SYSTEM Precautions Precautions LIQUID GASKET APPLICATION PROCEDURE 1. 2. I SEM164F I 3. 4. 5. NALC0013 Use a scraper to remove all traces of old liquid gasket from mating surfaces and grooves. Also, completely clean any oil from these areas. Apply a continuous bead of liquid gasket to mating surfaces. (Use Genuine RTV silicone sealant or equivalent. Refer to GI-53.) For oil pan, be sure liquid gasket diameter is 4.0 to 5.0 mm (0.157 to 0.197 in). For areas except oil pan, be sure liquid gasket diameter is 2.0 to 3.0 mm (0.079 to 0.118 in). Apply liquid gasket around the inner side of bolt holes (unless otherwise specified). Assembly should be done within 5 minutes after coating. Wait at least 30 minutes before refilling engine oil and engine coolant. AEM080 Preparation SPECIAL SERVICE TOOLS NALC0014 The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name Description WS39930000 ( — ) Tube pressure Pressing the tube of liquid gasket NT052 EG17650301 (J33984-A) Radiator cap tester adapter Adapting radiator cap tester to radiator filler neck a: 28 (1.10) dia. b: 31.4 (1.236) dia. c: 41.3 (1.626) dia. Unit: mm (in) NT564 KV99103510 ( — ) Radiator plate pliers A Installing radiator upper and lower tanks NT224 KV99103520 ( — ) Radiator plate pliers B Removing radiator upper and lower tanks NT225 LC-10 ENGINE COOLING SYSTEM Cooling Circuit Cooling Circuit NALC0015 GI MA EM EC FE CL MT AT TF SLC321BC PD AX SU BR ST RS BT HA SC EL SLC513B LC-11 IDX ENGINE COOLING SYSTEM System Check System Check NALC0016 WARNING: Never remove the radiator cap when the engine is hot; serious burns could be caused by high pressure fluid escaping from the radiator. Wrap a thick cloth around the cap and carefully remove it by turning it a quarter turn to allow built-up pressure to escape and then turn the cap all the way off. CHECKING COOLING SYSTEM HOSES NALC0016S01 Check hoses for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration. CHECKING RADIATOR NALC0016S02 Check radiator for mud or clogging. If necessary, clean radiator as follows. I Be careful not to bend or damage the radiator fins. I When radiator is cleaned without removal, remove all surrounding parts such as cooling fan, radiator shroud and horns. Then tape the harness and connectors to prevent water from entering. 1. Apply water by hose to the back side of the radiator core vertically downward. 2. Apply water again to all radiator core surfaces once per minute. 3. Stop washing if any stains no longer flow out from the radiator. 4. Blow air into the back side of radiator core vertically downward. I Use compressed air lower than 490 kPa (5 kg/cm2, 71 psi) and keep distance more than 30 cm (11.8 in). 5. Blow air again into all the radiator core surfaces once per minute until no water sprays out. CHECKING RADIATOR CAP To check radiator cap, apply pressure to cap with a tester. Radiator cap relief pressure: Standard 78 - 98 kPa (0.8 - 1.0 kg/cm2, 11 - 14 psi) Limit 59 kPa (0.6 kg/cm2, 9 psi) SLC755A Pull the negative pressure valve to open it. Check that it closes completely when released. SMA967B LC-12 NALC0016S03 ENGINE COOLING SYSTEM System Check (Cont’d) CHECKING COOLING SYSTEM FOR LEAKS NALC0016S04 To check for leakage, apply pressure to the cooling system with a tester. Testing pressure: 157 kPa (1.6 kg/cm2, 23 psi) CAUTION: Higher than the specified pressure may cause radiator damage. GI MA EM SLC756A EC Water Pump REMOVAL AND INSTALLATION NALC0017 CAUTION: I When removing water pump assembly, be careful not to get coolant on drive belt. I Water pump cannot be disassembled and should be replaced as a unit. I After installing water pump, connect hose and clamp securely, then check for leaks using radiator cap tester. FE CL MT AT TF PD AX SU BR ST RS BT SLC509B HA SC EL IDX LC-13 ENGINE COOLING SYSTEM Water Pump (Cont’d) REMOVAL =NALC0018 1. 2. 3. 4. 5. 6. 7. 8. Remove undercover. Remove suspension member stay. Drain coolant from radiator. Remove radiator shrouds. Remove drive belts. Remove cooling fan. Remove water drain plug on water pump side of cylinder block. Remove chain tensioner cover and water pump cover. 9. Pushing timing chain tensioner sleeve, apply a stopper pin so it does not return. Then remove the chain tensioner assembly. SLC499B SLC328B 10. Remove the 3 water pump fixing bolts. Secure a gap between water pump gear and timing chain, by turning crankshaft pulley 20° backwards. SLC941A 11. Put M8 bolts [pitch: 1.25 mm (0.0492 in), length: approx. 50 mm (1.97 in)] to two water pump fixing bolt holes. JLC357B LC-14 ENGINE COOLING SYSTEM Water Pump (Cont’d) 12. Tighten M8 bolts by turning half turn alternately until they reach timing chain rear case. I In order to prevent damages to water pump or timing chain rear case, do not tighten one bolt continuously. Always turn each bolt half turn each time. 13. Lift up water pump and remove it. I When lifting up water pump, do not allow water pump gear to hit timing chain. GI MA EM EC FE CL MT AT TF PD AX SU SLC116B INSPECTION 1. 2. Check for badly rusted or corroded body assembly. Check for rough operation due to excessive end play. NALC0019 BR ST RS BT SLC943A HA SC EL IDX LC-15 ENGINE COOLING SYSTEM Water Pump (Cont’d) INSTALLATION =NALC0020 1. I Apply engine oil and coolant to O-rings as shown in the figure. Install O-ring with a white paint mark to the front side. 2. I Install water pump. Do not allow cylinder block to nip O-rings when installing water pump. 3. Return the crankshaft pulley to its original position by turning it 20° forward. 4. I Install timing chain tensioner, then remove the stopper pin. When installing the timing chain tensioner, engine oil should be applied to the oil hole and tensioner. 5. a. Install chain tensioner cover and water pump cover. Before installing, remove all traces of liquid gasket from mating surface of water pump cover and chain tensioner cover using a scraper. Also remove traces of liquid gasket from mating surface of front cover. PBIC0855E SLC031B SLC156B SLC961A SLC944A LC-16 ENGINE COOLING SYSTEM Water Pump (Cont’d) b. Apply a continuous bead of liquid gasket to mating surface of chain tensioner cover and water pump cover. Use Genuine RTV silicone sealant or equivalent. Refer to GI-53. GI MA EM EC FE CL MT SLC500B 6. I Reinstall any parts removed in reverse order of removal. After starting engine, let idle for three minutes, then rev engine up to 3,000 rpm under no load to purge air from the high-pressure chamber of the chain tensioners. The engine may produce a rattling noise. This indicates that air still remains in the chamber and is not a matter of concern. AT TF PD AX SU BR ST RS BT HA SC EL IDX LC-17 ENGINE COOLING SYSTEM Thermostat Thermostat REMOVAL AND INSTALLATION =NALC0021 SLC354BA 1. 2. 3. 4. 5. 6. 7. I Remove undercover. Remove suspension member stay. Drain coolant from radiator. Remove drive belts. Remove water drain plug on water pump side of cylinder block. Disconnect lower radiator hose. Remove water inlet and thermostat assembly. Do not disassemble water inlet and thermostat assembly. Replace them as a unit, if necessary. 8. I Install thermostat with jiggle valve facing upward. After installation, run engine for a few minutes, and check for leaks. Be careful not to spill coolant over engine compartment. Use a rag to absorb coolant. Reinstall any removed parts in reverse order of removal. SLC962AB I 9. SLC948A INSPECTION 1. 2. NALC0022 Check valve seating condition at ordinary room temperatures. It should seat tightly. Check valve opening temperature and maximum valve lift. Standard Valve opening temperature Valve lift SLC949A LC-18 76.5°C (170°F) More than 8.6 mm/90°C (0.339 in/194°F) ENGINE COOLING SYSTEM Thermostat (Cont’d) 3. Then check if valve closes at 5°C (9°F) below valve opening temperature. GI MA EM EC Water Control Valve REMOVAL AND INSTALLATION NALC0032 FE CL MT AT TF PD AX SLC490BA SU 1. 2. Water outlet housing Water control valve 3. 4. Water outlet Water hose 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 5. 6. Cylinder block water outlet Engine coolant temperature sensor Release fuel pressure. Refer to EC-64, “Fuel Pressure Release”. Remove undercover. Remove suspension member stay. Drain coolant from radiator. Remove engine cover. Remove air duct with air cleaner assembly. Disconnect hoses, harness and so on. Remove upper intake manifold corrector. Remove intake manifold corrector support bolts. Remove lower intake manifold corrector. Disconnect injector harness connectors. Remove injector tube. Remove intake manifold. Remove water outlet housing and water control valve. BR ST RS BT HA SC EL IDX LC-19 ENGINE COOLING SYSTEM Water Control Valve (Cont’d) SLC334B 15. Install water control valve and water outlet housing. a. Install gum ring to thermostat. b. Point the arrow on the upper surface of the valve to the front of the engine, and also be sure to install the protrusions and the valve stopper so that they are aligned in a straight line. 16. Reinstall any removed parts in reverse order of removal. I When installing intake manifold, injector tube and intake manifold collectors, refer to EM-12, “TIGHTENING PROCEDURES”. I After installation, run engine for a few minutes, and check for leaks. I Be careful not to spill coolant over engine compartment. Use a rag to absorb coolant. INSPECTION 1. 2. NALC0033 Check valve seating condition at ordinary room temperatures. It should seat tightly. Check valve opening temperature and maximum valve lift. Standard Valve opening temperature Valve lift SLC252B 3. 95°C (203°F) More than 8.0 mm/108°C (0.315 in/226°F) Then check if valve closes at 5°C (9°F) below valve opening temperature. LC-20 ENGINE COOLING SYSTEM Radiator Radiator REMOVAL AND INSTALLATION GI =NALC0023 1. Remove undercover. 2. Remove suspension member stay. 3. Drain coolant from radiator. 4. Disconnect radiator upper and lower hoses. 5. Remove upper and lower radiator shroud. 6. Remove A/T oil cooler hoses. (A/T) 7. Disconnect reservoir tank hose. 8. Remove radiator mounting bracket. 9. Remove radiator. 10. After repairing or replacing radiator, install any part removed in reverse order of removal. When filling radiator with coolant, refer to MA-15, “Changing Engine Coolant”. MA EM EC FE CL MT AT TF PD AX SU BR ST SLC501B RS BT HA SC EL IDX LC-21 ENGINE COOLING SYSTEM Cooling Fan (Crankshaft driven) Cooling Fan (Crankshaft driven) REMOVAL AND INSTALLATION I I I =NALC0038 Do not release the drive belt tension by removing the fan pulley. Fan coupling cannot be disassembled and should be replaced as a unit. If front mark F is present, install fan so that side marked F faces the front. Install the drive belt only after the fan and fan coupling to fan pulley bracket flange bolts/nuts have been properly torqued. SLC502B INSPECTION NALC0039 Check fan coupling for rough operation, wobbling, oil leakage or bent bimetal. After assembly, verify the fan does not wobble or flap while the engine is running. WARNING: I When the engine is running, keep hands and clothing away from moving parts such as drive belts and fan. SLC067B Refilling Engine Coolant NALC0034 For details on refilling engine coolant, refer to MA-16, “REFILLING ENGINE COOLANT”. LC-22 ENGINE COOLING SYSTEM Radiator (Aluminum type) Radiator (Aluminum type) PREPARATION GI =NALC0025 MA EM EC FE CL MT SLC882AB 1. 2. 3. Attach the spacer to the tip of the radiator plate pliers A. Spacer specification: 1.5 mm (0.059 in) thick x 18 mm (0.71 in) wide x 8.5 mm (0.335 in) long. Make sure that when radiator plate pliers A are closed dimension H′′ is approx. 7.6 mm (0.299 in). Adjust dimension H′′ with the spacer, if necessary. AT TF PD AX SU SLC655CB DISASSEMBLY 1. NALC0026 Remove upper and lower tanks with Tool. BR ST RS BT SLC903-A I Grip the crimped edge and bend it upwards so that Tool slips off. Do not bend excessively. HA SC EL IDX SLC893 LC-23 ENGINE COOLING SYSTEM Radiator (Aluminum type) (Cont’d) I In areas where Tool cannot be used, use a screwdriver to bend the edge up. Be careful not to damage tank. 2. Remove sealing rubbers. SLC930 3. 4. Make sure the edge stands straight up. Remove oil cooler from tank. (A/T models only) SLC931 ASSEMBLY 1. Install oil cooler. (A/T models only) Pay attention to direction of conical washer. SLC894 2. Clean contact portion of tank. SLC932 3. Install sealing rubber. Push it in with fingers. Be careful not to twist sealing rubber. SLC917A LC-24 NALC0027 ENGINE COOLING SYSTEM Radiator (Aluminum type) (Cont’d) 4. Caulk tank in specified sequence with Tool. GI MA EM SLC904-A EC FE CL MT SLC896 I AT Use pliers in the locations where Tool cannot be used. TF PD AX SU SLC897 5. Make sure that the rim is completely crimped down. Standard height “H”: 8.0 - 8.4 mm (0.315 - 0.331 in) 6. Confirm that there is no leakage. Refer to Inspection. BR ST RS BT SLC554A INSPECTION 1. NALC0028 Apply pressure with Tool. Specified pressure value: 157 kPa (1.6 kg/cm2, 23 psi) WARNING: To prevent the risk of the hose coming undone while under pressure, securely fasten it down with a hose clamp. Attach a hose to the oil cooler to seal its inlet and outlet. (A/T models only) HA SC EL IDX SLC933-A LC-25 ENGINE COOLING SYSTEM Radiator (Aluminum type) (Cont’d) 2. Check for leakage by soaking radiator in water container. SLC934 Overheating Cause Analysis Symptom Check items Water pump malfunction Worn or loose drive belt Thermostat stuck closed Poor heat transfer NALC0029 — Dust contamination or paper clogging Damaged fins — Physical damage Clogged radiator cooling tube Excess foreign material (rust, dirt, sand, etc.) Cooling fan does not operate Reduced air flow High resistance to fan rotation Fan assembly — Damaged fan blades Cooling system parts malfunction Damaged radiator shroud — — — Improper coolant mixture ratio — — — Poor coolant quality — Coolant density — Loose clamp Cooling hose Cracked hose Water pump Poor sealing Loose Radiator cap Poor sealing Coolant leaks Insufficient coolant Radiator O-ring for damage, deterioration or improper fitting Cracked radiator tank Cracked radiator core Reservoir tank Overflowing reservoir tank LC-26 Exhaust gas leaks into cooling system Cracked reservoir tank Cylinder head deterioration Cylinder head gasket deterioration ENGINE COOLING SYSTEM Overheating Cause Analysis (Cont’d) Symptom GI Check items High engine rpm under no load Driving in low gear for extended time Abusive driving MA EM Driving at extremely high speed — Overload on engine Powertrain system malfunction Installed improper size wheels and tires Except cooling system parts malfunction EC — Dragging brakes FE Improper ignition timing Blocked bumper — CL Installed car brassiere Blocked radiator grille Blocked or restricted air flow Blocked radiator Mud contamination or paper clogging MT — — AT Blocked condenser Blocked airflow Installed large fog lamp TF PD AX SU Service Data and Specifications (SDS) THERMOSTAT NALC0030 Valve opening temperature BR 76.5°C (170°F) Valve lift ST More than 8.6 mm/90°C (0.339 in/194°F) WATER CONTROL VALVE NALC0035 Valve opening temperature RS 95°C (203°F) Valve lift More than 8.0 mm/108°C (0.315 in/226°F) RADIATOR BT NALC0031 Unit: kPa (kg/cm2, psi) Standard 78 - 98 (0.8 - 1.0, 11 - 14) Limit 59 (0.6, 9) HA Cap relief pressure Leakage test pressure SC 157 (1.6, 23) EL IDX LC-27 NOTES ENGINE MECHANICAL SECTION EM GI MA LC EC FE CONTENTS PRECAUTIONS ...............................................................3 Parts Requiring Angular Tightening.............................3 Liquid Gasket Application Procedure ..........................3 PREPARATION ...............................................................4 Special Service Tools ..................................................4 Commercial Service Tools ...........................................6 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING .....................................................8 NVH Troubleshooting - Engine Noise .........................9 OUTER COMPONENT PARTS .....................................10 Removal and Installation ...........................................10 TIGHTENING PROCEDURES ...................................12 MEASUREMENT OF COMPRESSION PRESSURE ....14 OIL PAN.........................................................................16 Components...............................................................16 Removal.....................................................................16 Installation..................................................................19 TIMING CHAIN ..............................................................21 Components...............................................................21 POSITION FOR APPLYING LIQUID GASKET ............22 Removal.....................................................................24 Inspection...................................................................31 Installation..................................................................31 OIL SEAL.......................................................................39 Replacement..............................................................39 VALVE OIL SEAL .....................................................39 OIL SEAL INSTALLATION DIRECTION .....................40 FRONT OIL SEAL ....................................................40 REAR OIL SEAL ......................................................40 CYLINDER HEAD..........................................................41 Components...............................................................41 Removal.....................................................................42 Disassembly...............................................................44 Inspection...................................................................44 CYLINDER HEAD DISTORTION ...............................44 CAMSHAFT VISUAL CHECK ....................................45 CAMSHAFT RUNOUT ..............................................45 CAMSHAFT CAM HEIGHT .......................................45 CAMSHAFT JOURNAL CLEARANCE ........................45 CAMSHAFT END PLAY............................................46 CAMSHAFT SPROCKET RUNOUT ...........................46 VALVE GUIDE CLEARANCE ....................................46 VALVE GUIDE REPLACEMENT ................................47 VALVE SEATS .........................................................47 REPLACING VALVE SEAT FOR SERVICE PARTS ....48 VALVE DIMENSIONS ...............................................48 VALVE SPRING .......................................................49 VALVE LIFTER ........................................................49 Assembly ...................................................................50 Installation..................................................................50 Valve Clearance.........................................................54 CHECKING .............................................................54 ADJUSTING ............................................................57 ENGINE ASSEMBLY.....................................................59 Removal and Installation ...........................................59 REMOVAL ...............................................................60 INSTALLATION........................................................62 CYLINDER BLOCK .......................................................63 Components...............................................................63 CYLINDER BLOCK HEATER ....................................64 Removal and Installation ...........................................64 Disassembly...............................................................64 PISTON, CRANKSHAFT AND OIL JET ......................64 Inspection...................................................................65 PISTON AND PISTON PIN CLEARANCE ..................65 PISTON RING SIDE CLEARANCE ............................66 PISTON RING END GAP..........................................66 CONNECTING ROD BEND AND TORSION ...............67 CYLINDER BLOCK DISTORTION AND WEAR ...........67 PISTON-TO-BORE CLEARANCE ..............................68 CRANKSHAFT.........................................................69 BEARING CLEARANCE ...........................................69 CONNECTING ROD BUSHING CLEARANCE (SMALL END) ..........................................................72 FLYWHEEL/DRIVE PLATE RUNOUT ........................73 Assembly ...................................................................73 PISTON ..................................................................73 OIL JET ..................................................................74 CRANKSHAFT.........................................................74 KNOCK SENSOR ....................................................76 CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX CONTENTS REPLACEMENT OF PILOT BUSHING (M/T) OR PILOT CONVERTER (A/T)........................................77 FLYWHEEL/DRIVE PLATE .......................................77 SERVICE DATA AND SPECIFICATIONS (SDS) .........78 General Specifications...............................................78 Compression Pressure ..............................................78 Cylinder Head ............................................................78 Valve ..........................................................................79 VALVE ....................................................................79 VALVE CLEARANCE................................................79 VALVE SPRING .......................................................79 VALVE LIFTER ........................................................79 AVAILABLE LIFTERS (SHIMLESS TYPE) ..................80 VALVE GUIDE .........................................................81 Valve Seat..................................................................81 Camshaft and Camshaft Bearing ..............................82 EM-2 (Cont’d) Cylinder Block............................................................83 Piston, Piston Ring and Piston Pin ...........................84 AVAILABLE PISTON ................................................84 PISTON RING .........................................................85 PISTON PIN ............................................................85 Connecting Rod .........................................................85 Crankshaft..................................................................86 Available Main Bearing..............................................87 UNDERSIZE ............................................................87 Available Connecting Rod Bearing............................88 CONNECTING ROD BEARING .................................88 UNDERSIZE ............................................................88 Miscellaneous Components.......................................88 BEARING CLEARANCE ...........................................88 PRECAUTIONS Parts Requiring Angular Tightening Parts Requiring Angular Tightening I a) b) c) d) I I I NAEM0001 Use an angle wrench for the final tightening of the following engine parts: Cylinder head bolts Main bearing cap bolts Connecting rod cap bolts Crankshaft pulley bolt Do not use a torque value for final tightening. The torque value for these parts are for a preliminary step. Ensure thread and seat surfaces are clean and coated with engine oil. GI MA LC EC FE CL MT Liquid Gasket Application Procedure 1. 2. I AT NAEM0002 Use a scraper to remove all traces of old liquid gasket from mating surfaces and grooves. Also, completely clean any oil from these areas. Apply a continuous bead of liquid gasket to mating surfaces. (Use Genuine RTV silicone sealant or equivalent. Refer to GI-53.) Be sure liquid gasket diameter is as specified. TF PD AX SU SEM164F 3. 4. 5. Apply liquid gasket around the inner side of bolt holes (unless otherwise specified). Assembly should be done within 5 minutes after coating. Wait at least 30 minutes before refilling engine oil and engine coolant. BR ST RS BT AEM080 HA SC EL IDX EM-3 PREPARATION Special Service Tools Special Service Tools NAEM0003 The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name Description ST0501S000 ( — ) Engine stand assembly 1 ST05011000 ( — ) Engine stand 2 ST05012000 ( — ) Base Disassembling and assembling NT042 KV10106500 ( — ) Engine stand shaft NT028 KV10117000 (J41262) Engine sub-attachment KV10117000 has been replaced with KV10117001 (KV10117000 is no longer in production, but it is usable). NT373 KV10117001 ( — ) Engine sub-attachment Installing on the cylinder block NT372 ST10120000 (J24239-01) Cylinder head bolt wrench Loosening and tightening cylinder head bolt a: 13 (0.51) dia. b: 12 (0.47) c: 10 (0.39) Unit: mm (in) NT583 KV10116200 (J26336-A) Valve spring compressor 1 KV10115900 (J26336-20) Attachment Disassembling valve mechanism NT022 EM-4 PREPARATION Special Service Tools (Cont’d) Tool number (Kent-Moore No.) Tool name GI Description (J39386) Valve oil seal drift Installing valve oil seal NT024 KV101151S0 (J38972) Lifter stopper set 1 KV10115110 (J38972-1) Camshaft pliers 2 KV10115120 (J38972-2) Lifter stopper MA LC Changing shims EC FE NT041 CL EM03470000 (J8037) Piston ring compressor Installing piston assembly into cylinder bore MT AT NT044 ST16610001 (J23907) Pilot bushing puller Removing crankshaft pilot bushing TF PD NT045 KV10111100 (J37228) Seal cutter Removing steel oil pan and rear timing chain case AX SU NT046 WS39930000 ( — Tube presser Pressing the tube of liquid gasket BR ) ST NT052 RS KV10112100 (BT8653-A) Angle wrench Tightening bolts for bearing cap, cylinder head, etc. BT HA NT014 SC EL IDX EM-5 PREPARATION Special Service Tools (Cont’d) Tool number (Kent-Moore No.) Tool name Description KV10117100 (J3647-A) Heated oxygen sensor wrench Loosening or tightening heated oxygen sensor For 22 mm (0.87 in) hexagon nut NT379 KV10114400 (J38365) Heated oxygen sensor wrench Loosening or tightening rear heated oxygen sensor a: 22 mm (0.87 in) NT636 KV10117700 (J44716) Ring gear stopper Removing and installing crankshaft pulley NT822 Commercial Service Tools Tool number (Kent-Moore No.) Tool name Description Spark plug wrench Removing and installing spark plug NT047 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 Intake & Exhaust: a = 9.5 mm (0.374 in) dia. b = 5.5 mm (0.217 in) dia. NT015 EM-6 NAEM0004 PREPARATION Commercial Service Tools (Cont’d) Tool number (Kent-Moore No.) Tool name GI Description Valve guide reamer Reaming valve guide 1 or hole for oversize valve guide 2 Intake & Exhaust: d1 = 6.0 mm (0.236 in) dia. d2 = 10.2 mm (0.402 in) dia. MA LC NT016 (J-43897-18) (J-43897-12) Oxygen sensor thread cleaner Reconditioning the exhaust system threads before installing a new heated oxygen sensor (Use with anti-seize lubricant shown below.) a = J-43897-18 (18 mm dia.) for zirconia heated oxygen sensor b = J-43897-12 (12 mm dia.) for titania heated oxygen sensor EC FE CL AEM488 Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specification MIL-A-907) Lubricating oxygen heated sensor thread cleaning tool when reconditioning exhaust system threads MT AT TF PD AEM489 AX SU BR ST RS BT HA SC EL IDX EM-7 NAEM0005 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING SEM472G EM-8 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting — Engine Noise NVH Troubleshooting — Engine Noise NAEM0005S01 Use the chart below to help you find the cause of the symptom. 1. Locate the area where noise occurs. 2. Confirm the type of noise. 3. Specify the operating condition of engine. 4. Check specified noise source. If necessary, repair or replace these parts. Operating condition of engine Location of noise Top of engine Rocker cover Cylinder head Type of noise Ticking or clicking Rattle Slap or knock Before After When warm-up warm-up starting C C — Crankshaft Slap or pulley rap Cylinder block (Side of engine) Oil pan Front of engine Timing chain cover A A A A — — — — — When idling A A B B When racing B B B B While driving Source of noise Check item — Valve clearance C Camshaft bearing noise Camshaft journal clearance EM-45, 45 Camshaft runout — Piston pin noise Piston and piston pin clearance Connecting rod bushing clearance A Piston-to-bore clearance Piston ring side clearPiston slap ance noise Piston ring end gap Connecting rod bend and torsion B C B B B Knock A B — A B C Main bearing oil clearMain bearance ing noise Crankshaft runout B Timing chain and chain tensioner noise C Drive belts (Sticking Drive belts deflection or slipping) Squeaking or fizzing Creaking A A B B — — A B B B B — A B Front of engine Squall Creak A: Closely related A B: Related B — C: Sometimes related B A —: Not related EM-9 B EM-65, 72 CL MT AT EM-66, 66, 67, 68 TF PD AX SU EM-69, 69 BR Timing chain cracks and wear Timing chain tensioner operation Drive belts Idler pulley bearing (Slipping) operation Water pump noise EM-57 Connecting rod bushing clearance (Small end) EM-72, 71 Connecting rod bearing clearance (Big end) A A LC FE Knock A MA EC Tappet noise Connecting rod bearing noise Tapping or ticking Reference page GI Water pump operation EM-31, 21 ST MA section (“Checking Drive Belts”, “ENGINE MAINTENANCE”) RS LC section (“Water Pump Inspection”, “ENGINE COOLING SYSTEM”) BT HA SC EL IDX OUTER COMPONENT PARTS Removal and Installation Removal and Installation NAEM0006 SEM924G 1. 2. 3. 4. 5. Intake manifold collector support Lower intake manifold collector Fuel damper and fuel feed hose assembly Fuel injector Fuel tube assembly 6. 7. 8. 9. 10. Fuel pressure regulator Ignition coil with power transistor Upper intake manifold collector Intake manifold Electric throttle control actuator EM-10 11. EVAP canister purge volume control solenoid valve 12. Swirl control valve actuator 13. Power valve actuator (A/T) 14. Oil level gauge OUTER COMPONENT PARTS Removal and Installation (Cont’d) GI MA LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SEM925G 1. 2. 3. 4. Heated oxygen sensor 1 (bank 1) Heated oxygen sensor 1 (bank 2) TWC (manifold) Thermostat with water inlet 5. 6. 7. Exhaust manifold Engine coolant temperature sensor Water control valve 8. 9. Water outlet housing Cylinder block water outlet SC EL IDX EM-11 OUTER COMPONENT PARTS Removal and Installation (Cont’d) TIGHTENING PROCEDURES Intake Manifold I 1. 2. I NAEM0006S01 NAEM0006S0101 Loosen in reverse order and tighten in numerical order shown in the figure. Tighten all bolts and nuts to 4.9 to 9.8 N·m (0.5 to 1.0 kg-m, 44 to 86 in-lb). Finally tighten all bolts and nuts to 26.5 to 31.4 N·m (2.7 to 3.2 kg-m, 20 to 23 ft-lb). Tighten all bolts and nuts to the final torque, evenly dividing the tightening into at least three steps. SEM926G Fuel Tube I 1. 2. NAEM0006S0102 Tighten in numerical order shown in the figure. Tighten all bolts to 9.3 to 10.8 N·m (0.95 to 1.1 kg-m, 83 to 95 in-lb). Then tighten all bolts to 20.6 to 26.5 N·m (2.1 to 2.7 kg-m, 16 to 19 ft-lb). SEM473G Fuel Pressure Regulator NAEM0006S0103 Tighten fuel pressure regulator to 2.9 to 3.8 N·m (0.3 to 0.39 kg-m, 26.0 to 33.9 in-lb). I Tighten screws evenly several times to have the fuel pressure regulator tightened at the specified torque. I Always replace O-ring with new ones. I Lubricate O-ring with new engine oil. SEM474G Electric Throttle Control Actuator I NAEM0006S0105 Tighten all bolts to 7.2 to 9.7 (0.74 to 0.98 kg-m, 64 to 85 in-lb) in numerical order shown in the figure. KBIA0957E Upper Intake Manifold Collector NAEM0006S0107 Loosen bolts and nuts in reverse order and tighten to 17.6 to 21.6 N·m (1.8 to 2.2 kg-m, 13 to 15 ft-lb) in numerical order shown in the figure. SEM927G EM-12 OUTER COMPONENT PARTS Removal and Installation (Cont’d) Lower Intake Manifold Collector NAEM0006S0108 Tighten bolts and nuts to 17.6 to 21.6 N·m (1.8 to 2.2 kg-m, 13 to 15 ft-lb) in numerical order shown in the figure. GI MA LC SEM477G Exhaust Manifold EC NAEM0006S0109 Tighten nuts to 28.5 to 32.4 N·m (2.9 to 3.3 kg-m, 21 to 23 ft-lb) in numerical order shown in the figure. FE CL MT SEM478G AT TF PD AX SU SEM479G TWC (Manifold) I NAEM0006S0110 Align the mating mark as shown for locating exhaust flange. BR ST RS BT SEM607G HA SC EL IDX EM-13 NAEM0007 MEASUREMENT OF COMPRESSION PRESSURE 1. 2. 3. Warm up engine. Turn ignition switch OFF. Release fuel pressure. Refer to EC-64, “Fuel Pressure Release”. 4. SEF933Y Disconnect fuel pump fuse to avoid injection during measurement. 5. Remove engine cover. 6. Remove air duct with air cleaner case. 7. Remove harness connectors and harness brackets around ignition coils. 8. Remove Electric throttle control actuator. 9. Disconnect ignition coil with power transistor harness connectors, then remove ignition coils. 10. Remove all spark plugs. I Clean area around plug with compressed air before removing the spark plug. 11. 12. 13. I Attach a compression tester to No. 1 cylinder. Crank engine and record highest gauge indication. Repeat the measurement on each cylinder as shown above. Always use a fully-charged battery to obtain specified engine speed. Unit: kPa (kg/cm2, psi)/rpm JEM482G Standard Minimum Difference limit between cylinders 1,275 (13.0, 185)/300 981 (10.0, 142)/300 98 (1.0, 14)/300 14. 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. I If adding oil helps compression, piston rings may be worn or damaged. If so, replace piston rings after checking piston. I If pressure stays low, a valve may be sticking or seating improperly. Inspect and repair valve and valve seat. (Refer to SDS, EM-79 and EM-81.) If valve or valve seat is damaged excessively, replace them. SEM387C EM-14 MEASUREMENT OF COMPRESSION PRESSURE I If compression stays low in two cylinders that are next to each other: a) The cylinder head gasket may be leaking, or b) Both cylinders may have valve component damage. Inspect and repair as necessary. 15. Install removed parts in reverse order of removal. 16. Perform “Self-diagnosis Procedure” referring to EC-100, “How to Erase DTC” if any DTC appears. GI MA LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EM-15 OIL PAN Components Components NAEM0008 SEM928G Removal NAEM0009 WARNING: I Place vehicle on a flat and solid surface. I You should not remove oil pan until exhaust system and cooling system have completely cooled off. Otherwise, you may burn yourself and/or fire may break out in the fuel line. I When removing front engine mounting nuts, lift up slightly engine for safety work. CAUTION: When removing the aluminum oil pan from engine, first remove the crankshaft position sensor (POS) from the assembly. Be careful not to damage sensor edges and signal plate teeth. 1. Remove front RH and LH wheels. 2. Remove battery. 3. Remove oil level gauge. 4. Remove engine undercover. 5. Remove suspension member stay. 6. Drain engine coolant from radiator drain plug. 7. Disconnect A/T oil cooler hoses. (A/T) 8. Drain engine oil. EM-16 OIL PAN Removal (Cont’d) 9. Remove the crankshaft position sensor (POS). 10. Remove drive belts and idler pulley with bracket. 11. Remove power steering oil pump, then put it aside holding with a suitable wire. 12. Remove alternator. GI MA LC SEM605G 13. Install engine slingers. 14. Remove front propeller shaft. (4WD) Refer to PD-8, “Removal and Installation”. 15. Remove exhaust front tube heat insulators, then remove rear heated oxygen sensors. 16. Remove exhaust front tube from both sides. Refer to FE-9, “Removal and Installation”. 17. Remove front final drive. (4WD) Refer to PD-19, “Removal and Installation”. 18. Remove starter motor. 19. Disconnect oil pressure switch harness connector. 20. Loosen and disconnect the bolts fixing the steering column assembly lower joint and the power steering gear. EC FE CL MT AT TF PD AX SU SEM528G 21. Set a suitable transmission jack under the front suspension member and hoist engine with engine slingers. BR ST RS BT SEM471G 22. Remove front engine mounting nuts from both sides. HA SC EL IDX EMQ0357D EM-17 OIL PAN Removal (Cont’d) 23. Remove front suspension member bolts and nuts. 24. Lower the transmission jack carefully to secure clearance between the oil pan and suspension member. 25. Remove A/T oil cooler tube. (A/T) 26. Remove water hose and tube. (A/T) SEM529G SEM530G 27. Remove the four engine-to-transmission bolts. 28. Loosen steel oil pan bolts in reverse order of tightening. Refer to “Components”, EM-16. SEM469G 29. Remove steel oil pan. a. Insert seal cutter (special service tool) between aluminum oil pan and steel oil pan. I Be careful not to damage aluminum mating surface. I Do not insert screwdriver, or oil pan flange will be deformed. b. Slide seal cutter by tapping on the side of the tool with a hammer. SEM365E 30. I 31. 32. a. I I b. Remove pulg from rear right of aluminum oil pan. Plug position is under No. 4 bolt in the figure. Remove aluminum oil pan bolts in numerical order. Remove aluminum oil pan. Insert seal cutter between aluminum oil pan and cylinder block. Be careful not to damage aluminum mating surface. Do not insert screwdriver, or oil pan flange will be deformed. Slide seal cutter by tapping its side with a hammer. SEM463G EM-18 OIL PAN Removal (Cont’d) 33. Remove O-rings from cylinder block and oil pump body. GI MA LC SEM464G 34. Remove front cover gasket and rear oil seal retainer gasket. EC FE CL MT SEM465G Installation 1. I I AT NAEM0010 Before installing oil pan, remove old liquid gasket from mating surface using a scraper. Also remove old liquid gasket from mating surface of cylinder block. Remove old liquid gasket from the bolt hole and thread. TF PD AX SU SEM466G 2. Apply sealant to front cover gasket and rear oil seal retainer gasket. BR ST RS BT SEM964E 3. Install front cover gasket and rear oil seal retainer gasket. HA SC EL IDX SEM465G EM-19 OIL PAN Installation (Cont’d) 4. I Apply a continuous bead of liquid gasket to mating surface of aluminum oil pan. Use Genuine RTV silicone sealant or equivalent. Refer to GI-53. SEM159F 5. I I I Apply liquid gasket to inner sealing surface as shown in figure. Be sure to apply it inside to all bolt holes. Be sure to apply it to part A at [4.5 to 5.5 mm (0.177 to 0.217 in)]. Attaching should be done within 5 minutes after coating. 6. Install O-rings, cylinder block and oil pump body. 7. I I 8. I Install aluminum oil pan. Tighten bolts in numerical order. Wait at least 30 minutes before refilling engine oil. Install plug to rear right of aluminum oil pan. Plug position is under No. 10 bolt in the figure. SEM929G SEM464G SEM468G 9. Install the four engine-to-transmission bolts. For tightening torque, refer to AT-277 or MT-8, “Installation”. 10. Reinstall in the reverse order of removal. SEM469G EM-20 TIMING CHAIN Components Components NAEM0011 GI MA LC EC FE CL MT AT TF PD AX SU BR ST RS SEM930G 1. 2. 3. 4. 5. 6. 7. 8. Rear timing chain case Left camshaft chain tensioner Internal guide Timing chain (Secondary) Right camshaft chain tensioner Timing chain tensioner Slack guide Timing chain (Primary) 9. 10. 11. 12. 13. 14. 15. 16. Crankshaft sprocket Lower chain guide Upper tension guide Front timing chain case Crankshaft pulley Water pump cover Chain tensioner cover Exhaust camshaft sprocket 17. 18. 19. 20. Intake valve timing control cover Intake camshaft sprocket Cover Camshaft position sensor (PHASE) 21. VIAS control solenoid valve (A/T) 22. Swirl control valve control solenoid valve 23. Vacuum tank BT HA SC EL IDX EM-21 TIMING CHAIN Components (Cont’d) POSITION FOR APPLYING LIQUID GASKET =NAEM0011S01 Refer to “Liquid Gasket Application Procedure” in “PRECAUTION”, EM-3. I Before installation, wipe off the protruding sealant. EM-22 TIMING CHAIN Components (Cont’d) GI MA LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL SEM411G IDX EM-23 TIMING CHAIN Components (Cont’d) CAUTION: I After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads. I When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting surfaces with new engine oil. I Apply new engine oil to bolt threads and seat surfaces when installing camshaft sprockets and crankshaft pulley. I Before disconnecting fuel hose, release fuel pressure. Refer to EC-64, “Fuel Pressure Release”. I Be careful not to damage sensor edges. I Do not spill engine coolant on drive belts. Removal 1. NAEM0012 Release fuel pressure. Refer to EC-64, “Fuel Pressure Release”. 2. Remove battery. 3. Remove radiator. Refer to LC-21, “REMOVAL AND INSTALLATION”. 4. Drain engine oil. 5. Remove drive belts and idler pulley with brackets. 6. Remove cooling fan with bracket. 7. Remove engine cover. 8. Remove air duct with air cleaner case, collector, PCV hose, vacuum hoses, fuel hoses, water hoses, harnesses, connectors and so on. 9. Remove the air conditioner compressor, and tie it down using rope or the like to keep it from interfering. 10. Remove the power steering oil pump and reservoir tank. Tie them down using rope or the like to keep them from interfering. 11. Remove alternator. 12. Remove the following. I Vacuum tank I Water bypass pipe I Brackets EM-24 TIMING CHAIN Removal (Cont’d) 13. I I I I Remove camshaft position sensors (PHASE). Avoid impact such as dropping. Do not disassemble the components. Do not place them on areas where iron powder may adhere. Keep away from the objects susceptible to magnetism. GI MA LC SEM931G 14. Remove upper intake manifold collector in reverse order of illustration. EC FE CL MT SEM927G 15. Remove intake manifold collector support bolts. AT TF PD AX SU SEM413G 16. Remove lower intake manifold collector in reverse order of illustration. BR ST RS BT SEM477G 17. Disconnect injector harness connectors. 18. Remove fuel tube assembly in reverse order of illustration. HA SC EL IDX SEM473G EM-25 TIMING CHAIN Removal (Cont’d) 19. Remove ignition coils. 20. Remove RH and LH rocker covers from cylinder head. I Loosen bolts in numerical order shown in the figure. SEM932G 21. Set No. 1 piston at TDC on the compression stroke by rotating crankshaft. I Align pointer with TDC mark on crankshaft pulley. KBIA1717J I Check that intake and exhaust cam nose on No. 1 cylinder are located as shown left. If not, turn the crankshaft one revolution (360°) and align as above. SEM418G 22. Remove starter motor, and set ring gear stopper using the mounting bolt hole. I Be careful not to damage the signal plate teeth. SEM485GA SEM541G EM-26 TIMING CHAIN Removal (Cont’d) 23. Loosen the crankshaft pulley bolt. GI MA LC SEM933G 24. Remove crankshaft pulley with a suitable puller. 25. Remove aluminum oil pan. Refer to EM-16, “Removal”. 26. Temporarily install the suspension member bolts and engine mounting nuts. EC FE CL MT SEM420G 27. Remove intake valve timing control covers. I Loosen bolts in numerical order as shown in the figure. I In the cover, the shaft is engaged with the center hole of the intake camshaft sprocket. Remove it straight out until the engagement comes off. AT TF PD AX SU SEM423G 28. Remove front timing chain case bolts. I Loosen bolts in numerical order as shown in the figure. BR ST RS BT SEM424G 29. Remove front timing chain case. a. Insert the appropriate size tool into the notch at the top of the front timing chain case as shown (1). b. Pry off the case by moving the tool as shown (2). I Use seal cutter (special service tool) or an equivalent tool to cut liquid gasket for removal. CAUTION: I Do not use screwdrivers or something similar. I After removal, handle it carefully so it does not tilt, cant, or warp under a load. SEM156F EM-27 HA SC EL IDX TIMING CHAIN Removal (Cont’d) 30. Remove internal guide. 31. Remove upper tension guide. 32. Remove timing chain tensioner and slack guide. SEM934G I Remove timing chain tensioner. (Push piston and insert a suitable pin into pinhole.) 33. Remove primary timing chain and crankshaft sprocket. SEM966F 34. Remove lower chain guide. SEM924E 35. Attach a suitable stopper pin to RH and LH camshaft chain tensioners. SEM923G EM-28 TIMING CHAIN Removal (Cont’d) 36. Remove intake and exhaust camshaft sprocket bolts. I Secure the hexagonal head of the camshaft using a spanner to loosen mounting bolts. GI MA LC KBIA1698J SEM922G 37. Remove secondary timing chains with camshaft sprockets. a. Rotate camshaft lightly, and slacken timing chain of timing chain tensioner-side. b. Insert metal or resin plate [thickness: 0.5 mm (0.020 in)] into guide between timing chain and chain tensioner plunger. Remove cam sprocket and secondary timing chain with timing chain floated from guide groove. CAUTION: Chain tensioner plunger may move, while fixed stopper pin and plunger both come off when timing chain is removed. Use caution during removal. I Intake camshaft sprocket is two-for-one structure of primary and secondary sprockets. I Handle intake camshaft sprocket, taking care of the following. CAUTION: I Avoid impact. I Do not disassemble (Never loosen inner hexagonal bolts). EC FE CL MT AT TF PD AX SU SEM935G 38. Remove rear timing chain case as follows if necessary. a. Loosen mounting bolts in numerical order shown in figure, and remove them. b. Disconnect liquid gasket applied portion using seal cutter (special service tool: KV10111100) or an equivalent tool. Then remove rear timing chain case. BR ST RS BT SEM442G CAUTION: I Do not remove plate metal cover of oil passage. I After removing chain case, do not apply any load which affects flatness. HA SC EL IDX KBIA1307E EM-29 TIMING CHAIN Removal (Cont’d) 39. Remove O-rings from cylinder head. SEM945G 40. Remove O-rings from cylinder block. PBIC0788E 41. Remove RH and LH camshaft chain tensioners from cylinder head as follows if necessary. a. Remove No. 1 camshaft brackets. Refer to EM-42, “Removal”. b. Remove chain tensioners with stopper pin attached. 42. Use a scraper to remove all traces of liquid gasket from front and rear timing chain case, and opposite mating surfaces. SEM428G I Remove old liquid gasket from the bolt hole and thread. 43. Remove front oil seal from front timing chain case. Refer to EM-40, “FRONT OIL SEAL”. 44. Remove water pump cover and chain tensioner cover from front timing chain case if necessary. SEM161F EM-30 TIMING CHAIN Removal (Cont’d) 45. Use a scraper to remove all traces of liquid gasket from intake valve timing control cover, water pump cover and chain tensioner cover. GI MA LC SEM429GA Inspection EC NAEM0013 Check for cracks and excessive wear at roller links. Replace chain if necessary. FE CL MT SEM936G Installation 1. a. b. AT NAEM0014 Install RH and LH camshaft chain tensioners to cylinder head as follows if removed. Install chain tensioners with stopper pin attached and new O-ring. Install No. 1 camshaft brackets. TF PD AX SU SEM947G 2. Install new O-rings to cylinder block if rear timing chain case is removed. BR ST RS BT PBIC0788E 3. 4. Install new O-rings to cylinder head if rear timing chain case is removed. Apply liquid gasket to rear timing chain case. Refer to EM-22, “POSITION FOR APPLYING LIQUID GASKET”. HA SC EL IDX SEM945G EM-31 TIMING CHAIN Installation (Cont’d) 5. I a. I b. 6. I Align rear timing chain case, if removed, with dowel pins (RH and LH) on cylinder block. Then install it. Do not allow O-ring to drop. Tighten mounting bolts in order as shown in the figure. Install two types of mounting bolts, referring to the following instructions and figure. Bolt length: 20 mm (0.79 in) (1, 2, 3, 6, 7, 8, 9, and 10 in the figure) 16 mm (0.63 in) (other than the above) After all bolts are temporarily tightened, retighten them to specified torque in order shown in the figure. After installing rear timing chain case, check surface height difference between following parts on oil pan mounting surface. Standard Rear timing chain case to cylinder block: −0.24 to 0.14 mm (−0.0094 to 0.0055 in) If not within standard, repeat above installation procedure. SEM448G 7. I Make sure that camshaft and crankshaft are at TDC position of No. 1 cylinder. Make sure that dowel pin and crankshaft key are located as shown in the figure. Camshaft dowel pin: At cylinder head upper face side in each bank Crankshaft key: At cylinder head side of RH bank SEM930E 8. Install lower chain guide on dowel pin, with front mark on the guide facing upside. 9. a. Install secondary timing chain and camshaft sprockets. Press and shrink the secondary chain tensioner sleeve, and fix it using stopper pins. Lubricate threads and seat surfaces of camshaft sprocket bolts with new engine oil. SEM931E I SEM430G EM-32 TIMING CHAIN Installation (Cont’d) b. I I Identify intake camshaft sprocket of the right and left bank. Identify by front identification mark [10 mm (0.39 in) dia. recess] number and cutout position difference for signal detection of front end circumference. Exhaust camshaft sprocket is a common part for both banks. GI MA LC SEM937G c. I I I Install secondary timing chain and sprocket. Align mating marks (golden links) on secondary timing chain with those (punched marks) on the intake and exhaust sprockets. Align camshaft dowel pins with the sprocket groove and hole. Because camshaft sprocket mounting bolts are tightened in step 10, perform manual tightening to the extent necessary to keep camshaft dowel pin from dislocating. EC FE CL MT SEM431G I Mating marks of the intake sprocket are on the back side of the secondary sprockets. There are two types of the marks; circle and oval types, which should be used for right and left banks respectively. Right bank: Circle Left bank: Oval AT TF PD AX SU SEM938G I It may be difficult to visually check the dislocation of mating marks during and after installation. To make the matching easier, make a mating mark on top of the sprocket teeth and its extended line in advance with paint. BR ST RS BT SEM433G 10. After confirming the mating marks are aligned, tighten the camshaft sprocket mounting bolts. I Secure the camshaft hexagonal head using a spanner to tighten mounting bolts. HA SC EL IDX KBIA1698J EM-33 TIMING CHAIN Installation (Cont’d) 11. Pull out the stopper pin from the secondary timing chain tensioner. 12. Install primary timing chain. SEM923G I Install crankshaft sprocket, with mating mark to timing chain facing front of engine. I Install primary timing chain so that mating mark (punched) on camshaft sprocket is aligned with that (dark blue link) on the timing chain, and mating mark (notched) on crankshaft sprocket is aligned with that (orange link) on the timing chain, respectively. When it is difficult to align mating marks of the primary timing chain with each sprocket, gradually turn the camshaft hexagonal head using a spanner so it is aligned with the mating mark. During alignment, be careful to prevent dislocation of mating marks on the secondary timing chain. SEM929E I I SEM739GA EM-34 TIMING CHAIN Installation (Cont’d) 13. Install internal guide. 14. Install upper tension guide and slack guide. GI MA LC EC FE CL MT SEM934G I Do not overtighten the slack guide mounting bolts. It is normal for a gap to exist under the bolt seats when the mounting bolts are tightened to specification. AT TF PD AX SU SEM741G 15. Install timing chain tensioner, then remove the stopper pin. I When installing the timing chain tensioner, engine oil should be applied to the oil hole and tensioner. BR ST RS BT SEM967F 16. Install O-rings on rear timing chain case. HA SC EL IDX SEM939G EM-35 TIMING CHAIN Installation (Cont’d) 17. Install the water pump cover and the chain tensioner cover to front timing chain case if removed. I Apply RTV silicone sealant or equivalent. Refer to GI-53, “RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS”. 18. Install new front oil seal, then apply liquid gasket to front timing chain case. I Refer to “OIL SEAL INSTALLATION DIRECTION”, EM-40. I Refer to “POSITION FOR APPLYING LIQUID GASKET”, EM-22. I Before installation, wipe off the protruding sealant. SEM744GA 19. Install rear timing chain case pin into dowel pin hole on front timing chain case. 20. Tighten bolts to the specified torque in order shown in the figure. I Leave the bolts unattended for 30 minutes or more after tightening. SEM436G 21. After installing front timing chain case, check surface height difference between following parts on oil pan mounting surface. Standard Front timing chain case to rear timing chain case: −0.14 to 0.14 mm (−0.0055 to 0.0055 in) I If not within standard, repeat above installation procedure. SEM943G 22. Install LH and RH intake valve timing control covers. a. Install collared O-rings in front timing chain case oil hole (RH and LH sides). SEM940G EM-36 TIMING CHAIN Installation (Cont’d) b. c. d. Install seal ring at intake valve timing control covers. Apply liquid gasket to intake valve timing control covers. Use genuine RTV silicone sealant or equivalent. Refer to GI-53. Being careful not to move the seal ring from the installation groove, align the dowel pins on the chain case with the holes to install the intake valve timing control cover. GI MA LC PBIC1123E e. Tighten in numerical order as shown in the figure. EC FE CL MT SEM438G SEM813G 23. Install RH and LH rocker covers. Rocker cover tightening procedure: I Tighten in numerical order as shown in the figure. a. Tighten bolts 1 to 10 in that order to 6.9 to 8.8 N·m (0.7 to 0.9 kg-m, 61 to 78 in-lb). b. Then tighten bolts 1 to 10 as indicated in figure to 6.9 to 8.8 N·m (0.7 to 0.9 kg-m, 61 to 78 in-lb). 24. Hang engine using the right and left side engine slingers with a suitable hoist. 25. Set a suitable transmission jack under the suspension member. 26. Remove right and left side engine mounting nuts. 27. Remove right and left side suspension member bolts. 28. Install oil pan. Refer to EM-19, “Installation”. 29. Set ring gear stopper using the mounting bolt hole. I Be careful not to damage the signal plate teeth. AT TF PD AX SU BR ST RS BT SEM440G 30. Install crankshaft pulley to crankshaft. I Align pointer with TDC mark on crankshaft pulley. HA SC EL IDX KBIA1717J EM-37 TIMING CHAIN Installation (Cont’d) 31. Install crankshaft pulley bolt. I Lubricate thread and seat surface of the bolt with new engine oil. a. Tighten to 39 to 49 N·m (4.0 to 5.0 kg-m, 29 to 36 ft-lb). b. Put a paint mark on the crankshaft pulley. SEM933G c. SEM751G Again tighten by turning 60° to 66°, about the angle from one hexagon bolt head corner to another. 32. Install camshaft position sensors (PHASE), crankshaft position sensor (POS). 33. Reinstall removed parts in the reverse order of removal. I When installing fuel tube and intake manifold collectors, refer to EM-12, “TIGHTENING PROCEDURES”. I Check oil level. Refer to MA-18, “Changing Engine Oil”. I After starting engine, keep idling for three minutes. Then rev engine up to 3,000 rpm under no load to purge air from the high-pressure chamber of the chain tensioners. The engine may produce a rattling noise. This indicates that air still remains in the chamber and is not a matter of concern. EM-38 OIL SEAL Replacement Replacement NAEM0015 CAUTION: When removing the oil pans, oil pump assembly and timing chain from engine, first remove the camshaft position sensors (PHASE), intake valve timing control position sensor and the crankshaft position sensor (POS) from the assembly. Be careful not to damage sensor edges. VALVE OIL SEAL PBIC1147E 1. 2. 3. 4. NAEM0015S01 Remove timing chain. Refer to “Removal”, EM-24. Remove camshaft brackets and camshaft. Refer to “Removal”, EM-42. Remove valve lifters. Remove valve spring with Tool. Before removing valve spring, fix valve as follows. Piston concerned should be set at TDC to prevent valve from falling. GI MA LC EC FE CL MT Remove spark plug, then install air hose adapter into spark plug hole and apply air pressure to hold valves in place. Apply a pressure of 490 kPa (5 kg/cm2, 71 psi). AT TF PD AX SU SEM826E 5. Remove valve oil seal. BR ST RS BT SEM827E 6. 7. Apply engine oil to new valve oil seal and install it with Tool. Reinstall any parts removed in reverse order of removal. HA SC EL IDX SEM828E EM-39 OIL SEAL Replacement (Cont’d) OIL SEAL INSTALLATION DIRECTION I NAEM0015S02 Install new oil seal in the direction shown in the figure. SEM715A FRONT OIL SEAL NAEM0015S03 1. I I I I I I Remove the following parts: Engine undercover Suspension member stay Drive belts Crankshaft pulley: Refer to EM-24, “Removal”. Radiator: Refer to LC-21, “REMOVAL AND INSTALLATION”. Cooling fan 2. Remove front oil seal using a suitable tool. Be careful not to scratch front cover. Apply engine oil to new oil seal and install it using a suitable tool until its front end is level with front end of front cover. 3. SEM829E REAR OIL SEAL NAEM0015S04 1. 2. 3. 4. Remove Remove Remove Remove transmission. Refer to MT-7 or AT-276, “Removal”. flywheel or drive plate. oil pan. Refer to EM-16. rear oil seal retainer. 5. I Apply liquid gasket to rear oil seal retainer. Assembly should be done within 5 minutes after coating. SEM830E PBIC0922E EM-40 CYLINDER HEAD Components Components NAEM0016 GI MA LC EC FE CL MT AT TF PD AX SU BR ST RS SEM941G 1. 2. 3. 4. 5. 6. 7. Oil filler cap Rocker cover Camshaft bracket Camshaft PCV valve Cylinder head Spark plug tube 8. 9. 10. 11. 12. 13. 14. Spark plug Valve Valve spring seat Valve spring Valve spring retainer Valve collet Valve lifter 15. 16. 17. 18. 19. PCV hose Tensioner sleeve Spring Chain tensioner Intake valve timing control solenoid valve BT HA SC EL IDX EM-41 CYLINDER HEAD Components (Cont’d) CAUTION: I When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting surfaces with new engine oil. I Apply new engine oil to threads and seat surfaces when installing cylinder head, camshaft sprocket, crankshaft pulley, and camshaft bracket. I Attach tags to valve lifters so as not to mix them up. Removal 1. 2. 3. I I I I I I 4. 5. 6. 7. 8. 9. NAEM0017 Release fuel pressure. Refer to EC-64, “Fuel pressure release”. Drain engine coolant and engine oil. Remove the following parts. Battery Engine undercover Radiator shroud Radiator: Refer to LC-21, “REMOVAL AND INSTALLATION”. Cooling fan Drive belts Remove exhaust front tubes. Refer to FE-9, “EXHAUST SYSTEM”. Remove exhaust manifolds in reverse order of installation. Refer to EM-13, “Exhaust Manifold”. Remove aluminum oil pan. Refer to EM-16, “Removal”. Remove front timing chain case, timing chain and rear timing chain case. Refer to EM-24, “Removal”. Remove intake manifold in reverse order of illustration. Remove water outlet. SEM926G 10. Remove intake valve timing control solenoid valves. SEM443GA EM-42 CYLINDER HEAD Removal (Cont’d) 11. Remove intake and exhaust camshafts and camshaft brackets. I Equally loosen camshaft bracket bolts in several steps in the numerical order shown in the figure. For reinstallation, be sure to put marks on camshaft bracket before removal. 12. Remove valve lifters. I Identify installation positions, and store them without mixing them up. GI MA LC SEM856E EC FE CL MT SEM857E 13. Remove RH and LH camshaft chain tensioners from cylinder head. I Remove chain tensioner with its stopper pin attached. I Stopper pin was attached when secondary timing chain was removed. AT TF PD AX SU SEM947G 14. Remove cylinder head bolts. I Cylinder head bolts should be loosened in two or three steps. I A warped or cracked cylinder head could result from removing in incorrect order. BR ST RS BT SEM859E HA SC EL IDX SEM860E EM-43 CYLINDER HEAD Removal (Cont’d) 15. Remove cylinder head. SEM863E Disassembly NAEM0043 1. Remove spark plug with spark plug wrench (commercial service tool). 2. Remove valve component parts. Refer to EM-39, “VALVE OIL SEAL”. I Check the clearance before removing the valve guide. Refer to EM-46, “VALVE GUIDE CLEARANCE”. 3. Remove spark plug tube, as necessary. I Using a pair of pilers, pull spark plug tube out of cylinder head. CAUTION: I Take care not to damage cylinder head. I Once removed, a spark plug tube will be deformed and cannot be reused. Do not remove it unless absolutely necessary. Inspection CYLINDER HEAD DISTORTION SEM861E NAEM0019 NAEM0019S01 Clean surface of cylinder head. Use a reliable straightedge and feeler gauge to check the flatness of cylinder head surface. Check along six positions shown in the figure. Head surface flatness: Limit 0.1 mm (0.004 in) If beyond the specified limit, resurface or replace it. The limit for cylinder head resurfacing is determined by the cylinder block resurfacing. Resurfacing limit: Amount of cylinder head resurfacing is “A”. Amount of cylinder block resurfacing is “B”. The maximum limit : 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: 126.3 - 126.5 mm (4.972 - 4.980 in) EM-44 CYLINDER HEAD Inspection (Cont’d) CAMSHAFT VISUAL CHECK NAEM0019S02 GI NAEM0019S03 MA Check camshaft for scratches, seizure and wear. CAMSHAFT RUNOUT 1. 2. 3. PBIC0929E 4. Put V block on precise flat bed, and support No. 2 and No. 4 journal of camshaft. Set dial gauge vertically to No. 3 journal. Turn camshaft to one direction with hands, and measure camshaft runout on dial gauge. Runout (Total indicator reading): Limit 0.05 mm (0.0020 in) If it exceeds the limit, replace camshaft. LC EC FE CL MT CAMSHAFT CAM HEIGHT 1. 2. AT NAEM0019S04 Measure camshaft cam height. Standard cam height: Intake and exhaust 44.465 - 44.655 mm (1.7506 - 1.7581 in) Cam wear limit: 0.2 mm (0.008 in) If wear is beyond the limit, replace camshaft. TF PD AX SU SEM549A CAMSHAFT JOURNAL CLEARANCE 1. 2. NAEM0019S05 Install camshaft bracket and tighten bolts to the specified torque. Measure inner diameter “A” of camshaft bearing. Standard inner diameter: No. 1: 26.000 - 26.021 mm (1.0236 - 1.0244 in) No. 2, 3, 4: 23.500 - 23.521 mm (0.9252 - 0.9260 in) ST RS BT SEM862E 3. 4. SEM012A BR Measure outer diameter of camshaft journal. Standard outer diameter: No. 1: 25.935 - 25.955 mm (1.0211 - 1.0218 in) No. 2, 3, 4: 23.445 - 23.465 mm (0.9230 - 0.9238 in) If clearance exceeds the limit, replace camshaft and/or cylinder head. Camshaft journal clearance: Standard No. 1: 0.045 - 0.086 mm (0.0018 - 0.0034 in) No. 2, 3, 4: 0.035 - 0.076 mm (0.0014 - 0.0030 in) EM-45 HA SC EL IDX CYLINDER HEAD Inspection (Cont’d) Limit 0.15 mm (0.0059 in) CAMSHAFT END PLAY 1. 2. NAEM0019S06 Install camshaft in cylinder head. Measure camshaft end play. Camshaft end play: Standard 0.115 - 0.188 mm (0.0045 - 0.0074 in) Limit 0.24 mm (0.0094 in) SEM864E CAMSHAFT SPROCKET RUNOUT 1. 2. 3. 4. NAEM0019S07 Put V block on precise flat bed, and support No. 2 and No. 4 journal of camshaft. Install sprocket on camshaft. Turn camshaft to one direction with hands, and measure camshaft sprocket runout on dial gauge. Runout (Total indicator reading): Less than 0.15 mm (0.0059 in) If it exceeds the limit, replace camshaft sprocket. PBIC0930E VALVE GUIDE CLEARANCE NAEM0019S08 1. Measure valve deflection as shown in the figure. (Valve and valve guide mostly wear in this direction.) Valve deflection limit (Dial gauge reading): Intake 0.24 mm (0.0094 in) Exhaust 0.28 mm (0.0110 in) 2. a. b. If it exceeds the limit, check valve to valve guide clearance. Measure valve stem diameter and valve guide inner diameter. Check that clearance is within specification. Valve to valve guide clearance limit: Intake 0.08 mm (0.0031 in) Exhaust 0.1 mm (0.004 in) If it exceeds the limit, replace valve or valve guide. SEM178F c. SEM938C EM-46 CYLINDER HEAD Inspection (Cont’d) VALVE GUIDE REPLACEMENT 1. NAEM0019S09 To remove valve guide, heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil. GI MA LC SEM008A 2. Drive out valve guide with a press [under a 20 kN (2 ton, 2.2 US ton, 2.0 Imp ton) pressure] or hammer and suitable tool. CAUTION: Cylinder head contains heat. When working, wear protective equipment to avoid getting burned. EC FE CL MT SEM931C 3. AT Ream cylinder head valve guide hole. Valve guide hole diameter (for service parts): 10.175 - 10.196 mm (0.4006 - 0.4014 in) TF PD AX SU SEM932C 4. Heat cylinder head to 110 to 130°C (230 to 266°F) and press service valve guide onto cylinder head. Projection “L”: 12.6 - 12.8 mm (0.496 - 0.504 in) CAUTION: Cylinder head contains heat. When working, wear protective equipment to avoid getting burned. 5. Ream valve guide. Finished size: 6.000 - 6.018 mm (0.2362 - 0.2369 in) SEM950E VALVE SEATS NAEM0019S10 Check valve seats for any evidence of pitting at valve contact surface, and reseat or replace if it has worn out excessively. I Before repairing valve seats, check valve and valve guide for wear. If they have worn, replace them. Then correct valve seat. I Use both hands to cut uniformly. BR ST RS BT HA SC EL IDX SEM934C EM-47 CYLINDER HEAD Inspection (Cont’d) REPLACING VALVE SEAT FOR SERVICE PARTS NAEM0019S11 1. SEM795A SEM892B Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess in cylinder head. Set the machine depth stop to ensure this. 2. Ream cylinder head recess for service valve seat. Oversize [0.5 mm (0.020 in)]: Intake 38.500 - 38.516 mm (1.5157 - 1.5164 in) Exhaust 32.700 - 32.716 mm (1.2874 - 1.2880 in) Be sure to ream in circles concentric to the valve guide center. This will enable valve seat to fit correctly. 3. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil. 4. Press fit valve seat until it seats on the bottom. CAUTION: Cylinder head contains heat. When working, wear protective equipment to avoid getting burned. 5. Cut or grind valve seat using suitable tool to the specified dimensions as shown in SDS (EM-81). 6. After cutting, lap valve seat with abrasive compound. 7. Check valve seating condition. Seat face angle “α”: 45° Contacting width “W”: Intake 1.09 - 1.31 mm (0.0429 - 0.0516 in) Exhaust 1.29 - 1.51 mm (0.0508 - 0.0594 in) 8. Use a depth gauge to measure the distance between the mounting surface of the cylinder head spring seat and the valve stem end. If the distance is shorter than specified, repeat step 5 above to adjust it. If it is longer, replace the valve seat with a new one. Valve seat resurface limit “L”: Intake 41.07 - 41.67 mm (1.6169 - 1.6405 in) Exhaust 41.00 - 41.60 mm (1.6142 - 1.6378 in) SEM621F VALVE DIMENSIONS NAEM0019S12 Check dimensions of each valve. For dimensions, refer to SDS (EM-79). When valve head has been worn down to 0.5 mm (0.020 in) in margin thickness, replace valve. Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or less. SEM188A EM-48 CYLINDER HEAD Inspection (Cont’d) VALVE SPRING Squareness 1. 2. NAEM0019S13 GI NAEM0019S1301 Measure dimension “S”. Out-of-square “S”: Less than 2.0 mm (0.079 in) If it exceeds the limit, replace spring. MA LC SEM288A Pressure EC NAEM0019S1302 Check valve spring pressure at specified spring height. Pressure: Installation 196 N (20.0 kg, 44.1 lb) at height 37.0 mm (1.457 in) Valve open More than 433 N (44.2 kg, 97.3 lb) at height 27.8 mm (1.094 in) If it exceeds the limit, replace spring. EM113 VALVE LIFTER 1. FE CL MT AT NAEM0019S14 Check contact and sliding surfaces for wear or scratches. TF PD AX SU KBIA0182J 2. Check diameter of valve lifter and valve lifter guide bore. Valve lifter outer diameter: 33.977 - 33.987 mm (1.3377 - 1.3381 in) BR ST RS BT JEM798G Lifter guide bore diameter: 34.000 - 34.016 mm (1.3386 - 1.3392 in) HA SC EL IDX SEM867E EM-49 CYLINDER HEAD Assembly Assembly NAEM0020 1. I a. KBIA1248E Install spark plug tube. Press-fit spark plug tube following procedure below. Remove old liquid gasket adhering to cylinder-head mounting hole. b. Apply liquid gasket to area within approximately 12 mm (0.47 in) from edge of spark plug tube press-fit side. I Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-53, “RECOMENDED CHEMICAL PRODUCTS AND SEALANTS”. c. Using a drift, press-fit spark plug tube so that its height “H” is as specified in the figure. Standard press-fit height “H”: 38.55 - 38.65 mm (1.5177 - 1.5217 in) CAUTION: I When press-fitting, take care not to deform spark plug tube. I After press-fitting, wipe off liquid gasket protruding onto cylinder-head upper face. 2. I I I I 3. Install valve component parts. Always use new valve oil seal. Refer to “VALVE OIL SEAL”, EM-39. Before installing valve oil seal, install valve spring seat. Install valve spring (uneven pitch type) with its narrow pitch side toward cylinder head side (paint mark). After installing valve component parts, tap valve stem tip with plastic hammer to assure a proper fit. Install spark plug. SEM085D Installation 1. I NAEM0021 Before installing rear timing chain case, remove old liquid gasket from mating surface using a scraper. Also remove old liquid gasket from mating surface of cylinder block. SEM891E I Remove old liquid gasket from the bolt hole and thread. SEM161F EM-50 CYLINDER HEAD Installation (Cont’d) 2. Before installing camshaft bracket, remove old liquid gasket from mating surface using a scraper. GI MA LC SEM892E 3. I Before installing the cylinder head gasket, be sure that No. 1 cylinder is at TDC. At this time, the crankshaft key should face toward the right bank. EC FE CL MT SEM532G 4. I Install cylinder heads with new gaskets. Do not rotate crankshaft and camshaft separately, or valves will strike piston heads. AT TF PD AX SU SEM445G CAUTION: Cylinder head bolts are tightened by plastic zone tightening method. Whenever the size difference between d1 and d2 exceeds the limit, replace them with new ones. Limit (d1 - d2): 0.11 mm (0.0043 in) I Lubricate threads and seat surfaces of the bolts with new engine oil. I If reduction of outer diameter appears in a position other than d2, use it as d2 point. SEM957E BR ST RS BT HA SC EL IDX EM-51 CYLINDER HEAD Installation (Cont’d) 5. I a. b. c. d. e. SEM877EA I Install cylinder head outside bolts. Tightening procedure: Tighten all bolts to 98.1 N·m (10 kg-m, 72 ft-lb). Completely loosen all bolts in reverse order shown. Tighten all bolts to 34.3 to 44.1 N·m (3.5 to 4.4 kg-m, 25 to 33 ft-lb). Turn all bolts 90 to 95 degrees clockwise [target: 90 degrees (angle tightening)]. Turn all bolts 90 to 95 degrees clockwise again [target: 90 degrees (angle tightening)]. Tighten in numerical order shown in the figure. SEM878EA SEM879EA 6. Install camshaft chain tensioners on both sides of cylinder head. 7. I Install exhaust and intake camshafts and camshaft brackets. Intake camshaft has a drill mark on camshaft sprocket mounting flange. Install it on the intake side. SEM947G SEM652F EM-52 CYLINDER HEAD Installation (Cont’d) I Identification marks are present on camshafts. GI Paint mark Bank INT/EXH ID mark Drill mark M1 M2 INT R3 Yes Yes No EXH R3 No No Yes INT L3 Yes Yes No EXH L3 No No Yes MA RH LH LC SEM653F I Position camshaft RH exhaust camshaft dowel pin at about 10 o’clock LH exhaust camshaft dowel pin at about 2 o’clock EC FE CL MT SEM533G 8. I I I I SEM564G I Before installing camshaft brackets, apply sealant to mating surface of No. 1 journal head. Use Genuine RTV silicone sealant or equivalent. Refer to GI-53. Refer to “POSITION FOR APPLYING LIQUID GASKET”, EM-22. Install camshaft brackets in their original positions. Align stamp mark as shown in the figure. If any part of valve assembly or camshaft is replaced, check valve clearance according to reference data. After completing assembly check valve clearance. Refer to “Checking” and “Adjusting” in “VALVE CLEARANCE”, EM-54 and 57. Reference data valve clearance (Cold): Intake 0.26 - 0.34 mm (0.010 - 0.013 in) Exhaust 0.29 - 0.37 mm (0.011 - 0.015 in) Lubricate threads and seat surfaces of camshaft bracket bolts with new engine oil before installing them. AT TF PD AX SU BR ST RS BT HA SC EL IDX SEM446G EM-53 CYLINDER HEAD Installation (Cont’d) I Tighten the camshaft brackets in the following steps. Step Tightening torque Tightening order 1 1.96 N·m (0.2 kg-m, 17 in-lb) Tighten in the order of 7 to 10, then tighten 1 to 6. 2 5.88 N·m (0.6 kg-m, 52 in-lb) Tighten in the numerical order. 9.02 - 11.8 N·m (0.92 - 1.20 kg-m, 79.9 - 104.2 in-lb) Tighten in the order of 1 to 6. 8.3 - 10.3 N·m (0.9 - 1.0 kg-m, 74 - 91 in-lb) Tighten in the order of 7 to 10. 3 SEM885EA SEM886EA 9. Install intake valve timing control solenoid valves. SEM443GB 10. Reinstall all removed parts in reverse order of removal. Valve Clearance CHECKING KBIA1717J NAEM0022 NAEM0022S01 Check valve clearance while engine is cold and not running. 1. Remove engine cover. 2. Remove air duct with air cleaner case, collectors, hoses, harnesses, connectors and so on. 3. Remove upper intake manifold collector. Refer to EM-12, “Upper Intake Manifold Collector”. 4. Remove lower intake manifold collector. Refer to EM-13, “Lower Intake Manifold Collector”. EM-54 CYLINDER HEAD Valve Clearance (Cont’d) 5. 6. 7. I Remove ignition coils and spark plugs. Remove RH and LH rocker covers. Set No. 1 cylinder at TDC on its compression stroke. Align pointer with TDC mark on crankshaft pulley. GI MA LC I Check that valve lifters on No. 1 cylinder are loose and valve lifters on No. 4 are tight. If not, turn crankshaft one revolution (360°) and align as above. EC FE CL MT SEM418G 8. AT Check only those valves shown in the figure. Measuring position (RH bank) No. 1 CYL. EXH No. 3 CYL. No. 5 CYL. TF X No. 1 CYL. at TDC INT Measuring position (LH bank) X No. 2 CYL. INT No. 6 CYL. X No. 1 CYL. at TDC EXH PD No. 4 CYL. AX X SU BR ST RS BT SEM893E HA SC EL IDX EM-55 CYLINDER HEAD Valve Clearance (Cont’d) I I SEM139D Using a feeler gauge, measure clearance between valve lifter and camshaft. Record any valve clearance measurements which are out of specification. They will be used later to determine the required replacement valve lifter. Valve clearance for checking: Cold Intake 0.26 - 0.34 mm (0.010 - 0.013 in) Exhaust 0.29 - 0.37 mm (0.011 - 0.015 in) Hot* Intake 0.304 - 0.416 mm (0.012 - 0.016 in) Exhaust 0.308 - 0.432 mm (0.012 - 0.017 in) *: Approximately 80°C (176°F) (Reference data) KBIA0185E 9. Turn crankshaft 240° and align as above. 10. Set No. 3 cylinder at TDC on its compression stroke. 11. Check only those valves shown in the figure. Measuring position (RH bank) No. 1 CYL. No. 3 CYL. EXH No. 5 CYL. X No. 3 CYL. at TDC INT Measuring position (LH bank) INT X No. 2 CYL. No. 4 CYL. X No. 3 CYL. at TDC EXH SEM894E EM-56 X No. 6 CYL. CYLINDER HEAD Valve Clearance (Cont’d) 12. Turn crankshaft 240° and align as above. 13. Set No. 5 cylinder at TDC on its compression stroke. 14. Check only those valves shown in the figure. Measuring position (RH bank) EXH No. 1 CYL. No. 3 CYL. GI MA No. 5 CYL. X No. 5 CYL. at TDC INT Measuring position (LH bank) INT X No. 2 CYL. No. 4 CYL. No. 6 CYL. LC X EC X No. 5 CYL. at TDC EXH 15. If all valve clearances are within specification, install the following parts. If they are out of specification, adjust the valve clearances. I Intake manifold collectors I RH and LH rocker covers I All spark plugs I All ignition coils SEM958E FE CL MT AT ADJUSTING NAEM0022S02 Adjust valve clearance while engine is cold. Perform adjustment by selecting head thickness of valve lifter (Adjusting shims are not used). 1. Remove camshaft. 2. Remove valve lifter at location where measured value is outside standard. TF PD AX SU 3. 4. SEM754G I Measure center thickness of removed valve lifter with micrometer. Use equation below to calculate valve lifter thickness for replacement. Valve lifter thickness calculation: Thickness of replacement valve lifter = t1 + (C1 − C2) t1 = Thickness of removed valve lifter C1 = Measured valve clearance C2 = Standard valve clearance: Intake: 0.30 mm (0.012 in) Exhaust: 0.33 mm (0.013 in) Thickness of new valve lifter can be identified by stamp mark on reverse side (inside cylinder). Unit: mm (in) I SEM755G Stamp mark Thickness of valve lifter Starting: 788U or 788R 7.88 (0.3102) Ending: 840U or 840R 8.40 (0.3307) Available thickness of valve lifter (Factory setting): 7.88 - 8.40 mm (0.3102 - 0.3307 in) [in 0.02 mm (0.0008 in) step] in 27 sizes (Intake/Exhaust) Refer to EM-80. EM-57 BR ST RS BT HA SC EL IDX CYLINDER HEAD Valve Clearance (Cont’d) 5. 6. 7. 8. 9. Install selected valve lifter. Install camshaft. Rotate crankshaft a few turns by hand. Confirm that valve clearance is within standard. After repair, confirm that valve clearance is within standard with engine warmed-up. Valve clearance: Unit: mm (in) Cold Hot* (reference data) Intake 0.26 - 0.34 (0.010 - 0.013) 0.304 - 0.416 (0.012 - 0.016) Exhaust 0.29 - 0.37 (0.011 - 0.015) 0.308 - 0.432 (0.012 - 0.017) *: Approximately 80°C (176°F) EM-58 ENGINE ASSEMBLY Removal and Installation Removal and Installation NAEM0042 WARNING: I Situate vehicle on a flat and solid surface. I Place chocks at front and back of rear wheels. I Do not remove engine until exhaust system has completely cooled off. Otherwise, you may burn yourself and/or fire may break out in fuel line. I For safety during subsequent steps, the tension of wires should be slackened against the engine. I Before disconnecting fuel hose, release fuel pressure from fuel line. Refer to EC-64, “Fuel Pressure Release”. I Before removing front axle from transmission, place safety stands under designated front supporting points. Refer to GI section for lifting points and towing. I Be sure to hoist engine and transmission in a safe manner. I For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS CATALOG. CAUTION: I When lifting engine, be careful not to strike adjacent parts, especially brake lines, and brake master cylinder. I In hoisting the engine, always use engine slingers in a safe manner. I Before separating engine and transmission, remove crankshaft position sensor (POS) from the assembly. I Always take extra care not to damage edge of crankshaft position sensor (POS), or ring gear teeth. GI MA LC EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EM-59 ENGINE ASSEMBLY Removal and Installation (Cont’d) REMOVAL Front Engine Mounting NAEM0042S01 NAEM0042S0101 SEM458G EM-60 ENGINE ASSEMBLY Removal and Installation (Cont’d) Rear Engine Mounting NAEM0042S0102 GI MA LC EC FE CL SEM542G MT AT TF PD AX SU BR ST SEM543G RS BT HA SC EL IDX EM-61 ENGINE ASSEMBLY Removal and Installation (Cont’d) 1. SEM605G 2. 3. 4. 5. I I I I I I I 6. 7. 8. SEM461G 9. 10. 11. 12. 13. 14. 15. SEM324F 16. Release fuel pressure. Refer to EC-64, “Fuel pressure release”. Remove engine hood and front RH and LH wheels. Remove engine undercover and suspension member stay. Drain coolant from radiator. Remove the following parts. Radiator shroud Radiator: Refer to LC-21, “REMOVAL AND INSTALLATION”. Cooling fan Drive belts Battery Engine cover Air duct with air cleaner case Disconnect vacuum hoses, fuel hoses, heater hoses, EVAP canister hoses, harnesses, connectors and so on. Remove air conditioner compressor from bracket, then put it aside holding with a suitable wire. Remove power steering oil pump and reservoir tank with bracket, then put it aside holding with a suitable wire. Remove alternator. Remove exhaust front tube heat insulators, then remove rear heated oxygen sensors. Remove exhaust front and rear tubes. Refer to FE-9, “Removal and Installation”. Remove transmission. Refer to AT-276, MT-7, “Removal”. Remove TWC (manifold) heat insulators, then remove TWC (manifold). Install engine slingers. Hoist engine with engine slingers and remove front engine mounting nuts. Remove engine from vehicle. INSTALLATION Installation is in the reverse order of removal. EM-62 NAEM0042S02 CYLINDER BLOCK Components Components NAEM0024 GI MA LC EC FE CL MT AT TF PD AX SU BR ST RS SEM942G 1. 2. 3. 4. 5. 6. 7. 8. 9. Rear oil seal retainer Cylinder block Knock sensor Upper main bearing Lower main bearing Oil jet Water drain plug (RH side) Water drain plug (Water pump side) Main bearing cap 10. Main bearing beam 11. Crankshaft 12. Pilot bushing (M/T) or pilot converter (A/T) 13. Flywheel with signal plate (M/T) 14. Drive plate with signal plate (A/T) 15. Flywheel reinforcement plate (M/T) 16. Drive plate reinforcement plate (A/T) 17. Oil ring 18. 19. 20. 21. 22. 23. 24. 25. Piston pin Connecting rod bearing Connecting rod Piston Top ring 2nd ring Baffle plate Water drain plug (LH side) BT HA SC EL IDX EM-63 CYLINDER BLOCK Components (Cont’d) CYLINDER BLOCK HEATER NAEM0024S02 SEM537GC Removal and Installation SEM180FA NAEM0025 CAUTION: I When installing bearings, pistons, or other sliding parts, lubricate contacting surfaces with new engine oil. I Place removed parts such as bearings and bearing caps in their proper order and direction. I When installing connecting rod nuts, and main bearing cap bolts, apply new engine oil to threads and seating surfaces. I Do not allow any magnetic materials to contact the signal plate teeth of flywheel or drive plate. Disassembly PISTON, CRANKSHAFT AND OIL JET 1. 2. 3. 4. 5. 6. NAEM0026 NAEM0026S01 Remove engine. Refer to “Removal and Installation”, EM-59. Place engine on a work stand. Drain coolant and oil. Remove oil pan. Refer to “Removal”, EM-16. Remove timing chain. Refer to “Removal”, EM-24. Remove cylinder head. Refer to “Removal”, EM-24. SEM190FA EM-64 CYLINDER BLOCK Disassembly (Cont’d) 7. 8. I Remove baffle plate from main bearing beam. Remove pistons with connecting rods. When disassembling piston and connecting rod, remove snap ring first, then heat piston to 60 to 70°C (140 to 158°F). 9. Remove rear oil seal retainer. CAUTION: I When piston rings are not replaced, make sure that piston rings are mounted in their original positions. I When replacing piston rings, if there is no punchmark, install with either side up. GI 10. Loosen bolts in numerical order as shown and remove main bearing beam, bearing cap and crankshaft. I Before removing bearing beam and bearing cap, measure crankshaft end play. Refer to EM-74. I Bolts should be loosened in two or three steps. EC MA LC SEM965A FE CL MT SEM842E AT 11. Remove oil jets. 12. Remove knock sensor. CAUTION: Carefully handle the sensor and avoid impacts. TF PD AX SU SEM454G Inspection PISTON AND PISTON PIN CLEARANCE 1. NAEM0027 NAEM0027S01 Measure inner diameter of piston pin hole “dp”. Standard diameter “dp”: Grade No. 0 21.993 - 21.999 mm (0.8659 - 0.8661 in) Grade No. 1 21.999 - 22.005 mm (0.8661 - 0.8663 in) BR ST RS BT AEM023 2. Measure outer diameter of piston pin “Dp”. Standard diameter “Dp”: Grade No. 0 21.989 - 21.995 mm (0.8657 - 0.8659 in) Grade No. 1 21.995 - 22.001 mm (0.8659 - 0.8662 in) 3. Calculate interference fit of piston pin to piston. Dp − dp = 0.002 - 0.006 mm (0.0001 - 0.0002 in) If it exceeds the above value, replace piston assembly with pin. AEM024 EM-65 HA SC EL IDX CYLINDER BLOCK Inspection (Cont’d) PISTON RING SIDE CLEARANCE SEM024AA PISTON RING END GAP SEM599A NAEM0027S02 Side clearance: Top ring 0.040 - 0.080 mm (0.0016 - 0.0031 in) 2nd ring 0.030 - 0.070 mm (0.0012 - 0.0028 in) Oil ring 0.015 - 0.050 mm (0.0006 - 0.0020 in) Max. limit of side clearance: Top ring 0.11 mm (0.0043 in) 2nd ring 0.1 mm (0.004 in) If out of specification, replace piston ring. If clearance exceeds maximum limit with new ring, replace piston. NAEM0027S03 End gap: Top ring 0.23 - 0.33 mm (0.0091 - 0.0130 in) 2nd ring 0.33 - 0.48 mm (0.0130- 0.0189 in) Oil ring 0.20 - 0.60 mm (0.0079 - 0.0236 in) Max. limit of ring gap: Top ring 0.54 mm (0.0213 in) 2nd ring 0.80 mm (0.0315 in) Oil ring 0.95 mm (0.0374 in) If out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, do the following. Rebore cylinder and use oversized piston and piston rings. Refer to SDS (EM-84). I When replacing the piston, check the cylinder block surface for scratches or seizure. If scratches or seizure is found, hone or replace the cylinder block. EM-66 CYLINDER BLOCK Inspection (Cont’d) CONNECTING ROD BEND AND TORSION NAEM0027S04 Bend: Limit 0.15 mm (0.0059 in) per 100 mm (3.94 in) length Torsion: Limit 0.30 mm (0.0118 in) per 100 mm (3.94 in) length If it exceeds the limit, replace connecting rod assembly. GI MA LC SEM038F EC FE CL MT SEM003F CYLINDER BLOCK DISTORTION AND WEAR I I SEM123C I AT NAEM0027S05 Clean upper surface of cylinder block. Use a reliable straightedge and feeler gauge to check the flatness of cylinder block surface. Check along six positions shown in the figure. Distortion limit: 0.10 mm (0.0039 in) If out of specification, resurface it. The limit for cylinder block resurfacing is determined by cylinder head resurfacing in engine. Resurfacing limit: 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: 214.95 - 215.05 mm (8.4626 - 8.4665 in) Refer to SDS (EM-83). If necessary, replace cylinder block. TF PD AX SU BR ST RS BT HA SC EL IDX EM-67 CYLINDER BLOCK Inspection (Cont’d) PISTON-TO-BORE CLEARANCE NAEM0027S06 1. Using a bore gauge, measure cylinder bore for wear, out-ofround and taper. Cylinder bore inner diameter Grade No. Standard inner diameter No. 1 95.500 - 95.510 mm (3.7598 - 3.7602 in) No. 2 95.510 - 95.520 mm (3.7602 - 3.7606 in) No. 3 95.520 - 95.530 mm (3.7606 - 3.7610 in) Wear limit 0.20 mm (0.0079 in) SEM843E 2. If it exceeds the limit, rebore all cylinders. Replace cylinder block if necessary. Out-of-round (Difference between X and Y): Limit 0.015 mm (0.0006 in) Taper (Difference between A and C): Limit 0.015 mm (0.0006 in) Check for scratches and seizure. If seizure is found, hone it. SEM321AA I If both cylinder block and piston are replaced with new ones, select piston of the same grade number punched on cylinder block rear position. These numbers are punched in either Arabic or Roman numerals. 3. Measure piston skirt diameter. Piston diameter “A”: Refer to SDS (EM-84). Measuring point “a” (Distance from the top): 41.0 mm (1.61 in) Check that piston-to-bore clearance is within specification. Piston-to-bore clearance “B”: 0.010 - 0.030 mm (0.0004 - 0.0012 in) Determine piston oversize according to amount of cylinder wear. Oversize pistons are available for service. Refer to SDS (EM-84). If oversize piston is used, use it for all cylinders with oversize piston rings. 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) SEM451G 4. 5. SEM258C I 6. EM-68 CYLINDER BLOCK Inspection (Cont’d) 7. Install main bearing caps, and tighten to the specified torque. Otherwise, cylinder bores may be distorted in final assembly. 8. Cut cylinder bores. I When any cylinder needs boring, all other cylinders must also be bored. I Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a time. 9. Hone cylinders to obtain specified piston-to-bore clearance. 10. Measure finished cylinder bore for out-of-round and taper. I Measurement should be done after cylinder bore cools down. CRANKSHAFT 1. 2. SEM316A GI MA LC EC NAEM0027S07 Check crankshaft main and pin journals for score, wear or cracks. With a micrometer, measure journals for taper and out-ofround. Out-of-round (X − Y): Standard 0.002 mm (0.0001 in) Taper (A − B): Standard 0.002 mm (0.0001 in) FE CL MT AT TF PD AX SU 3. Measure crankshaft runout. Runout (Total indicator reading): Limit 0.10 mm (0.0039 in) BR ST RS BT SEM346D BEARING CLEARANCE I NAEM0027S08 Use either of the following two methods, however, method “A” gives more reliable results and is preferable. Method A (Using bore gauge & micrometer) Main bearing 1. HA SC NAEM0027S0801 Set main bearings in their proper positions on cylinder block and main bearing cap. EL IDX SEM175F EM-69 CYLINDER BLOCK Inspection (Cont’d) 2. 3. Install main bearing cap and bearing beam to cylinder block. Tighten all bolts in correct order. Measure inner diameters “A” of each main bearing. SEM845E 4. 5. I I Measure outer diameters “Dm” of each crankshaft main journal. Calculate main bearing clearance. Main bearing clearance = A − Dm Standard: 0.035 - 0.045 mm (0.0014 - 0.0018 in) Limit: 0.065 mm (0.0026 in) If it exceeds the limit, replace bearing. If clearance cannot be adjusted using any standard bearing grade, grind crankshaft journal and use undersized bearing. AEM033 a. b. When grinding crankshaft journal, confirm that “L” dimension in fillet roll is more than the specified limit. “L”: 0.1 mm (0.004 in) Refer to SDS for grinding crankshaft and available service parts. SEM964 6. a. If crankshaft or cylinder block is replaced with a new one, select thickness of main bearings as follows: Grade number of each cylinder block main journal is punched on the respective cylinder block. These numbers are punched in either Arabic or Alphabet. Refer to SDS, EM-83. If measured diameter is out of grade punched, decide suitable grade using table in SDS. SEM451G b. c. Grade number of each crankshaft main journal is punched on the respective crankshaft. These numbers are punched in either Arabic or Alphabet. Refer to SDS, EM-86. If measured diameter is out of grade punched, decide suitable grade using table in SDS. Select main bearing with suitable thickness according to the following table. Refer to “SDS”, EM-87, for available main bearings. SEM452G EM-70 CYLINDER BLOCK Inspection (Cont’d) GI MA LC EC FE CL MT AT TF PD AX SU PBIC0814E BR ST RS BT Connecting Rod Bearing (Big end) 1. 2. 3. NAEM0027S0802 Install connecting rod bearing to connecting rod and cap. Install connecting rod cap to connecting rod. Tighten bolts to the specified torque. Measure inner diameter “C” of connecting rod. HA SC EL IDX AEM027 EM-71 CYLINDER BLOCK Inspection (Cont’d) 4. 5. 6. 7. Measure outer diameter “Dp” of each crankshaft pin journal. Calculate connecting rod bearing clearance. Connecting rod bearing clearance = C − Dp Standard: 0.034 - 0.059 mm (0.0013 - 0.0023 in) Limit: 0.070 mm (0.0028 in) If it exceeds the limit, replace bearing. If clearance cannot be adjusted within the standard of any bearing, grind crankshaft journal and use undersized bearing. Refer to “BEARING CLEARANCE — Main bearing”, EM-69. AEM034 8. SEM452G If crankshaft is replaced with a new one, select connecting rod bearing according to the following table. Connecting rod bearing grade number (Identification color): These numbers are punched in either Arabic or Roman numerals. Crankshaft pin journal grade number Connecting rod bearing grade number 0 0 (Black) 1 1 (Brown) 2 2 (Green) Method B (Using plastigage) CAUTION: I Do not turn crankshaft or connecting rod while plastigage is being inserted. I When bearing clearance exceeds the specified limit, ensure that the proper bearing has been installed. If incorrect bearing clearance exists, use a thicker or undersized main bearing to ensure specified clearance. EM142 CONNECTING ROD BUSHING CLEARANCE (SMALL END) NAEM0027S09 1. 2. 3. SEM673E Measure inner diameter “C” of bushing. Measure outer diameter “Dp” of piston pin. Calculate connecting rod bushing clearance. Connecting rod bushing clearance = C − Dp Standard: 0.005 - 0.017 mm (0.0002 - 0.0007 in) Limit: 0.030 mm (0.0012 in) If it exceeds the limit, replace connecting rod assembly or connecting rod bushing and/or piston set with pin. EM-72 CYLINDER BLOCK Inspection (Cont’d) FLYWHEEL/DRIVE PLATE RUNOUT SEM849EB NAEM0027S11 Runout (Total indicator reading): Flywheel (M/T model) Less than 0.15 mm (0.0059 in) Drive plate (A/T model) Less than 0.15 mm (0.0059 in) CAUTION: I The signal plate is built into the flywheel/drive plate assembly. Be careful not to damage the signal plate, especially the teeth. I Check the drive plate and signal plate for deformation or cracks. I Never place the flywheel assembly with the signal plate facing down. I Keep any magnetized objects away from the signal plate. I Do not allow any magnetic materials to contact the signal plate teeth. I Do not surface flywheel. Replace as necessary. GI MA LC EC FE CL MT SEM536G Assembly PISTON 1. 2. I I I SEM838F AT NAEM0028 NAEM0028S01 Install new snap ring on one side of piston pin hole. Heat piston to 60 to 70°C (140 to 158°F) and assemble piston, piston pin, connecting rod and new snap ring. Align the direction of piston and connecting rod. Numbers stamped on connecting rod and cap correspond to each cylinder. After assembly, make sure connecting rod swings smoothly. 3. Set piston rings as shown. CAUTION: I When piston rings are not replaced, make sure that piston rings are mounted in their original positions. I When replacing piston rings, these without punchmarks present, piston rings can be mounted with either side up. TF PD AX SU BR ST RS BT SEM814G I Align piston rings so that end gaps are positioned as shown in the figure. HA SC EL IDX SEM160B EM-73 CYLINDER BLOCK Assembly (Cont’d) OIL JET 1. I NAEM0028S05 Install oil jets. Insert oil jet knock pin into the cylinder block knock pin hole, and tighten the mounting bolts. SEM454G CRANKSHAFT 1. I NAEM0028S02 Set main bearings in their proper positions on cylinder block and main bearing beam. Confirm that correct main bearings are used. Refer to “Inspection” of this section. SEM175F 2. I Instructions for re-use of main bearing cap bolts. A plastic zone tightening method is used for tightening main bearing cap bolts. Measure d1 and d2 as shown in the figure. d2: Select minimum diameter in the measuring area. If the difference between d1 and d2 exceeds the limit, replace the bolts with new ones. Limit (d1 - d2): 0.11 mm (0.0043 in) 3. After installing crankshaft, main bearing cap, main bearing beam and bearing cap bolts, tighten bearing cap bolts in numerical order as shown. Make sure that the front mark on the main bearing beam faces the front of the engine. Tightening procedure Tighten all bolts to 32 to 38 N·m (3.3 to 3.9 kg-m, 24 to 28 ft-lb) in several different steps. Turn all bolts 90 to 95 degrees clockwise with angle wrench. Prior to tightening bearing cap bolts, place bearing beam SEM177F SEM456G I I a) b) SEM851E I EM-74 CYLINDER BLOCK Assembly (Cont’d) I I in its proper position by shifting crankshaft in the axial direction. After securing bearing cap bolts, make sure crankshaft turns smoothly by hand. Lubricate threads and seat surfaces of the bolts with new engine oil. GI MA LC 4. Measure crankshaft end play. Crankshaft end play: Standard 0.10 - 0.25 mm (0.0039 - 0.0098 in) Limit 0.30 mm (0.0118 in) If beyond the limit, replace bearing with a new one. EC FE CL MT SEM852E 5. I Install connecting rod bearings in connecting rods and connecting rod caps. Confirm that correct bearings are used. AT TF PD AX SU SEM455G 6. a. I I Install pistons with connecting rods. Install them into corresponding cylinders with Tool. Be careful not to scratch cylinder wall with the connecting rod. Arrange so that front mark on piston head faces toward engine front. BR ST RS BT SEM620 b. I I I Install connecting rod caps. Lubricate threads and seat surfaces with new engine oil. Install so that the cylinder number stamped on the connecting rod agrees with that stamped on cap side. Make sure that front mark on the connecting rod cap faces the front of the engine. HA SC EL IDX SEM457G EM-75 CYLINDER BLOCK Assembly (Cont’d) c. I I Re-use connecting rod cap bolts as follows. Make sure that the bolts can be smoothly screwed-in to the end manually. If not, measure the outer diameter “d” shown in the figure. Outer diameter “d” of connecting rod cap bolt: Standard 7.90 - 8.00 mm (0.3110 - 0.3150 in) Limit 7.75 mm (0.3051 in) SEM538G d. Tighten connecting rod cap bolts to the specified torque. Connecting rod cap bolt: (1) Tighten nuts to 19 to 21 N·m (1.9 to 2.1 kg-m, 14 to 15 ft-lb). (2) Turn nuts 90 to 95 degrees clockwise with angle wrench. 7. Measure connecting rod side clearance. Connecting rod side clearance: Standard 0.20 - 0.35 mm (0.0079 - 0.0138 in) Limit 0.40 mm (0.0157 in) If beyond the limit, replace connecting rod and/or crankshaft. Install baffle plate to main bearing beam. Install rear oil seal retainer. SEM953E 8. 9. SEM954E KNOCK SENSOR 1. I PBIC0810E NAEM0028S07 Install knock sensor. Make sure that there is no foreign material on the cylinder block mating surface and the back surface of the knock sensor. I Install knock sensor so that connector faces front of engine. I Do not tighten the mounting bolts while holding the connector. I Make sure that the knock sensor does not interfere with other parts. CAUTION: If any impact by dropping is applied to the knock sensor, replace it with new one. I After installing knock sensor, connect sub-harness, and lay it out to rear of engine. EM-76 CYLINDER BLOCK Assembly (Cont’d) REPLACEMENT OF PILOT BUSHING (M/T) OR PILOT GI CONVERTER (A/T) NAEM0028S04 1. Remove pilot bushing or pilot converter using tool or suitable tool. MA LC SEM005G 2. EC Install pilot bushing or pilot converter as shown. FE CL MT SEM163B FLYWHEEL/DRIVE PLATE AT NAEM0028S06 Install drive plate. I Install the drive plate and reinforce plate in the direction shown in the figure. I Align dowel pin of crankshaft rear end with pin holes of each part. I Secure the crankshaft using a ring gear stopper. I Tighten the installation bolts crosswise over several times. TF PD AX SU PBIC0910E BR ST RS BT HA SC EL IDX EM-77 SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications General Specifications Cylinder arrangement Displacement cm3 (cu in) Bore and stroke NAEM0029 V-6 3,498 (213.45) mm (in) 95.5 x 81.4 (3.760 x 3.205) Valve arrangement DOHC Firing order 1-2-3-4-5-6 Compression 2 Oil 1 Number of piston rings Number of main bearings 4 Compression ratio 10.0 Compression Pressure NAEM0030 Unit: kPa (kg/cm2, psi)/300 rpm Compression pressure Standard 1,275 (13.0, 185) Minimum 981 (10.0, 142) Differential limit between cylinders 98 (1.0, 14) Cylinder number SEM713A Cylinder Head NAEM0031 Unit: mm (in) Head surface distortion Standard Limit Less than 0.03 (0.0012) 0.1 (0.004) SEM949E EM-78 SERVICE DATA AND SPECIFICATIONS (SDS) Valve Valve NAEM0032 VALVE GI NAEM0032S01 Unit: mm (in) MA LC EC SEM188 Intake FE 37.0 - 37.3 (1.4567 - 1.4685) Valve head diameter “D” Exhaust 31.2 - 31.5 (1.228 - 1.240) Intake 96.12 - 96.62 (3.7842 - 3.8039) Exhaust 93.65 - 94.15 (3.6870 - 3.7067) Intake 5.965 - 5.980 (0.2348 - 0.2354) Exhaust 5.945 - 5.960 (0.2341 - 0.2346) CL Valve length “L” MT Valve stem diameter “d” AT Intake Valve seat angle “α” 45°15′ - 45°45′ TF Exhaust Intake 1.1 (0.044) Exhaust 1.3 (0.051) Valve margin “T” Valve margin “T” limit More than 0.5 (0.020) Valve stem end surface grinding limit Less than 0.2 (0.008) PD AX VALVE CLEARANCE NAEM0032S02 Unit: mm (in) Cold Hot* (reference data) Intake 0.26 - 0.34 (0.010 - 0.013) 0.304 - 0.416 (0.012 - 0.016) Exhaust 0.29 - 0.37 (0.011 - 0.015) 0.308 - 0.432 (0.012 - 0.017) BR ST *: Approximately 80°C (176°F) VALVE SPRING Free height Pressure NAEM0032S04 mm (in) RS 46.52 (1.8315) Installation 196 (20.0, 44.1) at 37.0 (1.457) Valve open 433 (44.2, 97.3) at 27.8 (1.094) N (kg, lb) at height mm (in) Out-of-square SU mm (in) BT Less than 2.0 (0.079) HA VALVE LIFTER NAEM0032S05 Unit: mm (in) Valve lifter outer diameter 33.977 - 33.987 (1.3377 - 1.3381) Lifter guide inner diameter 34.000 - 34.016 (1.3386 - 1.3392) Clearance between lifter and lifter guide 0.013 - 0.039 (0.0005 - 0.0015) SC EL IDX EM-79 SERVICE DATA AND SPECIFICATIONS (SDS) Valve (Cont’d) AVAILABLE LIFTERS (SHIMLESS TYPE) =NAEM0032S08 Identification mark Thickness mm (in) 788U or 788R 7.88 (0.3102) 790U or 790R 7.90 (0.3110) 792U or 792R 7.92 (0.3118) 794U or 794R 7.94 (0.3126) 796U or 796R 7.96 (0.3134) 798U or 798R 7.98 (0.3142) 800U or 800R 8.00 (0.3150) 802U or 802R 8.02 (0.3157) 804U or 804R 8.04 (0.3165) 806U or 806R 8.06 (0.3173) 808U or 808R 8.08 (0.3181) 810U or 810R 8.10 (0.3189) 812U or 812R 8.12 (0.3197) 814U or 814R 8.14 (0.3205) 816U or 816R 8.16 (0.3213) 818U or 818R 8.18 (0.3220) 820U or 820R 8.20 (0.3228) 822U or 822R 8.22 (0.3236) 824U or 824R 8.24 (0.3244) 826U or 826R 8.26 (0.3252) 828U or 828R 8.28 (0.3260) 830U or 830R 8.30 (0.3268) 832U or 832R 8.32 (0.3276) 834U or 834R 8.34 (0.3283) 836U or 836R 8.36 (0.3291) 838U or 838R 8.38 (0.3299) 840U or 840R 8.40 (0.3307) SEM758G EM-80 SERVICE DATA AND SPECIFICATIONS (SDS) Valve (Cont’d) VALVE GUIDE NAEM0032S06 GI Unit: mm (in) MA LC EC SEM950E Valve guide Outer diameter Valve guide Inner diameter (Finished size) Cylinder head valve guide hole diameter FE Standard Service 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029) CL 6.000 - 6.018 (0.2362 - 0.2369) 9.975 - 9.996 (0.3927 - 0.3935) Interference fit of valve guide 10.175 - 10.196 (0.4006 - 0.4014) MT 0.027 - 0.059 (0.0011 - 0.0023) Standard Max. tolerance Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.0031) Exhaust 0.040 - 0.073 (0.0016 - 0.0029) 0.1 (0.004) Intake — 0.24 (0.0094) Exhaust — 0.28 (0.0110) AT Stem to guide clearance TF Valve deflection limit Projection length “L” PD 12.6 - 12.8 (0.496 - 0.504) Valve Seat NAEM0033 AX Unit: mm (in) SU BR ST RS BT HA SC SEM021EB EL IDX EM-81 SERVICE DATA AND SPECIFICATIONS (SDS) Valve Seat (Cont’d) SEM621F Standard Service Intake 38.000 - 38.016 (1.4961 - 1.4967) 38.500 - 38.516 (1.5157 - 1.5164) Exhaust 32.200 - 32.216 (1.2677 - 1.2683) 32.700 - 32.716 (1.2874 - 1.2880) Cylinder head seat recess diameter (D) Intake 0.081 - 0.113 (0.0032 - 0.0044) Exhaust 0.064 - 0.096 (0.0025 - 0.0038) Valve seat interference fit Intake 38.097 - 38.113 (1.4999 - 1.5005) 38.597 - 38.613 (1.5196 - 1.5202) Exhaust 32.280 - 32.296 (1.2709 - 1.2715) 32.780 - 32.796 (1.2905 - 1.2912) Intake 5.9 - 6.0 (0.232 - 0.236) 5.05 - 5.15 (0.1988 - 0.2028) Exhaust 5.9 - 6.0 (0.232 - 0.236) 4.95 - 5.05 (0.1949 - 0.1988) Valve seat outer diameter (d) Height (h) Depth (H) 5.9 - 6.1 (0.232 - 0.240) Intake 41.07 - 41.67 (1.6169 - 1.6405) Exhaust 41.00 - 41.60 (1.6142 - 1.6378) Depth (L) Camshaft and Camshaft Bearing NAEM0034 Unit: mm (in) Standard Limit No. 1 0.045 - 0.086 (0.0018 - 0.0034) No. 2, 3, 4 0.035 - 0.076 (0.0014 - 0.0030) 0.15 (0.0059) Inner diameter of camshaft bearing No. 1 26.000 - 26.021 (1.0236 - 1.0244) No. 2, 3, 4 23.500 - 23.521 (0.9252 - 0.9260) — Outer diameter of camshaft journal No. 1 25.935 - 25.955 (1.0211 - 1.0218) No. 2, 3, 4 23.445 - 23.465 (0.9230 - 0.9238) — Camshaft runout [TIR*] Less than 0.02 (0.0008) 0.05 (0.0020) Camshaft sprocket runout [TIR*] Less than 0.15 (0.0059) — 0.115 - 0.188 (0.0045 - 0.0074) 0.24 (0.0094) Camshaft journal to bearing clearance Camshaft end play *: Total indicator reading EM-82 SERVICE DATA AND SPECIFICATIONS (SDS) Camshaft and Camshaft Bearing (Cont’d) GI MA EM671 Cam height “A” Intake and exhaust LC 44.465 - 44.655 (1.7506 - 1.7581) Wear limit of cam height EC 0.2 (0.008) FE CL Valve timing MT AT Unit: degree a b c d e f 232 230 –3 53 6 46 Cylinder Block TF PD NAEM0035 Unit: mm (in) AX SU BR ST SEM022EA Standard Less than 0.03 (0.0012) Surface flatness Limit 0.10 (0.0039) Standard Cylinder bore RS Grade No. 1 95.500 - 95.510 (3.7598 - 3.7602) Grade No. 2 95.510 - 95.520 (3.7602 - 3.7606) Grade No. 3 95.520 - 95.530 (3.7606 - 3.7610) BT HA Inner diameter Wear limit 0.20 (0.0079) Out-of-round (Difference between X and Y) Less than 0.015 (0.0006) Taper (Difference between A and C) Less than 0.015 (0.0006) SC EL IDX EM-83 SERVICE DATA AND SPECIFICATIONS (SDS) Cylinder Block (Cont’d) Main journal inner diameter grade (Without bearing) Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade No. A No. B No. C No. D No. E No. F No. G No. H No. J No. K No. L No. M No. N No. P No. R No. S No. T No. U No. V No. W No. X No. Y No. 4 No. 7 Difference in inner diameter between cylinders Standard 63.993 - 63.994 (2.5194 - 2.5194) 63.994 - 63.995 (2.5194 - 2.5195) 63.995 - 63.996 (2.5195 - 2.5195) 63.996 - 63.997 (2.5195 - 2.5196) 63.997 - 63.998 (2.5196 - 2.5196) 63.998 - 63.999 (2.5196 - 2.5196) 63.999 - 64.000 (2.5196 - 2.5197) 64.000 - 64.001 (2.5197 - 2.5197) 64.001 - 64.002 (2.5197 - 2.5198) 64.002 - 64.003 (2.5198 - 2.5198) 64.003 - 64.004 (2.5198 - 2.5198) 64.004 - 64.005 (2.5198 - 2.5199) 64.005 - 64.006 (2.5199 - 2.5199) 64.006 - 64.007 (2.5199 - 2.5200) 64.007 - 64.008 (2.5200 - 2.5200) 64.008 - 64.009 (2.5200 - 2.5200) 64.009 - 64.010 (2.5200 - 2.5201) 64.010 - 64.011 (2.5201 - 2.5201) 64.011 - 64.012 (2.5201 - 2.5202) 64.012 - 64.013 (2.5202 - 2.5202) 64.013 - 64.014 (2.5202 - 2.5202) 64.014 - 64.015 (2.5202 - 2.5203) 64.015 - 64.016 (2.5203 - 2.5203) 64.016 - 64.017 (2.5203 - 2.5203) Less than 0.03 (0.0012) Piston, Piston Ring and Piston Pin NAEM0036 AVAILABLE PISTON NAEM0036S01 Unit: mm (in) SEM882E Piston skirt diameter “A” Grade No. 1 95.480 - 95.490 (3.7590 - 3.7594) Grade No. 2* 95.490 - 95.500 (3.7594 - 3.7598) Grade No. 3 95.500 - 95.510 (3.7598 - 3.7602) 0.20 (0.0079) oversize (Service) 95.680 - 95.710 (3.7669 - 3.7681) Standard “a” dimension 41.0 (1.614) Grade No. 0 21.993 - 21.999 (0.8659 - 0.8661) Grade No. 1 21.999 - 22.005 (0.8661 - 0.8663) Piston pin hole diameter Piston clearance to cylinder block 0.010 - 0.030 (0.0004 - 0.0012) *: No grade No. is punched on piston. EM-84 SERVICE DATA AND SPECIFICATIONS (SDS) Piston, Piston Ring and Piston Pin (Cont’d) PISTON RING =NAEM0036S02 GI Unit: mm (in) Side clearance End gap Standard Limit Top 0.040 - 0.080 (0.0016 - 0.0031) 0.11 (0.0043) 2nd 0.030 - 0.070 (0.0012 - 0.0028) 0.1 (0.004) Oil ring 0.015 - 0.050 (0.0006 - 0.0020) — Top 0.23 - 0.33 (0.0091 - 0.0130) 0.54 (0.0213) 2nd 0.33 - 0.48 (0.0130 - 0.0189) 0.80 (0.0315) Oil (rail ring) 0.20 - 0.60 (0.0079 - 0.0236) 0.95 (0.0374) PISTON PIN MA LC EC NAEM0036S03 Unit: mm (in) Grade No. 0 21.989 - 21.995 (0.8657 - 0.8659) Grade No. 1 21.995 - 22.001 (0.8659 - 0.8662) FE Piston pin outer diameter Interference fit of piston pin to piston CL 0.002 - 0.006 (0.0001 - 0.0002) Standard MT 0.005 - 0.017 (0.0002 - 0.0007) Piston pin to connecting rod bushing clearance Limit 0.030 (0.0012) AT *: Values measured at ambient temperature of 20°C (68°F) Connecting Rod NAEM0037 Unit: mm (in) Center distance TF 144.15 - 144.25 (5.6752 - 5.6791) Bend [per 100 (3.94)] Limit 0.15 (0.0059) Torsion [per 100 (3.94)] Limit 0.30 (0.0118) Connecting rod small end inner diameter 23.980 - 24.000 (0.9441 - 0.9449) Grade No. 0 22.000 - 22.006 (0.8661 - 0.8664) Grade No. 1 22.006 - 22.012 (0.8664 - 0.8666) PD AX Piston pin bushing inner diameter* Connecting rod big end inner diameter SU 55.000 - 55.013 (2.1654 - 2.1659) Standard 0.20 - 0.35 (0.0079 - 0.0138) Side clearance Limit BR 0.40 (0.0157) ST *: After installing in connecting rod RS BT HA SC EL IDX EM-85 SERVICE DATA AND SPECIFICATIONS (SDS) Crankshaft Crankshaft NAEM0038 Unit: mm (in) Main journal dia. “Dm” grade Pin journal dia. “Dp” Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade No. A No. B No. C No. D No. E No. F No. G No. H No. J No. K No. L No. M No. N No. P No. R No. S No. T No. U No. V No. W No. X No. Y No. 4 No. 7 59.975 - 59.974 (2.3612 - 2.3612) 59.974 - 59.973 (2.3612 - 2.3611) 59.973 - 59.972 (2.3611 - 2.3611) 59.972 - 59.971 (2.3611 - 2.3611) 59.971 - 59.970 (2.3611 - 2.3610) 59.970 - 59.969 (2.3610 - 2.3610) 59.969 - 59.968 (2.3610 - 2.3609) 59.968 - 59.967 (2.3609 - 2.3609) 59.967 - 59.966 (2.3609 - 2.3609) 59.966 - 59.965 (2.3609 - 2.3608) 59.965 - 59.964 (2.3608 - 2.3608) 59.964 - 59.963 (2.3608 - 2.3607) 59.963 - 59.962 (2.3607 - 2.3607) 59.962 - 59.961 (2.3607 - 2.3607) 59.961 - 59.960 (2.3607 - 2.3606) 59.960 - 59.959 (2.3606 - 2.3606) 59.959 - 59.958 (2.3606 - 2.3605) 59.958 - 59.957 (2.3605 - 2.3605) 59.957 - 59.956 (2.3605 - 2.3605) 59.956 - 59.955 (2.3605 - 2.3604) 59.955 - 59.954 (2.3604 - 2.3604) 59.954 - 59.953 (2.3604 - 2.3603) 59.953 - 59.952 (2.3603 - 2.3603) 59.952 - 59.951 (2.3603 - 2.3603) Grade No. 0 51.968 - 51.974 (2.0460 - 2.0462) Grade No. 1 51.962 - 51.968 (2.0457 - 2.0460) Grade No. 2 51.956 - 51.962 (2.0445 - 2.0457) Center distance “r” 40.36 - 40.44 (1.5890 - 1.5921) Out-of-round (X − Y) Standard Less than 0.002 (0.0001) Taper (A − B) Standard Less than 0.002 (0.0001) Runout [TIR*] Limit Less than 0.10 (0.0039) Standard 0.10 - 0.25 (0.0039 - 0.0098) Free end play Limit 0.30 (0.0118) SEM645 *: Total indicator reading EM-86 EM715 SERVICE DATA AND SPECIFICATIONS (SDS) Available Main Bearing Available Main Bearing NAEM0039 GI MA LC EC SEM175F Grade number Thickness “T” Width “W” mm (in) mm (in) Identification color (UPR/LWR) 0 2.000 - 2.003 (0.0787 - 0.0789) Black 1 2.003 - 2.006 (0.0789 - 0.0790) Brown 2 2.006 - 2.009 (0.0790 - 0.0791) Green 3 2.009 - 2.012 (0.0791 - 0.0792) Yellow 4 2.012 - 2.015 (0.0792 - 0.0793) Blue 5 2.015 - 2.018 (0.0793 - 0.0794) Pink 6 2.018 - 2.021 (0.0794 - 0.0796) Purple 7 2.021 - 2.024 (0.0796 - 0.0797) White UPP 2.003 - 2.006 (0.0789 - 0.0790) LWR 2.000 - 2.003 (0.0787 - 0.0789) UPR 2.006 - 2.009 (0.0790 - 0.0791) LWR 2.003 - 2.006 (0.0789 - 0.0790) UPR 2.009 - 2.012 (0.0791 - 0.0792) LWR 2.006 - 2.009 (0.0790 - 0.0791) UPR 2.012 - 2.015 (0.0792 - 0.0793) LWR 2.009 - 2.012 (0.0791 - 0.0792) UPR 2.015 - 2.018 (0.0793 - 0.0794) LWR 2.012 - 2.015 (0.0792 - 0.0793) UPR 2.018 - 2.021 (0.0794 - 0.0796) LWR 2.015 - 2.018 (0.0793 - 0.0794) UPR 2.021 - 2.024 (0.0796 - 0.0797) LWR 2.018 - 2.021 (0.0794 - 0.0796) 01 12 19.9 - 20.1 (0.783 - 0.791) 23 34 CL MT Grade is the same for upper and lower bearings. AT TF Brown/Black PD Green/Brown AX Yellow/Green SU Blue/Yellow 45 56 67 FE Remarks Grade is different for upper and lower bearings. BR Pink/Blue ST Purple/Pink RS White/Purple BT UNDERSIZE NAEM0039S01 HA Unit: mm (in) 0.25 (0.0098) Thickness Main journal diameter “Dm” 2.132 - 2.140 (0.0839 - 0.0843) Grind so that bearing clearance is the specified value. SC EL IDX EM-87 SERVICE DATA AND SPECIFICATIONS (SDS) Available Connecting Rod Bearing Available Connecting Rod Bearing NAEM0040 CONNECTING ROD BEARING Grade number NAEM0040S01 Thickness “T” mm (in) Identification color (mark) 0 1.500 - 1.503 (0.0591 - 0.0592) Black 1 1.503 - 1.506 (0.0592 - 0.0593) Brown 2 1.506 - 1.509 (0.0593 - 0.0594) Green UNDERSIZE NAEM0040S02 Unit: mm (in) 0.25 (0.0098) Thickness Crank pin journal diameter “Dp” 1.626 - 1.634 (0.0640 - 0.0643) Grind so that bearing clearance is the specified value. Miscellaneous Components NAEM0041 Unit: mm (in) Flywheel runout [TIR]* Less than 0.15 (0.0059) Drive plate runout [TIR]* Less than 0.15 (0.0059) *: Total indicator reading BEARING CLEARANCE NAEM0041S01 Unit: mm (in) Standard 0.035 - 0.045 (0.0014 - 0.0018) Main bearing clearance Limit 0.065 (0.0026) Standard 0.034 - 0.059 (0.0013 - 0.0023) Connecting rod bearing clearance Limit 0.070 (0.0028) EM-88 ENGINE CONTROL SYSTEM SECTION EC GI MA EM LC FE CONTENTS MODIFICATION NOTICE ................................................9 Modification Notice ......................................................9 How to Check Vehicle Type ........................................9 TROUBLE DIAGNOSIS - INDEX ..................................10 Alphabetical Index .....................................................10 DTC No. Index...........................................................14 PRECAUTIONS .............................................................19 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″.............19 Precautions for On Board Diagnostic (OBD) System of Engine and A/T.........................................19 Engine Fuel & Emission Control System ..................20 Precautions ................................................................21 Wiring Diagrams and Trouble Diagnosis...................22 PREPARATION .............................................................23 Special Service Tools ................................................23 Commercial Service Tools .........................................24 ENGINE AND EMISSION CONTROL OVERALL SYSTEM.........................................................................26 Engine Control Component Parts Location...............26 Circuit Diagram ..........................................................31 System Diagram ........................................................34 Vacuum Hose Drawing ..............................................35 System Chart .............................................................36 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION ...............................................37 Multiport Fuel Injection (MFI) System .......................37 Electronic Ignition (EI) System ..................................39 Air Conditioning Cut Control......................................40 Fuel Cut Control (at no load & high engine speed) ........................................................................41 Evaporative Emission System ...................................41 On Board Refueling Vapor Recovery (ORVR) ..........47 Positive Crankcase Ventilation ..................................56 CAN Communication .................................................57 Automatic Speed Control Device (ASCD) System....62 BASIC SERVICE PROCEDURE ...................................64 Fuel Pressure Release ..............................................64 Fuel Pressure Check .................................................64 Fuel Pressure Regulator Check ................................65 Injector .......................................................................66 How to Check Idle Speed and Ignition Timing..........67 Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment .................................................................69 Accelerator Pedal Released Position Learning.........81 Throttle Valve Closed Position Learning ...................81 Idle Air Volume Learning ...........................................81 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ...............................................................85 Introduction ................................................................85 Two Trip Detection Logic ...........................................85 Emission-related Diagnostic Information ...................86 Malfunction Indicator Lamp (MIL)............................102 OBD System Operation Chart .................................105 CONSULT-II ............................................................. 111 Generic Scan Tool (GST) ........................................125 TROUBLE DIAGNOSIS - INTRODUCTION................127 Introduction ..............................................................127 Work Flow................................................................129 TROUBLE DIAGNOSIS - BASIC INSPECTION .........131 Basic Inspection.......................................................131 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION .............................................................137 DTC Inspection Priority Chart..................................137 Fail-safe Chart .........................................................138 Symptom Matrix Chart.............................................139 CONSULT-II Reference Value in Data Monitor Mode ........................................................................143 Major Sensor Reference Graph in Data Monitor Mode ........................................................................147 ECM Terminals and Reference Value .....................149 TROUBLE DIAGNOSIS - SPECIFICATION VALUE ..159 Description ...............................................................159 Testing Condition .....................................................159 Inspection Procedure...............................................159 Diagnostic Procedure ..............................................160 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT.....................................................................163 CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX CONTENTS Description ...............................................................163 Diagnostic Procedure ..............................................163 TROUBLE DIAGNOSIS FOR POWER SUPPLY........164 ECM Terminals and Reference Value .....................164 Main Power Supply and Ground Circuit..................165 DTC U1000, U1001 CAN COMMUNICATION LINE...172 Description ...............................................................172 On Board Diagnosis Logic.......................................172 DTC Confirmation Procedure ..................................172 Wiring Diagram ........................................................173 Diagnostic Procedure ..............................................174 DTC P0011, P0021 IVT CONTROL ............................175 Description ...............................................................175 CONSULT-II Reference Value in Data Monitor Mode ........................................................................176 On Board Diagnosis Logic.......................................176 DTC Confirmation Procedure ..................................176 Diagnostic Procedure ..............................................177 Component Inspection.............................................178 DTC P0031, P0032, P0051, P0052 HO2S1 HEATER.......................................................................179 Description ...............................................................179 CONSULT-II Reference Value in Data Monitor Mode ........................................................................179 ECM Terminals and Reference Value .....................179 On Board Diagnosis Logic.......................................180 DTC Confirmation Procedure ..................................180 Wiring Diagram ........................................................182 Diagnostic Procedure ..............................................184 DTC P0037, P0038, P0057, P0058 HO2S2 HEATER.......................................................................187 Description ...............................................................187 CONSULT-II Reference Value in Data Monitor Mode ........................................................................187 ECM Terminals and Reference Value .....................187 On Board Diagnosis Logic.......................................188 DTC Confirmation Procedure ..................................188 Wiring Diagram ........................................................190 Diagnostic Procedure ..............................................192 DTC P0101 MAF SENSOR (TYPE I) ..........................194 Application Notice ....................................................194 Component Description ...........................................194 CONSULT-II Reference Value in Data Monitor Mode ........................................................................194 ECM Terminals and Reference Value .....................194 On Board Diagnosis Logic.......................................195 DTC Confirmation Procedure ..................................195 Overall Function Check ...........................................196 Wiring Diagram ........................................................198 Diagnostic Procedure ..............................................199 DTC P0101 MAF SENSOR (TYPE II) .........................203 Application Notice ....................................................203 (Cont’d) Component Description ...........................................203 CONSULT-II Reference Value in Data Monitor Mode ........................................................................203 ECM Terminals and Reference Value .....................203 On Board Diagnosis Logic.......................................204 DTC Confirmation Procedure ..................................204 Overall Function Check ...........................................206 Wiring Diagram ........................................................207 Diagnostic Procedure ..............................................208 DTC P0102, P0103 MAF SENSOR (TYPE I)..............211 Application Notice ....................................................211 Component Description ...........................................211 CONSULT-II Reference Value in Data Monitor Mode ........................................................................211 ECM Terminals and Reference Value .....................211 On Board Diagnosis Logic.......................................212 DTC Confirmation Procedure ..................................212 Wiring Diagram ........................................................214 Diagnostic Procedure ..............................................215 DTC P0102, P0103 MAF SENSOR (TYPE II).............219 Application Notice ....................................................219 Component Description ...........................................219 CONSULT-II Reference Value in Data Monitor Mode ........................................................................219 ECM Terminals and Reference Value .....................219 On Board Diagnosis Logic.......................................220 DTC Confirmation Procedure ..................................220 Wiring Diagram ........................................................222 Diagnostic Procedure ..............................................223 DTC P0112, P0113 IAT SENSOR (TYPE I) ................226 Application Notice ....................................................226 Component Description ...........................................226 On Board Diagnosis Logic.......................................226 DTC Confirmation Procedure ..................................226 Wiring Diagram ........................................................228 Diagnostic Procedure ..............................................229 Component Inspection.............................................230 DTC P0112, P0113 IAT SENSOR (TYPE II) ...............231 Application Notice ....................................................231 Component Description ...........................................231 On Board Diagnosis Logic.......................................231 DTC Confirmation Procedure ..................................231 Wiring Diagram ........................................................233 Diagnostic Procedure ..............................................234 Component Inspection.............................................235 DTC P0117, P0118 ECT SENSOR..............................236 Component Description ...........................................236 On Board Diagnosis Logic.......................................236 DTC Confirmation Procedure ..................................237 Wiring Diagram ........................................................238 Diagnostic Procedure ..............................................239 DTC P0122, P0123 TP SENSOR................................241 EC-2 CONTENTS Component Description ...........................................241 CONSULT-II Reference Value in Data Monitor Mode ........................................................................241 ECM Terminals and Reference Value .....................241 On Board Diagnosis Logic.......................................242 DTC Confirmation Procedure ..................................242 Wiring Diagram ........................................................244 Diagnostic Procedure ..............................................245 Component Inspection.............................................247 DTC P0125 ECT SENSOR..........................................249 Description ...............................................................249 On Board Diagnosis Logic.......................................249 DTC Confirmation Procedure ..................................250 Diagnostic Procedure ..............................................250 DTC P0127 IAT SENSOR ...........................................252 Component Description ...........................................252 On Board Diagnosis Logic.......................................252 DTC Confirmation Procedure ..................................252 Diagnostic Procedure ..............................................253 DTC P0128 THERMOSTAT FUNCTION.....................254 On Board Diagnosis Logic.......................................254 DTC Confirmation Procedure ..................................254 Diagnostic Procedure ..............................................255 DTC P0132, P0152 HO2S1 .........................................256 Component Description ...........................................256 CONSULT-II Reference Value in Data Monitor Mode ........................................................................256 ECM Terminals and Reference Value .....................256 On Board Diagnosis Logic.......................................257 DTC Confirmation Procedure ..................................257 Wiring Diagram ........................................................258 Diagnostic Procedure ..............................................260 DTC P0133, P0153 HO2S1 .........................................264 Component Description ...........................................264 CONSULT-II Reference Value in Data Monitor Mode ........................................................................264 ECM Terminals and Reference Value .....................264 On Board Diagnosis Logic.......................................265 DTC Confirmation Procedure ..................................265 Overall Function Check ...........................................266 Wiring Diagram ........................................................267 Diagnostic Procedure ..............................................269 DTC P0134, P0154 HO2S1 .........................................278 Component Description ...........................................278 CONSULT-II Reference Value in Data Monitor Mode ........................................................................278 ECM Terminals and Reference Value .....................278 On Board Diagnosis Logic.......................................279 DTC Confirmation Procedure ..................................279 Overall Function Check ...........................................280 Wiring Diagram ........................................................281 Diagnostic Procedure ..............................................283 (Cont’d) DTC P0138, P0158 HO2S2 .........................................287 Component Description ...........................................287 CONSULT-II Reference Value in Data Monitor Mode ........................................................................287 ECM Terminals and Reference Value .....................287 On Board Diagnosis Logic.......................................287 DTC Confirmation Procedure ..................................288 Wiring Diagram ........................................................289 Diagnostic Procedure ..............................................291 DTC P0139, P0159 HO2S2 .........................................295 Component Description ...........................................295 CONSULT-II Reference Value in Data Monitor Mode ........................................................................295 ECM Terminals and Reference Value .....................295 On Board Diagnosis Logic.......................................295 DTC Confirmation Procedure ..................................296 Overall Function Check ...........................................296 Wiring Diagram ........................................................298 Diagnostic Procedure ..............................................300 DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION ...................................................................304 On Board Diagnosis Logic.......................................304 DTC Confirmation Procedure ..................................304 Wiring Diagram ........................................................306 Diagnostic Procedure ..............................................308 DTC P0172, P0175 FUEL INJECTION SYSTEM FUNCTION ...................................................................312 On Board Diagnosis Logic.......................................312 DTC Confirmation Procedure ..................................312 Wiring Diagram ........................................................314 Diagnostic Procedure ..............................................316 DTC P0181 FTT SENSOR ..........................................319 Component Description ...........................................319 On Board Diagnosis Logic.......................................319 DTC Confirmation Procedure ..................................319 Diagnostic Procedure ..............................................320 DTC P0182, P0183 FTT SENSOR..............................322 Component Description ...........................................322 On Board Diagnosis Logic.......................................322 DTC Confirmation Procedure ..................................322 Wiring Diagram ........................................................324 Diagnostic Procedure ..............................................325 DTC P0222, P0223 TP SENSOR................................327 Component Description ...........................................327 CONSULT-II Reference Value in Data Monitor Mode ........................................................................327 ECM Terminals and Reference Value .....................327 On Board Diagnosis Logic.......................................328 DTC Confirmation Procedure ..................................328 Wiring Diagram ........................................................330 Diagnostic Procedure ..............................................331 Component Inspection.............................................333 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-3 CONTENTS DTC P0300 - P0306 MULTIPLE CYLINDER MISFIRE, NO. 1 - 6 CYLINDER MISFIRE ..................335 On Board Diagnosis Logic.......................................335 DTC Confirmation Procedure ..................................336 Diagnostic Procedure ..............................................337 DTC P0327, P0328 KS................................................345 Component Description ...........................................345 ECM Terminals and Reference Value .....................345 On Board Diagnosis Logic.......................................345 DTC Confirmation Procedure ..................................345 Wiring Diagram ........................................................346 Diagnostic Procedure ..............................................347 DTC P0335 CKP SENSOR (POS) ..............................350 Component Description ...........................................350 CONSULT-II Reference Value in Data Monitor Mode ........................................................................350 On Board Diagnosis Logic.......................................350 DTC Confirmation Procedure ..................................351 Wiring Diagram ........................................................352 Diagnostic Procedure ..............................................353 Component Inspection.............................................356 DTC P0340, P0345 CMP SENSOR (PHASE) ............357 Component Description ...........................................357 On Board Diagnosis Logic.......................................357 DTC Confirmation Procedure ..................................357 Wiring Diagram ........................................................359 Diagnostic Procedure ..............................................361 Component Inspection.............................................365 DTC P0420, P0430 THREE WAY CATALYST FUNCTION ...................................................................366 On Board Diagnosis Logic.......................................366 DTC Confirmation Procedure ..................................366 Overall Function Check ...........................................367 Diagnostic Procedure ..............................................367 DTC P0441 EVAP CONTROL SYSTEM.....................371 System Description..................................................371 On Board Diagnosis Logic.......................................371 DTC Confirmation Procedure ..................................372 Overall Function Check ...........................................372 Diagnostic Procedure ..............................................374 DTC P0442 EVAP CONTROL SYSTEM.....................381 On Board Diagnosis Logic.......................................381 DTC Confirmation Procedure ..................................382 Diagnostic Procedure ..............................................383 DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE ..................396 Description ...............................................................396 CONSULT-II Reference Value in Data Monitor Mode ........................................................................396 ECM Terminals and Reference Value .....................397 On Board Diagnosis Logic.......................................397 DTC Confirmation Procedure ..................................398 (Cont’d) Wiring Diagram ........................................................399 Diagnostic Procedure ..............................................400 DTC P0447 EVAP CANISTER VENT CONTROL VALVE..........................................................................403 Component Description ...........................................403 CONSULT-II Reference Value in Data Monitor Mode ........................................................................403 ECM Terminals and Reference Value .....................403 On Board Diagnosis Logic.......................................403 DTC Confirmation Procedure ..................................404 Wiring Diagram ........................................................405 Diagnostic Procedure ..............................................406 DTC P0452 EVAP SYSTEM PRESSURE SENSOR ..410 Component Description ...........................................410 CONSULT-II Reference Value in Data Monitor Mode ........................................................................410 ECM Terminals and Reference Value .....................410 On Board Diagnosis Logic.......................................411 DTC Confirmation Procedure ..................................411 Wiring Diagram ........................................................412 Diagnostic Procedure ..............................................413 DTC P0453 EVAP SYSTEM PRESSURE SENSOR ..416 Component Description ...........................................416 CONSULT-II Reference Value in Data Monitor Mode ........................................................................416 ECM Terminals and Reference Value .....................416 On Board Diagnosis Logic.......................................417 DTC Confirmation Procedure ..................................417 Wiring Diagram ........................................................418 Diagnostic Procedure ..............................................419 DTC P0455 EVAP CONTROL SYSTEM.....................425 On Board Diagnosis Logic.......................................425 DTC Confirmation Procedure ..................................426 Diagnostic Procedure ..............................................427 DTC P0456 EVAP CONTROL SYSTEM.....................438 On Board Diagnosis Logic.......................................438 DTC Confirmation Procedure ..................................439 Overall Function Check ...........................................440 Diagnostic Procedure ..............................................441 DTC P0460 FUEL LEVEL SENSOR...........................454 Component Description ...........................................454 On Board Diagnostic Logic......................................454 DTC Confirmation Procedure ..................................454 Diagnostic Procedure ..............................................455 DTC P0461 FUEL LEVEL SENSOR...........................456 Component Description ...........................................456 On Board Diagnostic Logic......................................456 Overall Function Check ...........................................456 Diagnostic Procedure ..............................................457 DTC P0462, P0463 FUEL LEVEL SENSOR ..............458 Component Description ...........................................458 On Board Diagnostic Logic......................................458 EC-4 CONTENTS DTC Confirmation Procedure ..................................458 Diagnostic Procedure ..............................................459 DTC P0500 VSS ..........................................................460 Description ...............................................................460 On Board Diagnosis Logic.......................................460 DTC Confirmation Procedure ..................................460 Overall Function Check ...........................................461 Diagnostic Procedure ..............................................461 DTC P0506 ISC SYSTEM ...........................................462 Description ...............................................................462 On Board Diagnosis Logic.......................................462 DTC Confirmation Procedure ..................................462 Diagnostic Procedure ..............................................463 DTC P0507 ISC SYSTEM ...........................................464 Description ...............................................................464 On Board Diagnosis Logic.......................................464 DTC Confirmation Procedure ..................................464 Diagnostic Procedure ..............................................465 DTC P0550 PSP SENSOR..........................................466 Component Description ...........................................466 CONSULT-II Reference Value in Data Monitor Mode ........................................................................466 On Board Diagnosis Logic.......................................466 DTC Confirmation Procedure ..................................466 Wiring Diagram ........................................................467 Diagnostic Procedure ..............................................468 Component Inspection.............................................470 DTC P0605 ECM .........................................................471 Component Description ...........................................471 On Board Diagnosis Logic.......................................471 DTC Confirmation Procedure ..................................471 Diagnostic Procedure ..............................................472 DTC P1065 ECM POWER SUPPLY (BACK UP).......473 Component Description ...........................................473 ECM Terminals and Reference Value .....................473 On Board Diagnosis Logic.......................................473 DTC Confirmation Procedure ..................................473 Wiring Diagram ........................................................475 Diagnostic Procedure ..............................................476 DTC P1102 MAF SENSOR (TYPE I) ..........................478 Application Notice ....................................................478 Component Description ...........................................478 CONSULT-II Reference Value in Data Monitor Mode ........................................................................478 ECM Terminals and Reference Value .....................478 On Board Diagnosis Logic.......................................479 DTC Confirmation Procedure ..................................479 Wiring Diagram ........................................................480 Diagnostic Procedure ..............................................481 DTC P1110, P1135 IVT CONTROL.............................485 Description ...............................................................485 (Cont’d) CONSULT-II Reference Value in Data Monitor Mode ........................................................................485 On Board Diagnosis Logic.......................................486 DTC Confirmation Procedure ..................................486 Diagnostic Procedure ..............................................487 DTC P1111, P1136 IVT CONTROL SOLENOID VALVE..........................................................................488 Component Description ...........................................488 CONSULT-II Reference Value in Data Monitor Mode ........................................................................488 ECM Terminals and Reference Value .....................488 On Board Diagnosis Logic.......................................489 DTC Confirmation Procedure ..................................489 Wiring Diagram ........................................................490 Diagnostic Procedure ..............................................492 DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR .................................................................494 Component Description ...........................................494 On Board Diagnosis Logic.......................................494 DTC Confirmation Procedure ..................................494 Diagnostic Procedure ..............................................495 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION ...................................................................496 Description ...............................................................496 ECM Terminals and Reference Value .....................496 On Board Diagnosis Logic.......................................497 DTC Confirmation Procedure ..................................497 Wiring Diagram ........................................................498 Diagnostic Procedure ..............................................499 Component Inspection.............................................503 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY...........................................................504 Component Description ...........................................504 CONSULT-II Reference Value in Data Monitor Mode ........................................................................504 ECM Terminals and Reference Value .....................504 On Board Diagnosis Logic.......................................504 DTC Confirmation Procedure ..................................505 Wiring Diagram ........................................................506 Diagnostic Procedure ..............................................507 Component Inspection.............................................508 DTC P1128 THROTTLE CONTROL MOTOR.............509 Component Description ...........................................509 ECM Terminals and Reference Value .....................509 On Board Diagnosis Logic.......................................509 DTC Confirmation Procedure ..................................509 Wiring Diagram ........................................................511 Diagnostic Procedure ..............................................512 Component Inspection.............................................513 DTC P1130 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE......................................................514 Description ...............................................................514 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-5 CONTENTS CONSULT-II Reference Value in Data Monitor Mode ........................................................................515 ECM Terminals and Reference Value .....................515 On Board Diagnosis Logic.......................................516 DTC Confirmation Procedure ..................................516 Wiring Diagram ........................................................518 Diagnostic Procedure ..............................................519 DTC P1131 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE......................................................535 Component Description ...........................................535 CONSULT-II Reference Value in Data Monitor Mode ........................................................................535 ECM Terminals and Reference Value .....................535 On Board Diagnosis Logic.......................................535 DTC Confirmation Procedure ..................................536 Wiring Diagram ........................................................537 Diagnostic Procedure ..............................................538 DTC P1143, P1163 HO2S1 .........................................541 Component Description ...........................................541 CONSULT-II Reference Value in Data Monitor Mode ........................................................................541 ECM Terminals and Reference Value .....................541 On Board Diagnosis Logic.......................................542 DTC Confirmation Procedure ..................................542 Overall Function Check ...........................................543 Diagnostic Procedure ..............................................544 DTC P1144, P1164 HO2S1 .........................................549 Component Description ...........................................549 CONSULT-II Reference Value in Data Monitor Mode ........................................................................549 ECM Terminals and Reference Value .....................549 On Board Diagnosis Logic.......................................550 DTC Confirmation Procedure ..................................550 Overall Function Check ...........................................551 Diagnostic Procedure ..............................................552 DTC P1146, P1166 HO2S2 .........................................557 Component Description ...........................................557 CONSULT-II Reference Value in Data Monitor Mode ........................................................................557 ECM Terminals and Reference Value .....................557 On Board Diagnosis Logic.......................................557 DTC Confirmation Procedure ..................................558 Overall Function Check ...........................................558 Wiring Diagram ........................................................560 Diagnostic Procedure ..............................................562 DTC P1147, P1167 HO2S2 .........................................566 Component Description ...........................................566 CONSULT-II Reference Value in Data Monitor Mode ........................................................................566 ECM Terminals and Reference Value .....................566 On Board Diagnosis Logic.......................................566 DTC Confirmation Procedure ..................................567 (Cont’d) Overall Function Check ...........................................567 Wiring Diagram ........................................................569 Diagnostic Procedure ..............................................571 DTC P1148, P1168 CLOSED LOOP CONTROL........575 On Board Diagnosis Logic.......................................575 DTC Confirmation Procedure ..................................575 Overall Function Check ...........................................576 Diagnostic Procedure ..............................................576 DTC P1165 SWIRL CONTROL VALVE CONTROL VACUUM CHECK SWITCH.........................................577 Component Description ...........................................577 CONSULT-II Reference Value in Data Monitor Mode ........................................................................577 ECM Terminals and Reference Value .....................577 On Board Diagnosis Logic.......................................578 DTC Confirmation Procedure ..................................578 Wiring Diagram ........................................................579 Diagnostic Procedure ..............................................580 DTC P1211 ABS/TCS CONTROL UNIT .....................583 Description ...............................................................583 On Board Diagnosis Logic.......................................583 DTC Confirmation Procedure ..................................583 Diagnostic Procedure ..............................................584 DTC P1212 ABS/TCS COMMUNICATION LINE........585 Description ...............................................................585 On Board Diagnosis Logic.......................................585 DTC Confirmation Procedure ..................................585 Diagnostic Procedure ..............................................586 DTC P1217 ENGINE OVER TEMPERATURE............587 On Board Diagnosis Logic.......................................587 Overall Function Check ...........................................587 Diagnostic Procedure ..............................................588 Main 12 Causes of Overheating..............................591 DTC P1225 TP SENSOR ............................................592 Component Description ...........................................592 On Board Diagnosis Logic.......................................592 DTC Confirmation Procedure ..................................592 Diagnostic Procedure ..............................................593 DTC P1226 TP SENSOR ............................................594 Component Description ...........................................594 On Board Diagnosis Logic.......................................594 DTC Confirmation Procedure ..................................594 Diagnostic Procedure ..............................................595 DTC P1229 SENSOR POWER SUPPLY....................596 ECM Terminals and Reference Value .....................596 On Board Diagnosis Logic.......................................596 DTC Confirmation Procedure ..................................596 Wiring Diagram ........................................................598 Diagnostic Procedure ..............................................599 DTC P1442 EVAP CONTROL SYSTEM.....................601 On Board Diagnosis Logic.......................................601 DTC Confirmation Procedure ..................................602 EC-6 CONTENTS Diagnostic Procedure ..............................................603 DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE...................................616 Description ...............................................................616 CONSULT-II Reference Value in Data Monitor Mode ........................................................................616 ECM Terminals and Reference Value .....................617 On Board Diagnosis Logic.......................................617 DTC Confirmation Procedure ..................................617 Wiring Diagram ........................................................619 Diagnostic Procedure ..............................................620 DTC P1446 EVAP CANISTER VENT CONTROL VALVE..........................................................................628 Component Description ...........................................628 CONSULT-II Reference Value in Data Monitor Mode ........................................................................628 ECM Terminals and Reference Value .....................628 On Board Diagnosis Logic.......................................628 DTC Confirmation Procedure ..................................629 Wiring Diagram ........................................................630 Diagnostic Procedure ..............................................631 DTC P1448 EVAP CANISTER VENT CONTROL VALVE..........................................................................636 Component Description ...........................................636 CONSULT-II Reference Value in Data Monitor Mode ........................................................................636 ECM Terminals and Reference Value .....................636 On Board Diagnosis Logic.......................................636 DTC Confirmation Procedure ..................................637 Overall Function Check ...........................................638 Wiring Diagram ........................................................639 Diagnostic Procedure ..............................................640 DTC P1456 EVAP CONTROL SYSTEM.....................645 On Board Diagnosis Logic.......................................645 DTC Confirmation Procedure ..................................646 Overall Function Check ...........................................647 Diagnostic Procedure ..............................................648 DTC P1490 VACUUM CUT VALVE BYPASS VALVE..........................................................................661 Description ...............................................................661 CONSULT-II Reference Value in Data Monitor Mode ........................................................................661 ECM Terminals and Reference Value .....................661 On Board Diagnosis Logic.......................................662 DTC Confirmation Procedure ..................................662 Wiring Diagram ........................................................663 Diagnostic Procedure ..............................................664 DTC P1491 VACUUM CUT VALVE BYPASS VALVE..........................................................................667 Description ...............................................................667 CONSULT-II Reference Value in Data Monitor Mode ........................................................................667 (Cont’d) ECM Terminals and Reference Value .....................667 On Board Diagnosis Logic.......................................668 DTC Confirmation Procedure ..................................668 Overall Function Check ...........................................669 Wiring Diagram ........................................................670 Diagnostic Procedure ..............................................671 DTC P1564 ASCD STEERING SWITCH ....................679 Component Description ...........................................679 CONSULT-II Reference Value in Data Monitor Mode ........................................................................679 ECM Terminals and Reference Value .....................679 On Board Diagnosis Procedure...............................680 DTC Confirmation Procedure ..................................680 Wiring Diagram ........................................................681 Diagnostic Procedure ..............................................682 Component Inspection.............................................684 DTC P1572 ASCD BRAKE SWITCH..........................685 Component Description ...........................................685 CONSULT-II Reference Value in Data Monitor Mode ........................................................................685 ECM Terminals and Reference Value .....................685 On Board Diagnosis Procedure...............................686 DTC Confirmation Procedure ..................................686 Wiring Diagram ........................................................688 Diagnostic Procedure ..............................................689 Component Inspection.............................................694 DTC P1706 PNP SWITCH...........................................696 Component Description ...........................................696 CONSULT-II Reference Value in Data Monitor Mode ........................................................................696 ECM Terminals and Reference Value .....................696 On Board Diagnosis Logic.......................................696 DTC Confirmation Procedure ..................................696 Overall Function Check ...........................................697 Wiring Diagram ........................................................698 Diagnostic Procedure ..............................................699 DTC P1805 BRAKE SWITCH .....................................702 Description ...............................................................702 CONSULT-II Reference Value in Data Monitor Mode ........................................................................702 ECM Terminals and Reference Value .....................702 On Board Diagnosis Logic.......................................702 DTC Confirmation Procedure ..................................703 Wiring Diagram ........................................................704 Diagnostic Procedure ..............................................705 Component Inspection.............................................707 DTC P2122, P2123 APP SENSOR .............................708 Component Description ...........................................708 CONSULT-II Reference Value in Data Monitor Mode ........................................................................708 ECM Terminals and Reference Value .....................708 On Board Diagnosis Logic.......................................709 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-7 CONTENTS DTC Confirmation Procedure ..................................710 Wiring Diagram ........................................................711 Diagnostic Procedure ..............................................712 Component Inspection.............................................714 DTC P2127, P2128 APP SENSOR .............................715 Component Description ...........................................715 CONSULT-II Reference Value in Data Monitor Mode ........................................................................715 ECM Terminals and Reference Value .....................715 On Board Diagnosis Logic.......................................716 DTC Confirmation Procedure ..................................717 Wiring Diagram ........................................................718 Diagnostic Procedure ..............................................719 Component Inspection.............................................722 DTC P2135 TP SENSOR ............................................723 Component Description ...........................................723 CONSULT-II Reference Value in Data Monitor Mode ........................................................................723 ECM Terminals and Reference Value .....................723 On Board Diagnosis Logic.......................................724 DTC Confirmation Procedure ..................................724 Wiring Diagram ........................................................726 Diagnostic Procedure ..............................................727 Component Inspection.............................................729 DTC P2138 APP SENSOR..........................................731 Component Description ...........................................731 CONSULT-II Reference Value in Data Monitor Mode ........................................................................731 ECM Terminals and Reference Value .....................731 On Board Diagnosis Logic.......................................732 DTC Confirmation Procedure ..................................733 Wiring Diagram ........................................................734 Diagnostic Procedure ..............................................735 Component Inspection.............................................737 VARIABLE INDUCTION AIR CONTROL SYSTEM (VIAS)...........................................................................739 Description ...............................................................739 ECM Terminals and Reference Value .....................740 Wiring Diagram ........................................................741 Diagnostic Procedure ..............................................742 IGNITION SIGNAL.......................................................748 Component Description ...........................................748 ECM Terminals and Reference Value .....................748 Wiring Diagram ........................................................749 Diagnostic Procedure ..............................................752 INJECTOR ...................................................................758 Component Description ...........................................758 CONSULT-II Reference Value in Data Monitor Mode ........................................................................758 ECM Terminals and Reference Value .....................758 (Cont’d) Wiring Diagram ........................................................759 Diagnostic Procedure ..............................................760 FUEL PUMP.................................................................763 System Description..................................................763 Component Description ...........................................763 CONSULT-II Reference Value in Data Monitor Mode ........................................................................763 ECM Terminals and Reference Value .....................764 Wiring Diagram ........................................................765 Diagnostic Procedure ..............................................766 REFRIGERANT PRESSURE SENSOR ......................770 Description ...............................................................770 ECM Terminals and Reference Value .....................770 Wiring Diagram ........................................................771 Diagnostic Procedure ..............................................772 ASCD BRAKE SWITCH ..............................................775 Component Description ...........................................775 CONSULT-II Reference Value in Data Monitor Mode ........................................................................775 ECM Terminals and Reference Value .....................775 Wiring Diagram ........................................................776 Diagnostic Procedure ..............................................777 ASCD INDICATOR LAMP...........................................783 Component Description ...........................................783 CONSULT-II Reference Value in Data Monitor Mode ........................................................................783 Wiring Diagram ........................................................784 Diagnostic Procedure ..............................................785 ELECTRICAL LOAD SIGNAL.....................................786 ECM Terminals and Reference Value .....................786 Wiring Diagram ........................................................787 Diagnostic Procedure ..............................................788 MIL & DATA LINK CONNECTORS ............................791 Wiring Diagram ........................................................791 SERVICE DATA AND SPECIFICATIONS (SDS) .......792 Fuel Pressure Regulator..........................................792 Idle Speed and Ignition Timing................................792 Mass Air Flow Sensor (Type I) ................................792 Mass Air Flow Sensor (Type II) ...............................792 Engine Coolant Temperature Sensor ......................792 Heated Oxygen Sensor 1 Heater ............................792 Heated Oxygen Sensor 2 Heater ............................792 Fuel Pump ...............................................................792 Injector .....................................................................792 Calculated Load Value.............................................793 Intake Air Temperature Sensor................................793 Fuel Tank Temperature Sensor ...............................793 Crankshaft Position Sensor (POS)..........................793 Camshaft Position Sensor (PHASE) .......................793 EC-8 MODIFICATION NOTICE Modification Notice Modification Notice NAEC1413 GI Mass air flow (MAF) sensor has been changed. How to Check Vehicle Type NAEC1414 MA Confirm the type of the vehicle. Vehicle Type Vehicle Serial Number Type I 700001 - 712114 (2WD) 800001 - 826013, 826016 - 834317 (4WD) Type II 712115 - (2WD) 826014, 826015, 834318 - (4WD) EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-9 TROUBLE DIAGNOSIS — INDEX Alphabetical Index Alphabetical Index NAEC0001 APPLICATION NOTICE NAEC0001S03 Confirm the type of the vehicle. Refer to “How to Check Vehicle Type”, EC-9. ALPHABETICAL INDEX NAEC0001S04 NOTE: If DTC U1000 or U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC U1000, U1001. Refer to EC-172, “DTC U1000, U1001 CAN COMMUNICATION LINE”. X: Applicable —: Not applicable DTC*1 Items (CONSULT-II screen terms) Trip MIL lighting up Reference page 0731 2 X AT-126 P0732 0732 2 X AT-132 A/T 3RD GR FNCTN P0733 0733 2 X AT-138 A/T 4TH GR FNCTN P0734 0734 2 X AT-144 A/T TCC S/V FNCTN P0744 0744 2 X AT-157 APP SEN 1/CIRC P2122 2122 1 X EC-708 APP SEN 1/CIRC P2123 2123 1 X EC-708 APP SEN 2/CIRC P2127 2127 1 X EC-715 APP SEN 2/CIRC P2128 2128 1 X EC-715 APP SENSOR P2138 2138 1 X EC-731 ASCD BRAKE SW P1572 1572 1 — EC-685 ASCD SW P1564 1564 1 — EC-679 ATF TEMP SEN/CIRC P0710 0710 2 X AT-111 BRAKE SW/CIRCUIT P1805 1805 2 — EC-702 CAN COMM CIRCUIT U1000 1000*5 1 X EC-172 CAN COMM CIRCUIT U1001 1001*5 2 — EC-172 CKP SEN/CIRCUIT P0335 0335 2 X EC-350 CLOSED LOOP-B1 P1148 1148 1 X EC-575 CLOSED LOOP-B2 P1168 1168 1 X EC-575 CMP SEN/CIRC-B1 P0340 0340 2 X EC-357 CMP SEN/CIRC-B2 P0345 0345 2 X EC-357 CTP LEARNING P1225 1225 2 — EC-592 CTP LEARNING P1226 1226 2 — EC-594 CYL 1 MISFIRE P0301 0301 2 X EC-335 CYL 2 MISFIRE P0302 0302 2 X EC-335 CYL 3 MISFIRE P0303 0303 2 X EC-335 CYL 4 MISFIRE P0304 0304 2 X EC-335 CYL 5 MISFIRE P0305 0305 2 X EC-335 CYL 6 MISFIRE P0306 0306 2 X EC-335 ECM P0605 0605 1 or 2 X or — EC-471 CONSULT-II GST*2 ECM*3 A/T 1ST GR FNCTN P0731 A/T 2ND GR FNCTN EC-10 TROUBLE DIAGNOSIS — INDEX Alphabetical Index (Cont’d) GI DTC*1 Items (CONSULT-II screen terms) Trip MIL lighting up Reference page CONSULT-II GST*2 ECM*3 ECM BACK UP/CIRCUIT P1065 1065 2 X EC-473 ECT SEN/CIRCUIT P0117 0117 1 X EC-236 ECT SEN/CIRCUIT P0118 0118 1 X EC-236 ECT SENSOR P0125 0125 1 X EC-249 ENG OVER TEMP P1217 1217 1 X EC-587 ENGINE SPEED SIG P0725 0725 2 X AT-122 ETC ACTR P1121 1121 1 X EC-494 ETC FUNCTION/CIRC P1122 1122 1 X EC-496 ETC MOT P1128 1128 1 X EC-509 ETC MOT PWR P1124 1124 1 X EC-504 ETC MOT PWR P1126 1126 1 X EC-504 EVAP GROSS LEAK P0455 0455 2 X EC-425 EVAP PURG FLOW/MON P0441 0441 2 X EC-371 EVAP SMALL LEAK P0442 0442 2 X EC-381 EVAP SMALL LEAK P1442 1442 2 X EC-601 EVAP SYS PRES SEN P0452 0452 2 X EC-410 EVAP SYS PRES SEN P0453 0453 2 X EC-416 EVAP VERY SML LEAK P0456 0456 2 X EC-438 EVAP VERY SML LEAK P1456 1456 2 X EC-645 FTT SEN/CIRCUIT P0182 0182 2 X EC-322 FTT SEN/CIRCUIT P0183 0183 2 X EC-322 FTT SENSOR P0181 0181 2 X EC-319 FUEL LEV SEN SLOSH P0460 0460 2 X EC-454 FUEL LEVEL SENSOR P0461 0461 2 X EC-456 FUEL LEVL SEN/CIRC P0462 0462 2 X EC-458 FUEL LEVL SEN/CIRC P0463 0463 2 X EC-458 FUEL SYS-LEAN-B1 P0171 0171 2 X EC-304 FUEL SYS-LEAN-B2 P0174 0174 2 X EC-304 FUEL SYS-RICH-B1 P0172 0172 2 X EC-312 FUEL SYS-RICH-B2 P0175 0175 2 X EC-312 HO2S1 (B1) P0132 0132 2 X EC-256 HO2S1 (B1) P0133 0133 2 X EC-264 HO2S1 (B1) P0134 0134 2 X EC-278 HO2S1 (B1) P1143 1143 2 X EC-541 HO2S1 (B1) P1144 1144 2 X EC-549 HO2S1 (B2) P0152 0152 2 X EC-256 EC-11 MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX TROUBLE DIAGNOSIS — INDEX Alphabetical Index (Cont’d) DTC*1 Items (CONSULT-II screen terms) Trip MIL lighting up Reference page 0153 2 X EC-264 P0154 0154 2 X EC-278 HO2S1 (B2) P1163 1163 2 X EC-541 HO2S1 (B2) P1164 1164 2 X EC-549 HO2S1 HTR (B1) P0031 0031 2 X EC-179 HO2S1 HTR (B1) P0032 0032 2 X EC-179 HO2S1 HTR (B2) P0051 0051 2 X EC-179 HO2S1 HTR (B2) P0052 0052 2 X EC-179 HO2S2 (B1) P0138 0138 2 X EC-287 HO2S2 (B1) P0139 0139 2 X EC-295 HO2S2 (B1) P1146 1146 2 X EC-557 HO2S2 (B1) P1147 1147 2 X EC-566 HO2S2 (B2) P0158 0158 2 X EC-287 HO2S2 (B2) P0159 0159 2 X EC-295 HO2S2 (B2) P1166 1166 2 X EC-557 HO2S2 (B2) P1167 1167 2 X EC-566 HO2S2 HTR (B1) P0037 0037 2 X EC-187 HO2S2 HTR (B1) P0038 0038 2 X EC-187 HO2S2 HTR (B2) P0057 0057 2 X EC-187 HO2S2 HTR (B2) P0058 0058 2 X EC-187 IAT SEN/CIRCUIT P0112 0112 2 X EC-226, 231 IAT SEN/CIRCUIT P0113 0113 2 X EC-226, 231 IAT SENSOR P0127 0127 2 X EC-252 INT/V TIM CONT-B1 P0011 0011 2 X EC-175 INT/V TIM CONT-B1 P1110 1110 2 X EC-485 INT/V TIM CONT-B2 P0021 0021 2 X EC-175 INT/V TIM CONT-B2 P1135 1135 2 X EC-485 INT/V TIM V/CIR-B1 P1111 1111 2 X EC-488 INT/V TIM V/CIR-B2 P1136 1136 2 X EC-488 ISC SYSTEM P0506 0506 2 X EC-462 ISC SYSTEM P0507 0507 2 X EC-464 KNOCK SEN/CIRC-B1 P0327 0327 2 — EC-345 KNOCK SEN/CIRC-B1 P0328 0328 2 — EC-345 L/PRESS SOL/CIRC P0745 0745 2 X AT-168 MAF SEN/CIRCUIT P0101 0101 1 X EC-194, 203 MAF SEN/CIRCUIT P0102 0102 1 X EC-211, 219 CONSULT-II GST*2 ECM*3 HO2S1 (B2) P0153 HO2S1 (B2) EC-12 TROUBLE DIAGNOSIS — INDEX Alphabetical Index (Cont’d) GI DTC*1 Items (CONSULT-II screen terms) Trip MIL lighting up Reference page CONSULT-II GST*2 ECM*3 MAF SEN/CIRCUIT P0103 0103 1 X EC-211, 219 MAF SENSOR*7 P1102 1102 1 X EC-478 MULTI CYL MISFIRE P0300 0300 2 X EC-335 NATS MALFUNCTION P1610 P1615 1610 - 1615 2 — EL-375 NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED. No DTC Flashing*4 — Flashing*4 EC-103 NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED. P0000 0000 — — — O/R CLTCH SOL/CIRC P1760 1760 2 X AT-188 P-N POS SW/CIRCUIT P1706 1706 2 X EC-696 PNP SW/CIRC P0705 0705 2 X AT-105 PURG VOLUME CONT/V P0444 0444 2 X EC-396 PURG VOLUME CONT/V P0445 0445 2 X EC-396 PURG VOLUME CONT/V P1444 1444 2 X EC-616 PW ST P SEN/CIRC P0550 0550 2 — EC-466 SENSOR POWER/CIRC P1229 1229 1 X EC-596 SFT SOL A/CIRC P0750 0750 1 X AT-174 SFT SOL B/CIRC P0755 0755 1 X AT-178 SWIRL CONT SOL/V P1130 1130 2 X EC-514 SWIRL CONT SOL/V P1131 1131 2 X EC-535 SWL CON VC SW/CIRC P1165 1165 2 X EC-577 TCC SOLENOID/CIRC P0740 0740 2 X AT-154 TCS C/U FUNCTN P1211 1211 2 — EC-583 TCS/CIRC P1212 1212 2 — EC-585 THERMSTAT FNCTN P0128 0128 2 X EC-254 TP SEN 1/CIRC P0222 0222 1 X EC-327 TP SEN 1/CIRC P0223 0223 1 X EC-327 TP SEN 2/CIRC P0122 0122 1 X EC-241 TP SEN 2/CIRC P0123 0123 1 X EC-241 TP SEN/CIRC A/T P1705 1705 1 X AT-182 TP SENSOR P2135 2135 1 X EC-723 TW CATALYST SYS-B1 P0420 0420 2 X EC-366 TW CATALYST SYS-B2 P0430 0430 2 X EC-366 VC CUT/V BYPASS/V P1491 1491 2 X EC-667 VC/V BYPASS/V P1490 1490 2 X EC-661 MA EM LC FE EC-13 CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX TROUBLE DIAGNOSIS — INDEX Alphabetical Index (Cont’d) DTC*1 Items (CONSULT-II screen terms) Trip MIL lighting up Reference page 0720 2 X AT-117 P0500 0500 2 X EC-460 VENT CONTROL VALVE P0447 0447 2 X EC-403 VENT CONTROL VALVE P1446 1446 2 X EC-628 VENT CONTROL VALVE P1448 1448 2 X EC-636 CONSULT-II GST*2 ECM*3 VEH SPD SEN/CIR AT*6 P0720 VEH SPEED SEN/CIRC*6 *1: *2: *3: *4: *5: *6: *7: 1st trip DTC No. is the same as DTC No. These numbers are prescribed by SAE J2012. In Diagnostic Test Mode II (Self-diagnostic results), these numbers are controlled by NISSAN. When engine is running. The troubleshooting for these DTCs need CONSULT-II. When the fail-safe operations for both self-diagnoses occur, the MIL illuminates. For the type I vehicle (Refer to “How to Check Vehicle Type”, EC-9.). DTC No. Index NAEC1181 APPLICATION NOTICE NAEC1181S01 Confirm the type of the vehicle. Refer to “How to Check Vehicle Type”, EC-9. DTC NO. INDEX NAEC1181S02 NOTE: If DTC U1000 or U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC U1000, U1001. Refer to EC-172, “DTC U1000, U1001 CAN COMMUNICATION LINE”. X: Applicable —: Not applicable DTC*1 Items (CONSULT-II screen terms) Trip MIL lighting up Reference page NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED. — Flashing*4 EC-103 1000*5 CAN COMM CIRCUIT 1 X EC-172 U1001 1001*5 CAN COMM CIRCUIT 2 — EC-172 P0000 0000 NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED. — — — P0011 0011 INT/V TIM CONT-B1 2 X EC-175 P0021 0021 INT/V TIM CONT-B2 2 X EC-175 P0031 0031 HO2S1 HTR (B1) 2 X EC-179 P0032 0032 HO2S1 HTR (B1) 2 X EC-179 P0037 0037 HO2S2 HTR (B1) 2 X EC-187 P0038 0038 HO2S2 HTR (B1) 2 X EC-187 P0051 0051 HO2S1 HTR (B2) 2 X EC-179 P0052 0052 HO2S1 HTR (B2) 2 X EC-179 P0057 0057 HO2S2 HTR (B2) 2 X EC-187 P0058 0058 HO2S2 HTR (B2) 2 X EC-187 P0101 0101 MAF SEN/CIRCUIT 1 X EC-194, 203 CONSULT-II GST*2 ECM*3 No DTC Flashing*4 U1000 EC-14 TROUBLE DIAGNOSIS — INDEX DTC No. Index (Cont’d) GI DTC*1 Items (CONSULT-II screen terms) Trip MIL lighting up Reference page CONSULT-II GST*2 ECM*3 P0102 0102 MAF SEN/CIRCUIT 1 X EC-211, 219 P0103 0103 MAF SEN/CIRCUIT 1 X EC-211, 219 P0112 0112 IAT SEN/CIRCUIT 2 X EC-226, 231 P0113 0113 IAT SEN/CIRCUIT 2 X EC-226, 231 P0117 0117 ECT SEN/CIRCUIT 1 X EC-236 P0118 0118 ECT SEN/CIRCUIT 1 X EC-236 P0122 0122 TP SEN 2/CIRC 1 X EC-241 P0123 0123 TP SEN 2/CIRC 1 X EC-241 P0125 0125 ECT SENSOR 1 X EC-249 P0127 0127 IAT SENSOR 2 X EC-252 P0128 0128 THERMSTAT FNCTN 2 X EC-254 P0132 0132 HO2S1 (B1) 2 X EC-256 P0133 0133 HO2S1 (B1) 2 X EC-264 P0134 0134 HO2S1 (B1) 2 X EC-278 P0138 0138 HO2S2 (B1) 2 X EC-287 P0139 0139 HO2S2 (B1) 2 X EC-295 P0152 0152 HO2S1 (B2) 2 X EC-256 P0153 0153 HO2S1 (B2) 2 X EC-264 P0154 0154 HO2S1 (B2) 2 X EC-278 P0158 0158 HO2S2 (B2) 2 X EC-287 P0159 0159 HO2S2 (B2) 2 X EC-295 P0171 0171 FUEL SYS-LEAN-B1 2 X EC-304 P0172 0172 FUEL SYS-RICH-B1 2 X EC-312 P0174 0174 FUEL SYS-LEAN-B2 2 X EC-304 P0175 0175 FUEL SYS-RICH-B2 2 X EC-312 P0181 0181 FTT SENSOR 2 X EC-319 P0182 0182 FTT SEN/CIRCUIT 2 X EC-322 P0183 0183 FTT SEN/CIRCUIT 2 X EC-322 P0222 0222 TP SEN 1/CIRC 1 X EC-327 P0223 0223 TP SEN 1/CIRC 1 X EC-327 P0300 0300 MULTI CYL MISFIRE 2 X EC-335 P0301 0301 CYL 1 MISFIRE 2 X EC-335 P0302 0302 CYL 2 MISFIRE 2 X EC-335 P0303 0303 CYL 3 MISFIRE 2 X EC-335 P0304 0304 CYL 4 MISFIRE 2 X EC-335 P0305 0305 CYL 5 MISFIRE 2 X EC-335 MA EC-15 EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX TROUBLE DIAGNOSIS — INDEX DTC No. Index (Cont’d) DTC*1 Items (CONSULT-II screen terms) Trip MIL lighting up Reference page CYL 6 MISFIRE 2 X EC-335 0327 KNOCK SEN/CIRC-B1 2 — EC-345 P0328 0328 KNOCK SEN/CIRC-B1 2 — EC-345 P0335 0335 CKP SEN/CIRCUIT 2 X EC-350 P0340 0340 CMP SEN/CIRC-B1 2 X EC-357 P0345 0345 CMP SEN/CIRC-B2 2 X EC-357 P0420 0420 TW CATALYST SYS-B1 2 X EC-366 P0430 0430 TW CATALYST SYS-B2 2 X EC-366 P0441 0441 EVAP PURG FLOW/MON 2 X EC-371 P0442 0442 EVAP SMALL LEAK 2 X EC-381 P0444 0444 PURG VOLUME CONT/V 2 X EC-396 P0445 0445 PURG VOLUME CONT/V 2 X EC-396 P0447 0447 VENT CONTROL VALVE 2 X EC-403 P0452 0452 EVAP SYS PRES SEN 2 X EC-410 P0453 0453 EVAP SYS PRES SEN 2 X EC-416 P0455 0455 EVAP GROSS LEAK 2 X EC-425 P0456 0456 EVAP VERY SML LEAK 2 X EC-438 P0460 0460 FUEL LEV SEN SLOSH 2 X EC-454 P0461 0461 FUEL LEVEL SENSOR 2 X EC-456 P0462 0462 FUEL LEVL SEN/CIRC 2 X EC-458 P0463 0463 FUEL LEVL SEN/CIRC 2 X EC-458 P0500 0500 VEH SPEED SEN/CIRC*6 2 X EC-460 P0506 0506 ISC SYSTEM 2 X EC-462 P0507 0507 ISC SYSTEM 2 X EC-464 P0550 0550 PW ST P SEN/CIRC 2 — EC-466 P0605 0605 ECM 1 or 2 X or — EC-471 P0705 0705 PNP SW/CIRC 2 X AT-105 P0710 0710 ATF TEMP SEN/CIRC 2 X AT-111 P0720 0720 VEH SPD SEN/CIR AT*6 2 X AT-117 P0725 0725 ENGINE SPEED SIG 2 X AT-122 P0731 0731 A/T 1ST GR FNCTN 2 X AT-126 P0732 0732 A/T 2ND GR FNCTN 2 X AT-132 P0733 0733 A/T 3RD GR FNCTN 2 X AT-138 P0734 0734 A/T 4TH GR FNCTN 2 X AT-144 P0740 0740 TCC SOLENOID/CIRC 2 X AT-154 P0744 0744 A/T TCC S/V FNCTN 2 X AT-159 CONSULT-II GST*2 ECM*3 P0306 0306 P0327 EC-16 TROUBLE DIAGNOSIS — INDEX DTC No. Index (Cont’d) GI DTC*1 Items (CONSULT-II screen terms) Trip MIL lighting up Reference page CONSULT-II GST*2 ECM*3 P0745 0745 L/PRESS SOL/CIRC 2 X AT-168 P0750 0750 SFT SOL A/CIRC 1 X AT-174 P0755 0755 SFT SOL B/CIRC 1 X AT-178 P1065 1065 ECM BACK UP/CIRCUIT 2 X EC-473 P1102 1102 MAF SENSOR*7 1 X EC-478 P1110 1110 INT/V TIM CONT-B1 2 X EC-485 P1111 1111 INT/V TIM V/CIR-B1 2 X EC-488 P1121 1121 ETC ACTR 1 X EC-494 P1122 1122 ETC FUNCTION/CIRC 1 X EC-496 P1124 1124 ETC MOT PWR 1 X EC-504 P1126 1126 ETC MOT PWR 1 X EC-504 P1128 1128 ETC MOT 1 X EC-509 P1130 1130 SWIRL CONT SOL/V 2 X EC-514 P1131 1131 SWIRL CONT SOL/V 2 X EC-535 P1135 1135 INT/V TIM CONT-B2 2 X EC-485 P1136 1136 INT/V TIM V/CIR-B2 2 X EC-488 P1143 1143 HO2S1 (B1) 2 X EC-541 P1144 1144 HO2S1 (B1) 2 X EC-549 P1146 1146 HO2S2 (B1) 2 X EC-557 P1147 1147 HO2S2 (B1) 2 X EC-566 P1148 1148 CLOSED LOOP-B1 1 X EC-575 P1163 1163 HO2S1 (B2) 2 X EC-541 P1164 1164 HO2S1 (B2) 2 X EC-549 P1165 1165 SWL CON VC SW/CIRC 2 X EC-577 P1166 1166 HO2S2 (B2) 2 X EC-557 P1167 1167 HO2S2 (B2) 2 X EC-566 P1168 1168 CLOSED LOOP-B2 1 X EC-575 P1211 1211 TCS C/U FUNCTN 2 — EC-583 P1212 1212 TCS/CIRC 2 — EC-585 P1217 1217 ENG OVER TEMP 1 X EC-587 P1225 1225 CTP LEARNING 2 — EC-592 P1226 1226 CTP LEARNING 2 — EC-594 P1229 1229 SENSOR POWER/CIRC 1 X EC-596 P1442 1442 EVAP SMALL LEAK 2 X EC-601 P1444 1444 PURG VOLUME CONT/V 2 X EC-616 P1446 1446 VENT CONTROL VALVE 2 X EC-628 MA EC-17 EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX TROUBLE DIAGNOSIS — INDEX DTC No. Index (Cont’d) DTC*1 Items (CONSULT-II screen terms) Trip MIL lighting up Reference page VENT CONTROL VALVE 2 X EC-636 1456 EVAP VERY SML LEAK 2 X EC-645 P1490 1490 VC/V BYPASS/V 2 X EC-661 P1491 1491 VC CUT/V BYPASS/V 2 X EC-667 P1564 1564 ASCD SW 1 — EC-679 P1572 1572 ASCD BRAKE SW 1 — EC-685 P1610 - P1615 1610 - 1615 NATS MALFUNCTION 2 — EL-375 P1705 1705 TP SEN/CIRC A/T 1 X AT-182 P1706 1706 P-N POS SW/CIRCUIT 2 X EC-696 P1760 1760 O/R CLTCH SOL/CIRC 2 X AT-188 P1805 1805 BRAKE SW/CIRCUIT 2 — EC-702 P2122 2122 APP SEN 1/CIRC 1 X EC-708 P2123 2123 APP SEN 1/CIRC 1 X EC-708 P2127 2127 APP SEN 2/CIRC 1 X EC-715 P2128 2128 APP SEN 2/CIRC 1 X EC-715 P2135 2135 TP SENSOR 1 X EC-723 P2138 2138 APP SENSOR 1 X EC-731 *1: *2: *3: *4: *5: *6: *7: CONSULT-II GST*2 ECM*3 P1448 1448 P1456 1st trip DTC No. is the same as DTC No. These numbers are prescribed by SAE J2012. In Diagnostic Test Mode II (Self-diagnostic results), these numbers are controlled by NISSAN. When engine is running. The troubleshooting for these DTCs need CONSULT-II. When the fail-safe operations for both self-diagnoses occur, the MIL illuminates. For the type I vehicle (Refer to “How to Check Vehicle Type”, EC-9.). EC-18 PRECAUTIONS Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” GI NAEC0002 The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS composition which is available to NISSAN MODEL R50 is as follows: 쐌 For a frontal collision The Supplemental Restraint System consists of driver air bag module (located in the center of the steering wheel), front passenger air bag module (located on the instrument panel on passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. 쐌 For a side collision The Supplemental Restraint System consists of side air bag module (located in the outer side of front seat), side curtain air bag module (located in the headliner side of front and rear seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision). Information necessary to service the system safely is included in the RS section of this Service Manual. WARNING: 쐌 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. 쐌 Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, refer to RS section. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connector (and by yellow harness protector or yellow insulation tape before the harness connectors). Precautions for On Board Diagnostic (OBD) System of Engine and A/T NAEC0003 The ECM has an on board diagnostic system. It will light up the malfunction indicator lamp (MIL) to warn the driver of a malfunction causing emission deterioration. CAUTION: 쐌 Be sure to turn the ignition switch OFF and disconnect the negative battery terminal before any repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc. will cause the MIL to light up. 쐌 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.) 쐌 Certain systems and components, especially those related to OBD, may use a new style slidelocking type harness connector. For description and how to disconnect, refer to EL-8, “HARNESS CONNECTOR (SLIDE-LOCKING TYPE)”. 쐌 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. 쐌 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 fuel injection system, etc. 쐌 Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM and TCM (Transmission control module) before returning the vehicle to the customer. MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-19 PRECAUTIONS Engine Fuel & Emission Control System Engine Fuel & Emission Control System NAEC0004 SEF952RG EC-20 PRECAUTIONS Precautions Precautions 쐌 NAEC0005 Before connecting or disconnecting the ECM harness connector, turn ignition switch OFF and disconnect negative battery terminal. Failure to do so may damage the ECM because battery voltage is applied to ECM even if ignition switch is turned off. GI MA EM LC SEF289H 쐌 When connecting ECM harness connector, fasten it securely with a lever as far as it will go as shown at left. FE CL MT SEC406D 쐌 When connecting or disconnecting pin connectors into or from ECM, take care not to damage pin terminals (bend or break). Make sure that there are not any bends or breaks on ECM pin terminal, when connecting pin connectors. AT TF PD AX SU SEF291H 쐌 Before replacing ECM, perform “ECM Terminals and Reference Value” inspection and make sure ECM functions properly. Refer to EC-149. BR ST RS BT MEF040D 쐌 After performing each TROUBLE DIAGNOSIS, perform “DTC Confirmation Procedure” or “Overall Function Check”. The DTC should not be displayed in the “DTC Confirmation Procedure” if the repair is completed. The “Overall Function Check” should be a good result if the repair is completed. HA SC EL IDX SEF217U EC-21 PRECAUTIONS Precautions (Cont’d) 쐌 쐌 When measuring ECM signals with a circuit tester, never allow the two tester probes to contact. Accidental contact of probes will cause a short circuit and damage the ECM power transistor. Do not use ECM ground terminals when measuring input/ output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than the ECM terminals, such as the ground. SEF348N 쐌 쐌 “B1” indicates the bank 1 and “B2” indicates the bank 2 as shown in the figure. Bank 1 includes No. 1 cylinder. SEF099WB Wiring Diagrams and Trouble Diagnosis When you read Wiring diagrams, refer to the following: 쐌 GI-11, “HOW TO READ WIRING DIAGRAMS” 쐌 EL-11, “POWER SUPPLY ROUTING” for power distribution circuit When you perform trouble diagnosis, refer to the following: 쐌 GI-35, “HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES” 쐌 GI-24, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT” EC-22 NAEC0006 PREPARATION Special Service Tools Special Service Tools NAEC0007 GI The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name MA Description EG17650301 (J33984-A) Radiator cap tester adapter Adapting radiator cap tester to radiator cap and radiator filler neck a: 28 (1.10) dia. b: 31.4 (1.236) dia. a: 41.3 (1.626) dia. Unit: mm (in) EM LC NT564 KV10117100 (J36471-A) Heated oxygen sensor wrench Loosening or tightening heated oxygen sensors with 22 mm (0.87 in) hexagon nut FE CL MT NT379 (J44321) Fuel pressure gauge kit Checking fuel pressure with pressure gauge AT TF PD LEC642 KV109E0010 (J-46209) Break-out box Measuring the ECM signals with a circuit tester AX SU BR NT825 KV109E0080 (J-45819) Y-cable adapter Measuring the ECM signals with a circuit tester ST RS BT NT826 HA SC EL IDX EC-23 PREPARATION Commercial Service Tools Commercial Service Tools Tool name (Kent-Moore No.) NAEC0008 Description Fuel filler cap adapter (i.e.: MLR-8382) Checking fuel tank vacuum relief valve opening pressure NT815 Leak detector (i.e., J41416) Locating the EVAP leak NT703 EVAP service port adapter (i.e., J41413-OBD) Applying positive pressure through EVAP service port NT704 Socket wrench Removing and installing engine coolant temperature sensor NT705 Oxygen sensor thread cleaner i.e.: (J-43897-18) (J-43897-12) Reconditioning the exhaust system threads before installing a new oxygen sensor. Use with antiseize lubricant shown below. a: J-43897-18 18 mm diameter with pitch 1.5 mm, for Zirconia Oxygen Sensor b: J-43897-12 12 mm diameter with pitch 1.25 mm, for Titania Oxygen Sensor AEM488 EC-24 PREPARATION Commercial Service Tools (Cont’d) Tool name (Kent-Moore No.) GI Description Anti-seize lubricant i.e.: (PermatexTM 133AR or equivalent meeting MIL specification MIL-A907) Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads. MA EM LC NT779 FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-25 ENGINE AND EMISSION CONTROL OVERALL SYSTEM Engine Control Component Parts Location Engine Control Component Parts Location NAEC0009 SEC407D EC-26 ENGINE AND EMISSION CONTROL OVERALL SYSTEM Engine Control Component Parts Location (Cont’d) GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL SEC408D IDX EC-27 ENGINE AND EMISSION CONTROL OVERALL SYSTEM Engine Control Component Parts Location (Cont’d) SEC409D EC-28 ENGINE AND EMISSION CONTROL OVERALL SYSTEM Engine Control Component Parts Location (Cont’d) GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SEC410D SC EL IDX EC-29 ENGINE AND EMISSION CONTROL OVERALL SYSTEM Engine Control Component Parts Location (Cont’d) SEC576D SEC577D EC-30 ENGINE AND EMISSION CONTROL OVERALL SYSTEM Circuit Diagram Circuit Diagram APPLICATION NOTICE NAEC0010 GI NAEC0010S03 Confirm the type of the vehicle. Refer to “How to Check Vehicle Type”, EC-9. MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-31 ENGINE AND EMISSION CONTROL OVERALL SYSTEM Circuit Diagram (Cont’d) TYPE I NAEC0010S04 MEC075E EC-32 ENGINE AND EMISSION CONTROL OVERALL SYSTEM Circuit Diagram (Cont’d) TYPE II NAEC0010S05 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC514E EC-33 IDX ENGINE AND EMISSION CONTROL OVERALL SYSTEM System Diagram System Diagram NAEC0011 SEC423D EC-34 ENGINE AND EMISSION CONTROL OVERALL SYSTEM Vacuum Hose Drawing Vacuum Hose Drawing NAEC0012 GI Refer to “System Diagram”, EC-34 for Vacuum Control System. MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL SEC413D EC-35 IDX ENGINE AND EMISSION CONTROL OVERALL SYSTEM System Chart System Chart Input (Sensor) 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 *1: *2: *3: *4: Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Mass air flow sensor Engine coolant temperature sensor Heated oxygen sensor 1 Ignition switch Throttle position sensor Accelerator pedal position sensor Park/neutral position (PNP) switch Air conditioner switch Knock sensor Intake air temperature sensor EVAP control system pressure sensor Battery voltage Power steering pressure sensor Vehicle speed signal*3 Fuel tank temperature sensor *1 Heated oxygen sensor 2*2 TCM (Transmission control module)*3 ABS actuator and electric unit (Control unit)*3 Refrigerant pressure sensor Electrical load Fuel level sensor*1 ASCD steering switch ASCD brake switch ASCD clutch switch (MT models) Stop lamp switch This This This This NAEC0013 ECM Function Output (Actuator) Fuel injection & mixture ratio control Injectors Electronic ignition system Power transistor Idle air control system ASCD vehicle speed control Electric throttle control actuator Fuel pump control Fuel pump relay On board diagnostic system MIL (On the instrument panel)*4 Swirl control valve control Swirl control valve control solenoid valve Power valve control VIAS control solenoid valve Heated oxygen sensor 1 heater control Heated oxygen sensor 1 heater Heated oxygen sensor 2 heater control Heated oxygen sensor 2 heater EVAP canister purge flow control EVAP canister purge volume control solenoid valve Air conditioning cut control Air conditioner relay*4 ON BOARD DIAGNOSIS for EVAP system 쐌 EVAP canister vent control valve 쐌 Vacuum cut valve bypass valve sensor is not used to control the engine system. This is used only for the on board diagnosis. sensor is not used to control the engine system under normal conditions. input signal is sent to the ECM through CAN communication line. output signal is sent from the ECM through CAN communication line. EC-36 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Multiport Fuel Injection (MFI) System Multiport Fuel Injection (MFI) System DESCRIPTION Input/Output Signal Chart NAEC0014 NAEC0014S01 Sensor Crankshaft position sensor (POS) GI Input Signal to ECM Camshaft position sensor (PHASE) Engine speed*3 Piston position Mass air flow sensor Amount of intake air Engine coolant temperature sensor Engine coolant temperature Heated oxygen sensor 1 Density of oxygen in exhaust gas Throttle position sensor Throttle position Accelerator pedal position sensor Accelerator pedal position Park/neutral position (PNP) switch Gear position Vehicle speed signal*2 Vehicle speed Air conditioner switch Air conditioner operation Knock sensor Engine knocking condition Battery Battery voltage*3 EVAP control system pressure sensor Ambient air barometric pressure Power steering pressure sensor Power steering operation Heated oxygen sensor 2*1 Density of oxygen in exhaust gas ECM function Actuator EM LC FE Fuel injection & mixture ratio control CL Injectors MT AT TF PD *1: Under normal conditions, this sensor is not for engine control operation. *2: This signal is sent to the ECM through CAN communication line. *3: ECM determines the start signal status by the signals of engine speed and battery voltage. Basic Multiport Fuel Injection System MA AX NAEC0014S02 The amount of fuel injected from the fuel injector is determined by the ECM. The ECM controls the length of time the valve remains open (injection pulse duration). The amount of fuel injected is a program value in the ECM memory. The program value is preset by engine operating conditions. These conditions are determined by input signals (for engine speed and intake air) from both the crankshaft position sensor and the mass air flow sensor. Various Fuel Injection Increase/Decrease Compensation NAEC0014S03 In addition, the amount of fuel injected is compensated to improve engine performance under various operating conditions as listed below. 쐌 During warm-up 쐌 When starting the engine 쐌 During acceleration 쐌 Hot-engine operation 쐌 When selector lever is changed from “N” to “D” 쐌 High-load, high-speed operation 쐌 During deceleration 쐌 During high engine speed operation SU BR ST RS BT HA SC EL IDX EC-37 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Multiport Fuel Injection (MFI) System (Cont’d) Mixture Ratio Feedback Control (Closed loop control) NAEC0014S04 SEF336WC The mixture ratio feedback system provides the best air-fuel mixture ratio for driveability and emission control. The three way catalyst (manifold) can then better reduce CO, HC and NOx emissions. This system uses a heated oxygen sensor 1 in the exhaust manifold to monitor if the engine operation is rich or lean. The ECM adjusts the injection pulse width according to the sensor voltage signal. For more information about the heated oxygen sensor 1, refer to EC-278. 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. Heated oxygen sensor 2 is located downstream of the three way catalyst (manifold). Even if the switching characteristics of the heated oxygen sensor 1 shift, the air-fuel ratio is controlled to stoichiometric by the signal from the heated oxygen sensor 2. Open Loop Control NAEC0014S05 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. 쐌 Deceleration and acceleration 쐌 High-load, high-speed operation 쐌 Malfunction of heated oxygen sensor 1 or its circuit 쐌 Insufficient activation of heated oxygen sensor 1 at low engine coolant temperature 쐌 High engine coolant temperature 쐌 During warm-up 쐌 After shifting from “N” to “D” 쐌 When starting the engine Mixture Ratio Self-learning Control NAEC0014S06 The mixture ratio feedback control system monitors the mixture ratio signal transmitted from the heated oxygen sensor 1. This feedback signal is then sent to the ECM. The ECM controls the basic mixture ratio as close to the theoretical mixture ratio as possible. 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 operation (i.e., injector clogging) directly affect mixture ratio. Accordingly, the difference between the basic and theoretical mixture 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 heated oxygen sensor 1 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 individual engine differences, wear over time and changes in the usage environment. EC-38 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Multiport Fuel Injection (MFI) System (Cont’d) Fuel Injection Timing NAEC0014S07 GI MA EM LC SEF179U Two types of systems are used. Sequential Multiport Fuel Injection System NAEC0014S0701 Fuel is injected into each cylinder during each engine cycle according to the firing order. This system is used when the engine is running. Simultaneous Multiport Fuel Injection System NAEC0014S0702 Fuel is injected simultaneously into all six cylinders twice each engine cycle. In other words, pulse signals of the same width are simultaneously transmitted from the ECM. The six injectors will then receive the signals two times for each engine cycle. This system is used when the engine is being started and/or if the fail-safe system (CPU) is operating. FE CL MT AT Fuel Shut-off NAEC0014S08 Fuel to each cylinder is cut off during deceleration or operation of the engine at excessively high speeds. TF Electronic Ignition (EI) System DESCRIPTION Input/Output Signal Chart Sensor Crankshaft position sensor (POS) NAEC0015 PD NAEC0015S01 Input Signal to ECM Camshaft position sensor (PHASE) Engine speed*2 Piston position Mass air flow sensor Amount of intake air Engine coolant temperature sensor Engine coolant temperature Throttle position sensor Throttle position Accelerator pedal position sensor Accelerator pedal position Vehicle speed signal*1 Vehicle speed Knock sensor Engine knocking Park/neutral position (PNP) switch Gear position Battery Battery voltage*2 ECM function Actuator AX SU BR Ignition timPower transistor ing control *1: This signal is sent to the ECM through CAN communication line. *2: ECM determines the start signal status by the signals of engine speed and battery voltage. ST RS BT HA SC EL IDX EC-39 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Electronic Ignition (EI) System (Cont’d) System Description NAEC0015S02 SEF742M The ignition timing is controlled by the ECM to maintain the best air-fuel ratio for every running condition of the engine. The ignition timing data is stored in the ECM. This data forms the map shown. The ECM receives information such as the injection pulse width and camshaft position sensor signal. Computing this information, ignition signals are transmitted to the power transistor. e.g., N: 1,800 rpm, Tp: 1.50 msec A °BTDC During the following conditions, the ignition timing is revised by the ECM according to the other data stored in the ECM. 쐌 At starting 쐌 During warm-up 쐌 At idle 쐌 At low battery voltage 쐌 During acceleration The knock sensor retard system is designed only for emergencies. The basic ignition timing is programmed within the anti-knocking zone, if recommended fuel is used under dry conditions. The retard system does not operate under normal driving conditions. If engine knocking occurs, the knock sensor monitors the condition. The signal is transmitted to the ECM. The ECM retards the ignition timing to eliminate the knocking condition. Air Conditioning Cut Control DESCRIPTION Input/Output Signal Chart Sensor NAEC0016 NAEC0016S01 Input Signal to ECM Air conditioner switch*1 Air conditioner “ON” signal Throttle position sensor Throttle position Accelerator pedal position sensor Accelerator pedal position Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed*2 Engine coolant temperature sensor Engine coolant temperature Vehicle speed signal*1 Vehicle speed Refrigerant pressure sensor Refrigerant pressure Power steering pressure sensor Power steering operation Battery Battery voltage*2 ECM function Actuator Air conditioner cut Air conditioner relay control *1: This signal is sent to the ECM through CAN communication line. *2: ECM determines the start signal status by the signals of engine speed and battery voltage. System Description NAEC0016S02 This system improves engine operation when the air conditioner is used. Under the following conditions, the air conditioner is turned off. 쐌 When the accelerator pedal is fully depressed. EC-40 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Air Conditioning Cut Control (Cont’d) 쐌 쐌 쐌 쐌 쐌 쐌 When cranking the engine. At high engine speeds. When the engine coolant temperature becomes excessively high. When operating power steering during low engine speed or low vehicle speed. When engine speed is excessively low. When refrigerant pressure is excessively low or high. GI MA EM Fuel Cut Control (at no load & high engine speed) DESCRIPTION Input/Output Signal Chart Sensor LC NAEC0017 NAEC0017S01 Input Signal to ECM Vehicle speed signal*1 Vehicle speed Park/neutral position (PNP) switch Neutral position Throttle position sensor Throttle position Accelerator pedal position sensor Accelerator pedal position Engine coolant temperature sensor Engine coolant temperature Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed ECM function Actuator FE CL Fuel cut control Injectors MT AT *1: This signal is sent to the ECM through CAN communication line. If the engine speed is above 1,800 rpm with no load (for example, in neutral and engine speed over 1,800 rpm) fuel will be cut off after some time. The exact time when the fuel is cut off varies based on engine speed. Fuel cut will operate until the engine speed reaches 1,500 rpm, then fuel cut is cancelled. NOTE: This function is different from deceleration control listed under “Multiport Fuel Injection (MFI) System”, EC-37. PD AX Evaporative Emission System DESCRIPTION TF NAEC0018 SU BR ST RS BT HA SC SEF569XB EL 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 canister which contains activated carbon and the vapor is stored there when the engine is not operating or when refueling to the fuel tank. EC-41 IDX ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Evaporative Emission System (Cont’d) 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 solenoid valve is controlled by ECM. When the engine operates, the flow rate of vapor controlled by EVAP canister purge volume control solenoid valve is proportionally regulated as the air flow increases. EVAP canister purge volume control solenoid valve also shuts off the vapor purge line during decelerating and idling. INSPECTION EVAP Canister NAEC0019 NAEC0019S01 Check EVAP canister as follows: 1. Pinch the fresh air hose. 2. Blow air into port A and check that it flows freely out of port B. SEF428T Tightening Torque NAEC0019S02 Tighten EVAP canister as shown in the figure. Make sure new O-ring is installed properly between EVAP canister and EVAP canister vent control valve. SEF231SB Fuel Tank Vacuum Relief Valve (Built into fuel fillerNAEC0019S03 cap) 1. 2. SEF445Y Wipe clean valve housing. Check valve opening pressure and vacuum. Pressure: 15.3 - 20.0 kPa (0.156 - 0.204 kg/cm2, 2.22 - 2.90 psi) Vacuum: −6.0 to −3.3 kPa (−0.061 to −0.034 kg/cm2, −0.87 to −0.48 psi) 3. If out of specification, replace fuel filler cap as an assembly. CAUTION: Use only a genuine fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. SEF943S EC-42 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Evaporative Emission System (Cont’d) Vacuum Cut Valve and Vacuum Cut Valve Bypass NAEC0019S04 Valve GI Refer to EC-667. EVAP Canister Purge Volume Control Solenoid Valve MA NAEC0019S05 Refer to EC-396. Fuel Tank Temperature Sensor NAEC0019S06 Refer to EC-319. EM LC Evap Service Port NAEC0019S07 Positive pressure is delivered to the EVAP system through the EVAP service port. If fuel vapor leakage in the EVAP system occurs, use a leak detector to locate the leak. FE CL MT SEF462UA How to Detect Fuel Vapor Leakage SEF200U PEF838U AT NAEC0019S08 CAUTION: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in EVAP system. NOTE: 쐌 Do not start engine. 쐌 Improper installation of EVAP service port adapter to the EVAP service port may cause a leak. With CONSULT-II NAEC0019S0801 1) Attach the EVAP service port adapter securely to the EVAP service port. 2) Also attach the pressure pump and hose to the EVAP service port adapter. 3) Turn ignition switch “ON”. 4) Select the “EVAP SYSTEM CLOSE” of “WORK SUPPORT MODE” with CONSULT-II. 5) Touch “START”. A bar graph (Pressure indicating display) will appear on the screen. 6) Apply positive pressure to the EVAP system until the pressure indicator reaches the middle of the bar graph. 7) Remove EVAP service port adapter and hose with pressure pump. 8) Locate the leak using a leak detector. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-45. TF PD AX SU BR ST RS BT HA SC EL IDX PEF917U EC-43 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Evaporative Emission System (Cont’d) 1) 2) 3) 4) SEF462UA 5) 6) Without CONSULT-II NAEC0019S0802 Attach the EVAP service port adapter securely to the EVAP service port. Also attach the pressure pump with pressure gauge to the EVAP service port adapter. Apply battery voltage to between the terminals of both EVAP canister vent control valve and vacuum cut valve bypass valve to make a closed EVAP system. To locate the leak, deliver positive pressure to the EVAP system until pressure gauge points reach 1.38 to 2.76 kPa (0.014 to 0.028 kg/cm2, 0.2 to 0.4 psi). Remove EVAP service port adapter and hose with pressure pump. Locate the leak using a leak detector. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-45. SEC930C EC-44 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Evaporative Emission System (Cont’d) EVAPORATIVE EMISSION LINE DRAWING NAEC0020 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL SEC414D EC-45 IDX ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Evaporative Emission System (Cont’d) SEC927C EC-46 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION On Board Refueling Vapor Recovery (ORVR) On Board Refueling Vapor Recovery (ORVR) NAEC0744 SYSTEM DESCRIPTION GI NAEC0744S01 MA EM LC FE CL MT SEF206VA AT TF PD AX SU BR ST SEC883C From the beginning of refueling, the fuel tank pressure goes up. When the pressure reaches the setting value of the refueling control valve (RCV) opening pressure, the RCV is opened. After RCV opens, the air and vapor inside the fuel tank go through refueling EVAP vapor cut valve, RCV and refueling vapor line to the EVAP canister. The vapor is absorbed by the EVAP canister and the air is released to the atmosphere. When the refueling has reached the full level of the fuel tank, the refueling EVAP vapor cut valve is closed and refueling is stopped because of auto shut-off. The vapor which was absorbed by the EVAP canister is purged during driving. The RCV is always closed during driving and the evaporative emission control system is operated the same as conventional system. WARNING: When conducting inspections below, be sure to observe the following: 쐌 Put a “CAUTION: INFLAMMABLE” sign in workshop. 쐌 Do not smoke while servicing fuel system. Keep open flames and sparks away from work area. 쐌 Be sure to furnish the workshop with a CO2 fire extinguisher. EC-47 RS BT HA SC EL IDX ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION On Board Refueling Vapor Recovery (ORVR) (Cont’d) CAUTION: 쐌 Before removing fuel line parts, carry out the following procedures: a) Put drained fuel in an explosion-proof container and put lid on securely. b) Release fuel pressure from fuel line. Refer to “Fuel Pressure Release”, EC-64. c) Disconnect battery ground cable. 쐌 Always replace O-ring when the fuel gauge retainer is removed. 쐌 Do not kink or twist hose and tube when they are installed. 쐌 Do not tighten hose and clamps excessively to avoid damaging hoses. 쐌 After installation, run engine and check for fuel leaks at connection. 쐌 Do not attempt to top off the fuel tank after the fuel pump nozzle shuts off automatically. Continued refueling may cause fuel overflow, resulting in fuel spray and possibly a fire. DIAGNOSTIC PROCEDURE Symptom: Fuel Odor from EVAP Canister Is Strong. 1 NAEC0744S02 NAEC0744S0201 CHECK EVAP CANISTER 1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Weigh the EVAP canister with EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb). OK or NG OK 䊳 GO TO 2. NG 䊳 GO TO 3. 2 CHECK IF EVAP CANISTER SATURATED WITH WATER Does water drain from the EVAP canister? SEF596U Yes or No Yes 䊳 GO TO 3. No (With CONSULT-II) 䊳 GO TO 6. No (Without CONSULTII) 䊳 GO TO 7. 3 REPLACE EVAP CANISTER Replace EVAP canister with a new one. 䊳 GO TO 4. EC-48 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION On Board Refueling Vapor Recovery (ORVR) (Cont’d) 4 1. 2. 3. 4. GI CHECK WATER SEPARATOR Check Check Check Check visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged. MA EM LC FE PBIB1032E 5. In case of NG in items 2 - 4, replace the parts. NOTE: 쐌 Do not disassemble water separator. CL OK or NG OK 䊳 GO TO 5. NG 䊳 Replace water separator. 5 DETECT MALFUNCTIONING PART MT AT TF Check the EVAP hose between EVAP canister and water separator for clogging or poor connection. 䊳 Repair or replace EVAP hose. PD AX SU BR ST RS BT HA SC EL IDX EC-49 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION On Board Refueling Vapor Recovery (ORVR) (Cont’d) 6 1. 2. a. b. c. 3. 4. a. b. c. d. CHECK REFUELING EVAP VAPOR CUT VALVE With CONSULT-II Remove fuel tank. Refer to FE-4, “FUEL SYSTEM. Drain fuel from the tank as follows: Remove fuel feed hose located on the fuel gauge retainer. Connect a spare fuel hose, one side to fuel gauge retainer where the hose was removed and the other side to a fuel container. Drain fuel using “FUEL PUMP RELAY” in “ACTIVE TEST” mode with CONSULT-II. Check refueling EVAP vapor cut valve for being stuck to close as follows. Blow air into the refueling EVAP vapor cut valve (from hose end B), and check that the air flows freely into the tank. Check EVAP vapor cut valve for being stuck to open as follows. Connect vacuum pump to hose ends A and B using a suitable 3-way connector. Remove fuel gauge retainer with fuel gauge unit. Always replace O-ring with new one. Put fuel tank upside down. Apply vacuum pressure to both hose ends A and B [−13.3 kPa (−100 mmHg, −3.94 inHg)] with fuel gauge retainer remaining open and check that the pressure is applicable. SEF968X OK or NG OK 䊳 GO TO 8. NG 䊳 Replace refueling EVAP vapor cut valve with fuel tank. EC-50 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION On Board Refueling Vapor Recovery (ORVR) (Cont’d) 7 1. 2. a. b. 3. 4. a. b. c. d. GI CHECK REFUELING EVAP VAPOR CUT VALVE Without CONSULT-II Remove fuel tank. Refer to FE-4, “FUEL SYSTEM”. Drain fuel from the tank as follows: Remove fuel gauge retainer. Drain fuel from the tank using a hand pump into a fuel container. Check refueling EVAP vapor cut valve for being stuck to close as follows. Blow air into the refueling EVAP vapor cut valve (from hose end B), and check that the air flows freely into the tank. Check EVAP vapor cut valve for being stuck to open as follows. Connect vacuum pump to hose ends A and B using a suitable 3-way connector. Remove fuel gauge retainer with fuel gauge unit. Always replace O-ring with new one. Put fuel tank upside down. Apply vacuum pressure to both hose ends A and B [−13.3 kPa (−100 mmHg, −3.94 inHg)] with fuel gauge retainer remaining open and check that the pressure is applicable. MA EM LC FE CL MT AT SEF968X TF OK or NG OK 䊳 GO TO 8. NG 䊳 Replace refueling EVAP vapor cut valve with fuel tank. 8 PD AX CHECK REFUELING CONTROL VALVE 1. Remove fuel filler cap. 2. Check air continuity between hose ends A and B. Blow air into the hose end B. Air should flow freely into the fuel tank. 3. Blow air into hose end A and check there is no leakage. 4. Apply pressure to both hose ends A and B [20 kPa (150 mmHg, 5.91 inHg)] using a pressure pump and a suitable 3-way connector. Check that there is no leakage. SU BR ST RS BT HA SEF968X OK or NG OK 䊳 INSPECTION END NG 䊳 Replace refueling control valve with fuel tank. SC EL IDX EC-51 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION On Board Refueling Vapor Recovery (ORVR) (Cont’d) Symptom: Cannot Refuel/Fuel Odor From The Fuel Filler Opening Is Strong While Refueling. 1 NAEC0744S0202 CHECK EVAP CANISTER 1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Weigh the EVAP canister with EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb). OK or NG OK 䊳 GO TO 2. NG 䊳 GO TO 3. 2 CHECK IF EVAP CANISTER SATURATED WITH WATER Does water drain from the EVAP canister? SEF596U Yes or No Yes 䊳 GO TO 3. No 䊳 GO TO 6. 3 REPLACE EVAP CANISTER Replace EVAP canister with a new one. 䊳 GO TO 4. EC-52 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION On Board Refueling Vapor Recovery (ORVR) (Cont’d) 4 1. 2. 3. 4. GI CHECK WATER SEPARATOR Check Check Check Check visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged. MA EM LC FE PBIB1032E 5. In case of NG in items 2 - 4, replace the parts. NOTE: 쐌 Do not disassemble water separator. CL OK or NG OK 䊳 GO TO 5. NG 䊳 Replace water separator. 5 DETECT MALFUNCTIONING PART MT AT TF Check the EVAP hose between EVAP canister and water separator for clogging or poor connection. 䊳 6 Repair or replace EVAP hose. CHECK VENT HOSES AND VENT TUBES Check hoses and tubes between EVAP canister and refueling control valve for clogging, kink, looseness and improper connection. OK or NG OK 䊳 GO TO 7. NG 䊳 Repair or replace hoses and tubes. 7 CHECK FILLER NECK TUBE PD AX SU BR ST Check signal line and recirculation line for clogging, dents and cracks. OK or NG OK 䊳 GO TO 8. NG 䊳 Replace filler neck tube. RS BT HA SC EL IDX EC-53 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION On Board Refueling Vapor Recovery (ORVR) (Cont’d) 8 CHECK REFUELING CONTROL VALVE 1. Remove fuel filler cap. 2. Check air continuity between hose ends A and B. Blow air into the hose end B. Air should flow freely into the fuel tank. 3. Blow air into hose end A and check there is no leakage. 4. Apply pressure to both hose ends A and B [20 kPa (150 mmHg, 5.91 inHg)] using a pressure pump and a suitable 3-way connector. Check that there is no leakage. SEF968X OK or NG OK (With CONSULT-II) 䊳 GO TO 9. OK (Without CONSULTII) 䊳 GO TO 10. NG 䊳 Replace refueling control valve with fuel tank. 9 1. 2. a. b. c. 3. 4. a. b. c. d. CHECK REFUELING EVAP VAPOR CUT VALVE With CONSULT-II Remove fuel tank. Refer to FE-4, “FUEL SYSTEM”. Drain fuel from the tank as follows: Remove fuel feed hose located on the fuel gauge retainer. Connect a spare fuel hose, one side to fuel gauge retainer where the hose was removed and the other side to a fuel container. Drain fuel using “FUEL PUMP RELAY” in “ACTIVE TEST” mode with CONSULT-II. Check refueling EVAP vapor cut valve for being stuck to close as follows. Blow air into the refueling EVAP vapor cut valve (from hose end B), and check that the air flows freely into the tank. Check EVAP vapor cut valve for being stuck to open as follows. Connect vacuum pump to hose ends A and B using a suitable 3-way connector. Remove fuel gauge retainer with fuel gauge unit. Always replace O-ring with new one. Put fuel tank upside down. Apply vacuum pressure to both hose ends A and B [−13.3 kPa (−100 mmHg, −3.94 inHg)] with fuel gauge retainer remaining open and check that the pressure is applicable. SEF968X OK or NG OK 䊳 GO TO 11. NG 䊳 Replace refueling EVAP vapor cut valve with fuel tank. EC-54 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION On Board Refueling Vapor Recovery (ORVR) (Cont’d) 10 1. 2. a. b. 3. 4. a. b. c. d. GI CHECK REFUELING EVAP VAPOR CUT VALVE Without CONSULT-II Remove fuel tank. Refer to FE-4, “FUEL SYSTEM”. Drain fuel from the tank as follows: Remove fuel gauge retainer. Drain fuel from the tank using a hand pump into a fuel container. Check refueling EVAP vapor cut valve for being stuck to close as follows. Blow air into the refueling EVAP vapor cut valve (from hose end B), and check that the air flows freely into the tank. Check EVAP vapor cut valve for being stuck to open as follows. Connect vacuum pump to hose ends A and B using a suitable 3-way connector. Remove fuel gauge retainer with fuel gauge unit. Always replace O-ring with new one. Put fuel tank upside down. Apply vacuum pressure to both hose ends A and B [−13.3 kPa (−100 mmHg, −3.94 inHg)] with fuel gauge retainer remaining open and check that the pressure is applicable. MA EM LC FE CL MT AT SEF968X TF OK or NG OK 䊳 GO TO 11. NG 䊳 Replace refueling EVAP vapor cut valve with fuel tank. 11 PD AX CHECK FUEL FILLER TUBE Check filler neck tube and hose connected to the fuel tank for clogging, dents and cracks. OK or NG OK 䊳 GO TO 12. NG 䊳 Replace fuel filler tube. 12 SU BR ST CHECK ONE-WAY FUEL VALVE-I Check one-way valve for clogging. OK or NG OK 䊳 GO TO 13. NG 䊳 Repair or replace one-way fuel valve with fuel tank. RS BT HA SC EL IDX EC-55 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION On Board Refueling Vapor Recovery (ORVR) (Cont’d) 13 CHECK ONE-WAY FUEL VALVE-II 1. Make sure that fuel is drained from the tank. 2. Remove fuel filler tube and hose. 3. Check one-way fuel valve for operation as follows. When a stick is inserted, the valve should open, when removing stick it should close. SEF665U Do not drop any material into the tank. OK or NG OK 䊳 INSPECTION END NG 䊳 Replace fuel filler tube or replace one-way fuel valve with fuel tank. Positive Crankcase Ventilation DESCRIPTION SEF372Q NAEC0021 This system returns blow-by gas to the intake manifold. The positive crankcase ventilation (PCV) valve is provided to conduct crankcase blow-by gas to the intake manifold. During partial throttle operation of the engine, the intake manifold sucks the blow-by gas through the PCV valve. Normally, the capacity of the valve is sufficient to handle any blow-by and a small amount of ventilating air. The ventilating air is then drawn from the air inlet tubes into the crankcase. In this process the air passes through the hose connecting air inlet tubes to 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 air inlet tubes under all conditions. PBIB1588E INSPECTION PCV (Positive Crankcase Ventilation) Valve NAEC0022 NAEC0022S01 With engine running at idle, remove PCV valve ventilation hose from PCV valve; if the valve is working properly, a hissing noise will be heard as air passes through it and a strong vacuum should be felt immediately when a finger is placed over valve inlet. PBIB1589E EC-56 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Positive Crankcase Ventilation (Cont’d) PCV Valve Ventilation Hose 1. 2. NAEC0022S02 Check hoses and hose connections for leaks. Disconnect all hoses and clean with compressed air. If any hose cannot be freed of obstructions, replace. GI MA EM LC ET277 CAN Communication SYSTEM DESCRIPTION NAEC1368 CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. CAN COMMUNICATION UNIT CL MT NAEC1369 Body type Axle FE Wide/Wagon 4WD (All-mode) 4WD (Part time) Engine AT 2WD 4WD (Part time) VQ35DE Transmission TF A/T Brake control M/T VDC PD ABS CAN communication unit ECM X X X X TCM X X X X Transfer control unit X Steering angle sensor X X X ABS actuator and electric unit (control unit) X X X Combination meter X X X CAN communication type (Reference page) X AX SU BR Type 1 (EC-58) Type 2 (EC-60) X X Type 3 (EC-61) Type 4 (EC-62) ST RS X: Applicable BT HA SC EL IDX EC-57 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION CAN Communication (Cont’d) Type 1 =NAEC1369S01 System Diagram NAEC1369S0101 SEL683Y Input/Output Signal Chart NAEC1369S0102 T: Transmit R: Receive Signals ECM TCM Transfer control unit ABS actuaSteering tor and elec- Combination angle sensor tric unit (conmeter trol unit) Engine speed signal T R R Accelerator pedal position signal T R R Closed throttle position signal T R Wide open throttle position signal T R VDC operation signal R R T TCS operation signal R R T ABS operation signal R R T Output shaft revolution signal R ETC fail signal T During shifting signal R T R R T R Steering wheel angle sensor signal R T Wheel speed sensor signal R Stop lamp switch signal R R T R T MIL signal T R Engine coolant temperature signal T R Fuel consumption signal T R T R Vehicle speed signal R T Lock-up prohibition signal T R Lock-up signal R T Neutral range switch signal R T Parking range switch signal R T Overdrive control switch signal R T A/C compressor feedback signal T R Fuel level sensor signal R T EC-58 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION CAN Communication (Cont’d) Signals ECM TCM Transfer control unit ABS actuaSteering tor and elec- Combination angle sensor tric unit (conmeter trol unit) A/T position indicator signal T R O/D OFF indicatorsignal T R GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-59 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION CAN Communication (Cont’d) Type 2 =NAEC1369S02 System Diagram NAEC1369S0201 SEL682Y Input/Output Signal Chart NAEC1369S0202 T: Transmit R: Receive Signals ECM TCM Steering angle sensor ABS actuator and electric unit (control unit) Combination meter R Engine speed signal T R Accelerator pedal position signal T R Closed throttle position signal T R Wide open throttle position signal T R VDC operation signal R T TCS operation signal R T ABS operation signal R T Steering wheel angle sensor signal T R MIL signal T R Engine coolant temperature signal T R Fuel consumption signal T R T R Vehicle speed signal R T Stop lamp switch signal R Lock-up prohibition signal T R Lock-up signal R T T Neutral range switch signal R T Parking range switch signal R T Overdrive control switch signal R T A/C compressor feedback signal T R Fuel level sensor signal R T A/T position indicator signal T R O/D OFF indicator signal T R EC-60 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION CAN Communication (Cont’d) Type 3 =NAEC1369S03 System Diagram GI NAEC1369S0301 MA EM LC SEL684Y Input/Output Signal Chart NAEC1369S0302 FE T: Transmit R: Receive Signals ECM TCM Engine speed signal T Closed throttle position signal T R Wide open throttle position signal T R Stop lamp switch signal Combination meter CL R R Lock-up prohibition signal T R Lock-up signal R T MT T AT TF Neutral range switch signal R T Parking range switch signal R T Overdrive control switch signal R T MIL signal T R Engine coolant temperature signal T R Fuel consumption signal T R Vehicle speed signal R T A/C compressor feedback signal T R Fuel level sensor signal R T A/T position indicator signal T R O/D OFF indicator signal T R PD AX SU BR ST RS BT HA SC EL IDX EC-61 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION CAN Communication (Cont’d) Type 4 =NAEC1369S04 System Diagram NAEC1369S0401 SEL681Y Input/Output Signal Chart NAEC1369S0402 T: Transmit R: Receive Signals ECM Combination meter Engine speed signal T R MIL signal T R Engine coolant temperature signal T R Fuel consumption signal T R Vehicle speed signal R T A/C compressor feedback signal T R Fuel level sensor signal R T Automatic Speed Control Device (ASCD) System DESCRIPTION Input/Output Signal Chart Sensor NAEC1370 NAEC1370S01 Input signal to ECM ASCD brake switch Brake pedal operation Stop lamp switch Brake pedal operation ASCD clutch switch (MT models) Clutch pedal operation ASCD steering switch ASCD steering switch operation Combination meter Vehicle speed TCM Power train revolution Basic ASCD System ECM function ASCD vehicle speed control Actuator Electric throttle control actuator NAEC1370S02 Refer to Owner’s Manual for ASCD operating instructions. Automatic Speed Control Device (ASCD) allows a driver to keep vehicle at predetermined constant speed without depressing accelerator pedal. Driver can set vehicle speed in advance between approximately 40 km/h (25 MPH) and 144 km/h (89 MPH). ECM controls throttle angle of electric throttle control actuator to regulate engine speed. Operation status of ASCD is indicated by CRUISE indicator and SET indicator in combination meter. If any malfunction occurs in ASCD system, it automatically deactivates control. Set Operation NAEC1370S03 Press ASCD CRUISE switch (Main switch). (Then CRUISE indicator in combination meter illuminates.) When vehicle speed reaches a desired speed between approximately 40 km/h (25 MPH) and 144 km/h (89 MPH), press SET switch. (Then SET indicator in combination meter illuminates.) EC-62 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Automatic Speed Control Device (ASCD) System (Cont’d) Accel Operation NAEC1370S04 If the RESUME/ACCEL switch is depressed during cruise control driving, increase the vehicle speed until the switch is released or vehicle speed reaches maximum speed controlled by the system. And then ASCD will keep the new set speed. Cancel Operation NAEC1370S05 When any of following conditions exist, cruise operation will be canceled. 쐌 CANCEL switch is depressed. 쐌 More than 2 switches at ASCD steering switch are depressed at the same time (Set speed will be cleared.). 쐌 Brake pedal is depressed. 쐌 Clutch pedal is depressed (M/T models). 쐌 A/T selector lever is shifted to P, N or R position (A/T models). 쐌 Vehicle speed decreased to 13 km/h (8 MPH) lower than the set speed 쐌 TCS system is operated When the ECM detects any of the following conditions, the ECM will cancel the cruise operation and inform the driver by blinking indicator lamp. 쐌 Engine coolant temperature is slightly higher than the normal operating temperature: CRUISE lamp may blink slowly. When the engine coolant temperature decreases to the normal operating temperature, CRUISE lamp will stop blinking and the cruise operation will be able to work by depressing SET switch or RESUME switch. 쐌 Malfunction for self-diagnosis regarding ASCD control: SET lamp will blink quickly. If MAIN switch is turned to OFF while ASCD is activated, all of ASCD operations will be canceled and vehicle speed memory will be erased. Coast Operation NAEC1370S06 GI MA EM LC FE CL MT AT When the SET/COAST switch is depressed during cruise control driving, decrease vehicle set speed until the switch is released. And then ASCD will keep the new set speed. TF Resume Operation PD NAEC1370S07 When the RESUME/ACCEL switch is depressed after cancel operation other than depressing MAIN switch is performed, vehicle speed will return to last set speed. To resume vehicle set speed, vehicle condition must meet following conditions. 쐌 Brake pedal is released. 쐌 Clutch pedal is released (M/T models). 쐌 A/T selector lever is in other than P, N and R positions (A/T models). 쐌 Vehicle speed is greater than 40 km/h (25 MPH) and 144 km/h (89 MPH). AX SU BR ST RS BT HA SC EL IDX EC-63 BASIC SERVICE PROCEDURE Fuel Pressure Release Fuel Pressure Release NAEC0023 Before disconnecting fuel line, release fuel pressure from fuel line to eliminate danger. WITH CONSULT-II 1. 2. 3. 4. SEF941Y 5. NAEC0023S01 Turn ignition switch “ON”. Perform “FUEL PRESSURE RELEASE” in “WORK SUPPORT” mode with CONSULT-II. Start engine. After engine stalls, crank it two or three times to release all fuel pressure. Turn ignition switch “OFF”. SEF214Y WITHOUT CONSULT-II 1. 2. 3. 4. 5. NAEC0023S02 Remove fuel pump fuse located in fuse box. Start engine. After engine stalls, crank it two or three times to release all fuel pressure. Turn ignition switch “OFF”. Reinstall fuel pump fuse after servicing fuel system. SEF933Y Fuel Pressure Check 쐌 쐌 쐌 쐌 쐌 SEF327Z 1. 2. NAEC0024 When reconnecting fuel line, always use new clamps. Make sure that clamp screw does not contact adjacent parts. Use a torque driver to tighten clamps. Use Pressure Gauge to check fuel pressure. Do not perform fuel pressure check with electrical system operating (i.e. lights, rear window defogger, A/C etc.). Fuel pressure gauge may indicate false readings due to varying engine loads and changes in manifold vacuum. Release fuel pressure to zero. Disconnect fuel tube joint between fuel damper and injector tube and set fuel pressure check adapter (J44321). EC-64 BASIC SERVICE PROCEDURE Fuel Pressure Check (Cont’d) 3. SEF328Z Install pressure gauge to the fuel pressure check adapter as shown in the figure. 4. Start engine and check for fuel leakage. 5. Read the indication of fuel pressure gauge. At idling: With vacuum hose connected Approximately 235 kPa (2.4 kg/cm2, 34 psi) With vacuum hose disconnected Approximately 294 kPa (3.0 kg/cm2, 43 psi) If results are unsatisfactory, perform Fuel Pressure Regulator Check. GI MA EM LC FE CL MT Fuel Pressure Regulator Check 1. 2. 3. AT NAEC0025 Stop engine and disconnect fuel pressure regulator vacuum hose from vacuum gallery. Plug vacuum gallery with a blind cap. Connect variable vacuum source to fuel pressure regulator. TF PD AX SU SEF329ZA 4. Start engine and read indication of fuel pressure gauge as vacuum is changed. Fuel pressure should decrease as vacuum increases. If results are unsatisfactory, replace fuel pressure regulator. BR ST RS BT SEF718BA HA SC EL IDX EC-65 BASIC SERVICE PROCEDURE Injector Injector REMOVAL AND INSTALLATION 1. 2. 3. SEF937Y 4. 5. 쐌 쐌 6. 쐌 쐌 쐌 7. 쐌 NAEC0026 Release fuel pressure to zero. Remove intake manifold collector. Refer to EM-21, “TIMING CHAIN”. Remove fuel tube assemblies in numerical sequence as shown in the figure at left. Expand and remove clips securing fuel injectors. Extract fuel injectors straight from fuel tubes. Be careful not to damage injector nozzles during removal. Do not bump or drop fuel injectors. Carefully install O-rings, including the one used with the pressure regulator. Lubricate O-rings with a smear of engine oil. Be careful not to damage O-rings with service tools, finger nails or clips. Do not expand or twist O-rings. Discard old clips; replace with new ones. Position clips in grooves on fuel injectors. Make sure that protrusions of fuel injectors are aligned with cutouts of clips after installation. SEF703X SEF938Y 8. 9. Align protrusions of fuel tubes with those of fuel injectors. Insert fuel injectors straight into fuel tubes. After properly inserting fuel injectors, check to make sure that fuel tube protrusions are engaged with those of fuel injectors, and that flanges of fuel tubes are engaged with clips. EC-66 BASIC SERVICE PROCEDURE Injector (Cont’d) SEF939Y 10. Tighten fuel tube assembly mounting nuts in numerical sequence (indicated in the figure at left) and in two stages. : Tightening torque N·m (kg-m, ft-lb) 1st stage: 9.3 - 10.8 (1.0 - 1.1, 6.9 - 7.9) 2nd stage: 20.6 - 26.5 (2.1 - 2.7, 16 - 19) 11. Install all parts removed in reverse order of removal. CAUTION: After properly connecting fuel tube assembly to injector and fuel hose, check connection for fuel leakage. GI MA EM LC How to Check Idle Speed and Ignition Timing NAEC0607 IDLE SPEED NAEC0607S01 WITH CONSULT-II Check idle speed in “DATA MONITOR” mode with CONSULT-II. WITH GST Check idle speed with GST. FE CL MT SEF058Y IGNITION TIMING Any of following two methods may be used. 쐌 Method A a) Attach timing light to loop wire as shown. b) Check ignition timing. AT NAEC0607S02 TF PD AX SU SEF940Y 쐌 a) Method B Remove No. 1 ignition coil. BR ST RS BT SEC411D HA SC EL IDX EC-67 BASIC SERVICE PROCEDURE How to Check Idle Speed and Ignition Timing (Cont’d) b) c) Connect No. 1 ignition coil and No. 1 spark plug with suitable high-tension wire as shown, and attach timing light clamp to this wire. Check ignition timing. SEC412D SEC580D SEF311Q EC-68 BASIC SERVICE PROCEDURE Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment GI =NAEC0028 PREPARATION 1) 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 2) 3) 4) 5) 6) NAEC0028S01 Make sure that the following parts are in good order. Battery Ignition system Engine oil and coolant levels Fuses ECM harness connector Vacuum hoses Air intake system (Oil filler cap, oil level gauge, etc.) Fuel pressure Engine compression Throttle valve Evaporative emission system On air conditioner equipped models, checks should be carried out while the air conditioner is “OFF”. On automatic transmission equipped models, when checking idle rpm, ignition timing and mixture ratio, checks should be carried out while shift lever is in “N” position. When measuring “CO” percentage, insert probe more than 40 cm (15.7 in) into tail pipe. Turn off headlamps, heater blower, rear defogger. Keep front wheels pointed straight ahead. MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-69 BASIC SERVICE PROCEDURE Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d) Overall Inspection Sequence NAEC0028S0101 PBIB1054E EC-70 BASIC SERVICE PROCEDURE Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d) INSPECTION PROCEDURE 1 =NAEC0028S02 GI INSPECTION START 1. Check service records for any recent repairs that may indicate a related malfunction, or a current need for scheduled maintenance. 2. Open engine hood and check the following: – Harness connectors for improper connections – Wiring harness for improper connections, pinches and cut – Vacuum hoses for splits, kinks and improper connections – Hoses and ducts for leaks – Air cleaner clogging – Gasket MA EM LC FE CL SEF983U 3. – – – – 4. Confirm that electrical or mechanical loads are not 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. Start engine and warm it up until engine coolant temperature indicator points the middle of gauge. Ensure engine stays below 1,000 rpm. MT AT TF PD AX SU SEF976U 5. Run engine at about 2,000 rpm for about 2 minutes under no-load. BR ST RS BT SEF977U 6. Make sure that no DTC is displayed with CONSULT-II or GST. HA OK or NG OK 䊳 GO TO 3. NG 䊳 GO TO 2. 2 SC EL REPAIR OR REPLACE Repair or replace components as necessary according to corresponding “Diagnostic Procedure”. 䊳 IDX GO TO 3. EC-71 BASIC SERVICE PROCEDURE Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d) 3 CHECK TARGET IDLE SPEED With CONSULT-II 1. Run engine at about 2,000 rpm for about 2 minutes under no-load. 2. Rev engine (2,000 to 3,000 rpm) two or three times under no-load, then run engine at idle speed for about 1 minute. SEF978U 3. Read idle speed in “DATA MONITOR” mode with CONSULT-II. SEF058Y M/T: 750±50 rpm A/T: 750±50 rpm (in “P” or “N” position) Without CONSULT-II 1. Run engine at about 2,000 rpm for about 2 minutes under no-load. 2. Rev engine (2,000 to 3,000 rpm) two or three times under no-load, then run engine at idle speed for about 1 minute. 3. Check idle speed. M/T: 750±50 rpm A/T: 750±50 rpm (in “P” or “N” position) OK or NG OK 䊳 GO TO 10. NG 䊳 GO TO 4. 4 PERFORM ACCELERATOR PEDAL RELEASED POSITION LEARNING 1. Stop engine. 2. Perform “Accelerator Pedal Released Position Learning”, EC-81. 䊳 5 GO TO 5. PERFORM THROTTLE VALVE CLOSED POSITION LEARNING Perform “Throttle Valve Closed Position Learning”, EC-81. 䊳 GO TO 6. EC-72 BASIC SERVICE PROCEDURE Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d) 6 GI PERFORM IDLE AIR VOLUME LEARNING Perform “Idle Air Volume Learning”, EC-81. Is Idle Air Volume Learning carried out successfully? MA Yes or No Yes 䊳 GO TO 7. No 䊳 1. Follow the instruction of “Idle Air Volume Learning”. 2. GO TO 4. EM LC 7 CHECK TARGET IDLE SPEED AGAIN With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Read idle speed in “DATA MONITOR” mode with CONSULT-II. M/T: 750±50 rpm A/T: 750±50 rpm (in “P” or “N” position) Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. M/T: 750±50 rpm A/T: 750±50 rpm (in “P” or “N” position) OK or NG OK 䊳 GO TO 10. NG 䊳 GO TO 8. 8 FE CL MT AT TF DETECT MALFUNCTIONING PART PD Check the following. 쐌 Check camshaft position sensor (PHASE) and circuit. Refer to ”DTC P0340, P0345 CMP SENSOR (PHASE)”, EC-357. 쐌 Check crankshaft position sensor (POS) and circuit. Refer to “DTC P0335 CKP SENSOR (POS)”, EC-350. AX OK or NG OK 䊳 GO TO 9. NG 䊳 1. Repair or replace. 2. GO TO 4. 9 SU BR CHECK ECM FUNCTION 1. Substitute another known-good ECM to check ECM function. (ECM may be the cause of an incident, but this is the rarely the case.) 2. Perform initialization of NVIS (NATS) system and registration of NVIS (NATS) ignition key IDs. Refer to NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS)”, EC-101. 䊳 ST RS GO TO 4. BT HA SC EL IDX EC-73 BASIC SERVICE PROCEDURE Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d) 10 CHECK IGNITION TIMING 1. Run engine at idle. 2. Check ignition timing with a timing light. SEC580D M/T: 15°±5° BTDC A/T: 15°±5° BTDC (in “P” or “N” position) OK or NG OK (With CONSULT-II) 䊳 GO TO 19. OK (Without CONSULTII) 䊳 GO TO 20. NG 䊳 GO TO 11. 11 PERFORM ACCELERATOR PEDAL RELEASED POSITION LEARNING 1. Stop engine. 2. Perform “Accelerator Pedal Released Position Learning”, EC-81. 䊳 12 GO TO 12. PERFORM THROTTLE VALVE CLOSED POSITION LEARNING Perform “Throttle Valve Closed Position Learning”, EC-81. 䊳 13 GO TO 13. PERFORM IDLE AIR VOLUME LEARNING Perform “Idle Air Volume Learning”, EC-81. Is Idle Air Volume Learning carried out successfully? Yes or No Yes 䊳 GO TO 14. No 䊳 1. Follow the instruction of “Idle Air Volume Learning”. 2. GO TO 4. EC-74 BASIC SERVICE PROCEDURE Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d) 14 GI CHECK TARGET IDLE SPEED AGAIN With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Read idle speed in “DATA MONITOR” mode with CONSULT-II. M/T: 750±50 rpm A/T: 750±50 rpm (in “P” or “N” position) MA EM Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. M/T: 750±50 rpm A/T: 750±50 rpm (in “P” or “N” position) LC OK or NG OK 䊳 GO TO 15. NG 䊳 GO TO 17. FE CL 15 CHECK IGNITION TIMING AGAIN 1. Run engine at idle. 2. Check ignition timing with a timing light. MT AT TF PD SEC580D M/T: 15°±5° BTDC A/T: 15°±5° BTDC (in “P” or “N” position) AX SU OK or NG OK (With CONSULT-II) 䊳 GO TO 19. OK (Without CONSULTII) 䊳 GO TO 20. NG 䊳 GO TO 16. 16 CHECK TIMING CHAIN INSTALLATION BR ST RS Check timing chain installation. Refer to EM-21, “TIMING CHAIN”. OK or NG OK 䊳 GO TO 17. NG 䊳 1. Repair the timing chain installation. 2. GO TO 4. BT HA SC EL IDX EC-75 BASIC SERVICE PROCEDURE Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d) 17 DETECT MALFUNCTIONING PART Check the following. 쐌 Check camshaft position sensor (PHASE) and circuit. Refer to “DTC P0340, P0345 CMP SENSOR (PHASE)”, EC-357. 쐌 Check crankshaft position sensor (POS) and circuit. Refer to “DTC P0335 CKP SENSOR (POS)”, EC-350. OK or NG OK 䊳 GO TO 18. NG 䊳 1. Repair or replace. 2. GO TO 4. 18 CHECK ECM FUNCTION 1. Substitute another known-good ECM to check ECM function. (ECM may be the cause of an incident, but this is the rarely the case.) 2. Perform initialization of NVIS (NATS) system and registration of NVIS (NATS) ignition key IDs. Refer to “NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS)”, EC-101. 䊳 19 GO TO 4. CHECK HEATED OXYGEN SENSOR 1 (BANK 1) SIGNAL With CONSULT-II 1. Run engine at about 2,000 rpm for about 2 minutes under no-load. 2. See “HO2S1 MNTR (B1)” in “DATA MONITOR” mode. 3. Running engine at 2,000 rpm under no-load (The engine is warmed up to normal operating temperature.), check that the monitor fluctuates between LEAN and RICH more than 5 times during 10 seconds. PBIB0120E 1 time: RICH → LEAN → RICH 2 times: RICH → LEAN → RICH → LEAN → RICH OK or NG OK 䊳 GO TO 21. NG (Monitor does not fluctuate.) 䊳 GO TO 23. NG (Monitor fluctuates less than 5 times.) 䊳 GO TO 31. EC-76 BASIC SERVICE PROCEDURE Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d) 20 GI CHECK HEATED OXYGEN SENSOR 1 (BANK 1) SIGNAL Without CONSULT-II 1. Stop engine and set ECM to Self-diagnostic mode II (Heated oxygen sensor 1 monitor). Refer to “HOW TO SWITCH DIAGNOSTIC TEST MODE”, EC-103. 2. Start engine and run it at about 2,000 rpm for about 2 minutes under no-load. 3. Running engine at 2,000 rpm under no-load (The engine is warmed up to normal operating temperature.), check that the MIL comes on more than 5 times during 10 seconds. OK or NG OK 䊳 GO TO 22. NG (MIL does not come on) 䊳 GO TO 23. NG (MIL comes on less than 5 times) 䊳 GO TO 31. 21 MA EM LC FE CHECK HEATED OXYGEN SENSOR 1 (BANK 2) SIGNAL With CONSULT-II 1. See “HO2S1 MNTR (B2)” in “DATA MONITOR” mode. 2. Running engine at 2,000 rpm under no-load (The engine is warmed up to normal operating temperature.), check that the monitor fluctuates between LEAN and RICH more than 5 times during 10 seconds. CL MT AT TF PD PBIB0120E 1 time: RICH → LEAN → RICH 2 times: RICH → LEAN → RICH → LEAN → RICH AX SU OK or NG OK 䊳 INSPECTION END NG (Monitor does not fluctuate.) 䊳 GO TO 24. NG (Monitor fluctuates less than 5 times.) 䊳 GO TO 31. 22 BR ST CHECK HEATED OXYGEN SENSOR 1 (BANK 2) SIGNAL Without CONSULT-II 1. Switch the monitored sensor from bank 1 to bank 2. Refer to “How to Switch Monitored Sensor from Bank 1 to Bank 2 or Vice Versa”, EC-103. 2. Running engine at 2,000 rpm under no-load (The engine is warmed up to normal operating temperature.), check that the MIL comes on more than 5 times during 10 seconds. RS BT HA OK or NG OK 䊳 INSPECTION END NG (MIL does not come on) 䊳 GO TO 24. NG (MIL comes on less than 5 times) 䊳 GO TO 31. SC EL IDX EC-77 BASIC SERVICE PROCEDURE Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d) 23 CHECK HEATED OXYGEN SENSOR 1 (BANK 1) HARNESS 1. 2. 3. 4. Turn ignition switch “OFF” and disconnect battery ground cable. Disconnect ECM harness connector. Disconnect heated oxygen sensor 1 (bank 1) harness connector. Check harness continuity between ECM terminal 35 and heated oxygen sensor 1 (bank 1) terminal 1. Refer to “Wiring Diagram”, EC-258. Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 25. NG 䊳 1. Repair or replace harness between ECM and heated oxygen sensor 1 (bank 1). 2. GO TO 4. 24 CHECK HEATED OXYGEN SENSOR 1 (BANK 2) HARNESS 1. 2. 3. 4. Turn ignition switch “OFF” and disconnect battery ground cable. Disconnect ECM harness connector. Disconnect heated oxygen sensor 1 (bank 2) harness connector. Check harness continuity between ECM terminal 16 and heated oxygen sensor 1 (bank 2) terminal 1. Refer to “Wiring Diagram”, EC-259. Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 25. NG 䊳 1. Repair or replace harness between ECM and heated oxygen sensor 1 (bank 2). 2. GO TO 4. 25 PERFORM ACCELERATOR PEDAL RELEASED POSITION LEARNING 1. Reconnect ECM harness connector. 2. Perform “Accelerator pedal released position learning”, EC-81. 䊳 26 GO TO 26. PERFORM THROTTLE VALVE CLOSED POSITION LEARNING Perform “Throttle Valve Closed Position Learning”, EC-81. 䊳 27 GO TO 27. PERFORM IDLE AIR VOLUME LEARNING Perform “Idle Air Volume Learning”, EC-81. Is Idle Air Volume Learning carried out successfully? Yes or No Yes (With CONSULT-II) 䊳 GO TO 28. Yes (Without CONSULTII) 䊳 GO TO 29. No 䊳 1. Follow the instruction of “Idle Air Volume Learning”. 2. GO TO 4. EC-78 BASIC SERVICE PROCEDURE Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d) 28 1. 2. 3. 4. 5. 6. GI CHECK “CO” % With CONSULT-II Start engine and warm it up until engine coolant temperature indicator points to the middle of gauge. Turn ignition switch “OFF”, wait at least 10 seconds and then turn “ON”. Select “ENG COOLANT TEMP” in “ACTIVE TEST” mode. Set “ENG COOLANT TEMP” to 5°C (41°F) by touching “DWN” and “Qd”. Start engine and rev it (2,000 to 3,000 rpm) two or three times under no-load, then run engine at idle speed. Check “CO” %. MA EM LC FE CL SEF172Y Idle CO: 0.7 - 9.9 % and engine runs smoothly. MT OK or NG OK 䊳 GO TO 31. NG 䊳 GO TO 30. 29 AT TF CHECK “CO” % Without CONSULT-II Start engine and warm it up until engine coolant temperature indicator points to the middle of gauge. Turn ignition switch “OFF”. Disconnect engine coolant temperature sensor harness connector. Connect a resistor (4.4 kΩ) between terminals of engine coolant temperature sensor harness connector. Start engine and rev it (2,000 to 3,000 rpm) two or three times under no-load, then run engine at idle speed. Check “CO” %. Idle CO: 0.7 - 9.9 % and engine runs smoothly. 7. After checking “CO” %, turn ignition switch “OFF”, disconnect the resistor from the terminals of engine coolant temperature sensor harness connector, and then connect engine coolant temperature sensor harness connector to engine coolant temperature sensor. 1. 2. 3. 4. 5. 6. PD AX SU BR ST RS BT SEF982UA OK or NG OK 䊳 GO TO 31. NG 䊳 GO TO 30. 30 SC RECONNECT HEATED OXYGEN SENSOR 1 HARNESS CONNECTOR 1. Turn ignition switch “OFF”. 2. Reconnect heated oxygen sensor 1 harness connector. 䊳 HA EL IDX GO TO 34. EC-79 BASIC SERVICE PROCEDURE Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d) 31 REPLACE HEATED OXYGEN SENSOR 1 1. Stop engine. 2. Replace heated oxygen sensor 1 on the malfunctioning bank. With CONSULT-II 䊳 GO TO 32. Without CONSULT-II 䊳 GO TO 33. 32 CHECK HEATED OXYGEN SENSOR 1 (BANK 1)/(BANK 2) SIGNAL With CONSULT-II 1. Start engine and warm it up until engine coolant temperature indicator points to the middle of gauge. 2. See “HO2S1 MNTR (B1)/(B2)” in “DATA MONITOR” mode. 3. Running engine at 2,000 rpm under no-load (The engine is warmed up to normal operating temperature.), check that the monitor fluctuates between LEAN and RICH more than 5 times during 10 seconds. 1 time: RICH → LEAN → RICH 2 times: RICH → LEAN → RICH → LEAN → RICH OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 34. 33 CHECK HEATED OXYGEN SENSOR 1 (BANK 1)/(BANK 2) SIGNAL Without CONSULT-II 1. Set ECM to Self-diagnostic mode II (Heated oxygen sensor 1 monitor). Refer to “How to Switch Diagnostic Test Mode”, EC-103. 2. Switch the monitored sensor to the malfunctioning bank. Refer to “How to Switch Monitored Sensor from Bank 1 to Bank 2 or Vice Versa”, EC-103. 3. Running engine at 2,000 rpm under no-load (The engine is warmed up to normal operating temperature.), check that the MIL comes on more than 5 times during 10 seconds. OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 34. 34 DETECT MALFUNCTIONING PART Check the following. 쐌 Check mass air flow sensor and its circuit, and repair or replace if necessary. Refer to EC-211, EC-219. 쐌 Check injector and its circuit, and repair or replace if necessary. Refer to EC-758. 쐌 Check engine coolant temperature sensor and its circuit, and repair or replace if necessary. Refer to EC-236. 쐌 Check fuel pressure and repair or replace if necessary. Refer to EC-64. OK or NG OK 䊳 GO TO 36. NG 䊳 1. Repair or replace. 2. GO TO 35. 35 ERASE UNNECESSARY DTC After this inspection, unnecessary DTC might be displayed. Erase the stored memory in ECM and TCM. Refer to “How to Erase Emission-related Diagnostic Information”, EC-100 and AT-60. 䊳 GO TO 4. EC-80 BASIC SERVICE PROCEDURE Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment (Cont’d) 36 GI CHECK ECM FUNCTION 1. Substitute another known-good ECM to check ECM function. (ECM may be the cause of an incident, but this is the rarely the case.) 2. Perform initialization of NVIS (NATS) system and registration of NVIS (NATS) ignition key IDs. Refer to “NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS”, EC-101. 䊳 MA EM GO TO 4. Accelerator Pedal Released Position Learning NAEC1183 DESCRIPTION LC NAEC1183S01 “Accelerator Pedal Released Position Learning” is an operation to learn the fully released position of the accelerator pedal by monitoring the accelerator pedal position sensor output signal. It must be performed each time harness connector of accelerator pedal position sensor or ECM is disconnected. OPERATION PROCEDURE 1. 2. 3. 4. 5. NAEC1183S02 Make sure that accelerator pedal is fully released. Turn ignition switch “ON” and wait at least 2 seconds. Turn ignition switch “OFF” wait at least 10 seconds. Turn ignition switch “ON” and wait at least 2 seconds. Turn ignition switch “OFF” wait at least 10 seconds. CL MT Throttle Valve Closed Position Learning DESCRIPTION NAEC1184 NAEC1184S01 “Throttle Valve Closed Position Learning” is an operation to learn the fully closed position of the throttle valve by monitorizing the throttle position sensor output signal. It must be performed each time harness connector of electric throttle control actuator or ECM is disconnected. OPERATION PROCEDURE FE AT TF NAEC1184S02 1. Make sure that accelerator pedal is fully released. 2. Turn ignition switch “ON”. 3. Turn ignition switch “OFF” wait at least 10 seconds. Make sure that throttle valve moves during above 10 seconds by confirming the operating sound. PD AX SU Idle Air Volume Learning DESCRIPTION NAEC1182 NAEC1182S01 “Idle Air Volume Learning” is an operation to learn the idle air volume that keeps each engine within the specific range. It must be performed under any of the following conditions: 쐌 Each time electric throttle control actuator or ECM is replaced. 쐌 Idle speed or ignition timing is out of specification. PREPARATION ST RS NAEC1182S02 Before performing “Idle Air Volume Learning”, make sure that all of the following conditions are satisfied. Learning will be cancelled if any of the following conditions are missed for even a moment. 쐌 Battery voltage: More than 12.9V (At idle) 쐌 Engine coolant temperature: 70 - 100°C (158 - 212°F) 쐌 PNP switch: ON 쐌 Electric load switch: OFF (Air conditioner, headlamp, rear window defogger) On vehicles equipped with daytime light systems, set lighting switch to the 1st position to light only small lamps. 쐌 Steering wheel: Neutral (Straight-ahead position) EC-81 BR BT HA SC EL IDX BASIC SERVICE PROCEDURE Idle Air Volume Learning (Cont’d) 쐌 쐌 Vehicle speed: Stopped Transmission: Warmed-up For A/T models with CONSULT-II, drive vehicle until “FLUID TEMP SE” in “DATA MONITOR” mode of “A/T” system indicates less than 0.9V. For A/T models without CONSULT-II and M/T models, drive vehicle for 10 minutes. OPERATION PROCEDURE With CONSULT-II NAEC1182S03 NAEC1182S0301 NOTE: Before perform “Idle Air Volume Learning”, make sure that “Accelerator Pedal Released Position Learning” and “Throttle Valve Closed Position Learning” are completed. If not, perform “Accelerator Pedal Released Position Learning”, EC-81 and “Throttle Valve Closed Position Learning”, EC-81. 1. Start engine and warm it up to normal operating temperature. 2. Check that all items listed under the topic “PREPARATION” (previously mentioned) are in good order. 3. Select “IDLE AIR VOL LEARN” in “WORK SUPPORT” mode. 4. Touch “START” and wait 20 seconds. 5. Make sure that “CMPLT” is displayed on CONSULT-II screen. If “CMPLT” is not displayed, “Idle Air Volume Learning” will not be carried out successfully. In this case, find the cause of the incident by referring to the “Diagnostic Procedure” below. Rev up the engine two or three times and make sure that idle speed and ignition timing are within the specifications. SEF452Y SEF454Y 6. ITEM Idle speed MBIB0238E EC-82 SPECIFICATION MT: 750±50 rpm AT: 750±50 rpm (in “P” or “N” position) BASIC SERVICE PROCEDURE Idle Air Volume Learning (Cont’d) Ignition timing MT: 15±5° BTDC AT: 15±5° BTDC (in “P” or “N” position) GI MA Without CONSULT-II NAEC1182S0302 NOTE: 쐌 It is better to count the time accurately with a clock. 쐌 It is impossible to switch the diagnostic mode when an accelerator pedal position sensor circuit has a malfunction. NOTE: Before perform “Idle Air Volume Learning”, make sure that “Accelerator Pedal Released Position Learning” and “Throttle Valve Closed Position Learning” are completed. If not, perform “Accelerator Pedal Released Position Learning”, EC-81 and “Throttle Valve Closed Position Learning”, EC-81. 1. Start engine and warm it up to normal operating temperature. 2. Check that all items listed under the topic “PREPARATION” (previously mentioned) are in good order. 3. Turn ignition switch “OFF” and wait at least 10 seconds. 4. Confirm that accelerator pedal is fully released, turn ignition switch “ON” and wait 3 seconds. 5. Repeat the following procedure quickly five times within 5 seconds. 1) Fully depress the accelerator pedal. 2) Fully release the accelerator pedal. 6. Wait 7 seconds, fully depress the accelerator pedal and keep it for approx. 20 seconds until the MIL stops blinking and turns ON. 7. Fully release the accelerator pedal within 3 seconds after the MIL turned ON. 8. Start engine and let it idle. 9. Wait 20 seconds. EM LC FE CL MT AT TF PD AX SU BR ST RS SEC897C 10. Rev up the engine two or three times and make sure that idle speed and ignition timing are within the specifications. ITEM SPECIFICATION Idle speed MT: 750±50 rpm AT: 750±50 rpm (in “P” or “N” position) Ignition timing MT: 15±5° BTDC AT: 15±5° BTDC (in “P” or “N” position) 11. If idle speed and ignition timing are not within the specification, “Idle Air Volume Learning” will not be carried out successfully. In this case, find the cause of the incident by referring to the “Diagnostic Procedure” below. EC-83 BT HA SC EL IDX BASIC SERVICE PROCEDURE Idle Air Volume Learning (Cont’d) DIAGNOSTIC PROCEDURE NAEC1182S04 If idle air volume learning cannot be performed successfully, proceed as follows: 1. Check that throttle valve is fully closed. 2. Check PCV valve operation. 3. Check that downstream of throttle valve is free from air leakage. 4. When the above three items check out OK, engine component parts and their installation condition are questionable. Check and eliminate the cause of the incident. It is useful to perform EC-159, “TROUBLE DIAGNOSIS SPECIFICATION VALUE”. 5. If any of the following conditions occur after the engine has started, eliminate the cause of the incident and perform “Idle air volume learning” all over again: − Engine stalls. − Erroneous idle. EC-84 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Introduction Introduction NAEC0029 The ECM has an on board diagnostic system, which detects malfunctions related to engine sensors or actuators. The ECM also records various emission-related diagnostic information including: Emission-related diagnostic information GI MA SAE Mode 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 EM LC 1st Trip Freeze Frame data Test values and Test limits Mode 6 of SAE J1979 Calibration ID Mode 9 of SAE 1979 FE The above information can be checked using procedures listed in the table below. X: Applicable —: Not applicable DTC 1st trip DTC Freeze Frame data 1st trip Freeze Frame data SRT code Test value CONSULT-II X X X X X — GST X X*1 X — X X ECM X X*2 — — — — MT AT *1: 1st trip DTCs for self-diagnoses concerning SRT items cannot be shown on the GST display. *2: When DTC and 1st trip DTC simultaneously appear on the display, they cannot be clearly distinguished from each other. TF 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-138.) 쐌 When there is an open circuit on MIL circuit, the ECM cannot warn the driver by lighting MIL up when there is a malfunction on engine control system. Therefore, when electrically controlled throttle and part of ECM related diagnosis is continuously detected as NG for 5 trips, ECM warns the driver that engine control system has a malfunction and MIL circuit is open by means of operating fail-safe function. The fail-safe function also operates when a DTC is detected during the above diagnosis except MIL circuit, and demands the driver to repair the malfunction. Engine operating condition in fail-safe mode Engine speed will not rise more than 2,500 rpm due to the fuel cut Two Trip Detection Logic CL NAEC0030 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. PD AX SU BR ST RS BT HA SC EL IDX EC-85 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Two Trip Detection Logic (Cont’d) X: Applicable MIL DTC 1st trip Items —: Not Exit 1st trip DTC 2nd trip 1st trip 2nd trip 1st trip 2nd trip displaying displaying displaying displaying Blinking Lighting up Blinking Lighting up Misfire (Possible three way catalyst damage) — DTC: P0300 - P0306 is being detected X — — — — — X — Misfire (Possible three way catalyst damage) — DTC: P0300 - P0306 is being detected — — X — — X — — One trip detection diagnoses (Refer to EC-10.) — X — — X — — — Except above — — — X — X X — *1: Except “ECM” Emission-related Diagnostic Information DTC AND 1ST TRIP DTC NAEC0031 NAEC0031S01 The 1st trip DTC (whose number is the same as the DTC number) is displayed for the latest self-diagnostic result obtained. If the ECM memory was cleared previously, and the 1st trip DTC did not reoccur, the 1st trip DTC will not be displayed. If 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). If 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. If the same malfunction 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. If a 1st trip DTC is stored and a non-diagnostic operation is performed 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 for clearing the DTC and the 1st trip DTC from the ECM memory are described in “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-100. For malfunctions in which 1st trip DTCs are displayed, refer to EC-95. These items are required by legal regulations to continuously monitor the system/component. In addition, the items monitored non-continuously are also displayed on CONSULT-II. 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 malfunction. However, 1st trip DTC detection will not prevent the vehicle from being tested, for example during Inspection/Maintenance (I/M) 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 EC-129. Then perform “DTC Confirmation Procedure” or “Overall Function Check” to try to duplicate the malfunction. If the malfunction is duplicated, the item requires repair. How to Read DTC and 1st Trip DTC NAEC0031S0101 DTC and 1st trip DTC can be read by the following methods. With CONSULT-II With GST CONSULT-II or GST (Generic Scan Tool) Examples: P0117, P0340, P1065, etc. These DTCs are prescribed by SAE J2012. (CONSULT-II also displays the malfunctioning component or system.) No TOOLS The number of times the MIL blinks in Diagnostic Test Mode II (Self-diagnostic Results) indicates the DTC. (Example: 0117, 0340, 1065, etc.) 쐌 1st trip DTC No. is the same as DTC No. 쐌 Output of a DTC indicates a malfunction. However, GST does not indicate whether the malfunction is still occurring or has occurred in the past and has returned to normal. CONSULT-II can identify malfunction status as shown below. Therefore, using CONSULT-II (if available) is recommended. EC-86 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Emission-related Diagnostic Information (Cont’d) A sample of CONSULT-II display for DTC and 1st trip DTC is shown below. DTC or 1st trip DTC of a malfunction is displayed in SELF-DIAGNOSTIC RESULTS mode of CONSULT-II. Time data indicates how many times the vehicle was driven after the last detection of a DTC. If the DTC is being detected currently, the time data will be “0”. If a 1st trip DTC is stored in the ECM, the time data will be “[1t]”. GI MA EM LC FE PBIB0911E FREEZE FRAME DATA AND 1ST TRIP FREEZE FRAME DATA NAEC0031S02 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, vehicle speed and absolute pressure at the moment a malfunction 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 displayed on CONSULT-II or GST. The 1st trip freeze frame data can only be displayed on the CONSULT-II screen, not on the GST. For details, see EC-115. 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 priority 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 following priorities to update the data. Priority 1 2 3 MT AT TF PD AX Items Freeze frame data CL Misfire — DTC: P0300 - P0306 Fuel Injection System Function — DTC: P0171, P0172, P0174, P0175 SU Except the above items (Includes A/T related items) 1st trip freeze frame data BR 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 malfunction 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 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 EMISSIONRELATED DIAGNOSTIC INFORMATION”, EC-100. SYSTEM READINESS TEST (SRT) CODE ST RS BT HA NAEC0031S03 System Readiness Test (SRT) code is specified in Mode 1 of SAE J1979. As part of an enhanced emissions test for Inspection & Maintenance (I/M), certain states require the status of SRT be used to indicate whether the ECM has completed self-diagnosis of major emission systems and components. Completion must be verified in order for the emissions inspection to proceed. If a vehicle is rejected for a State emissions inspection due to one or more SRT items indicating “INCMP”, use the information in this Service Manual to set the SRT to “CMPLT”. In most cases the ECM will automatically complete its self-diagnosis cycle during normal usage, and the SRT status will indicate “CMPLT” for each application system. Once set as “CMPLT”, the SRT status remains EC-87 SC EL IDX ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Emission-related Diagnostic Information (Cont’d) “CMPLT” until the self-diagnosis memory is erased. Occasionally, certain portions of the self-diagnostic test may not be completed as a result of the customer’s normal driving pattern; the SRT will indicate “INCMP” for these items. NOTE: The SRT will also indicate “INCMP” if the self-diagnosis memory is erased for any reason or if the ECM memory power supply is interrupted for several hours. If, during the state emissions inspection, the SRT indicates “CMPLT” for all test items, the inspector will continue with the emissions test. However, if the SRT indicates “INCMP” for one or more of the SRT items the vehicle is returned to the customer untested. NOTE: If MIL is “ON” during the state emissions inspection, the vehicle is also returned to the customer untested even though the SRT indicates “CMPLT” for all test items. Therefore, it is important to check SRT (“CMPLT”) and DTC (No DTCs) before the inspection. SRT Item NAEC0031S0310 The table below shows required self-diagnostic items to set the SRT to “CMPLT”. SRT item (CONSULT-II indication) Performance Priority* Required self-diagnostic items to set the SRT to “CMPLT” Corresponding DTC No. CATALYST 2 Three way catalyst function P0420, P0430 EVAP SYSTEM 1 EVAP control system (small leak) (negative pressure) P0442, P1442 2 EVAP control system (very small leak) (negative pressure)/ (positive pressure) P0456, P1456 2 EVAP control system purge flow monitoring P0441 2 Heated oxygen sensor 1 (circuit) P0134, P0154 Heated oxygen sensor 1 (lean shift monitoring) P1143, P1163 Heated oxygen sensor 1 (rich shift monitoring) P1144, P1164 Heated oxygen sensor 1 (response monitoring) P0133, P0153 Heated oxygen sensor 1 (high voltage) P0132, P0152 Heated oxygen sensor 2 (min. voltage monitoring) P1146, P1166 Heated oxygen sensor 2 (max. voltage monitoring) P1147, P1167 Heated oxygen sensor 2 (response monitoring) P0139, P0159 Heated oxygen sensor 2 (high voltage) P0138, P0158 Heated oxygen sensor 1 heater P0031, P0032, P0051, P0052 Heated oxygen sensor 2 heater P0037, P0038, P0057, P0058 HO2S HO2S HTR 2 *: If completion of several SRTs is required, perform driving patterns (DTC confirmation procedure), one by one based on the priority for models with CONSULT-II. EC-88 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Emission-related Diagnostic Information (Cont’d) SRT Set Timing =NAEC0031S0311 SRT is set as “CMPLT” after self-diagnosis has been performed one or more times. Completion of SRT is done regardless of whether the result is OK or NG. The set timing is different between OK and NG results and is shown in the table below. GI MA Example Self-diagnosis result Diagnosis All OK Case 1 Case 2 NG exists Case 3 + ON , OFF Ignition cycle + ON , OFF + ON , EM OFF + ON , LC P0400 OK (1) — (1) OK (2) — (2) P0402 OK (1) — (1) — (1) OK (2) P1402 OK (1) OK (2) — (2) — (2) SRT of EGR “CMPLT” “CMPLT” “CMPLT” “CMPLT” P0400 OK (1) — (1) — (1) — (1) P0402 — (0) — (0) OK (1) — (1) P1402 OK (1) OK (2) — (2) — (2) SRT of EGR “INCMP” “INCMP” “CMPLT” “CMPLT” P0400 OK OK — — P0402 — — — — P1402 NG — NG NG (Consecutive NG) (1st trip) DTC 1st trip DTC — 1st trip DTC DTC (= MIL “ON”) TF SRT of EGR “INCMP” “INCMP” “INCMP” “CMPLT” PD OK: Self-diagnosis is carried out and the result is OK. NG: Self-diagnosis is carried out and the result is NG. —: Self-diagnosis is not carried out. FE CL MT AT AX When all SRT related self-diagnoses showed OK results in a single cycle (Ignition OFF-ON-OFF), the SRT will indicate “CMPLT”. , Case 1 above When all SRT related self-diagnoses showed OK results through several different cycles, the SRT will indicate “CMPLT” at the time the respective self-diagnoses have at least one OK result. , Case 2 above If one or more SRT related self-diagnoses showed NG results in 2 consecutive cycles, the SRT will also indicate “CMPLT”. , Case 3 above The table above shows that the minimum number of cycles for setting SRT as “INCMP” is one (1) for each self-diagnosis (Case 1 & 2) or two (2) for one of self-diagnoses (Case 3). However, in preparation for the state emissions inspection, it is unnecessary of each self-diagnosis to be executed twice (Case 3) for the following reasons: 쐌 The SRT will indicate “CMPLT” at the time the respective self-diagnoses have one (1) OK result. 쐌 The emissions inspection requires “CMPLT” of the SRT only with OK self-diagnosis results. 쐌 When, during SRT driving pattern, 1st trip DTC (NG) is detected prior to “CMPLT” of SRT, the self-diagnosis memory must be erased from ECM after repair. 쐌 If the 1st trip DTC is erased, all the SRT will indicate “INCMP”. NOTE: SRT can be set as “CMPLT” together with the DTC(s). Therefore, DTC check must always be carried out prior to the state emission inspection even though the SRT indicates “CMPLT”. SU BR ST RS BT HA SC SRT Service Procedure NAEC0031S0312 If a vehicle has failed the state emissions inspection due to one or more SRT items indicating “INCMP”, review the flowchart diagnostic sequence on the next page. EL IDX EC-89 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Emission-related Diagnostic Information (Cont’d) SEF170Z *1 EC-86 *2 EC-90 *3 How to Display SRT Code EC-91 NAEC0031S0301 With CONSULT-II Selecting “SRT STATUS” in “DTC CONFIRMATION” mode with CONSULT-II. For items whose SRT codes are set, a “CMPLT” is displayed on the CONSULT-II screen; for items whose SRT codes are not set, “INCMP” is displayed. With GST Selecting Mode 1 with GST (Generic Scan Tool) A sample of CONSULT-II display for SRT code is shown below. “INCMP” means the self-diagnosis is incomplete and SRT is not set. “CMPLT” means the self-diagnosis is complete and SRT is set. EC-90 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Emission-related Diagnostic Information (Cont’d) GI MA EM LC SEF935Z How to Set SRT Code NAEC0031S0302 To set all SRT codes, self-diagnosis for the items indicated above must be performed one or more times. Each diagnosis may require a long period of actual driving under various conditions. With CONSULT-II Perform corresponding DTC Confirmation Procedure one by one based on “Performance Priority” in the table on EC-88. Without CONSULT-II The most efficient driving pattern in which SRT codes can be properly set is explained on the next page. The driving pattern should be performed one or more times to set all SRT codes. FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-91 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Emission-related Diagnostic Information (Cont’d) Driving Pattern NAEC0031S0303 PBIB1053E EC-92 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Emission-related Diagnostic Information (Cont’d) 쐌 The time required for each diagnosis varies with road surface conditions, weather, altitude, individual driving habits, etc. Zone A refers to the range where the time required, for the diagnosis under normal conditions*, is the shortest. Zone B refers to the range where the diagnosis can still be performed if the diagnosis is not completed within zone A. *: Normal conditions refer to the following: − Sea level − Flat road − Ambient air temperature: 20 - 30°C (68 - 86°F) − Diagnosis is performed as quickly as possible under normal conditions. Under different conditions [For example: ambient air temperature other than 20 - 30°C (68 - 86°F)], diagnosis may also be performed. Pattern 1: 쐌 The engine is started at the engine coolant temperature of −10 to 35°C (14 to 95°F) (where the voltage between the ECM terminal 73 and ground is 3.0 - 4.3V). 쐌 The engine must be operated at idle speed until the engine coolant temperature is greater than 70°C (158°F) (where the voltage between the ECM terminal 73 and ground is lower than 1.4V). 쐌 The engine is started at the fuel tank temperature of warmer than 0°C (32°F) (where the voltage between the ECM terminal 107 and ground is less than 4.1V). Pattern 2: 쐌 When steady-state driving is performed again even after it is interrupted, each diagnosis can be conducted. In this case, the time required for diagnosis may be extended. Pattern 3: 쐌 The driving pattern outlined in *2 must be repeated at least 3 times. Pattern 4: 쐌 Tests are performed after the engine has been operated for at least 17 minutes. 쐌 The accelerator pedal must be held very steady during steady-state driving. 쐌 If the accelerator pedal is moved, the test must be conducted all over again. *1: Depress the accelerator pedal until vehicle speed is 90 km/h (56 MPH), then release the accelerator pedal and keep it released for more than 10 seconds. Depress the accelerator pedal until vehicle speed is 90 km/h (56 MPH) again. *2: Operate the vehicle in the following driving pattern. 1) Decelerate vehicle to 0 km/h (0 MPH) and let engine idle. 2) Repeat driving pattern shown below at least 10 times. 쐌 During acceleration, hold the accelerator pedal as steady as possible. GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SEF414S *3: Checking the vehicle speed with GST is advised. Suggested Transmission Gear Position for A/T Models Set the selector lever in the “D” position with the overdrive switch turned ON. Suggested upshift speeds for M/T models Shown below are suggested vehicle speeds for shifting into a higher gear. These suggestions relate to fuel economy and vehicle performance. Actual upshift speeds will vary according to road conditions, the weather and individual driving habits. EC-93 SC EL IDX ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Emission-related Diagnostic Information (Cont’d) For normal acceleration in low altitude areas [less than 1,219 m (4,000 ft)]: For quick acceleration in low altitude areas and high altitude areas [over 1,219 m (4,000 ft)]: ACCEL shift point km/h (MPH) CRUISE shift point km/h (MPH) km/h (MPH) 1st to 2nd 21 (13) 21 (13) 24 (15) 2nd to 3rd 37 (23) 26 (16) 40 (25) 3rd to 4th 53 (33) 44 (27) 64 (40) 4th to 5th 63 (39) 58 (36) 72 (45) Gear change Suggested Maximum Speed in Each Gear Downshift to a lower gear if the engine is not running smoothly, or if you need to accelerate. Do not exceed the maximum suggested speed (shown below) in any gear. For level road driving, use the highest gear suggested for that speed. Always observe posted speed limits and drive according to the road conditions to ensure safe operation. Do not over-rev the engine when shifting to a lower gear as it may cause engine damage or loss of vehicle control. Gear km/h (MPH) 1st 50 (30) 2nd 89 (55) 3rd 128 (80) 4th — 5th — TEST VALUE AND TEST LIMIT (GST ONLY — NOT APPLICABLE TO CONSULT-II) NAEC0031S04 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 (30 test items). These data (test value and test limit) are specified by Test ID (TID) and Component ID (CID) and can be displayed on the GST screen. X: Applicable —: Not applicable Test value (GST display) SRT item Self-diagnostic test item Test limit Application 01H Max. X 03H 02H Max. X EVAP control system (Small leak) 05H 03H Max. X EVAP control system purge flow monitoring 06H 83H Min. X TID CID Three way catalyst function (bank 1) 01H Three way catalyst function (bank 2) CATALYST EVAP SYSTEM EC-94 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Emission-related Diagnostic Information (Cont’d) GI Test value (GST display) SRT item Self-diagnostic test item Test limit Application TID CID 09H 04H Max. X 0AH 84H Min. X 0BH 04H Max. X 0CH 04H Max. X 0DH 04H Max. X 11H 05H Max. X 12H 85H Min. X 13H 05H Max. X 14H 05H Max. X 15H 05H Max. X 19H 86H Min. X 1AH 86H Min. X 1BH 06H Max. X 1CH 06H Max. X 21H 87H Min. X 22H 87H Min. X 23H 07H Max. X 24H 07H Max. X 29H 08H Max. X 2AH 88H Min. X 2BH 09H Max. X 2CH 89H Min. X Heated oxygen sensor 2 heater (bank 1) 2DH 0AH Max. X 2EH 8AH Min. X Heated oxygen sensor 2 heater (bank 2) 2FH 0BH Max. X 30H 8BH Min. X Heated oxygen sensor 1 (bank 1) Heated oxygen sensor 1 (bank 2) MA EM LC FE HO2S Heated oxygen sensor 2 (bank 1) CL MT AT TF Heated oxygen sensor 2 (bank 2) Heated oxygen sensor 1 heater (bank 1) Heated oxygen sensor 1 heater (bank 2) PD AX SU HO2S HTR EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS Application Notice NAEC0031S05 ST RS NAEC0031S0501 Confirm the type of the vehicle. Refer to “How to Check Vehicle Type”, EC-9. BT Emission-related Diagnostic Information Items NAEC0031S0502 X: Applicable —: Not applicable DTC*1 Items (CONSULT-II screen terms) BR SRT code Test value/Test 1st trip DTC*1 limit Reference page CONSULT-II GST*2 ECM*3 CAN COMM CIRCUIT U1000 1000*6 — — — EC-172 CAN COMM CIRCUIT U1001 1001*6 — — X EC-172 HA SC EL IDX EC-95 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Emission-related Diagnostic Information (Cont’d) DTC*1 Items (CONSULT-II screen terms) SRT code Test value/Test 1st trip DTC*1 limit Reference page CONSULT-II GST*2 ECM*3 NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED. P0000 0000 — — — — INT/V TIM CONT-B1 P0011 0011 — — X EC-175 INT/V TIM CONT-B2 P0021 0021 — — X EC-175 HO2S1 HTR (B1) P0031 0031 X X X*5 EC-179 HO2S1 HTR (B1) P0032 0032 X X X*5 EC-179 HO2S2 HTR (B1) P0037 0037 X X X*5 EC-187 HO2S2 HTR (B1) P0038 0038 X X X*5 EC-187 HO2S1 HTR (B2) P0051 0051 X X X*5 EC-179 HO2S1 HTR (B2) P0052 0052 X X X*5 EC-179 HO2S2 HTR (B2) P0057 0057 X X X*5 EC-187 HO2S2 HTR (B2) P0058 0058 X X X*5 EC-187 MAF SEN/CIRCUIT P0101 0101 — — — EC-194, 203 MAF SEN/CIRCUIT P0102 0102 — — — EC-211, 219 MAF SEN/CIRCUIT P0103 0103 — — — EC-211, 219 IAT SEN/CIRCUIT P0112 0112 — — X EC-226, 231 IAT SEN/CIRCUIT P0113 0113 — — X EC-226, 231 ECT SEN/CIRCUIT P0117 0117 — — — EC-236 ECT SEN/CIRCUIT P0118 0118 — — — EC-236 TP SEN 2/CIRC P0122 0122 — — — EC-241 TP SEN 2/CIRC P0123 0123 — — — EC-241 ECT SENSOR P0125 0125 — — — EC-249 IAT SENSOR P0127 0127 — — X EC-252 THERMSTAT FNCTN P0128 0128 — — X EC-254 HO2S1 (B1) P0132 0132 X X X*5 EC-256 HO2S1 (B1) P0133 0133 X X X*5 EC-264 HO2S1 (B1) P0134 0134 X X X*5 EC-278 HO2S2 (B1) P0138 0138 X X X*5 EC-287 HO2S2 (B1) P0139 0139 X X X*5 EC-295 HO2S1 (B2) P0152 0152 X X X*5 EC-256 HO2S1 (B2) P0153 0153 X X X*5 EC-264 HO2S1 (B2) P0154 0154 X X X*5 EC-278 HO2S2 (B2) P0158 0158 X X X*5 EC-287 HO2S2 (B2) P0159 0159 X X X*5 EC-295 FUEL SYS-LEAN-B1 P0171 0171 — — X EC-304 FUEL SYS-RICH-B1 P0172 0172 — — X EC-312 EC-96 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Emission-related Diagnostic Information (Cont’d) GI DTC*1 Items (CONSULT-II screen terms) SRT code Test value/Test 1st trip DTC*1 limit Reference page CONSULT-II GST*2 ECM*3 FUEL SYS-LEAN-B2 P0174 0174 — — X EC-304 FUEL SYS-RICH-B2 P0175 0175 — — X EC-312 FTT SENSOR P0181 0181 — — X EC-319 FTT SEN/CIRCUIT P0182 0182 — — X EC-322 FTT SEN/CIRCUIT P0183 0183 — — X EC-322 TP SEN 1/CIRC P0222 0222 — — — EC-327 TP SEN 1/CIRC P0223 0223 — — — EC-327 MULTI CYL MISFIRE P0300 0300 — — X EC-335 CYL 1 MISFIRE P0301 0301 — — X EC-335 CYL 2 MISFIRE P0302 0302 — — X EC-335 CYL 3 MISFIRE P0303 0303 — — X EC-335 CYL 4 MISFIRE P0304 0304 — — X EC-335 CYL 5 MISFIRE P0305 0305 — — X EC-335 CYL 6 MISFIRE P0306 0306 — — X EC-335 KNOCK SEN/CIRC-B1 P0327 0327 — — X EC-345 KNOCK SEN/CIRC-B1 P0328 0328 — — X EC-345 CKP SEN/CIRCUIT P0335 0335 — — X EC-350 CMP SEN/CIRC-B1 P0340 0340 — — X EC-357 CMP SEN/CIRC-B2 P0345 0345 — — X EC-357 TW CATALYST SYS-B1 P0420 0420 X X X*5 EC-366 TW CATALYST SYS-B2 P0430 0430 X X X*5 EC-366 EVAP PURG FLOW/MON P0441 0441 X X X*5 EC-371 EVAP SMALL LEAK P0442 0442 X X X*5 EC-381 PURG VOLUME CONT/V P0444 0444 — — X EC-396 PURG VOLUME CONT/V P0445 0445 — — X EC-396 VENT CONTROL VALVE P0447 0447 — — X EC-403 EVAP SYS PRES SEN P0452 0452 — — X EC-410 EVAP SYS PRES SEN P0453 0453 — — X EC-416 EVAP GROSS LEAK P0455 0455 X X X*5 EC-425 EVAP VERY SML LEAK P0456 0456 X*4 X X*5 EC-438 FUEL LEV SEN SLOSH P0460 0460 — — X EC-454 FUEL LEVEL SENSOR P0461 0461 — — X EC-456 FUEL LEVL SEN/CIRC P0462 0462 — — X EC-458 FUEL LEVL SEN/CIRC P0463 0463 — — X EC-458 VEH SPEED SEN/CIRC*7 P0500 0500 — — X EC-460 ISC SYSTEM P0506 0506 — — X EC-462 EC-97 MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Emission-related Diagnostic Information (Cont’d) DTC*1 Items (CONSULT-II screen terms) SRT code Test value/Test 1st trip DTC*1 limit Reference page CONSULT-II GST*2 ECM*3 ISC SYSTEM P0507 0507 — — X EC-464 PW ST P SEN/CIRC P0550 0550 — — X EC-466 ECM P0605 0605 — — X EC-471 PNP SW/CIRC P0705 0705 — — X AT-105 ATF TEMP SEN/CIRC P0710 0710 — — X AT-111 VEH SPD SEN/CIR AT*7 P0720 0720 — — X AT-117 ENGINE SPEED SIG P0725 0725 — — X AT-122 A/T 1ST GR FNCTN P0731 0731 — — X AT-126 A/T 2ND GR FNCTN P0732 0732 — — X AT-132 A/T 3RD GR FNCTN P0733 0733 — — X AT-138 A/T 4TH GR FNCTN P0734 0734 — — X AT-144 TCC SOLENOID/CIRC P0740 0740 — — X AT-154 A/T TCC S/V FNCTN P0744 0744 — — X AT-159 L/PRESS SOL/CIRC P0745 0745 — — X AT-168 SFT SOL A/CIRC P0750 0750 — — — AT-174 SFT SOL B/CIRC P0755 0755 — — — AT-178 ECM BACK UP/CIRCUIT P1065 1065 — — X EC-473 MAF SENSOR*8 P1102 1102 — — — EC-478 INT/V TIM CONT-B1 P1110 1110 — — X EC-485 INT/V TIM V/CIR-B1 P1111 1111 — — X EC-488 ETC ACTR P1121 1121 — — — EC-494 ETC FUNCTION/CIRC P1122 1122 — — — EC-496 ETC MOT PWR P1124 1124 — — — EC-504 ETC MOT PWR P1126 1126 — — — EC-504 ETC MOT P1128 1128 — — — EC-509 SWIRL CONT SOL/V P1130 1130 — — X EC-514 SWIRL CONT SOL/V P1131 1131 — — X EC-535 INT/V TIM CONT-B2 P1135 1135 — — X EC-485 INT/V TIM V/CIR-B2 P1136 1136 — — X EC-488 HO2S1 (B1) P1143 1143 X X X*5 EC-541 HO2S1 (B1) P1144 1144 X X X*5 EC-549 HO2S2 (B1) P1146 1146 X X X*5 EC-557 HO2S2 (B1) P1147 1147 X X X*5 EC-566 CLOSED LOOP-B1 P1148 1148 — — — EC-575 HO2S1 (B2) P1163 1163 X X X*5 EC-541 HO2S1 (B2) P1164 1164 X X X*5 EC-549 EC-98 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Emission-related Diagnostic Information (Cont’d) GI DTC*1 Items (CONSULT-II screen terms) SRT code Test value/Test 1st trip DTC*1 limit Reference page CONSULT-II GST*2 ECM*3 SWL CON VC SW/CIRC P1165 1165 — — X EC-577 HO2S2 (B2) P1166 1166 X X X*5 EC-557 HO2S2 (B2) P1167 1167 X X X*5 EC-566 CLOSED LOOP-B2 P1168 1168 — — — EC-575 TCS C/U FUNCTN P1211 1211 — — X EC-583 TCS/CIRC P1212 1212 — — X EC-585 ENG OVER TEMP P1217 1217 — — — EC-587 CTP LEARNING P1225 1225 — — X EC-592 CTP LEARNING P1226 1226 — — X EC-594 SENSOR POWER/CIRC P1229 1229 — — — EC-596 EVAP SMALL LEAK P1442 1442 X X X*5 EC-601 PURG VOLUME CONT/V P1444 1444 — — X EC-616 VENT CONTROL VALVE P1446 1446 — — X EC-628 VENT CONTROL VALVE P1448 1448 — — X EC-636 EVAP VERY SML LEAK P1456 1456 X*4 X X*5 EC-645 VC/V BYPASS/V P1490 1490 — — X EC-661 VC CUT/V BYPASS/V P1491 1491 — — X EC-667 ASCD SW P1564 1564 — — — EC-679 ASCD BRAKE SW P1572 1572 — — — EC-685 P1610 P1615 1610 - 1615 — — X EL-375 TP SEN/CIRC A/T P1705 1705 — — — AT-182 P-N POS SW/CIRCUIT P1706 1706 — — X EC-696 O/R CLTCH SOL/CIRC P1760 1760 — — X AT-188 BRAKE SW/CIRCUIT P1805 1805 — — X EC-702 APP SEN 1/CIRC P2122 2122 — — — EC-708 APP SEN 1/CIRC P2123 2123 — — — EC-708 APP SEN 2/CIRC P2127 2127 — — — EC-715 APP SEN 2/CIRC P2128 2128 — — — EC-715 TP SENSOR P2135 2135 — — — EC-723 APP SENSOR P2138 2138 — — — EC-731 NATS MALFUNCTION *1: *2: *3: *4: *5: *6: *7: *8: MA EM LC FE CL MT AT TF PD AX SU 1st trip DTC No. is the same as DTC No. These numbers are prescribed by SAE J2012. In Diagnostic Test Mode II (Self-diagnostic results), these numbers are controlled by NISSAN. SRT code will not be set if the self-diagnostic result is NG. These are not displayed with GST. The troubleshooting for these DTCs need CONSULT-II. When the fail-safe operations for both self-diagnoses occur, the MIL illuminates. For the type I vehicle (Refer to “How to Check Vehicle Type”, EC-9.). EC-99 BR ST RS BT HA SC EL IDX ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Emission-related Diagnostic Information (Cont’d) HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION How to Erase DTC NAEC0031S06 NAEC0031S0601 With CONSULT-II NOTE: If the DTC is not for A/T related items (see EC-10), 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 10 seconds and then turn it “ON” (engine stopped) again. 2. Turn CONSULT-II “ON” and touch “A/T”. 3. Touch “SELF-DIAG RESULTS”. 4. Touch “ERASE”. [The DTC in the TCM (Transmission control module) 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.) 쐌 If DTCs are displayed for both ECM and TCM (Transmission control module), they need to be erased individually from the ECM and TCM (Transmission control module). SAT857K The emission related diagnostic information in the ECM can be erased by selecting “ERASE” in the “SELFDIAG RESULTS” mode with CONSULT-II. If DTCs are displayed for both ECM and TCM (Transmission control module), they need to be erased individually from the ECM and TCM (Transmission control module). With GST NOTE: If the DTC is not for A/T related items (see EC-10), skip step 2. 8. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least EC-100 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Emission-related Diagnostic Information (Cont’d) 10 seconds and then turn it “ON” (engine stopped) again. 9. Perform “SELF-DIAGNOSTIC PROCEDURE (Without CONSULT-II)” in AT section titled “TROUBLE DIAGNOSIS”, “Self-diagnosis”. (The engine warm-up step can be skipped when performing the diagnosis only to erase the DTC.) 10. Select Mode 4 with GST (Generic Scan Tool). The emission related diagnostic information in the ECM can be erased by selecting Mode 4 with GST. 쐌 If the battery is disconnected, the emission-related diagnostic information will be lost within 24 hours. 쐌 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. GI NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS) MT MA EM LC FE CL NAEC0031S08 AT TF PD AX SEF515Y 쐌 쐌 쐌 If the security indicator lights up with the ignition switch in the “ON” position or “NATS MALFUNCTION” is displayed on “SELF-DIAG RESULTS” screen, perform self-diagnostic results mode with CONSULT-II using NATS program card. Refer to EL-375, “NVIS (Nissan Vehicle Immobilizer System — NATS)”. Confirm no self-diagnostic results of NVIS (NATS) is displayed before touching “ERASE” in “SELFDIAG RESULTS” mode with CONSULT-II. When replacing ECM, initialization of NVIS (NATS) system and registration of all NVIS (NATS) ignition key IDs must be carried out with CONSULT-II using NATS program card. Therefore, be sure to receive all keys from vehicle owner. Regarding the procedures of NVIS (NATS) initialization and NVIS (NATS) ignition key ID registration, refer to CONSULT-II operation manual, IVIS/NVIS. SU BR ST RS BT HA SC EL IDX EC-101 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Malfunction Indicator Lamp (MIL) Malfunction Indicator Lamp (MIL) DESCRIPTION NAEC0032 SEF217U The MIL is located on the instrument panel. 1. The MIL will light up when the ignition switch is turned ON without the engine running. This is a bulb check. 쐌 If the MIL does not light up, refer to EL-139, “WARNING LAMPS” or see EC-791. 2. When the engine is started, the MIL should go off. If the MIL remains on, the on board diagnostic system has detected an engine system malfunction. On Board Diagnostic System Function NAEC0032S01 The on board diagnostic system has the following four functions. Diagnostic Test Mode KEY and ENG. Status Function Explanation of Function Mode I Ignition switch in “ON” position BULB CHECK This function checks the MIL bulb for damage (blown, open circuit, etc.). If the MIL does not come on, check MIL circuit. Engine running MALFUNCTION WARNING This is a usual driving condition. When a malfunction is detected twice 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. 쐌 One trip detection diagnoses 쐌 “Misfire (Possible three way catalyst damage)” Ignition switch in “ON” position SELF-DIAGNOSTIC RESULTS This function allows DTCs and 1st trip DTCs to be read. Engine stopped Mode II Engine stopped Engine running 쐌 HEATED OXYGEN SENSOR 1 This function allows the fuel mixture condition (lean or MONITOR rich), monitored by heated oxygen sensor 1, to be read. When there is an open circuit on MIL circuit, the ECM cannot warn the driver by lighting MIL up when there is a malfunction on engine control system. Therefore, when electrically controlled throttle and part of ECM related diagnosis is continuously detected as NG for 5 trips, ECM warns the driver that engine control system has a malfunction and MIL circuit is open by means of operating fail-safe function. EC-102 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Malfunction Indicator Lamp (MIL) (Cont’d) The fail-safe function also operates when a DTC is detected during the above diagnosis except MIL circuit, and demands the driver to repair the malfunction. Engine operating condition in fail-safe mode Engine speed will not rise more than 2,500 rpm due to the fuel cut MIL Flashing without DTC NAEC0032S0102 If the ECM is in Diagnostic Test Mode II, MIL may flash when engine is running. In this case, check ECM diagnostic test mode. How to Switch Diagnostic Test Mode. How to switch the diagnostic test (function) modes, and details of the above functions are described later.How to Switch Diagnostic Test Mode. The following emission-related diagnostic information is 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 How to Switch Diagnostic Test Mode NAEC0032S07 NOTE: 쐌 It is better to count the time accurately with a clock. 쐌 It is impossible to switch the diagnostic mode when an accelerator pedal position sensor circuit has a malfunction. 쐌 Always ECM returns to Diagnostic Test Mode I after ignition switch is turned “OFF”. How to Set Diagnostic Test Mode II (Self-diagnostic Results) NAEC0032S0701 1. Confirm that accelerator pedal is fully released, turn ignition switch “ON” and wait 3 seconds. 2. Repeat the following procedure quickly five times within 5 seconds. 1) Fully depress the accelerator pedal. 2) Fully release the accelerator pedal. 3. Wait 7 seconds, fully depress the accelerator pedal and keep it for approx. 10 seconds until the MIL starts blinking. 4. Fully release the accelerator pedal. ECM has entered to Diagnostic Test Mode II (Self-diagnostic results). GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT PBIB0092E How to Set Diagnostic Test Mode II (Heated Oxygen Sensor 1 Monitor) NAEC0032S0702 1. Set the ECM in Diagnostic Test Mode II (Self-diagnostic results). Refer to How to Set Diagnostic Test Mode II (Self-diagnostic Results). 2. Start Engine. ECM has entered to Diagnostic Test Mode II (Heated oxygen sensor 1 monitor). ECM will start heated oxygen sensor 1 monitoring from the bank 1 sensor. How to Set Diagnostic Switch Monitored Sensor from Bank 1 to Bank 2 or Vice versa NAEC0032S0703 1. Fully depress the accelerator pedal quickly and then release it immediately. 2. Make sure that monitoring sensor has changed by MIL blinking as follows. EC-103 HA SC EL IDX ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Malfunction Indicator Lamp (MIL) (Cont’d) PBIB0093E How to Erase Diagnostic Test Mode II (Self-diagnostic Results) NAEC0032S0704 1. Set ECM in Diagnostic Test Mode II (Self-diagnostic results). Refer to How to Set Diagnostic Test Mode II (Self-diagnostic Results). 2. Fully depress the accelerator pedal and keep it for more than 10 seconds. The emission-related diagnostic information has been erased from the backup memory in the ECM. 3. Fully release the accelerator pedal, and confirm the DTC 0000 is displayed. Diagnostic Test Mode I — Bulb Check NAEC0032S03 In this mode, the MIL on the instrument panel should stay ON. If it remains OFF, check the bulb. Refer to EL-139, “WARNING LAMPS” or see EC-791. Diagnostic Test Mode I — Malfunction Warning MIL 쐌 NAEC0032S04 Condition ON When the malfunction is detected or the ECM’s CPU is malfunctioning. OFF No malfunction. These DTC numbers are clarified in Diagnostic Test Mode II (SELF-DIAGNOSTIC RESULTS). Diagnostic Test Mode II — Self-Diagnostic Results NAEC0032S08 In this mode, the DTC and 1st trip DTC are indicated by the number of blinks of the MIL as shown below. The DTC and 1st trip DTC are displayed at the same time. If the MIL does not illuminate in diagnostic test mode I (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 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-II or GST. A DTC will be used as an example for how to read a code. SEF952W EC-104 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Malfunction Indicator Lamp (MIL) (Cont’d) A particular trouble code can be identified by the number of four-digit numeral flashes. The “zero” is indicated by the number of ten flashes. The length of time the 1,000th-digit numeral flashes on and off is 1.2 seconds consisting of an ON (0.6-second) - OFF (0.6-second) cycle. The 100th-digit numeral and lower digit numerals consist of a 0.3-second ON and 0.3-second OFF cycle. A change from one digit numeral to another occurs at an interval of 1.0-second OFF. In other words, the later numeral appears on the display 1.3 seconds after the former numeral has disappeared. A change from one trouble code to another occurs at an interval of 1.8-second OFF. In this way, all the detected malfunctions are classified by their DTC numbers. The DTC “0000” refers to no malfunction. (See “TROUBLE DIAGNOSIS — INDEX”, EC-10.) How to Erase Diagnostic Test Mode II (Self-diagnostic Results) NAEC0032S0801 The DTC can be erased from the back up memory in the ECM by depressing accelerator pedal. Refer to How to Switch Diagnostic Test Mode. 쐌 If the battery is disconnected, the DTC will be lost from the backup memory within 24 hours. 쐌 Be careful not to erase the stored memory before starting trouble diagnoses. ON Lean Rich *Remains ON or OFF Any condition LC CL Air fuel ratio feedback control condition MT Closed loop system OFF EM NAEC0032S09 In this mode, the MIL displays the condition of the fuel mixture (lean or rich) which is monitored by the heated oxygen sensor 1. Fuel mixture condition in the exhaust gas MA FE Diagnostic Test Mode II — Heated Oxygen Sensor 1 Monitor MIL GI AT Open loop system *: Maintains conditions just before switching to open loop. To check the heated oxygen sensor 1 function, start engine in the Diagnostic Test Mode II and warm it up until engine coolant temperature indicator points to the middle of the gauge. Next run engine at about 2,000 rpm for about 2 minutes under no-load conditions. Then make sure that the MIL comes ON more than 5 times within 10 seconds with engine running at 2,000 rpm under no-load. OBD System Operation Chart NAEC0033 RELATIONSHIP BETWEEN MIL, 1ST TRIP DTC, DTC, AND DETECTABLE ITEMS 쐌 쐌 쐌 쐌 쐌 NAEC0033S01 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-85. 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 (driving pattern C) without the same malfunction recurring. The “TIME” in “SELF-DIAGNOSTIC RESULTS” mode of CONSULT-II 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 MIL (goes off) DTC, Freeze Frame Data (no display) 1st Trip DTC (clear) 1st Trip Freeze Frame Data (clear) NAEC0033S02 Fuel Injection System Misfire Other 3 (pattern B) 3 (pattern B) 3 (pattern B) 80 (pattern C) 80 (pattern C) 40 (pattern A) 1 (pattern C), *1 1 (pattern C), *1 1 (pattern B) *1, *2 *1, *2 1 (pattern B) EC-105 TF PD AX SU BR ST RS BT HA SC EL IDX ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION OBD System Operation Chart (Cont’d) For details about patterns “B” and “C” under “Fuel Injection System” and “Misfire”, see EC-108. For details about patterns “A” and “B” under “Other”, see EC-110. *1: Clear timing is at the moment OK is detected. *2: Clear timing is when the same malfunction is detected in the 2nd trip. EC-106 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION OBD System Operation Chart (Cont’d) RELATIONSHIP BETWEEN MIL, DTC, 1ST TRIP DTC AND DRIVING PATTERNS FOR “MISFIRE” , “FUEL INJECTION SYSTEM” GI =NAEC0033S03 MA EM LC FE CL MT AT TF PD AX SU BR ST RS SEF392S *1: When the same malfunction is detected in two consecutive trips, MIL will light up. *2: MIL will go off after vehicle is driven 3 times (pattern B) without any malfunctions. *3: When the same malfunction is detected in two consecutive trips, the DTC and the freeze frame data will be stored in ECM. *4: The DTC and the freeze frame data will not be displayed any longer after vehicle is driven 80 times (pattern C) without the same malfunction. (The DTC and the freeze frame data still remain in ECM.) *5: When a malfunction is detected for the first time, the 1st trip DTC and the 1st trip freeze frame data will be stored in ECM. *6: The 1st trip DTC and the 1st trip freeze frame data will be cleared at the moment OK is detected. *7: When the same malfunction is detected in the 2nd trip, the 1st trip freeze frame data will be cleared. *8: 1st trip DTC will be cleared when vehicle is driven once (pattern C) without the same malfunction after DTC is stored in ECM. BT HA SC EL IDX EC-107 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION OBD System Operation Chart (Cont’d) EXPLANATION FOR DRIVING PATTERNS FOR “MISFIRE ”, “FUEL INJECTION SYSTEM” NAEC0033S04 NAEC0033S0401 Driving pattern B means the vehicle operation as follows: All components and systems should be monitored at least once by the OBD system. 쐌 The B counter will be cleared when the malfunction is detected once regardless of the driving pattern. 쐌 The B counter will be counted up when driving pattern B is satisfied without any malfunction. 쐌 The MIL will go off when the B counter reaches 3. (*2 in “OBD SYSTEM OPERATION CHART”) NAEC0033S0402 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: 쐌 When the freeze frame data shows lower than 70°C (158°F), “T” should be lower than 70°C (158°F). 쐌 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) 쐌 The C counter will be cleared when the malfunction is detected regardless of (1). 쐌 The C counter will be counted up when (1) is satisfied without the same malfunction. 쐌 The DTC will not be displayed after C counter reaches 80. 쐌 The 1st trip DTC will be cleared when C counter is counted once without the same malfunction after DTC is stored in ECM. EC-108 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION OBD System Operation Chart (Cont’d) RELATIONSHIP BETWEEN MIL, DTC, 1ST TRIP DTC AND DRIVING PATTERNS EXCEPT GI FOR “MISFIRE ”, “FUEL INJECTION SYSTEM”NAEC0033S05 MA EM LC FE CL MT AT TF PD AX SU BR ST RS SEF393S *1: When the same malfunction is detected in two consecutive trips, MIL will light up. *2: MIL will go off after vehicle is driven 3 times (pattern B) without any malfunctions. *3: When the same malfunction is detected in two consecutive trips, the DTC and the freeze frame data will be stored in ECM. *4: The DTC and the freeze frame data will not be displayed any longer after vehicle is driven 40 times (pattern A) without the same malfunction. (The DTC and the freeze frame data still remain in ECM.) *5: When a malfunction is detected for the first time, the 1st trip DTC and the 1st trip freeze frame data will be stored in ECM. *6: 1st trip DTC will be cleared after vehicle is driven once (pattern B) without the same malfunction. *7: When the same malfunction is detected in the 2nd trip, the 1st trip freeze frame data will be cleared. BT HA SC EL IDX EC-109 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION OBD System Operation Chart (Cont’d) EXPLANATION FOR DRIVING PATTERNS EXCEPT FOR “MISFIRE ”, “FUEL INJECTION SYSTEM” NAEC0033S06 NAEC0033S0601 AEC574 쐌 쐌 쐌 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. NAEC0033S0602 Driving pattern B means the vehicle operation as follows: All components and systems should be monitored at least once by the OBD system. 쐌 The B counter will be cleared when the malfunction is detected once regardless of the driving pattern. 쐌 The B counter will be counted up when driving pattern B is satisfied without any malfunctions. 쐌 The MIL will go off when the B counter reaches 3 (*2 in “OBD System Operation Chart”, EC-105). EC-110 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II CONSULT-II CONSULT-II INSPECTION PROCEDURE 1. 2. =NAEC0034 GI NAEC0034S01 Turn ignition switch OFF. Connect CONSULT-II and CONSULT-II CONVERTER to data link connector, which is located under LH dash panel near the fuse box cover. MA EM LC SEF941Y 3. 4. Turn ignition switch ON. Touch “START (NISSAN BASED VHCL)”. FE CL MT MBIB0233E 5. Touch “ENGINE”. If “ENGINE” is not indicated, go to GI-41, “CONSULT-II Data Link Connector (DLC) Circuit”. AT TF PD AX SU SEF948Y 6. Perform each diagnostic test mode according to each service procedure. For further information, see the CONSULT-II Operation Manual. BR ST RS BT PBIB2308E HA SC EL IDX EC-111 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) ENGINE CONTROL COMPONENT PARTS/CONTROL SYSTEMS APPLICATION NAEC0034S02 DIAGNOSTIC TEST MODE SELF-DIAGNOSTIC RESULTS INPUT ENGINE CONTROL COMPONENT PARTS Item WORK SUPPORT DATA MONITOR DATA MONITOR (SPEC) X X X X X X DTC & SRT CONFIRMATION ACTIVE TEST SRT STATUS DTC WORK SUPPORT DTC*1 FREEZE FRAME DATA*2 Crankshaft position sensor (POS) X X Crankshaft position sensor (PHASE) X Mass air flow sensor X Engine coolant temperature sensor X Heated oxygen sensor 1 X X X X X Heated oxygen sensor 2 X X X X X Vehicle speed sensor X X X Accelerator pedal position sensor X X X Throttle position sensor X X X Fuel tank temperature sensor X X X EVAP control system pressure sensor X X X Intake air temperature sensor X X X Knock sensor X Refrigerant pressure sensor X X Ignition switch (start signal) X X Closed throttle position switch (Accelerator pedal position sensor signal) X X Air conditioner switch X X X X Park/neutral position (PNP) switch X X X Power steering pressure sensor X X X Battery voltage X X Load signal X X Swirl control valve control vacuum check switch X X X Fuel level sensor X X X Intake valve timing control position sensor X X X ASCD steering switch X X X ASCD brake switch X X X EC-112 X X ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) GI DIAGNOSTIC TEST MODE SELF-DIAGNOSTIC RESULTS DATA MONITOR ACTIVE TEST Injectors X X X Power transistor (Ignition timing) X X X Item WORK SUPPORT DTC*1 FREEZE FRAME DATA*2 Throttle control motor X Throttle control motor relay X X X EVAP canister purge volume control solenoid valve X X X X X X X Air conditioner relay Fuel pump relay OUTPUT ENGINE CONTROL COMPONENT PARTS DTC & SRT CONFIRMATION DATA MONITOR (SPEC) X SRT STATUS X X CL X X X Heated oxygen sensor 2 heater X X X X EVAP canister vent control valve X X X X X Vacuum cut valve bypass valve X X X X X X X X X X X X X X X X X Intake valve timing control solenoid valve Calculated load value X X FE X X VIAS control solenoid valve EM LC Heated oxygen sensor 1 heater Swirl control valve control solenoid valve DTC WORK SUPPORT MA MT AT 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-II screen in freeze frame data mode only if a 1st trip DTC or DTC is detected. For details, refer to EC-87. TF PD AX SU BR ST RS BT HA SC EL IDX EC-113 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) FUNCTION Diagnostic test mode =NAEC0034S03 Function WORK SUPPORT This mode enables a technician to adjust some devices faster and more accurately by following the indications on the CONSULT-II unit. SELF-DIAG RESULTS Self-diagnostic results such as 1st trip DTC, 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. DATA MONITOR (SPEC) Input/Output specification of the basic fuel schedule, AFM, A/F feedback control value and the other data monitor items can be read. CAN diagnostic support monitor The results of transmit/receive diagnosis of CAN communication can be read. ACTIVE TEST Diagnostic Test Mode in which CONSULT-II drives some actuators apart from the ECMs and also shifts some parameters in a specified range. FUNCTION TEST Conducted by CONSULT-II instead of a technician to determine whether each system is “OK” or “NG”. DTC & SRT CONFIRMATION The status of system monitoring tests and the self-diagnosis status/result can be confirmed. ECM PART NUMBER ECM part number can be read. *1 The following emission-related diagnostic information is 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 NAEC0034S04 USAGE FUEL PRESSURE RELEASE 쐌 FUEL PUMP WILL STOP BY TOUCHING “START” DURING IDLING. CRANK A FEW TIMES AFTER ENGINE STALLS. When releasing fuel pressure from fuel line IDLE AIR VOL LEARN 쐌 THE IDLE AIR VOLUME THAT KEEPS THE ENGINE WITHIN THE SPECIFIED RANGE IS MEMORIZED IN ECM. When learning the idle air volume SELF-LEARNING CONT 쐌 THE COEFFICIENT OF SELF-LEARNING CONTROL MIXTURE RATIO RETURNS TO THE ORIGINAL COEFFICIENT. When clearing the coefficient of self-learning control value EC-114 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) WORK ITEM CONDITION EVAP SYSTEM CLOSE OPEN THE VACUUM CUT VALVE BYPASS VALVE AND CLOSE When detecting EVAP vapor THE EVAP CANISTER VENT CONTROL VALVE IN ORDER TO leak point of EVAP system MAKE EVAP SYSTEM CLOSE UNDER THE FOLLOWING CONDITIONS. 쐌 IGN SW “ON” 쐌 ENGINE NOT RUNNING 쐌 AMBIENT TEMPERATURE IS ABOVE 0°C (32°F). 쐌 NO VACUUM AND NO HIGH PRESSURE IN EVAP SYSTEM 쐌 TANK FUEL TEMP. IS MORE THAN 0°C (32°F). 쐌 WITHIN 10 MINUTES AFTER STARTING “EVAP SYSTEM CLOSE” 쐌 WHEN TRYING TO EXECUTE “EVAP SYSTEM CLOSE” UNDER THE CONDITION EXCEPT ABOVE, CONSULT-II WILL DISCONTINUE IT AND DISPLAY APPROPRIATE INSTRUCTION. NOTE: WHEN STARTING ENGINE, CONSULT-II MAY DISPLAY “BATTERY VOLTAGE IS LOW. CHARGE BATTERY”, EVEN IN USING CHARGED BATTERY. 쐌 IDLE CONDITION TARGET IGN TIM ADJ* TARGET IDLE RPM ADJ* GI USAGE 쐌 When adjusting target ignition timing 쐌 If once the “TARGET IDLE RPM ADJ” has been done, the Idle Air Volume Learning procedure will not be completed. 쐌 IDLE CONDITION When setting target idle speed SELF-DIAGNOSTIC MODE DTC and 1st Trip DTC NAEC0034S0501 Freeze Frame Data and 1st Trip Freeze Frame Data NAEC0034S0502 FUEL SYS-B1 FUEL SYS-B2 CAL/LD VALUE [%] Description 쐌 The engine control component part/control system has a trouble code, it is displayed as “PXXXX”. (Refer to “TROUBLE DIAGNOSIS — INDEX”, EC-10.) 쐌 “Fuel injection system status” at the moment a malfunction is detected is displayed. 쐌 One mode in the following is displayed. “MODE 2”: Open loop due to detected system malfunction “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 쐌 The calculated load value at the moment a malfunction is detected is displayed. COOLANT TEMP [°C] 쐌 The engine coolant temperature at the moment a malfunction is detected is displayed. or [°F] S-FUEL TRIM-B1 [%] S-FUEL TRIM-B2 [%] L-FUEL TRIM-B1 [%] L-FUEL TRIM-B2 [%] 쐌 “Short-term fuel trim” at the moment a malfunction is detected is displayed. 쐌 The short-term fuel trim indicates dynamic or instantaneous feedback compensation to the base fuel schedule. 쐌 “Long-term fuel trim” at the moment a malfunction is detected is displayed. 쐌 The long-term fuel trim indicates much more gradual feedback compensation to the base fuel schedule than short-term fuel trim. EC-115 LC FE CL MT AT TF NAEC0034S05 Regarding items of “DTC and 1st trip DTC”, refer to “TROUBLE DIAGNOSIS — INDEX” (See EC-10.) DIAG TROUBLE CODE [PXXXX] EM PD *: This function is not necessary in the usual service procedure. Freeze frame data item*1 MA AX SU BR ST RS BT HA SC EL IDX ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) Freeze frame data item*1 Description ENGINE SPEED [rpm] 쐌 The engine speed at the moment a malfunction is detected is displayed. VEHICL SPEED [km/h] or [mph] 쐌 The vehicle speed at the moment a malfunction is detected is displayed. B/FUEL SCHDL [msec] 쐌 The base fuel schedule at the moment a malfunction is detected is displayed. INT/A TEMP SE [°C] or [°F] 쐌 The intake air temperature at the moment a malfunction is detected is displayed. *1: The items are the same as those of 1st trip freeze frame data. EC-116 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) DATA MONITOR MODE =NAEC0034S06 GI ECM input signals Main signals ENG SPEED [rpm] 쎻 쎻 쐌 Indicates the engine speed computed from the REF signal (120° signal) of the crankshaft position sensor (REF). EM MAS A/F SE-B1 [V] 쎻 쎻 쐌 The signal voltage of the mass air flow sen- 쐌 When the engine is stopped, a cersor is displayed. tain value is indicated. LC 쎻 쐌 When the engine coolant temperature sensor is open or shortcircuited, ECM enters fail-safe mode. The engine coolant temperature determined by the ECM is displayed. Monitored item [Unit] COOLAN TEMP/S [°C] or [°F] 쎻 HO2S1 (B1) [V] 쎻 HO2S1 (B2) [V] 쎻 HO2S2 (B1) [V] 쎻 HO2S2 (B2) [V] 쎻 HO2S1 MNTR (B1) [RICH/LEAN] 쎻 HO2S1 MNTR (B2) [RICH/LEAN] 쎻 HO2S2 MNTR (B1) [RICH/LEAN] 쎻 HO2S2 MNTR (B2) [RICH/LEAN] 쎻 쎻 쎻 Description 쐌 The engine coolant temperature (determined by the signal voltage of the engine coolant temperature sensor) is displayed. FE CL 쐌 The signal voltage of the rear heated oxygen sensor is displayed. MT 쐌 Display of heated oxygen sensor 1 signal during air-fuel ratio feedback control: RICH ... means the mixture became “rich”, and control is being affected toward a leaner mixture. LEAN ... means the mixture became “lean”, and control is being affected toward a rich mixture. 쐌 After turning ON the ignition switch, “RICH” is displayed until air-fuel mixture ratio feedback control begins. 쐌 When the air-fuel ratio feedback is clamped, the value just before the clamping is displayed continuously. AT 쐌 Display of heated oxygen sensor 2 signal: RICH ... means the amount of oxygen after three way catalyst is relatively small. LEAN ... means the amount of oxygen after three way catalyst is relatively large. 쐌 When the engine is stopped, a certain value is indicated. AX 쎻 쎻 쐌 The vehicle speed computed from the vehicle speed sensor signal is displayed. BATTERY VOLT [V] 쎻 쎻 쐌 The power supply voltage of ECM is displayed. ACCEL SEN 1 [V] 쎻 쎻 ACCEL SEN 2 [V] 쎻 쐌 The accelerator pedal position sensor signal voltage is displayed. THRTL SEN 1 [V] 쎻 쎻 THRTL SEN 2 [V] 쎻 쐌 The throttle position sensor signal voltage is displayed. 쎻 쐌 The fuel temperature judged from the tank fuel temperature sensor signal voltage is displayed. INT/A TEMP SE [°C] or [°F] 쎻 쐌 The intake air temperature determined by the signal voltage of the intake air temperature sensor is indicated. EVAP SYS PRES [V] 쎻 쐌 The signal voltage of EVAP control system pressure sensor is displayed. FUEL LEVEL SE [V] 쎻 쐌 The signal voltage of the fuel level sensor is displayed. 쎻 MA 쐌 The signal voltage of the front heated oxygen sensor is displayed. VHCL SPEED SE [km/h] or [mph] FUEL T/TMP SE [°C] or [°F] Remarks TF PD SU BR ST RS BT HA SC EL IDX EC-117 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) ECM input signals Main signals Description START SIGNAL [ON/OFF] 쎻 쎻 쐌 Indicates start signal status [ON/OFF] computed by the ECM according to the signals of engine speed and battery voltage. CLSD THL POS [ON/OFF] 쎻 쎻 쐌 Indicates idle position [ON/OFF] computed by ECM according to the accelerator pedal position sensor signal. AIR COND SIG [ON/OFF] 쎻 쎻 쐌 Indicates [ON/OFF] condition of the air conditioner switch as determined by the air conditioner signal. P/N POSI SW [ON/OFF] 쎻 쎻 쐌 Indicates [ON/OFF] condition from the park/ neutral position (PNP) switch signal. PW/ST SIGNAL [ON/OFF] 쎻 쎻 쐌 [ON/OFF] condition of the power steering oil pressure switch determined by the power steering oil pressure signal is indicated. 쎻 쐌 Indicates [ON/OFF] condition from the electrical load signal and/or lighting switch. ON ... rear defogger is operating and/or lighting switch is on. OFF ... rear defogger is not operating and lighting switch is not on. Monitored item [Unit] LOAD SIGNAL [ON/OFF] 쎻 IGNITION SW [ON/OFF] 쎻 쐌 After starting the engine, [OFF] is displayed regardless of the starter signal. 쐌 Indicates [ON/OFF] condition from ignition switch. BRAKE SW [ON/OFF] 쐌 Indicates [ON/OFF] condition from the stop lamp switch signal. SWRL CONT S/V [ON/OFF] 쐌 The control condition of the swirl control valve control solenoid valve (determined by ECM according to the input signals) is indicated. 쐌 ON ... Swirl control valve is closed. OFF ... Swirl control valve is opened. INJ PULSE-B1 [msec] Remarks 쎻 INJ PULSE-B2 [msec] 쐌 Indicates the actual fuel injection pulse width compensated by ECM according to the input signals. B/FUEL SCHDL [msec] 쎻 쐌 “Base fuel schedule” indicates the fuel injection pulse width programmed into ECM, prior to any learned on board correction. IGN TIMING [BTDC] 쎻 쐌 Indicates the ignition timing computed by ECM according to the input signals. 쐌 When the engine is stopped, a certain computed value is indicated. 쐌 When the engine is stopped, a certain value is indicated. 쐌 Indicates the EVAP canister purge volume control solenoid valve control value computed by the ECM according to the input signals. 쐌 The opening becomes larger as the value increases. PURG VOL C/V [%] A/F ALPHA-B1 [%] 쎻 A/F ALPHA-B2 [%] 쎻 쐌 When the engine is stopped, a certain value is indicated. 쐌 The mean value of the air-fuel ratio feedback correction factor per cycle is indicated. 쐌 This data also includes the data for the air-fuel ratio learning control. EC-118 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) ECM input signals GI Main signals Description AIR COND RLY [ON/OFF] 쎻 쐌 The air conditioner relay control condition (determined by ECM according to the input signal) is indicated. FUEL PUMP RLY [ON/OFF] 쎻 Monitored item [Unit] 쐌 Indicates the fuel pump relay control condition determined by ECM according to the input signals. VENT CONT/V [ON/OFF] 쐌 The control condition of the EVAP canister vent control valve (determined by ECM according to the input signal) is indicated. 쐌 ON ... Closed OFF ... Open THRTL RELAY [ON/OFF] 쐌 Indicates the throttle control motor relay control condition determined by the ECM according to the input signals. HO2S1 HTR (B1) [ON/OFF] 쐌 Indicates [ON/OFF] condition of front heated oxygen sensor heater determined by ECM according to the input signals. HO2S1 HTR (B2) [ON/OFF] Remarks MA EM LC FE CL MT AT HO2S2 HTR (B1) [ON/OFF] 쐌 Indicates [ON/OFF] condition of rear heated oxygen sensor heater determined by ECM according to the input signals. HO2S2 HTR (B2) [ON/OFF] 쐌 The control condition of the vacuum cut valve bypass valve (determined by ECM according to the input signal) is indicated. 쐌 ON ... Open OFF ... Closed VC/V BYPASS/V [ON/OFF] TF PD AX CAL/LD VALUE [%] 쐌 “Calculated load value” indicates the value of the current airflow divided by peak airflow. SU MASS AIRFLOW [g·m/s] 쐌 Indicates the mass airflow computed by ECM according to the signal voltage of the mass airflow sensor. BR 쐌 Indicate [°CA] of intake camshaft advanced angle. ST 쐌 The control condition of the intake valve timing control solenoid valve is indicated. RS INT/V SOL (B2) [%] TRVL AFTER MIL [km] or [Mile] 쐌 Distance traveled while MIL is activated VIAS S/V [ON/OFF] 쐌 The control condition of the VIAS control solenoid valve (determined by ECM according to the input signal) is indicated. 쐌 OFF ... VIAS control solenoid valve is not operating. ON ... VIAS control solenoid valve is operating. SWL CON VC SW 쐌 Indicates [ON/OFF] condition from the swirl control valve control vacuum check switch. ON ... Swirl control valve is not operational. OFF ... Swirl control valve is operational. INT/V TIM (B1) [°CA] INT/V TIM (B2) [°CA] INT/V SOL (B1) [%] 쎻 EC-119 BT HA SC EL IDX ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) Monitored item [Unit] ECM input signals Main signals Description IDL A/V LEARN 쐌 Display the condition of idle air volume learning YET ... Idle air volume learning has not been performed yet. CMPLT ... Idle air volume learning has already been performed successfully. AC PRESS SEN [V] 쐌 The signal voltage from the refrigerant pressure sensor is displayed. SET VHCL SPD [km/h] or [mph] 쐌 The preset vehicle speed is displayed. MAIN SW [ON/OFF] 쐌 Indicates [ON/OFF] condition from CRUISE switch signal. CANCEL SW [ON/OFF] 쐌 Indicates [ON/OFF] condition from CANCEL switch signal. RESUME/ACC SW [ON/OFF] 쐌 Indicates [ON/OFF] condition from ACCEL/ RES switch signal. SET SW [ON/OFF] 쐌 Indicates [ON/OFF] condition from COAST/ SET switch signal. BRAKE SW1 [ON/OFF] 쐌 Indicates [ON/OFF] condition from ASCD brake switch signal, and ASCD clutch switch signal (M/T models). BRAKE SW2 [ON/OFF] 쐌 Indicates [ON/OFF] condition of stop lamp switch signal. VHCL SPD CUT [NON/CUT] 쐌 Indicates the vehicle cruise condition. NON ... Vehicle speed is maintained at the ASCD set speed. CUT ...Vehicle speed increased to excessively high compared with the ASCD set speed, and ASCD operation is cut off. LO SPEED CUT [NON/CUT] 쐌 Indicates the vehicle cruise condition. NON ... Vehicle speed is maintained at the ASCD set speed. CUT ...Vehicle speed decreased to excessively low compared with the ASCD set speed, and ASCD operation is cut off. AT OD MONITOR [ON/OFF] 쐌 Indicates [ON/OFF] condition of A/T O/D according to the input signal from the TCM. AT OD CANCEL [ON/OFF] 쐌 Indicates [ON/OFF] condition of A/T O/D cancel signal sent from the TCM. CRUISE LAMP [ON/OFF] 쐌 Indicates [ON/OFF] condition of CRUISE lamp determined by the ECM according to the input signals. SET LAMP [ON/OFF] 쐌 Indicates [ON/OFF] condition of SET lamp determined by the ECM according to the input signals. EC-120 Remarks ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) Monitored item [Unit] ECM input signals GI Main signals Description Remarks MA Voltage [V] Frequenty [msec], [Hz] or [%] 쐌 Voltage, frequency, duty cycle or pulse width measured by the probe. DUTY-HI DUTY-LOW PLS WIDTH-HI 쐌 Only “#” is displayed if item is unable to be measured. 쐌 Figures with “#”s are temporary ones. They are the same figures as an actual piece of data which was just previously measured. EM LC PLS WIDTH-LOW NOTE: 쐌 Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically. DATA MONITOR (SPEC) MODE Monitored item [Unit] MAS A/F SE-B1 [V] ECM input signals 쎻 FE NAEC0034S11 CL Main signals 쎻 Description Remarks 쐌 The signal voltage of the mass air flow sen- 쐌 When the engine is running, specifisor specification is displayed. cation range is indicated. 쐌 “Base fuel schedule” indicates the fuel injec쐌 When the engine is running, specifition pulse width programmed into ECM, cation range is indicated. prior to any learned on board correction. B/FUEL SCHDL [msec] A/F ALPHA-B1 [%] 쎻 A/F ALPHA-B2 [%] 쎻 쐌 When the engine is running, specifi쐌 Indicates the mean value of the air-fuel ratio cation range is indicated. feedback correction factor per cycle. 쐌 This data also includes the data for the air-fuel ratio learning control. NOTE: 쐌 Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically. ACTIVE TEST MODE TEST ITEM CONDITION AT TF PD AX NAEC0034S07 JUDGEMENT CHECK ITEM (REMEDY) 쐌 Engine: Return to the original 쐌 Harness and connector trouble condition If trouble symptom disappears, see FUEL INJECTION 쐌 Fuel injectors 쐌 Change the amount of fuel injec- CHECK ITEM. 쐌 Heated oxygen sensor tion using CONSULT-II. 쐌 Engine: Return to the original trouble condition IGNITION TIMING 쐌 Timing light: Set 쐌 Retard the ignition timing using CONSULT-II. MT SU BR ST If trouble symptom disappears, see 쐌 Adjust initial ignition timing CHECK ITEM. POWER BALANCE 쐌 Engine: After warming up, idle the engine. 쐌 A/C switch “OFF” 쐌 Shift lever “N” 쐌 Cut off each injector signal one at a time using CONSULT-II. Engine runs rough or dies. ENG COOLANT TEMP 쐌 Engine: Return to the original trouble condition 쐌 Change the engine coolant temperature using CONSULT-II. 쐌 Harness and connector If trouble symptom disappears, see 쐌 Engine coolant temperature senCHECK ITEM. sor 쐌 Fuel injectors 쐌 쐌 쐌 쐌 쐌 쐌 Harness and connector Compression Injectors Power transistor Spark plugs Ignition coils RS BT HA SC EL IDX EC-121 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) TEST ITEM CONDITION JUDGEMENT CHECK ITEM (REMEDY) FUEL PUMP RELAY 쐌 Ignition switch: ON (Engine stopped) 쐌 Turn the fuel pump relay “ON” and “OFF” using CONSULT-II and listen to operating sound. Fuel pump relay makes the operat- 쐌 Harness and connector ing sound. 쐌 Fuel pump relay VIAS SOL VALVE 쐌 Ignition switch: ON 쐌 Turn solenoid valve “ON” and “OFF” with CONSULT-II and listen for operating sound. Solenoid valve makes an operating 쐌 Harness and connector sound. 쐌 Solenoid valve SWIRL CONT SOL VALVE 쐌 Ignition switch: ON 쐌 Turn solenoid valve “ON” and “OFF” with CONSULT-II and listen for operating sound. Solenoid valve makes an operating 쐌 Harness and connector sound. 쐌 Solenoid valve PURG VOL CONT/V 쐌 Engine: After warming up, run engine at 1,500 rpm. 쐌 Change the EVAP canister purge Engine speed changes according volume control solenoid valve to the opening percent. opening percent using CONSULT-II. FUEL/T TEMP SEN 쐌 Change the fuel tank temperature using CONSULT-II. VENT CONTROL/V 쐌 Ignition switch: ON (Engine stopped) 쐌 Turn solenoid valve “ON” and “OFF” with the CONSULT-II and listen to operating sound. Solenoid valve makes an operating 쐌 Harness and connector sound. 쐌 Solenoid valve VC/V BYPASS/V 쐌 Ignition switch: ON (Engine stopped) 쐌 Turn solenoid valve “ON” and “OFF” with the CONSULT-II and listen to operating sound. Solenoid valve makes an operating 쐌 Harness and connector sound. 쐌 Solenoid valve V/T ASSIGN ANGLE 쐌 Engine: After warming up, hold engine speed at 2,500 rpm. 쐌 Change the intake valve timing using CONSULT-II. 쐌 Harness and connector If trouble symptom disappears, see 쐌 Intake valve timing control soleCHECK ITEM. noid valve 쐌 Harness and connector 쐌 Solenoid valve DTC & SRT CONFIRMATION MODE SRT STATUS Mode NAEC0034S08 NAEC0034S0801 For details, refer to “SYSTEM READINESS TEST (SRT) CODE”, EC-87. SRT Work Support Mode NAEC0034S0803 This mode enables a technician to drive a vehicle to set the SRT while monitoring the SRT status. EC-122 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) DTC Work Support Mode Test mode Test item Condition NAEC0034S0802 Reference page EVP SML LEAK P0442/P1442 EC-381, 601 EVP V/S LEAK P0456/P1456 EC-438, 645 EVAPORATIVE SYSTEM PURG VOL CN/V P1444 EC-616 PURGE FLOW P0441 EC-371 VC CUT/V BP/V P1491 EC-667 HO2S1 (B1) P0134 EC-278 HO2S1 (B1) P1143 EC-541 HO2S1 (B1) P1144 EC-549 HO2S1 (B1) P0133 EC-264 Refer to corresponding trouble diagnosis for DTC. HO2S1 HO2S1 (B2) P0154 HO2S1 (B2) P1163 GI EC-278 MA EM LC FE CL EC-541 HO2S1 (B2) P1164 EC-549 HO2S1 (B2) P0153 EC-264 HO2S2 (B1) P1146 EC-557 HO2S2 (B1) P1147 EC-566 HO2S2 (B1) P0139 EC-295 HO2S2 (B2) P1166 EC-557 HO2S2 (B2) P1167 EC-566 HO2S2 (B2) P0159 EC-295 HO2S2 MT AT TF PD AX SU REAL TIME DIAGNOSIS IN DATA MONITOR MODE (RECORDING VEHICLE DATA) NAEC0034S10 SEF705Y CONSULT-II has two kinds of triggers and they can be selected by touching “SETTING” in “DATA MONITOR” mode. 1) “AUTO TRIG” (Automatic trigger): 쐌 The malfunction will be identified on the CONSULT-II screen in real time. In other words, DTC/1st trip DTC and malfunction item will be displayed if the malfunction is detected by ECM. At the moment a malfunction is detected by ECM, “MONITOR” in “DATA MONITOR” screen is changed to “Recording Data ... xx%” as shown at left, and the data after the malfunction detection is recorded. Then when the percentage reached 100%, “REAL-TIME DIAG” screen is displayed. If “STOP” is touched on the screen during “ Recording Data ... xx%”, “REAL-TIME DIAG” screen is also displayed. The recording time after the malfunction detection and the recording speed can be changed by “TRIGGER POINT” and “Recording Speed”. Refer to CONSULT-II OPERATION MANUAL. 2) “MANU TRIG” (Manual trigger): 쐌 DTC/1st trip DTC and malfunction item will not be displayed SEF707X EC-123 BR ST RS BT HA SC EL IDX ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) automatically on CONSULT-II 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” 쐌 While trying to detect the DTC/1st trip DTC by performing the “DTC Confirmation Procedure”, be sure to select to “DATA MONITOR (AUTO TRIG)” mode. You can confirm the malfunction at the moment it is detected. 쐌 While narrowing down the possible causes, CONSULT-II 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, components and harness in the “DTC Confirmation Procedure”, the moment a malfunction is found the DTC/1st trip DTC will be displayed. (Refer to GI-25, “Incident Simulation Tests”.) 2) “MANU TRIG” 쐌 If the malfunction is displayed as soon as “DATA MONITOR” is selected, reset CONSULT-II to “MANU TRIG”. By selecting “MANU TRIG” you can monitor and store the data. The data can be utilized for further diagnosis, such as a comparison with the value for the normal operating condition. SEF714Y EC-124 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Generic Scan Tool (GST) Generic Scan Tool (GST) DESCRIPTION =NAEC0035 GI NAEC0035S01 Generic Scan Tool (OBDII scan tool) complying with SAE J1978 has 8 different functions explained on the next page. ISO9141 is used as the protocol. The name “GST” or “Generic Scan Tool” is used in this service manual. MA EM LC SEF139P GST INSPECTION PROCEDURE 1. 2. NAEC0035S02 Turn ignition switch OFF. Connect GST to data link connector, which is located under LH dash panel near the fuse box cover. FE CL MT SEF941Y 3. 4. Turn ignition switch ON. Enter the program according to instruction on the screen or in the operation manual. (*: Regarding GST screens in this section, sample screens are shown.) AT TF PD AX SU SEF398S 5. Perform each diagnostic mode according to each service procedure. For further information, see the GST Operation Manual of the tool maker. BR ST RS BT SEF416S HA SC EL IDX EC-125 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Generic Scan Tool (GST) (Cont’d) FUNCTION Diagnostic test mode NAEC0035S03 Function MODE 1 READINESS TESTS This mode gains access to current emission-related data values, including analog inputs and outputs, digital inputs and outputs, and system status information. MODE 2 (FREEZE DATA) This mode gains access to emission-related data value which were stored by ECM during the freeze frame. [For details, refer to “Freeze Frame Data” (EC-115).] MODE 3 DTCs This mode gains access to emission-related power train trouble codes which were stored by ECM. MODE 4 CLEAR DIAG INFO This mode can clear all emission-related diagnostic information. This includes: 쐌 Clear number of diagnostic trouble codes (MODE 1) 쐌 Clear diagnostic trouble codes (MODE 3) 쐌 Clear trouble code for freeze frame data (MODE 1) 쐌 Clear freeze frame data (MODE 2) 쐌 Reset status of system monitoring test (MODE 1) 쐌 Clear on board monitoring test results (MODE 6 and 7) MODE 6 (ON BOARD TESTS) This mode accesses the results of on board diagnostic monitoring tests of specific components/systems that are not continuously monitored. MODE 7 (ON BOARD TESTS) This mode enables the off board test drive to obtain test results for emission-related powertrain components/systems that are continuously monitored during normal driving conditions. MODE 8 MODE 9 — (CALIBRATION ID) This mode can close EVAP system in ignition switch “ON” position (Engine stopped). When this mode is performed, the following parts can be opened or closed. 쐌 EVAP canister vent control valve open 쐌 Vacuum cut valve bypass valve closed In the following conditions, this mode cannot function. 쐌 Low ambient temperature 쐌 Low battery voltage 쐌 Engine running 쐌 Ignition switch “OFF” 쐌 Low fuel temperature 쐌 Too much pressure is applied to EVAP system This mode enables the off-board test device to request specific vehicle information such as Vehicle Identification Number (VIN) and Calibration IDs. EC-126 TROUBLE DIAGNOSIS — INTRODUCTION Introduction Introduction MEF036D SEF233G NAEC0036 The engine has an ECM to control major systems such as fuel control, ignition control, idle air control system, etc. The ECM 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 incidents such as vacuum leaks, fouled spark plugs, or other incidents with the engine. It is much more difficult to diagnose an incident that occurs intermittently rather than continuously. Most intermittent incidents are 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 incidents. A road test with CONSULT-II (or GST) or a circuit tester connected should be performed. Follow the “Work Flow” on EC-129. Before undertaking actual checks, take a few minutes to talk with a customer who approaches with a driveability complaint. The customer can supply good information about such incidents, especially intermittent ones. Find out what symptoms are present and under what conditions they occur. A “Diagnostic Worksheet” like the example on next page should be used. Start your diagnosis by looking for “conventional” malfunctions first. This will help troubleshoot driveability malfunctions on an electronically controlled engine vehicle. GI MA EM LC FE CL MT AT TF PD AX SU SEF234G DIAGNOSTIC WORKSHEET SEF907L NAEC0036S01 There are many operating conditions that lead to the malfunction of engine components. A good grasp of such conditions can make trouble-shooting faster and more accurate. In general, each customer feels differently about an incident. It is important to fully understand the symptoms or conditions for a customer complaint. Utilize a diagnostic worksheet like the one on the next page in order to organize all the information for troubleshooting. Some conditions may cause the MIL to come on steady or blink and DTC to be detected. Examples: 쐌 Vehicle ran out of fuel, which caused the engine to misfire. 쐌 Fuel filler cap was left off or incorrectly screwed on, allowing fuel to evaporate into the atmosphere. BR ST RS BT HA SC EL IDX EC-127 TROUBLE DIAGNOSIS — INTRODUCTION Introduction (Cont’d) Worksheet Sample NAEC0036S0101 MTBL0017 EC-128 TROUBLE DIAGNOSIS — INTRODUCTION Work Flow Work Flow NAEC0037 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS PBIB1043E *1 *2 If time data of “SELF-DIAG RESULTS” is other than “0” or “[1t]”, perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. If the incident cannot be verified, perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. *3 *4 If the on board diagnostic system cannot be performed, check main power supply and ground circuit. Refer to “TROUBLE DIAGNOSIS FOR POWER SUPPLY”, EC-165. If malfunctioning part cannot be *5 *6 detected, perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. EC-92 EC-159 BT HA SC EL IDX EC-129 TROUBLE DIAGNOSIS — INTRODUCTION Work Flow (Cont’d) DESCRIPTION FOR WORK FLOW STEP NAEC0037S01 DESCRIPTION STEP I Get detailed information about the conditions and the environment when the incident/symptom occurred using the “DIAGNOSTIC WORK SHEET”, EC-128. STEP II Before confirming the concern, check and write down (print out using CONSULT-II or GST) the (1st trip) DTC and the (1st trip) freeze frame data, then erase the DTC and the data. (Refer to EC-100.) The (1st trip) DTC and the (1st trip) freeze frame data can be used when duplicating the incident at STEP III & IV. If the incident cannot be verified, perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 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-139.) Also check related service bulletins for information. STEP III 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-II to the vehicle in DATA MONITOR (AUTO TRIG) mode and check real time diagnosis results. If the incident cannot be verified, perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. If the malfunction code is detected, skip STEP IV and perform STEP V. STEP IV Try to detect the (1st trip) DTC by driving in (or performing) the “DTC Confirmation Procedure”. Check and read the (1st trip) DTC and (1st trip) freeze frame data by using CONSULT-II or GST. During the (1st trip) DTC verification, be sure to connect CONSULT-II to the vehicle in DATA MONITOR (AUTO TRIG) mode and check real time diagnosis results. If the incident cannot be verified, perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. In case the “DTC Confirmation Procedure” is not available, perform the “Overall Function Check” instead. The (1st trip) DTC cannot be displayed by this check, however, this simplified “check” is an effective alternative. The “NG” result of the “Overall Function Check” is the same as the (1st trip) DTC detection. STEP V 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. If the normal code is indicated, proceed to the BASIC INSPECTION. (Refer to EC-131.) If CONSULT-II is available, perform “DATA MONITOR (SPEC)” mode with CONSULT-II and proceed to the “TROUBLE DIAGNOSIS — SPECIFICATION VALUE”, EC-159. (If malfunction is detected, proceed to “REPAIR REPLACE”.) Then perform inspections according to the Symptom Matrix Chart. (Refer to EC-139.) STEP VI 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-II 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 CONSULT-II. Refer to EC-143, 149. 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 GI-27, “Circuit Inspection”. Repair or replace the malfunction parts. If malfunctioning part cannot be detected, perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. STEP VII 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. Perform the “DTC Confirmation Procedure” and confirm the normal code [DTC No. P0000] 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 TCM (Transmission control module). (Refer to EC-100.) EC-130 TROUBLE DIAGNOSIS — BASIC INSPECTION Basic Inspection Basic Inspection NAEC0038 Precaution: Perform Basic Inspection without electrical or mechanical loads applied; 쐌 Headlamp switch is OFF, 쐌 Air conditioner switch is OFF, 쐌 Rear window defogger switch is OFF, 쐌 Steering wheel is in the straight-ahead position, etc. 1 INSPECTION START 1. Check service records for any recent repairs that may indicate a related malfunction, or a current need for scheduled maintenance. 2. Open engine hood and check the following: 쐌 Harness connectors for improper connections 쐌 Vacuum hoses for splits, kinks and improper connections 쐌 Wiring for improper connections, pinches and cuts 쐌 Air cleaner clogging 쐌 Hoses and ducts for leaks GI MA EM LC FE CL MT AT TF SEF983U 䊳 2 PD GO TO 2. AX REPAIR OR REPLACE Repair or replace components as necessary according to corresponding “Diagnostic Procedure”. 䊳 SU GO TO 3. BR ST RS BT HA SC EL IDX EC-131 TROUBLE DIAGNOSIS — BASIC INSPECTION Basic Inspection (Cont’d) 3 CHECK TARGET IDLE SPEED With CONSULT-II 1. Run engine at about 2,000 rpm for about 2 minutes under no-load. 2. Rev engine (2,000 to 3,000 rpm) two or three times under no-load, then run engine at idle speed for about 1 minute. SEF978U 3. Read idle speed in “DATA MONITOR” mode with CONSULT-II. MT: 750±50 rpm AT: 750±50 rpm (in “P” or “N” position) SEF058Y Without CONSULT-II 1. Run engine at about 2,000 rpm for about 2 minutes under no-load. 2. Rev engine (2,000 to 3,000 rpm) two or three times under no-load, then run engine at idle speed for about 1 minute. 3. Check idle speed. MT: 750±50 rpm AT: 750±50 rpm (in “P” or “N” position) OK or NG OK 䊳 GO TO 10. NG 䊳 GO TO 4. 4 PERFORM ACCELERATOR PEDAL RELEASED POSITION LEARNING 1. Stop engine. 2. Perform “Accelerator Pedal Released Position Learning”, EC-81. 䊳 5 GO TO 5. PERFORM THROTTLE VALVE CLOSED POSITION LEARNING Perform “Throttle Valve Closed Position Learning”, EC-81. 䊳 GO TO 6. EC-132 TROUBLE DIAGNOSIS — BASIC INSPECTION Basic Inspection (Cont’d) 6 GI PERFORM IDLE AIR VOLUME LEARNING Refer to “Idle Air Volume Learning”, EC-81. Is Idle Air Volume Learning carried out successfully? MA Yes or No Yes 䊳 GO TO 7. No 䊳 1. Follow the instruction of “Idle Air Volume Learning”. 2. GO TO 4. EM LC 7 CHECK TARGET IDLE SPEED AGAIN With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Read idle speed in “DATA MONITOR” mode with CONSULT-II. MT: 750±50 rpm AT: 750±50 rpm (in “P” or “N” position) Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. MT: 750±50 rpm AT: 750±50 rpm (in “P” or “N” position) OK or NG OK 䊳 GO TO 10. NG 䊳 GO TO 8. 8 FE CL MT AT TF DETECT MALFUNCTIONING PART PD Check the following. 쐌 Check camshaft position sensor (PHASE) and circuit. Refer to EC-357. 쐌 Check crankshaft position sensor (POS) and circuit. Refer to EC-350. AX OK or NG OK 䊳 GO TO 9. NG 䊳 1. Repair or replace. 2. GO TO 4. 9 SU BR CHECK ECM FUNCTION 1. Substitute another known-good ECM to check ECM function. (ECM may be the cause of an incident, but this is the rarely the case.) 2. Perform initialization of NVIS (NATS) system and registration of NVIS (NATS) ignition key IDs. Refer to “NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS)”, EC-101. 䊳 ST RS GO TO 4. BT HA SC EL IDX EC-133 TROUBLE DIAGNOSIS — BASIC INSPECTION Basic Inspection (Cont’d) 10 CHECK IGNITION TIMING 1. Run engine at idle. 2. Check ignition timing with a timing light. SEC580D MT: 15°±5° BTDC AT: 15°±5° BTDC (in “P” or “N” position) OK or NG OK 䊳 INSPECTION END NG 䊳 GO TO 11. 11 PERFORM ACCELERATOR PEDAL RELEASED POSITION LEARNING 1. Stop engine. 2. Perform “Accelerator Pedal Released Position Learning”, EC-81. 䊳 12 GO TO 12. PERFORM THROTTLE VALVE CLOSED POSITION LEARNING Perform “Throttle Valve Closed Position Learning”, EC-81. 䊳 13 GO TO 13. PERFORM IDLE AIR VOLUME LEARNING Refer to “Idle Air Volume Learning”, EC-81. Is Idle Air Volume Learning carried out successfully? Yes or No Yes 䊳 GO TO 14. No 䊳 1. Follow the instruction of “Idle Air Volume Learning”. 2. GO TO 4. EC-134 TROUBLE DIAGNOSIS — BASIC INSPECTION Basic Inspection (Cont’d) 14 GI CHECK TARGET IDLE SPEED AGAIN With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Read idle speed in “DATA MONITOR” mode with CONSULT-II. MT: 750±50 rpm AT: 750±50 rpm (in “P” or “N” position) MA EM Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. MT: 750±50 rpm AT: 750±50 rpm (in “P” or “N” position) LC OK or NG OK 䊳 GO TO 15. NG 䊳 GO TO 17. FE CL 15 CHECK IGNITION TIMING AGAIN 1. Run engine at idle. 2. Check ignition timing with a timing light. MT AT TF PD SEC580D MT: 15°±5° BTDC AT: 15°±5° BTDC (in “P” or “N” position) AX SU OK or NG OK 䊳 INSPECTION END NG 䊳 GO TO 16. 16 CHECK TIMING CHAIN INSTALLATION BR ST Check timing chain installation. Refer to EM-21, “TIMING CHAIN”. OK or NG OK 䊳 GO TO 17. NG 䊳 1. Repair the timing chain installation. 2. GO TO 4. RS BT HA 17 DETECT MALFUNCTIONING PART Check the following. 쐌 Check camshaft position sensor (PHASE) and circuit. Refer to EC-357. 쐌 Check crankshaft position sensor (POS) and circuit. Refer to EC-350. OK or NG OK 䊳 GO TO 18. NG 䊳 1. Repair or replace. 2. GO TO 4. SC EL IDX EC-135 TROUBLE DIAGNOSIS — BASIC INSPECTION Basic Inspection (Cont’d) 18 CHECK ECM FUNCTION 1. Substitute another known-good ECM to check ECM function. (ECM may be the cause of an incident, but this is the rarely the case.) 2. Perform initialization of NVIS (NATS) system and registration of NVIS (NATS) ignition key IDs. Refer to “NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS)”, EC-101. 䊳 GO TO 4. EC-136 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION DTC Inspection Priority Chart DTC Inspection Priority Chart NAEC0039 If some DTCs are displayed at the same time, perform inspections one by one based on the following priority chart. Priority 1 2 3 GI MA Detected items (DTC) 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 U1000, U1001 CAN communication line P0101, P0102, P0103, P1102* MAF sensor P0112, P0113, P0127 IAT sensor P0117, P0118, P0125 ECT sensor P0122, P0123, P0222, P0223, P1225, P1226, P2135 Throttle position sensor P0128 Thermostat function P0181, P0182, P0183 FTT sensor P0327, P0328 KS P0335 CKP sensor (POS) P0340, P0345 CMP sensor (PHASE) P0460, P0461, P0462, P0463 Fuel level sensor P0500 VSS P0605 ECM P1229 Sensor power supply P1706 PNP switch P2122, P2123, P2127, P2128, P2138 Accelerator pedal position sensor EM 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 P0031, P0032, P0051, P0052 HO2S1 heater P0037, P0038, P0057, P0058 HO2S2 heater P0132-P0134, P1143, P1144 and P0152-P0154, P1163, P1164 HO2S1 P0138, P0139, P1146, P1147 and P0158, P0159, P1166, P1167 HO2S2 P0441 EVAP control system purge flow monitoring P0444, P0445, P1444 EVAP canister purge volume control solenoid valve P0447, P1446, P1448 EVAP canister vent control valve P0452, P0453 EVAP control system pressure sensor P0550 Power steering pressure sensor P0705-P0755, P1705, P1760 A/T related sensors, solenoid valves and switches P1065 ECM power supply P1111 Intake valve timing control solenoid valve P1122 Electric throttle control function P1165 Swirl control valve control vacuum check switch P1217 Engine over temperature (OVERHEAT) P1490, P1491 Vacuum cut valve bypass valve P1805 Brake switch MT 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 P0011, P0021, P1110, P1135 Intake valve timing control P0171, P0172 and P0174, P0175 Fuel injection system function P0300-P0306 Misfire P0420, P0430 Three way catalyst function P0442, P0455, P0456, P1442, P1456 EVAP control system P0506, P0507 ISC system P0731-P0734, P0744 A/T function P1121 Electric throttle control actuator P1124, P1126, P1128 Electric throttle control actuator P1130, P1131 Swirl control valve control solenoid valve P1148, P1168 Closed loop control P1211 ABS/TCS control unit P1212 ABS/TCS communication line P1564 ASCD steering switch P1572 ASCD brake switch LC FE CL AT TF PD AX SU BR ST RS BT HA *: For the type I vehicle (Refer to “How to Check Vehicle Type”, EC-9.). SC EL IDX EC-137 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Fail-safe Chart Fail-safe Chart =NAEC0040 When the DTC listed below is detected, the ECM enters fail-safe mode and the MIL lights up. DTC No. Detected items Engine operating condition in fail-safe mode P0102 P0103 P1102* Mass air flow sensor circuit Engine speed will not rise more than 2,400 rpm due to the fuel cut. P0117 P0118 Engine coolant temperature sensor circuit Engine coolant temperature will be determined by ECM based on the time after turning ignition switch “ON” or “START”. CONSULT-II displays the engine coolant temperature decided by ECM. Condition Engine coolant temperature decided (CONSULT-II display) Just as ignition switch is turned ON or Start 40°C (104°F) More than approx. 4 minutes after ignition ON or Start 80°C (176°F) Except as shown above 40 - 80°C (104 - 176°F) (Depends on the time) When the fail-safe system for engine coolant temperature sensor is activated, the cooling fan operates while engine is running. P0122 P0123 P0222 P0223 P2135 Throttle position sensor The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. P1121 Electric throttle control actuator (When electric throttle control actuator does not function properly due to the return spring malfunction:) ECM controls the electric throttle actuator by regulating the throttle opening around the idle position. The engine speed will not rise more than 2,000 rpm. (When throttle valve opening angle in fail-safe mode is not in specified range:) ECM controls the electric throttle control actuator by regulating the throttle opening to 20 degrees or less. (When ECM detects the throttle valve is stuck open:) While the vehicle is driving, it slows down gradually by fuel cut. After the vehicle stops, the engine stalls. The engine can restart in N or P position, and engine speed will not exceed 1,000 rpm or more. P1122 Electric throttle control func- ECM stops the electric throttle control actuator control, throttle valve is maintained tion at a fixed opening (approx. 5 degrees) by the return spring. P1124 P1126 Throttle control relay ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. P1128 Throttle control motor ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. P1229 Sensor power supply ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. P2122 P2123 P2127 P2128 P2138 Accelerator pedal position sensor The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. *: For the type I vehicle (Refer to “How to Check Vehicle Type”, EC-9.). 쐌 When there is an open circuit on MIL circuit, the ECM cannot warn the driver by lighting MIL up when there is a malfunction on engine control system. Therefore, when electrically controlled throttle and part of ECM related diagnosis is continuously detected EC-138 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Fail-safe Chart (Cont’d) as NG for 5 trips, ECM warns the driver that engine control system has a malfunction and MIL circuit is open by means of operating fail-safe function. The fail-safe function also operates when a DTC is detected during the above diagnosis except MIL circuit, and demands the driver to repair the malfunction. Engine operating condition in fail-safe mode Engine speed will not rise more than 2,500 rpm due to the fuel cut GI MA EM LC Symptom Matrix Chart NAEC0041 SYSTEM — BASIC ENGINE CONTROL SYSTEM NAEC0041S01 BATTERY DEAD (UNDER CHARGE) EXCESSIVE OIL CONSUMPTION EXCESSIVE FUEL CONSUMPTION OVERHEATS/WATER TEMPERATURE HIGH SLOW/NO RETURN TO IDLE LACK OF POWER/POOR ACCELERATION SPARK KNOCK/DETONATION AH AJ AK AL AM HA 2 2 3 4 4 2 2 Fuel pump circuit 1 1 2 3 2 Fuel pressure regulator system 3 3 4 4 4 Injector circuit 1 1 2 3 2 HIGH IDLE/LOW IDLE AA AB AC AD AE AF AG ENGINE STALL IDLING VIBRATION Fuel 4 4 2 Positive crankcase ventilation system Ignition Reference page AT TF PD AX EC-763 EC-65 2 EC-758 SU BR EC-41 4 3 4 4 4 4 4 4 4 1 3 Incorrect idle speed adjustment Electric throttle control actuator MT 4 Evaporative emission system Air FE CL ROUGH IDLE/HUNTING Warranty symptom code HESITATION/SURGING/FLAT SPOT HARD/NO START/RESTART (EXCP. HA) SYMPTOM 1 1 1 1 1 2 2 2 2 2 EC-56 EC-131 1 2 3 3 Incorrect ignition timing adjustment 3 3 1 1 1 1 1 1 EC-131 Ignition circuit 1 1 2 2 2 2 2 EC-748 2 2 3 3 3 3 2 Main power supply and ground circuit 2 EC-494, 496, 504, 509 1 2 3 Air conditioner circuit 3 EC-165 ST RS BT HA 3 3 2 HA section SC 1 - 6: The numbers refer to the order of inspection. (continued on next page) EL IDX EC-139 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Matrix Chart (Cont’d) Engine control 2 2 Camshaft position sensor (PHASE) circuit 3 2 EC-357 1 EC-194, 203, 211, 219, 478 2 EC-278 1 2 3 2 1 Accelerator pedal position sensor circuit 3 Vehicle speed sensor circuit 2 Knock sensor circuit 2 3 1 2 2 2 3 3 EC-236, 249 2 2 EC-241, 327, 592, 594, 723 2 2 EC-596, 708, 715, 731 3 EC-460 2 2 2 Park/Neutral position switch circuit Power steering pressure sensor circuit 3 3 3 3 3 3 3 3 3 3 3 3 2 3 EC-345 EC-471 3 EC-696 EC-466 Electrical load signal circuit EC-787 Intake valve timing control solenoid valve circuit 3 Refrigerant pressure sensor circuit 2 ABS actuator and electric unit (control unit) BATTERY DEAD (UNDER CHARGE) EC-350 Throttle position sensor circuit ECM Reference page AJ AK AL AM HA Heated oxygen sensor 1 circuit Engine coolant temperature sensor circuit EXCESSIVE OIL CONSUMPTION EXCESSIVE FUEL CONSUMPTION OVERHEATS/WATER TEMPERATURE HIGH SLOW/NO RETURN TO IDLE HIGH IDLE/LOW IDLE IDLING VIBRATION LACK OF POWER/POOR ACCELERATION AH Crankshaft position sensor (POS) circuit Mass air flow sensor circuit SPARK KNOCK/DETONATION AA AB AC AD AE AF AG ENGINE STALL ROUGH IDLE/HUNTING Warranty symptom code HESITATION/SURGING/FLAT SPOT HARD/NO START/RESTART (EXCP. HA) SYMPTOM 2 1 3 3 4 2 2 3 3 EC-488 3 4 EC-770 EC-583, 585 Swirl control valve control solenoid valve circuit 1 EC-514 VIAS control solenoid valve circuit 1 EC-739 1 - 6: The numbers refer to the order of inspection. (continued on next page) EC-140 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Matrix Chart (Cont’d) SYSTEM — ENGINE MECHANICAL & OTHER NAEC0041S02 GI Fuel BATTERY DEAD (UNDER CHARGE) EXCESSIVE OIL CONSUMPTION MA EXCESSIVE FUEL CONSUMPTION OVERHEATS/WATER TEMPERATURE HIGH SLOW/NO RETURN TO IDLE AH HIGH IDLE/LOW IDLE IDLING VIBRATION LACK OF POWER/POOR ACCELERATION SPARK KNOCK/DETONATION AA AB AC AD AE AF AG ENGINE STALL ROUGH IDLE/HUNTING Warranty symptom code HESITATION/SURGING/FLAT SPOT HARD/NO START/RESTART (EXCP. HA) SYMPTOM EM LC Reference section FE CL AJ AK AL AM HA Fuel tank FE section MT 5 Fuel piping 5 5 5 5 5 5 AT Vapor lock 5 Valve deposit Poor fuel (Heavy weight gasoline, Low octane) Air 5 5 5 5 5 5 TF 5 Air duct — PD Air cleaner AX Air leakage from air duct (Mass air flow sensor — electric throttle control actuator Air leakage from intake manifold/ Collector/Gasket Cranking 5 5 5 5 5 5 5 5 5 SU 5 BR Battery 1 1 1 1 Alternator circuit 1 1 1 1 EL section ST Starter circuit 3 Flywheel/Drive plate 6 EM section PNP switch 4 AT section 1 - 6: The numbers refer to the order of inspection. (continued on next page) RS BT HA SC EL IDX EC-141 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Matrix Chart (Cont’d) Engine BATTERY DEAD (UNDER CHARGE) EXCESSIVE OIL CONSUMPTION EXCESSIVE FUEL CONSUMPTION OVERHEATS/WATER TEMPERATURE HIGH SLOW/NO RETURN TO IDLE AH HIGH IDLE/LOW IDLE IDLING VIBRATION LACK OF POWER/POOR ACCELERATION SPARK KNOCK/DETONATION AA AB AC AD AE AF AG ENGINE STALL ROUGH IDLE/HUNTING Warranty symptom code HESITATION/SURGING/FLAT SPOT HARD/NO START/RESTART (EXCP. HA) SYMPTOM Reference section AJ AK AL AM HA Cylinder head 5 5 5 5 5 5 5 5 Cylinder head gasket 4 3 Cylinder block Piston 4 Piston ring 6 6 6 6 6 6 6 6 Connecting rod Bearing EM section Crankshaft Valve Timing chain mechanism Camshaft Intake valve timing control 5 5 5 5 5 5 5 5 Intake valve 3 Exhaust valve Exhaust Exhaust manifold/Tube/Muffler/ Gasket 5 5 5 5 5 5 5 5 5 5 5 5 5 FE section Three way catalyst Lubrication Oil pan/Oil strainer/Oil pump/Oil filter/Oil gallery 5 5 5 MA, EM, LC section Oil level (Low)/Filthy oil Cooling Radiator/Hose/Radiator filler cap Thermostat Water pump 5 5 5 5 5 5 5 5 LC section 4 5 Water gallery Coolant level (low)/Contaminated coolant MA section 1 - 6: The numbers refer to the order of inspection. EC-142 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Matrix Chart (Cont’d) GI NVIS (NISSAN Vehicle Immobilizer System — NATS) 1 BATTERY DEAD (UNDER CHARGE) EXCESSIVE OIL CONSUMPTION MA EXCESSIVE FUEL CONSUMPTION OVERHEATS/WATER TEMPERATURE HIGH SLOW/NO RETURN TO IDLE AH HIGH IDLE/LOW IDLE IDLING VIBRATION LACK OF POWER/POOR ACCELERATION SPARK KNOCK/DETONATION AA AB AC AD AE AF AG ENGINE STALL ROUGH IDLE/HUNTING Warranty symptom code HESITATION/SURGING/FLAT SPOT HARD/NO START/RESTART (EXCP. HA) SYMPTOM EM Reference section FE CL AJ AK AL AM HA EC-101 or EL section 1 LC MT 1 - 6: The numbers refer to the order of inspection. CONSULT-II Reference Value in Data Monitor Mode NAEC0042 APPLICATION NOTICE AT TF NAEC0042S01 Confirm the type of the vehicle. Refer to “How to Check Vehicle Type”, EC-9. PD CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE NAEC0042S02 Remarks: 쐌 Specification data are reference values. 쐌 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. MONITOR ITEM ENG SPEED CONDITION 쐌 Run engine and compare CONSULT-II value with the tachometer indication. SPECIFICATION Almost the same speed as the tachometer indication. AX SU BR ST 1.2 - 1.8V (Type I) MAS A/F SE-B1 쐌 쐌 쐌 쐌 Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load Idle 1.0 - 1.3V (Type II) 2,500 rpm 1.7 - 2.1V (Type II) COOLAN TEMP/S 쐌 Engine: After warming up HO2S1 MNTR (B1) HO2S1 MNTR (B2) HO2S2 (B1) HO2S2 (B2) HO2S2 MNTR (B1) HO2S2 MNTR (B2) 0 - 0.3V +, Approx. 0.6 1.0V 쐌 Engine: After warming up 쐌 After keeping engine speed between 3,500 and 4,000 rpm for one minute and at idle for one minute under no load BT More than 70°C (158°F) HO2S1 (B1) HO2S1 (B2) 쐌 Engine: After warming up RS 1.6 - 2.2V (Type I) Maintaining engine speed at 2,000 rpm Revving engine from idle up to 3,000 rpm quickly EC-143 LEAN +, RICH Changes more than 5 times during 10 seconds. HA SC 0 - 0.3V +, Approx. 0.6 1.0V EL LEAN +, RICH IDX TROUBLE DIAGNOSIS — GENERAL DESCRIPTION CONSULT-II Reference Value in Data Monitor Mode (Cont’d) MONITOR ITEM CONDITION BATTERY VOLT 쐌 Ignition switch: ON (Engine stopped) ACCEL SEN 1 쐌 Ignition switch: ON (Engine stopped) 쐌 Shift lever: “D” (A/T models) “1st” (M/T models) ACCEL SEN 2* 쐌 Ignition switch: ON (Engine stopped) 쐌 Shift lever: “D” (A/T models) “1st” (M/T models) 0.5 - 1.0V Accelerator pedal: Fully depressed 4.0 - 4.7V Accelerator pedal: Fully released 0.3 - 1.2V Accelerator pedal: Fully depressed 3.9 - 4.8V Accelerator pedal: Fully released More than 0.36V Accelerator pedal: Fully depressed Less than 4.75V 쐌 Ignition switch: ON (Engine stopped) 쐌 Shift lever: “D” (A/T models) “1st” (M/T models) START SIGNAL 쐌 Ignition switch: ON , START , ON CLSD THL POS 쐌 Ignition switch: ON (Engine stopped) 쐌 Shift lever: “D” (A/T models) “1st” (M/T models) P/N POSI SW PW/ST SIGNAL 11 - 14V Accelerator pedal: Fully released THRTL SEN 1 THRTL SEN 2* AIR COND SIG SPECIFICATION Accelerator pedal: Fully released OFF , ON , OFF ON Accelerator pedal: Slightly depressed OFF 쐌 Engine: After warming up, idle the engine 쐌 Ignition switch: ON 쐌 Engine: After warming up, idle the engine Air conditioner switch: “OFF” OFF Air conditioner switch: “ON” (Compressor operates.) ON Shift lever: “P” or “N” ON Except above OFF Steering wheel in neutral position (forward direction) OFF The steering wheel is turned ON IGNITION SW 쐌 Ignition switch: ON , OFF , ON INJ PULSE-B1 INJ PULSE-B2 쐌 쐌 쐌 쐌 Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load Idle 2.4 - 3.2 msec 2,000 rpm 1.9 - 2.8 msec Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load Idle 2.0 - 3.2 msec B/FUEL SCHDL 쐌 쐌 쐌 쐌 2,000 rpm 1.4 - 2.6 msec 쐌 쐌 쐌 쐌 Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load Idle 15°±5° BTDC 2,000 rpm More than 25° BTDC Rear window defogger switch is ON and/or lighting switch is in 2nd. ON IGN TIMING LOAD SIGNAL PURG VOL C/V 쐌 Ignition switch: ON 쐌 쐌 쐌 쐌 Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load A/F ALPHA-B1 A/F ALPHA-B2 쐌 Engine: After warming up EVAP SYS PRES 쐌 Ignition switch: ON ON , OFF , ON Rear window defogger switch is OFF OFF and lighting switch is OFF. Idle 0% 2,000 rpm — Maintaining engine speed at 2,000 rpm 54 - 155% 1.8 - 4.8V EC-144 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION CONSULT-II Reference Value in Data Monitor Mode (Cont’d) MONITOR ITEM CONDITION SPECIFICATION AIR COND RLY 쐌 Air conditioner switch: OFF , ON OFF , ON ON FUEL PUMP RLY 쐌 Ignition switch is turned to ON (Operates for 1 second) 쐌 Engine running and cranking Except as shown above OFF 쐌 Ignition switch: ON OFF 쐌 Engine: After warming up 쐌 Engine speed: Below 3,600 rpm ON 쐌 Engine speed: Above 3,600 rpm OFF 쐌 Ignition switch: ON (Engine stopped) 쐌 Engine speed: Above 3,200 rpm OFF 쐌 Engine speed: Below 3,200 rpm after the following conditions are met. 쐌 After warming up 쐌 After keeping the engine speed between 3,500 and 4,000 rpm for one minute and at idle for one minute under no load ON VC/V BYPASS/V Ignition switch: ON OFF CAL/LD VALUE 쐌 쐌 쐌 쐌 VENT CONT/V HO2S1 HTR (B1) HO2S1 HTR (B2) HO2S2 HTR (B1) HO2S2 HTR (B2) BRAKE SW MASS AIRFLOW SWRL CONT S/V Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load 쐌 Ignition switch: ON 쐌 쐌 쐌 쐌 Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load 쐌 Engine speed: Idle MA EM LC FE Idle 14.0 - 33.0% 2,500 rpm 12.0 - 25.0% Brake pedal: Fully released OFF Brake pedal: Slightly depressed ON Idle 2.0 - 6.0 g·m/s 2,500 rpm 7.0 - 20.0 g·m/s Engine coolant temperature is between 15°C (59°F) to 50°C (122°F). GI CL MT AT TF PD AX ON SU Engine coolant temperature is above OFF 55°C (131°F). SWL CON VC SW VIAS S/V AC PRESS SEN INT/V TIM (B1) INT/V TIM (B2) BR 쐌 Engine speed: Idle 쐌 Engine coolant temperature is between 15°C (59°F) to 50°C (122°F). OFF 쐌 Engine speed: Idle 쐌 Engine coolant temperature is above 55°C (131°F). ON 쐌 Engine: After warming up 1,800 - 3,600 rpm ON Except above conditions OFF 쐌 Ignition switch: ON (Engine stopped) Approx. 0V 쐌 Engine: Idle 쐌 Air conditioner switch: OFF 1.0 - 4.0V 쐌 Engine: After warming up 쐌 Shift lever “N” 쐌 Quickly depressed accelerator pedal 쐌 No-load ST RS BT HA Idle 0° CA 2,000 rpm Approximately 12 - 18° CA SC EL IDX EC-145 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION CONSULT-II Reference Value in Data Monitor Mode (Cont’d) MONITOR ITEM INT/V SOL (B1) INT/V SOL (B2) CONDITION 쐌 Engine: After warming up 쐌 Shift lever “N” 쐌 Quickly depressed accelerator pedal 쐌 No-load SPECIFICATION Idle 0% 2,000 rpm Approximately 40% Vehicle has traveled after MIL has turned ON. 0 - 65,535 km (0 - 40,723 mile) TRVL AFTER MIL 쐌 Ignition switch: ON VEH SPEED SE 쐌 Turn drive wheels and compare CONSULT-II value with the speedometer indication. Almost the same speed as the speedometer indication SET VHCL SPD 쐌 Engine: Running ASCD: Operating The preset vehicle speed is displayed. 쐌 Ignition switch: ON CRUISE switch: Pressed ON MAIN SW CRUISE switch: Released OFF CANCEL switch: Pressed ON CANCEL switch: Released OFF ACCEL/RES switch: Pressed ON ACCEL/RES switch: Released OFF COAST/SET switch: Pressed ON COAST/SET switch: Released OFF Brake pedal: Fully released Clutch pedal: Fully released (M/T) ON Brake pedal: Slightly depressed Clutch pedal: Slightly depressed (M/T) OFF Brake pedal: Fully released OFF Brake pedal: Slightly depressed ON CRUISE lamp: Illuminated ON CRUISE lamp: Not illuminated OFF SET lamp: Illuminated ON SET lamp: Not illuminated OFF CANCEL SW RESUME/ACC SW SET SW BRAKE SW1 BRAKE SW2 CRUISE LAMP SET LAMP 쐌 Ignition switch: ON 쐌 Ignition switch: ON 쐌 Ignition switch: ON 쐌 Ignition switch: ON 쐌 Ignition switch: ON 쐌 Ignition switch: ON 쐌 Ignition switch: ON *: Accelerator pedal position sensor 2 signal and throttle position sensor 2 signal are converted by ECM internally. Thus, they differ from ECM terminals voltage signal. EC-146 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Major Sensor Reference Graph in Data Monitor Mode Major Sensor Reference Graph in Data Monitor Mode GI =NAEC0043 The following are the major sensor reference graphs in “DATA MONITOR” mode. MA CLSD THL POS, ACCEL SEN 1, THRTL SEN 1 NAEC0043S01 Below is the data for “CLSD THL POS”, “ACCEL SEN 1” and “THRTL SEN 1” when depressing the accelerator pedal with the ignition switch “ON” and with selector lever in ″D″ position (A/T models) or with shift lever in ″1st″ position (M/T models). The signal of “ACCEL SEN 1” and “THRTL SEN 1” should rise gradually without any intermittent drop or rise after “CLSD THL POS” is changed from “ON” to “OFF”. EM LC FE CL PBIB0198E ENG SPEED, MAS A/F SE-B1, THRTL SEN 1, HO2S2 (B1), HO2S1 (B1), INJ PULSE-B1 NAEC0043S02 Below is the data for “ENG SPEED”, “MAS A/F SE-B1”, “THRTL SEN 1”, “HO2S2 (B1)”, “HO2S1 (B1)” and “INJ PULSE-B1” when revving engine quickly up to 4,800 rpm under no load after warming up engine sufficiently. Each value is for reference, the exact value may vary. MT AT TF PD AX SU BR ST RS BT SEF241Y HA SC EL IDX EC-147 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Major Sensor Reference Graph in Data Monitor Mode (Cont’d) PBIB0668E EC-148 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION ECM Terminals and Reference Value ECM Terminals and Reference Value PREPARATION 1. 2. NAEC0044 GI NAEC0044S01 ECM is located behind the driver side instrument lower panel. For this inspection, remove driver side instrument lower panel. Remove ECM harness connector. MA EM LC SEC405D 3. 4. 쐌 쐌 When disconnecting ECM harness connector, loosen it with levers as far as they will go as shown in the figure. Connect a break-out box (SST) and Y-cable adapter (SST) between the ECM and ECM harness connector. Use extreme care not to touch 2 pins at one time. Data is for comparison and may not be exact. FE CL MT SEC406D ECM HARNESS CONNECTOR TERMINAL LAYOUTNAEC0044S02 AT TF PD AX SU PBIB1192E ECM INSPECTION TABLE Application Notice NAEC0044S03 NAEC0044S0301 Confirm the type of the vehicle. Refer to “How to Check Vehicle Type”, EC-9. ECM Inspection Table NAEC0044S0302 Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULTII. CAUTION: Do not use ECM ground terminals when measuring the input/ output voltage. Doing so may result in damage to the ECM’s transistor. Use ground other than the ECM terminals, such as the ground. TERMIWIRE NAL NO. COLOR 1 B BR ST RS BT HA SC ITEM ECM ground CONDITION [Engine is running] 쐌 Idle speed DATA (DC Voltage) Engine ground EL IDX EC-149 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION ECM Terminals and Reference Value (Cont’d) TERMIWIRE NAL NO. COLOR ITEM CONDITION DATA (DC Voltage) Approximately 7V★ 2 R/G [Engine is running] 쐌 Warm-up condition Heated oxygen sensor 쐌 Engine speed is below 3,600 rpm. 1 heater (bank 2) PBIB0519E 3 OR Throttle control motor relay power supply [Engine is running] 쐌 Engine speed is above 3,600 rpm. BATTERY VOLTAGE (11 - 14V) [Ignition switch “ON”] BATTERY VOLTAGE (11 - 14V) 0 - 14V★ 4 L/W Throttle control motor (Close) [Ignition switch “ON”] 쐌 Engine stopped 쐌 Shift lever: “D” (A/T models) 쐌 Shift lever position is “1st” (M/T models) 쐌 Accelerator pedal is releasing PBIB1104E 0 - 14V★ 5 L/B Throttle control motor (Open) [Ignition switch “ON”] 쐌 Engine stopped 쐌 Shift lever: “D” (A/T models) 쐌 Shift lever position is “1st” (M/T models) 쐌 Accelerator pedal is depressing PBIB1105E 6 R/W [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is below 3,200 rpm. 쐌 After keeping engine speed between 3,500 and 4,000 rpm for one minute and at idle Heated oxygen sensor for one minute 2 heater (bank 2) 0 - 1.0V [Ignition switch “ON”] 쐌 Engine stopped [Engine is running] 쐌 Engine speed is above 3,200 rpm. BATTERY VOLTAGE (11 - 14V) [Engine is running] 쐌 Warm-up condition 쐌 Idle speed BATTERY VOLTAGE (11 - 14V) 7 - 8V★ 10 P/L Intake valve timing control solenoid valve (bank 2) [Engine is running] 쐌 Warm-up condition 쐌 When revving engine up to 2,000 rpm quickly. PBIB1790E EC-150 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION ECM Terminals and Reference Value (Cont’d) TERMIWIRE NAL NO. COLOR GI ITEM CONDITION [Engine is running] 쐌 Warm-up condition 쐌 Idle speed DATA (DC Voltage) MA BATTERY VOLTAGE (11 - 14V) EM 7 - 8V★ 11 OR/B Intake valve timing control solenoid valve (bank 1) [Engine is running] 쐌 Warm-up condition 쐌 When revving engine up to 2,000 rpm quickly. LC PBIB1790E 12 R/B Power steering pressure sensor FE [Engine is running] 쐌 Steering wheel is being turned. 0.5 - 4.0V [Engine is running] 쐌 Steering wheel is not being turned. 0.4 - 0.8V CL Approximately 1.6V★ MT [Engine is running] 쐌 Warm-up condition 쐌 Idle speed AT TF 13 Y PBIB1041E Crankshaft position sensor (POS) Approximately 1.5V★ PD [Engine is running] 쐌 Engine speed is 2,000 rpm. AX SU PBIB1042E 1.0 - 4.0V★ BR [Engine is running] 쐌 Warm-up condition 쐌 Idle speed 14 OR ST RS Camshaft position sensor (PHASE) (bank 2) PBIB1039E 1.0 - 4.0V★ BT HA [Engine is running] 쐌 Engine speed is 2,000 rpm. SC PBIB1040E 15 W Knock sensor [Engine is running] 쐌 Idle speed Approximately 2.5V EL IDX EC-151 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION ECM Terminals and Reference Value (Cont’d) TERMIWIRE NAL NO. COLOR 16 G/B ITEM CONDITION [Engine is running] Heated oxygen sensor 쐌 Warm-up condition 1 (bank 2) 쐌 Engine speed is 2,000 rpm. DATA (DC Voltage) 0 - Approximately 1.0V (Periodically change) BATTERY VOLTAGE (11 - 14V)★ [Engine is running] 쐌 Warm-up condition 쐌 Idle speed 21 22 23 L/W R/Y R/B Injector No. 5 Injector No. 3 Injector No. 1 SEC984C BATTERY VOLTAGE (11 - 14V)★ [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm SEC985C Approximately 7V★ 24 L/OR [Engine is running] 쐌 Warm-up condition Heated oxygen sensor 쐌 Engine speed is below 3,600 rpm. 1 heater (bank 1) PBIB0519E [Engine is running] 쐌 Engine speed is above 3,600 rpm. 25 P/B [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is below 3,200 rpm. 쐌 After keeping engine speed between 3,500 and 4,000 rpm for one minute and at idle Heated oxygen sensor for one minute 2 heater (bank 1) [Ignition switch “ON”] 쐌 Engine stopped [Engine is running] 쐌 Engine speed is above 3,200 rpm. 27 29 G Y/G Swirl control valve control solenoid valve VIAS control solenoid valve BATTERY VOLTAGE (11 - 14V) 0 - 1.0V BATTERY VOLTAGE (11 - 14V) [Engine is running] 쐌 Idle speed 0 - 1.0V 쐌 Engine coolant temperature is between 15 50°C (59 - 122°F). [Engine is running] 쐌 Idle speed 쐌 Engine coolant temperature is above 55°C (131°F). BATTERY VOLTAGE (11 - 14V) [Engine is running] 쐌 Idle speed BATTERY VOLTAGE (11 - 14V) [Engine is running] 쐌 Engine speed is above 5,000 rpm. 0 - 1.0V EC-152 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION ECM Terminals and Reference Value (Cont’d) TERMIWIRE NAL NO. COLOR 32 L/G GI ITEM EVAP control system pressure sensor CONDITION [Ignition switch “ON”] DATA (DC Voltage) MA 1.8 - 4.8V 1.0 - 4.0V★ EM [Engine is running] 쐌 Warm-up condition 쐌 Idle speed 33 Y/G Camshaft position sensor (PHASE) (bank 1) LC PBIB1039E 1.0 - 4.0V★ FE [Engine is running] 쐌 Engine speed is 2,000 rpm. CL MT PBIB1040E 34 B/P Intake air temperature [Engine is running] sensor Approximately 0 - 4.8V Output voltage varies with intake air temperature. 35 G [Engine is running] Heated oxygen sensor 쐌 Warm-up condition 1 (bank 1) 쐌 Engine speed is 2,000 rpm. 0 - Approximately 1.0V (Periodically change) TF PD BATTERY VOLTAGE (11 - 14V)★ AX [Engine is running] 쐌 Warm-up condition 쐌 Idle speed 40 41 42 PU/R R/L R/W Injector No. 6 Injector No. 4 Injector No. 2 AT SU SEC984C BATTERY VOLTAGE (11 - 14V)★ BR ST [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm RS BT SEC985C HA SC EL IDX EC-153 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION ECM Terminals and Reference Value (Cont’d) TERMIWIRE NAL NO. COLOR ITEM CONDITION DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)★ [Engine is running] 쐌 Idle speed 45 L/Y EVAP canister purge volume control solenoid valve SEC990C BATTERY VOLTAGE (11 - 14V)★ [Engine is running] 쐌 Engine speed is about 2,000 rpm (More than 100 seconds after starting engine). SEC991C 47 L Sensors’ power supply (Throttle position sensor) [Ignition switch “ON”] Approximately 5V 48 P/B Sensors’ power supply [Ignition switch “ON”] Approximately 5V P/B Sensor’s power supply (Refrigerant pressure sensor) [Ignition switch “ON”] Approximately 5V [Ignition switch “ON”] 쐌 Engine stopped 쐌 Gear position: “D” (A/T models) 쐌 Shift lever position is “1st” (M/T models) 쐌 Accelerator pedal fully released More than 0.36V [Ignition switch “ON”] 쐌 Engine stopped 쐌 Gear position: “D” (A/T models) 쐌 Shift lever position is “1st” (M/T models) 쐌 Accelerator pedal fully depressed Less than 4.75V 49 50 51 55 BR OR OR/L Throttle position sensor 1 Mass air flow sensor [Engine is running] 쐌 Warm-up condition 쐌 Idle speed 1.2 - 1.8V (Type I) [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,500 rpm. 1.6 - 2.2V (Type I) [Engine is running] 쐌 Warm-up condition 쐌 Revving engine from idle up to 3,000 rpm Heated oxygen sensor after the following conditions are met. 2 (bank 2) 쐌 After keeping the engine speed between 3,500 and 4,000 rpm for one minute and at idle for one minute under no load EC-154 1.0 - 1.3V (Type II) 1.7 - 2.1V (Type II) 0 - Approximately 1.0V TROUBLE DIAGNOSIS — GENERAL DESCRIPTION ECM Terminals and Reference Value (Cont’d) TERMIWIRE NAL NO. COLOR 59 W/B GI ITEM Swirl control valve control vacuum check switch CONDITION DATA (DC Voltage) MA [Engine is running] 쐌 Idle speed Approximately 5V 쐌 Engine coolant temperature is between 15 50°C (59 - 122°F). [Engine is running] 쐌 Idle speed 쐌 Engine coolant temperature is above 55°C (131°F). EM 0 - 1.0V LC 0 - 0.2V★ [Engine is running] 쐌 Warm-up condition 쐌 Idle speed FE CL 60 61 62 PU/W L/R Y/R Ignition signal No. 5 Ignition signal No. 3 Ignition signal No. 1 SEC986C 0.1 - 0.3V★ MT [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,500 rpm. AT TF SEC987C 66 BR/Y Sensors’ ground (Throttle position sensor) [Engine is running] 쐌 Warm-up condition 쐌 Idle speed Approximately 0V 67 B/P Sensors’ ground [Engine is running] 쐌 Warm-up condition 쐌 Idle speed Approximately 0V L Sensor’s power supply (Power steering pressure sensor) [Ignition switch “ON”] Approximately 5V 68 69 70 73 BR/W W/PU LG/R AX SU BR [Ignition switch “ON”] 쐌 Engine stopped 쐌 Gear position: “D” (A/T models) 쐌 Shift lever position is “1st”. (M/T models) 쐌 Accelerator pedal fully released Less than 4.75V [Ignition switch “ON”] 쐌 Engine stopped 쐌 Gear position: “D” (A/T models) 쐌 Shift lever position is “1st”. (M/T models) 쐌 Accelerator pedal fully depressed More than 0.36V Refrigerant pressure sensor [Engine is running] 쐌 Warm-up condition 쐌 Both A/C switch and blower switch are “ON”. (Compressor operates.) 1.0 - 4.0V Engine coolant temperature sensor [Engine is running] Approximately 0 - 4.8V Output voltage varies with engine coolant temperature. Throttle position sensor 2 PD ST RS BT HA SC EL IDX EC-155 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION ECM Terminals and Reference Value (Cont’d) TERMIWIRE NAL NO. COLOR ITEM CONDITION 74 OR [Engine is running] 쐌 Warm-up condition 쐌 Revving engine from idle up to 3,000 rpm Heated oxygen sensor after the following conditions are met. 2 (bank 1) 쐌 After keeping the engine speed between 3,500 and 4,000 rpm for one minute and at idle for one minute under no load 78 B Sensors’ ground (Heated oxygen sensor) [Engine is running] 쐌 Warm-up condition 쐌 Idle speed DATA (DC Voltage) 0 - Approximately 1.0V Approximately 0V 0 - 0.2V★ [Engine is running] 쐌 Warm-up condition 쐌 Idle speed 79 80 81 GY/R GY G/R Ignition signal No. 6 Ignition signal No. 4 Ignition signal No. 2 SEC986C 0.1 - 0.3V★ [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,500 rpm. SEC987C 82 B/R Sensor’s ground (APP sensor 1) [Engine is running] 쐌 Warm-up condition 쐌 Idle speed Approximately 0V 83 L Sensor’s ground (APP sensor 2) [Engine is running] 쐌 Warm-up condition 쐌 Idle speed Approximately 0V [Ignition switch “ON”] 쐌 Lighting switch is in 2nd. BATTERY VOLTAGE (11 - 14V) [Ignition switch “ON”] 쐌 Lighting switch is “OFF”. 0V 84 OR Lighting switch 85 LG/R Data link connector [Ignition switch “ON”] 쐌 CONSULT-II or GST is disconnected. Approximately 5V 86 R CAN communication line [Ignition switch “ON”] Approximately 1.7 - 2.3V Output voltage varies with the communication status. 90 L Sensor’s power supply (APP sensor 1) [Ignition switch “ON”] Approximately 5V 91 W/R Sensor’s power supply (APP sensor 2) [Ignition switch “ON”] Approximately 5V B/L [Ignition switch “ON”] Rear window defogger 쐌 Rear window defogger switch is ON. switch [Ignition switch “ON”] 쐌 Rear window defogger switch is OFF. 93 EC-156 BATTERY VOLTAGE (11 - 14V) 0V TROUBLE DIAGNOSIS — GENERAL DESCRIPTION ECM Terminals and Reference Value (Cont’d) TERMIWIRE NAL NO. COLOR 94 98 99 101 102 104 106 107 L R L/Y G/Y L L L G/B GI ITEM CAN communication line Accelerator pedal position sensor 2 ASCD steering switch Stop lamp switch PNP switch Throttle control motor relay Accelerator pedal position sensor 1 CONDITION [Ignition switch “ON”] DATA (DC Voltage) Approximately 2.6 - 3.2V Output voltage varies with the communication status. MA EM [Ignition switch “ON”] 쐌 Engine stopped 쐌 Shift lever: “D” (A/T models) 쐌 Shift lever position is “1st” (M/T models) 쐌 Accelerator pedal fully released 0.15 - 0.6V [Ignition switch “ON”] 쐌 Engine stopped 쐌 Shift lever: “D” (A/T models) 쐌 Shift lever position is “1st” (M/T models) 쐌 Accelerator pedal fully depressed 1.95 - 2.4V [Ignition switch “ON”] 쐌 ASCD steering switch is “OFF”. Approximately 4V [Ignition switch “ON”] 쐌 CRUISE switch is “ON”. Approximately 0V [Ignition switch “ON”] 쐌 CANCEL switch is “ON”. Approximately 1V [Ignition switch “ON”] 쐌 COAST/SET switch is “ON”. Approximately 2V [Ignition switch “ON”] 쐌 ACCEL/RESUME switch is “ON”. Approximately 3V TF [Ignition switch “ON”] 쐌 Brake pedal is fully released Approximately 0V PD [Ignition switch “ON”] 쐌 Brake pedal is depressed BATTERY VOLTAGE (11 - 14V) AX [Ignition switch “ON”] 쐌 Gear position is “P” or “N”. Approximately 0V [Ignition switch “ON”] 쐌 Except the above gear position BATTERY VOLTAGE (11 - 14V) [Ignition switch “OFF”] BATTERY VOLTAGE (11 - 14V) [Ignition switch “ON”] 0 - 1.0V ST [Ignition switch “ON”] 쐌 Engine stopped 쐌 Shift lever: “D” (A/T models) 쐌 Shift lever position is “1st” (M/T models) 쐌 Accelerator pedal fully released 0.5 - 1.0V RS [Ignition switch “ON”] 쐌 Engine stopped 쐌 Shift lever: “D” (A/T models) 쐌 Shift lever position is “1st” (M/T models) 쐌 Accelerator pedal fully depressed 3.9 - 4.7V HA Approximately 0 - 4.8V Output voltage varies with fuel tank temperature. SC Fuel tank temperature [Engine is running] sensor LC FE CL MT AT SU BR BT EL IDX EC-157 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION ECM Terminals and Reference Value (Cont’d) TERMIWIRE NAL NO. COLOR 108 109 111 112 113 L/Y R L/B G/W R/L ITEM ASCD brake switch CONDITION [Ignition switch “ON”] 쐌 Brake pedal is depressed 쐌 Clutch pedal is depressed (M/T models) Approximately 0V [Ignition switch “ON”] 쐌 Brake pedal is fully released 쐌 Clutch pedal is fully released (M/T models) BATTERY VOLTAGE (11 - 14V) [Ignition switch “OFF”] 0V [Ignition switch “ON”] BATTERY VOLTAGE (11 - 14V) [Engine is running] [Ignition switch “OFF”] 쐌 For a few seconds after turning ignition switch “OFF” 0 - 1.5V [Ignition switch “OFF”] 쐌 A few seconds passed after turning ignition switch “OFF” BATTERY VOLTAGE (11 - 14V) [Ignition switch “ON”] BATTERY VOLTAGE (11 - 14V) [Ignition switch “ON”] 쐌 For 1 second after turning ignition switch “ON” [Engine is running] 0 - 1.5V [Ignition switch “ON”] 쐌 More than 1 second after turning ignition switch “ON”. BATTERY VOLTAGE (11 - 14V) Ignition switch ECM relay (Self shut-off) Vacuum cut valve bypass valve Fuel pump relay DATA (DC Voltage) 115 116 B B ECM ground [Engine is running] 쐌 Idle speed Engine ground 117 G/R EVAP canister vent control valve [Ignition switch “ON”] BATTERY VOLTAGE (11 - 14V) 119 120 B/W B/W Power supply for ECM [Ignition switch “ON”] BATTERY VOLTAGE (11 - 14V) 121 W/R Power supply for ECM [Ignition switch “OFF”] (Back-up) BATTERY VOLTAGE (11 - 14V) ★: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) EC-158 TROUBLE DIAGNOSIS — SPECIFICATION VALUE Description Description NAEC0717 The specification (SP) value indicates the tolerance of the value that is displayed in “DATA MONITOR (SPEC)” mode of CONSULT-II during normal operation of the Engine Control System. When the value in “DATA MONITOR (SPEC)” mode is within the SP value, the Engine Control System is confirmed OK. When the value in “DATA MONITOR (SPEC)” mode is NOT within the SP value, the Engine Control System may have one or more malfunctions. The SP value is used to detect malfunctions that may affect the Engine Control System, but will not light the MIL. The SP value will be displayed for the following three items: 쐌 B/FUEL SCHDL (The fuel injection pulse width programmed into ECM prior to any learned on board correction) 쐌 A/F ALPHA-B1/B2 (The mean value of air-fuel ratio feedback correction factor per cycle) 쐌 MAS A/F SE-B1 (The signal voltage of the mass air flow sensor) Testing Condition NAEC0718 쐌 Vehicle driven distance: More than 5,000 km (3,107 miles) 쐌 Barometric pressure: 98.3 - 104.3 kPa (1.003 - 1.064 kg/cm2, 14.25 - 15.12 psi) 쐌 Atmospheric temperature: 20 - 30°C (68 - 86°F) 쐌 Engine coolant temperature: 75 - 95°C (167 - 203°F) 쐌 Transmission: Warmed-up*1 쐌 Electrical load: Not applied*2 쐌 Engine speed: Idle *1: For A/T models, after the engine is warmed up to normal operating temperature, drive vehicle until “FLUID TEMP SE” (A/T fluid temperature sensor signal) indicates less than 0.9V. For M/T models, drive vehicle for 10 minutes after the engine is warmed up to normal operating temperature. *2: Rear window defogger switch, air conditioner switch, lighting switch are “OFF”. Steering wheel is straight ahead. GI MA EM LC FE CL MT AT TF PD AX SU Inspection Procedure SEF601Z NAEC0719 NOTE: Perform “DATA MONITOR (SPEC)” mode in maximum scale display. 1. Perform “Basic Inspection”, EC-131. 2. Confirm that the testing conditions indicated above are met. 3. Select “B/FUEL SCHDL”, “A/F ALPHA-B1”, “A/F ALPHA-B2” and “MAS A/F SE-B1” in “DATA MONITOR (SPEC)” mode with CONSULT-II. 4. Make sure that monitor items are within the SP value. 5. If NG, go to “Diagnostic Procedure”, EC-160. BR ST RS BT HA SC EL IDX EC-159 TROUBLE DIAGNOSIS — SPECIFICATION VALUE Diagnostic Procedure Diagnostic Procedure NAEC0720 SEF613ZD EC-160 TROUBLE DIAGNOSIS — SPECIFICATION VALUE Diagnostic Procedure (Cont’d) GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL SEF768Z IDX EC-161 TROUBLE DIAGNOSIS — SPECIFICATION VALUE Diagnostic Procedure (Cont’d) SEF615ZA EC-162 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT Description Description NAEC0045 Intermittent incidents (I/I) may occur. In many cases, the malfunction resolves itself (the part or circuit function returns to normal without intervention). It is important to realize that the symptoms described in the customer’s complaint often do not recur on (1st trip) DTC visits. Realize also that the most frequent cause of I/I occurrences is poor electrical connections. Because of this, the conditions under which the incident occurred may not be clear. Therefore, circuit checks made as part of the standard diagnostic procedure may not indicate the specific malfunctioning area. COMMON I/I REPORT SITUATIONS NAEC0045S01 STEP in Work Flow GI MA EM LC Situation II The CONSULT-II is used. The SELF-DIAG RESULTS screen shows time data other than “0” or “[1t]”. III The symptom described by the customer does not recur. IV (1st trip) DTC does not appear during the DTC Confirmation Procedure. VI The Diagnostic Procedure for PXXXX does not indicate the malfunctioning area. FE CL MT Diagnostic Procedure 1 INSPECTION START AT NAEC0046 TF Erase (1st trip) DTCs. Refer to “HOW TO ERASE EMISSION — RELATED INFORMATION”, EC-100. 䊳 2 GO TO 2. PD CHECK GROUND TERMINALS Check ground terminals for corroding or loose connection. Refer to GI-30, “GROUND INSPECTION”. OK or NG OK 䊳 GO TO 3. NG 䊳 Repair or replace. 3 AX SU BR SEARCH FOR ELECTRICAL INCIDENT ST Perform GI-25, “Incident Simulation Tests”. OK or NG OK 䊳 GO TO 4. NG 䊳 Repair or replace. 4 RS BT CHECK CONNECTOR TERMINALS Refer to GI-22, “How to Check Enlarged Contact Spring of Terminal”. OK or NG OK 䊳 INSPECTION END NG 䊳 Repair or replace connector. HA SC EL IDX EC-163 TROUBLE DIAGNOSIS FOR POWER SUPPLY ECM Terminals and Reference Value ECM Terminals and Reference Value NAEC0648 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM 1 B ECM ground 109 R Ignition switch 111 L/B ECM relay (Self shutt-off) CONDITION DATA (DC Voltage) [Engine is running] 쐌 Idle speed Engine ground [Ignition switch “OFF”] 0V [Ignition switch “ON”] BATTERY VOLTAGE (11 - 14V) [Engine is running] [Ignition switch “OFF”] 쐌 For a few seconds after turning ignition switch “OFF” 0 - 1.5V [Ignition switch “OFF”] 쐌 A few seconds passed after turning ignition switch “OFF” BATTERY VOLTAGE (11 - 14V) 115 B ECM ground [Engine is running] 쐌 Idle speed Engine ground 116 B ECM ground [Engine is running] 쐌 Idle speed Engine ground 119 120 B/W B/W Power supply for ECM [Ignition switch “ON”] BATTERY VOLTAGE (11 - 14V) EC-164 TROUBLE DIAGNOSIS FOR POWER SUPPLY Main Power Supply and Ground Circuit Main Power Supply and Ground Circuit WIRING DIAGRAM GI NAEC0047 MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC076E EC-165 IDX TROUBLE DIAGNOSIS FOR POWER SUPPLY Main Power Supply and Ground Circuit (Cont’d) MEC077E EC-166 TROUBLE DIAGNOSIS FOR POWER SUPPLY Main Power Supply and Ground Circuit (Cont’d) DIAGNOSTIC PROCEDURE 1 NAEC0049 INSPECTION START MA Start engine. Is engine running? Yes or No Yes 䊳 GO TO 10. No 䊳 GO TO 2. 2 GI EM LC CHECK ECM POWER SUPPLY CIRCUIT-I 1. Turn ignition switch “OFF” and then “ON”. 2. Check voltage between ECM terminal 109 and ground with CONSULT-II or tester. FE CL MT AT MBIB0015E Voltage: Battery voltage TF OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 3. 3 PD AX DETECT MALFUNCTIONING PART Check the following. 쐌 10A fuse 쐌 Harness connectors M32, F23 쐌 Fuse block (J/B) connectors E4, M10 쐌 Harness for open or short between ECM and ignition switch 䊳 SU BR Repair harness or connectors. ST 4 CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT-I 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminals 1, 115, 116 and engine ground. Refer to WIRING DIAGRAM. Continuity should exist. 4. Also check harness for short to power. OK or NG OK 䊳 GO TO 6. NG 䊳 GO TO 5. RS BT HA SC EL IDX EC-167 TROUBLE DIAGNOSIS FOR POWER SUPPLY Main Power Supply and Ground Circuit (Cont’d) 5 DETECT MALFUNCTIONING PART Check the following. 쐌 Joint connector 쐌 Harness connectors F27, M94 쐌 Harness connectors F22, M33 쐌 Harness for open between ECM relay and ground 䊳 6 Repair open circuit or short to power in harness or connectors. CHECK ECM POWER SUPPLY CIRCUIT-II 1. Disconnect ECM relay. SEC425D 2. Check voltage between ECM relay terminals 1, 5 and ground with CONSULT-II or tester. SEF956Y OK or NG OK 䊳 GO TO 8. NG 䊳 GO TO 7. 7 DETECT MALFUNCTIONING PART Check the following. 쐌 10A fuse 쐌 Harness for open or short between ECM relay and battery 䊳 8 Repair open circuit or short to ground or short to power in harness or connectors. CHECK OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 111 and ECM relay terminal 2. Refer to wiring diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK 䊳 Go to “IGNITION SIGNAL”, EC-748. NG 䊳 GO TO 9. EC-168 TROUBLE DIAGNOSIS FOR POWER SUPPLY Main Power Supply and Ground Circuit (Cont’d) 9 GI DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors E1, M1 쐌 Harness connectors M32, F23 쐌 Harness for open or short between ECM relay and ECM 䊳 10 MA Repair open circuit or short to ground or short to power in harness or connectors. CHECK ECM POWER SUPPLY CIRCUIT-III EM LC 1. Stop engine. 2. Turn ignition switch “ON” and then “OFF”. 3. Check voltage between ECM terminals 119, 120 and ground with CONSULT-II or tester. FE CL MT PBIB1630E Voltage: After turning ignition switch “OFF”, battery voltage will exist for a few seconds, then drop approximately 0V. AT TF OK or NG OK 䊳 GO TO 16. NG (Battery voltage does not exist.) 䊳 GO TO 11. NG (Battery voltage exists for more than a few seconds.) 䊳 GO TO 13. PD AX SU BR ST RS BT HA SC EL IDX EC-169 TROUBLE DIAGNOSIS FOR POWER SUPPLY Main Power Supply and Ground Circuit (Cont’d) 11 CHECK ECM POWER SUPPLY CIRCUIT-IV 1. Disconnect ECM relay. SEC425D 2. Check voltage between ECM relay terminal 7 and ground with CONSULT-II or tester. SEF957Y OK or NG OK 䊳 GO TO 13. NG 䊳 GO TO 12. 12 DETECT MALFUNCTIONING PART Check the following. 쐌 7.5A fuse 쐌 Harness for open or short between ECM relay and fuse 䊳 13 Repair open circuit or short to ground or short to power in harness or connectors. CHECK ECM POWER SUPPLY CIRCUIT-V 1. Check harness continuity between ECM terminals 119, 120 and ECM relay terminal 6. Refer to WIRING DIAGRAM. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 15. NG 䊳 GO TO 14. 14 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors E1, M1 쐌 Harness connectors M32, F23 쐌 Harness for open or short between ECM and ECM relay 䊳 Repair open circuit or short to ground or short to power in harness or connectors. EC-170 TROUBLE DIAGNOSIS FOR POWER SUPPLY Main Power Supply and Ground Circuit (Cont’d) 15 GI CHECK ECM RELAY 1. Apply 12V direct current between ECM relay terminals 1 and 2. 2. Check continuity between relay terminals 3 and 5, 6 and 7. MA EM LC SEF296X FE OK or NG OK 䊳 GO TO 16. NG 䊳 Replace ECM relay. 16 CL CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT-II 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminals 1, 115, 116 and engine ground. Refer to WIRING DIAGRAM. Continuity should exist. 4. Also check harness for short to power. OK or NG OK 䊳 GO TO 18. NG 䊳 GO TO 17. 17 AT TF PD AX DETECT MALFUNCTIONING PART SU Check the following. 쐌 Joint connector 쐌 Harness connectors F27, M94 쐌 Harness connectors F22, M33 쐌 Harness for open between ECM relay and ground 䊳 18 MT BR Repair open circuit or short to power in harness or connectors. CHECK INTERMITTENT INCIDENT ST RS Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END BT HA SC EL IDX EC-171 DTC U1000, U1001 CAN COMMUNICATION LINE Description Description NAEC1185 CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electonic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. On Board Diagnosis Logic DTC No. U1000*1 1000*1 U1001*2 1001*2 Trouble diagnosis name DTC detecting condition NAEC1186 Possible cause 쐌 ECM cannot communicate to other control 쐌 Harness or connectors units. CAN communication line (CAN communication line is open or 쐌 ECM cannot communicate for more than shorted.) the specified time. *1: This self-diagnosis has the one trip detection logic. *2: The MIL will not light up for this diagnosis. DTC Confirmation Procedure 1. 2. 3. NAEC1187 Turn ignition switch “ON” and wait at least 3 seconds. Select “DATA MONITOR” mode with CONSULT-II. If 1st trip DTC is detected, go to “Diagnostic Procedure” EC-174. EC-172 DTC U1000, U1001 CAN COMMUNICATION LINE Wiring Diagram Wiring Diagram NAEC1188 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC124E EC-173 IDX DTC U1000, U1001 CAN COMMUNICATION LINE Diagnostic Procedure Diagnostic Procedure Go to EL-447, “CAN Communication Unit”. EC-174 NAEC1189 DTC P0011, P0021 IVT CONTROL Description Description NAEC0821 SYSTEM DESCRIPTION Sensor GI NAEC0821S01 Input signal to ECM function ECM MA Actuator Crankshaft position sensor (POS) Engine speed and piston position Camshaft position sensor (PHASE) Engine coolant temperature sensor Engine coolant temperature Vehicle speed signal*1 Vehicle speed Intake valve timing control Intake valve timing control solenoid valve EM LC *1: This signal is sent to the ECM through CAN communication line. FE CL MT AT TF PD SEC419D This mechanism hydraulically controls cam phases continuously with the fixed operating angle of the intake valve. The ECM receives signals such as crankshaft position, camshaft position, engine speed, and engine coolant temperature. Then, the ECM sends ON/OFF pulse duty signals to the camshaft timing control valve depending on driving status. This makes it possible to control the shut/open timing of the intake valve to increase engine torque in low/mid speed range and output in high-speed range. AX SU BR ST RS BT HA SC EL IDX EC-175 DTC P0011, P0021 IVT CONTROL CONSULT-II Reference Value in Data Monitor Mode CONSULT-II Reference Value in Data Monitor Mode =NAEC0822 Specification data are reference values. MONITOR ITEM INT/V TIM (B1) INT/V TIM (B2) INT/V SOL (B1) INT/V SOL (B2) CONDITION 쐌 Engine: After warming up 쐌 Shift lever “N” 쐌 Quickly depressed accelerator pedal 쐌 No-load 쐌 Engine: After warming up 쐌 Shift lever “N” 쐌 Quickly depressed accelerator pedal 쐌 No-load SPECIFICATION Idle 0° CA 2,000 rpm Approximately 12 - 18° CA Idle 0% 2,000 rpm Approximately 40% On Board Diagnosis Logic DTC No. P0011 0011 (Bank 1) P0021 0021 (Bank 2) Trouble diagnosis name Intake valve timing control performance DTC Detecting Condition There is a gap between angle of target and phase-control angle degree. NAEC0824 Possible Cause 쐌 Intake valve timing control solenoid valve FAIL-SAFE MODE NAEC0824S01 When malfunction is detected, the ECM enters fail-safe mode. Detected items Intake valve timing control Engine operating condition in fail-safe mode The signal is not energized to the solenoid valve and the valve control does not function. DTC Confirmation Procedure NAEC0825 CAUTION: Always drive at a safe speed. NOTE: 쐌 If DTC P0011 or P0021 is displayed with DTC P1111 or P1136, first perform trouble diagnosis for DTC P1111 or P1136, EC-488. 쐌 If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1) 2) 3) NAEC0825S03 Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Maintain the following conditions for at least 20 conecutive seconds. ENG SPEED 1,200 - 2,000 rpm (A constant rotation is maintained.) COOLANT TEMPS More than 60°C (140°F) Selector lever 1st position SEF353Z EC-176 DTC P0011, P0021 IVT CONTROL DTC Confirmation Procedure (Cont’d) Driving location 4) Driving vehicle uphill (Increased engine load will help maintain the driving conditions required for this test.) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-177. WITH GST NAEC0825S04 Follow the procedure “With CONSULT-II” above. Diagnostic Procedure 1 CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE Refer to “Component Inspection”, EC-178. OK or NG OK 䊳 GO TO 2. NG 䊳 Replace intake valve timing control solenoid valve. 2 GI MA EM LC NAEC1191 FE CL MT CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. For Wiring Diagram, refer to EC-352 for CKP sensor (POS) and EC-359 for CMP sensor (PHASE). OK or NG 䊳 AT TF INSPECTION END PD AX SU BR ST RS BT HA SC EL IDX EC-177 DTC P0011, P0021 IVT CONTROL Component Inspection Component Inspection =NAEC1192 INTAKE VALVE TIMING CONTROL SOLENOID VALVE NAEC1192S01 1. 2. SEC557D Disconnect intake valve timing control solenoid valve harness connector. Check resistance between intake valve timing control solenoid valve terminals as follows. Terminals Resistance 1 and 2 7.0 - 7.5Ω at 20°C (68°F) 1 or 2 and ground ∞Ω (Continuity should not exist) EC-178 DTC P0031, P0032, P0051, P0052 HO2S1 HEATER Description Description NAEC0826 SYSTEM DESCRIPTION GI NAEC0826S01 Sensor ECM function Input Signal to ECM Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed Engine coolant temperature sensor Engine coolant temperature MA Actuator Heated oxygen Heated oxygen sensor 1 heatsensor 1 ers heater control EM LC The ECM performs ON/OFF control of the heated oxygen sensor 1 heaters corresponding to the engine speed and engine coolant temperature. The duty percent varies with engine coolant temperature when engine is started. OPERATION NAEC0826S02 Engine speed rpm Heated oxygen sensor 1 heaters Above 3,600 OFF Below 3,600 after warming up ON CL MT CONSULT-II Reference Value in Data Monitor Mode NAEC0827 Specification data are reference values. MONITOR ITEM HO2S1 HTR (B1) HO2S1 HTR (B2) CONDITION SPECIFICATION 쐌 Engine: After warming up 쐌 Engine speed: Below 3,600 rpm ON 쐌 Engine speed: Above 3,600 rpm OFF PD NAEC0828 Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. WIRE COLOR ITEM CONDITION AT TF ECM Terminals and Reference Value TERMINAL NO. FE AX SU BR DATA (DC Voltage) ST Approximately 7V★ RS 2 R/G Heated oxygen sensor 1 heater (bank 2) [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is below 3,600 rpm. BT PBIB0519E [Engine is running] 쐌 Engine speed is above 3,600 rpm. BATTERY VOLTAGE (11 - 14V) HA SC EL IDX EC-179 DTC P0031, P0032, P0051, P0052 HO2S1 HEATER ECM Terminals and Reference Value (Cont’d) TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) Approximately 7V★ 24 L/OR Heated oxygen sensor 1 heater (bank 1) [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is below 3,600 rpm. PBIB0519E [Engine is running] 쐌 Engine speed is above 3,600 rpm. BATTERY VOLTAGE (11 - 14V) ★: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) On Board Diagnosis Logic DTC No. Trouble diagnosis name DTC Detecting Condition NAEC0829 Possible Cause 쐌 Harness or connectors (The heated oxygen sensor 1 heater circuit is open or shorted.) 쐌 Heated oxygen sensor 1 heater P0031 0031 (Bank 1) P0051 0051 (Bank 2) Heated oxygen sensor 1 heater control circuit low The current amperage in the heated oxygen sensor 1 heater circuit is out of the normal range. (An excessively low voltage signal is sent to ECM through the heated oxygen sensor 1 heater.) P0032 0032 (Bank 1) P0052 0052 (Bank 2) Heated oxygen sensor 1 heater control circuit high The current amperage in the heated oxygen sen- 쐌 Harness or connectors sor 1 heater circuit is out of the normal range. (The heated oxygen sensor 1 heater (An excessively high voltage signal is sent to ECM circuit is shorted.) through the heated oxygen sensor 1 heater.) 쐌 Heated oxygen sensor 1 heater DTC Confirmation Procedure NAEC0830 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is between 11V and 16V at idle. WITH CONSULT-II SEF058Y 1) NAEC0830S01 Start engine and warm it up to normal operating temperature. EC-180 DTC P0031, P0032, P0051, P0052 HO2S1 HEATER DTC Confirmation Procedure (Cont’d) 2) 3) 4) 5) Turn ignition switch “OFF” and wait at least 10 seconds. Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. Start engine and run it for at least 6 seconds at idle speed. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-184. WITH GST 1) 2) 3) 4) 5) 6) 7) 쐌 GI MA EM NAEC0830S02 Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF” and wait at least 10 seconds. Start engine and run it for at least 6 seconds at idle speed. Turn ignition switch “OFF” and wait at least 10 seconds. Start engine and run it for at least 6 seconds at idle speed. Select “MODE 3” with GST. If DTC is detected, go to “Diagnostic Procedure”, EC-184. When using GST, “DTC Confirmation Procedure” should be performed twice as much as when using CONSULT-II because GST cannot display MODE 7 (1st trip DTC) concerning this diagnosis. Therefore, using CONSULT-II is recommended. LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-181 DTC P0031, P0032, P0051, P0052 HO2S1 HEATER Wiring Diagram Wiring Diagram BANK 1 NAEC0831 NAEC0831S01 MEC078E EC-182 DTC P0031, P0032, P0051, P0052 HO2S1 HEATER Wiring Diagram (Cont’d) BANK 2 NAEC0831S02 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC079E EC-183 IDX DTC P0031, P0032, P0051, P0052 HO2S1 HEATER Diagnostic Procedure Diagnostic Procedure 1 NAEC0832 CHECK HO2S1 POWER SUPPLY CIRCUIT 1. Turn ignition switch “OFF”. 2. Disconnect corresponding heated oxygen sensor 1 harness connector. SEC426D SEC427D 3. Turn ignition switch “ON”. 4. Check voltage between HO2S1 terminal 3 and ground with CONSULT-II or tester. PBIB0112E Voltage: Battery voltage OK or NG OK 䊳 GO TO 3. NG 䊳 GO TO 2. 2 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors M32, F23 쐌 Fuse block (J/B) connector M10 쐌 15A fuse 쐌 Harness for open or short between heated oxygen sensor 1 and fuse 䊳 Repair harness or connectors. EC-184 DTC P0031, P0032, P0051, P0052 HO2S1 HEATER Diagnostic Procedure (Cont’d) 3 GI CHECK HO2S1 OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal and HO2S1 terminal as follows. Refer to Wiring Diagram. MA EM LC MTBL1349 Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 4. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-185 DTC P0031, P0032, P0051, P0052 HO2S1 HEATER Diagnostic Procedure (Cont’d) 4 CHECK HEATED OXYGEN SENSOR 1 HEATER Check resistance between HO2S1 terminals as follows. SEF249Y MTBL1782 CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK 䊳 GO TO 5. NG 䊳 Replace malfunctioning heated oxygen sensor 1. 5 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-186 DTC P0037, P0038, P0057, P0058 HO2S2 HEATER Description Description NAEC0833 SYSTEM DESCRIPTION GI NAEC0833S01 Sensor ECM function Input Signal to ECM Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed Engine coolant temperature sensor Engine coolant temperature Mass air flow sensor Amount of intake air MA Actuator EM Heated oxygen sensor heater 2 control Heated oxygen sensor 2 heaters LC The ECM performs ON/OFF control of the heated oxygen sensor 2 heaters corresponding to the engine speed, amount of intake air and engine coolant temperature. OPERATION NAEC0833S02 Heated oxygen sensor 2 heaters Above 3,200 OFF CL ON MT Below 3,200 (After the following conditions are met.) 쐌 After warming up 쐌 After keeping the engine speed between 3,500 and 4,000 rpm for one minute and at idle for one minute under no load CONSULT-II Reference Value in Data Monitor Mode NAEC0834 Specification data are reference values. MONITOR ITEM CONDITION 쐌 Engine speed: Below 3,200 rpm after the following conditions are met. 쐌 After warming up ON 쐌 After keeping the engine speed between 3,500 and 4,000 rpm for one minute and at idle for one minute under no load AX SU NAEC0835 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. 6 WIRE COLOR R/W ITEM Heated oxygen sensor 2 heater (bank 2) TF PD OFF ECM Terminals and Reference Value TERMINAL NO. AT SPECIFICATION 쐌 Ignition switch: ON (Engine stopped) 쐌 Engine is running above 3,200 rpm. HO2S2 HTR (B1) HO2S2 HTR (B2) FE Engine speed rpm CONDITION DATA (DC Voltage) [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is below 3,200 rpm. 쐌 After keeping engine speed between 3,500 and 4,000 rpm for one minute and at idle for one minute 0 - 1.0V [Ignition switch “ON”] 쐌 Engine stopped [Engine is running] 쐌 Engine speed is above 3,200 rpm. BATTERY VOLTAGE (11 - 14V) BR ST RS BT HA SC EL IDX EC-187 DTC P0037, P0038, P0057, P0058 HO2S2 HEATER ECM Terminals and Reference Value (Cont’d) TERMINAL NO. 25 WIRE COLOR P/B ITEM CONDITION Heated oxygen sensor 2 heater (bank 1) DATA (DC Voltage) [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is below 3,200 rpm. 쐌 After keeping engine speed between 3,500 and 4,000 rpm for one minute and at idle for one minute 0 - 1.0V [Ignition switch “ON”] 쐌 Engine stopped [Engine is running] 쐌 Engine speed is above 3,200 rpm. BATTERY VOLTAGE (11 - 14V) On Board Diagnosis Logic DTC No. Trouble diagnosis name DTC Detecting Condition NAEC0836 Possible Cause 쐌 Harness or connectors (The heated oxygen sensor 2 heater circuit is open or shorted.) 쐌 Heated oxygen sensor 2 heater P0037 0037 (Bank 1) P0057 0057 (Bank 2) Heated oxygen sensor 2 heater control circuit low The current amperage in the heated oxygen sensor 2 heater circuit is out of the normal range. (An excessively low voltage signal is sent to ECM through the heated oxygen sensor 2 heater.) P0038 0038 (Bank 1) P0058 0058 (Bank 2) Heated oxygen sensor 2 heater control circuit high The current amperage in the heated oxygen sen- 쐌 Harness or connectors sor 2 heater circuit is out of the normal range. (The heated oxygen sensor 2 heater (An excessively high voltage signal is sent to ECM circuit is shorted.) through the heated oxygen sensor 2 heater.) 쐌 Heated oxygen sensor 2 heater DTC Confirmation Procedure NAEC0837 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is between 11V and 16V at idle. WITH CONSULT-II SEF058Y 1) 2) 3) 4) 5) 6) NAEC0837S01 Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to the normal operating temperature. Turn ignition switch “OFF” and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least one minute under no load. Let engine idle for one minute. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-192. EC-188 DTC P0037, P0038, P0057, P0058 HO2S2 HEATER DTC Confirmation Procedure (Cont’d) WITH GST 1) 2) 3) 4) 5) 6) 7) 8) 9) 쐌 NAEC0837S02 Start engine and warm it up to the normal operating temperature. Turn ignition switch “OFF” and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least one minute under no load. Let engine idle for one minute. Turn ignition switch “OFF” and wait at least 10 seconds. Start engine and keep the engine speed at between 3,500 to 4,000 rpm for at least one minute under no load. Let engine idle for one minute. Select “MODE 3” with GST. If DTC is detected, go to “Diagnostic Procedure”, EC-192. When using GST, “DTC Confirmation Procedure” should be performed twice as much as when using CONSULT-II because GST cannot display MODE 7 (1st trip DTC) concerning this diagnosis. Therefore, using CONSULT-II is recommended. GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-189 DTC P0037, P0038, P0057, P0058 HO2S2 HEATER Wiring Diagram Wiring Diagram BANK 1 NAEC0838 NAEC0838S01 MEC080E EC-190 DTC P0037, P0038, P0057, P0058 HO2S2 HEATER Wiring Diagram (Cont’d) BANK 2 NAEC0838S02 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC081E EC-191 IDX DTC P0037, P0038, P0057, P0058 HO2S2 HEATER Diagnostic Procedure Diagnostic Procedure 1 NAEC0839 CHECK HO2S2 POWER SUPPLY CIRCUIT 1. Turn ignition switch “OFF”. 2. Disconnect corresponding heated oxygen sensor 2 harness connector. SEC426D SEC427D 3. Turn ignition switch “ON”. 4. Check voltage between HO2S2 terminal 3 and ground. SEF314X OK or NG OK 䊳 GO TO 3. NG 䊳 GO TO 2. 2 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors M32, F23 쐌 Fuse block (J/B) connector M10 쐌 15A fuse 쐌 Harness for open or short between heated oxygen sensor 2 and fuse 䊳 Repair harness or connectors. EC-192 DTC P0037, P0038, P0057, P0058 HO2S2 HEATER Diagnostic Procedure (Cont’d) 3 GI CHECK HO2S2 OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal and HO2S2 terminal as follows. Refer to Wiring Diagram. MA EM LC MTBL1351 Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG FE OK 䊳 GO TO 4. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. 4 CHECK HEATED OXYGEN SENSOR 2 HEATER CL MT Check the resistance between HO2S2 terminals as follows. AT TF PD SEF315XB CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. AX SU BR OK or NG OK 䊳 GO TO 5. NG 䊳 Replace malfunctioning heated oxygen sensor 2. 5 ST RS CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 BT INSPECTION END HA SC EL IDX EC-193 DTC P0101 MAF SENSOR (TYPE I) Application Notice Application Notice NAEC1384 Confirm the type of the vehicle. Refer to “How to Check Vehicle Type”, EC-9. Component Description SEC266C NAEC0840 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 film that is supplied with electric current from the ECM. The temperature of the hot film is controlled by the ECM a certain amount. The heat generated by the hot film is reduced as the intake air flows around it. The more air, the greater the heat loss. Therefore, the ECM must supply more electric current to maintain the temperature of the hot film as air flow increases. The ECM detects the air flow by means of this current change. CONSULT-II Reference Value in Data Monitor Mode NAEC0841 Specification data are reference values. MONITOR ITEM MAS A/F SE-B1 CAL/LD VALUE MASS AIRFLOW CONDITION 쐌 쐌 쐌 쐌 Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load SPECIFICATION Idle 1.2 - 1.8V 2,500 rpm 1.6 - 2.2V Idle 14.0 - 33.0% 2,500 rpm 12.0 - 25.0% Idle 2.0 - 6.0 g·m/s 2,500 rpm 7.0 - 20.0 g·m/s ditto ditto ECM Terminals and Reference Value NAEC0842 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 48 51 WIRE COLOR P/B OR ITEM Sensors’ power supply Mass air flow sensor CONDITION DATA (DC Voltage) [Ignition switch “ON”] Approximately 5V [Engine is running] 쐌 Warm-up condition 쐌 Idle speed 1.2 - 1.8V [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,500 rpm. 1.6 - 2.2V EC-194 DTC P0101 MAF SENSOR (TYPE I) ECM Terminals and Reference Value (Cont’d) GI TERMINAL NO. 67 WIRE COLOR B/P ITEM CONDITION Mass air flow sensor ground DATA (DC Voltage) MA [Engine is running] 쐌 Warm-up condition 쐌 Idle speed Approximately 0V EM LC On Board Diagnosis Logic NAEC0843 This self-diagnosis has the one trip detection logic. NOTE: If DTC P0101 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to EC-596. DTC No. P0101 0101 Trouble diagnosis name Mass air flow sensor circuit range/ performance problem DTC Detecting Condition A) B) A high voltage from the sensor is sent to ECM under light load driving condition. A low voltage from the sensor is sent to ECM under heavy load driving condition. FE CL Possible Cause MT 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Mass air flow sensor AT 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Intake air leaks 쐌 Mass air flow sensor TF PD AX SU DTC Confirmation Procedure NAEC0844 Perform “PROCEDURE FOR MALFUNCTION A” first. If the DTC cannot be confirmed, perform “PROCEDURE FOR MALFUNCTION B”. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. BR ST RS BT PROCEDURE FOR MALFUNCTION A NAEC0844S01 NOTE: If engine will not start or stops soon, wait at least 10 seconds with engine stopped (Ignition switch “ON”) instead of running engine at idle speed. With CONSULT-II SEF174Y 1) 2) 3) 4) NAEC0844S0101 Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to normal operating temperature. Run engine for at least 10 seconds at idle speed. EC-195 HA SC EL IDX DTC P0101 MAF SENSOR (TYPE I) DTC Confirmation Procedure (Cont’d) 5) If DTC is detected, go to “Diagnostic Procedure”, EC-199. With GST NAEC0844S0102 Follow the procedure “With CONSULT-II” above. PROCEDURE FOR MALFUNCTION B NAEC0844S02 CAUTION: Always drive vehicle at a safe speed. With CONSULT-II 1) 2) 3) 4) 5) 6) 7) SEF243Y NAEC0844S0201 Turn ignition switch “ON”. Start engine and warm it up to normal operating temperature. If engine cannot be started, go to “Diagnostic Procedure”, EC-199. Select “DATA MONITOR” mode with CONSULT-II. Check the voltage of MAS AIR/FL SE with “DATA MONITOR”. Increases engine speed to about 4,000 rpm. Monitor the linear voltage rise in response to engine speed increases. If NG, go to “Diagnostic Procedure”, EC-199. If OK, go to following step. Maintain the following conditions for at least 10 consecutive seconds. ENG SPEED More than 2,000 rpm THRTL SEN 1 THRTL SEN 2 More than 3V Selector lever Suitable position Driving location Driving vehicle uphill (Increased engine load) will help maintain the driving conditions required for this test. 8) If DTC is detected, go to “Diagnostic Procedure”, EC-199. PBIB0199E Overall Function Check PROCEDURE FOR MALFUNCTION B NAEC0845 NAEC0845S01 Use this procedure to check the overall function of the mass air flow sensor circuit. During this check, a DTC might not be confirmed. With GST 1) 2) 3) 4) SEF534P NAEC0845S0101 Start engine and warm it up to normal operating temperature. Select “MODE 1” with GST. Check the mass air flow sensor signal with “MODE 1”. Check for linear mass air flow sensor signal value rise in response to increases to about 4,000 rpm in engine speed. EC-196 DTC P0101 MAF SENSOR (TYPE I) Overall Function Check (Cont’d) 5) If NG, go to “Diagnostic Procedure”, EC-199. GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-197 DTC P0101 MAF SENSOR (TYPE I) Wiring Diagram Wiring Diagram NAEC0846 MEC082E EC-198 DTC P0101 MAF SENSOR (TYPE I) Diagnostic Procedure Diagnostic Procedure 1 NAEC0847 GI INSPECTION START MA Which malfunction (A or B) is duplicated? A or B A 䊳 GO TO 3. B 䊳 GO TO 2. EM LC 2 CHECK INTAKE SYSTEM Check the following for connection. 쐌 Air duct 쐌 Vacuum hoses 쐌 Intake air passage between air duct and intake manifold collector FE OK or NG OK 䊳 GO TO 3. NG 䊳 Reconnect the parts. 3 CL MT RETIGHTEN GROUND SCREWS 1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. AT TF PD AX SEF959Y 䊳 GO TO 4. SU BR ST RS BT HA SC EL IDX EC-199 DTC P0101 MAF SENSOR (TYPE I) Diagnostic Procedure (Cont’d) 4 CHECK MAF SENSOR POWER SUPPLY CIRCUIT 1. Disconnect mass air flow (MAF) sensor harness connector. SEF960YA 2. Turn ignition switch “ON”. 3. Check voltage between MAF sensor terminals 2, 4 and ground with CONSULT-II or tester. SEC428D MTBL1352 OK or NG OK 䊳 GO TO 6. NG 䊳 GO TO 5. 5 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connector E1, M1 쐌 Harness connector M32, F23 쐌 Harness for open or short between ECM relay and mass air flow sensor 쐌 Harness for open or short between mass air flow sensor and ECM 䊳 Repair harness or connectors. EC-200 DTC P0101 MAF SENSOR (TYPE I) Diagnostic Procedure (Cont’d) 6 CHECK MAF SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. 4. Turn ignition switch “OFF”. Disconnect ECM harness connector. Disconnect TCM harness connector. Check harness continuity between MAF sensor terminal 3 and ECM terminal 67, MAF sensor terminal 3 and TCM terminal 42. Refer to Wiring Diagram. Continuity should exist. 5. Also check harness for short to ground and short to power. GI MA EM LC OK or NG OK 䊳 GO TO 8. NG 䊳 GO TO 7. 7 FE DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors F22, M33 쐌 Joint connector 쐌 Harness for open or short between mass air flow sensor and ECM 쐌 Harness for open or short between mass air flow sensor and TCM 䊳 CL MT Repair open circuit or short to ground or short to power in harness or connectors. AT 8 CHECK MAF SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between MAF sensor terminal 5 and ECM terminal 51. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. TF PD OK or NG OK 䊳 GO TO 9. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. AX SU BR ST RS BT HA SC EL IDX EC-201 DTC P0101 MAF SENSOR (TYPE I) Diagnostic Procedure (Cont’d) 9 CHECK MASS AIR FLOW SENSOR 1. Reconnect harness connectors disconnected. 2. Start engine and warm it up to normal operating temperature. 3. Check voltage between ECM terminal 51 (Mass air flow sensor signal) and ground. SEF100V MTBL1353 4. If the voltage is out of specification, disconnect MAF sensor harness connector and connect it again. Then repeat above check. OK or NG OK 䊳 GO TO 10. NG 䊳 Replace mass air flow sensor. 10 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-202 DTC P0101 MAF SENSOR (TYPE II) Application Notice Application Notice NAEC1393 Confirm the type of the vehicle. Refer to “How to Check Vehicle Type”, EC-9. GI MA EM LC Component Description PBIB1604E NAEC1385 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 film that is supplied with electric current from the ECM. The temperature of the hot film is controlled by the ECM a certain amount. The heat generated by the hot film is reduced as the intake air flows around it. The more air, the greater the heat loss. Therefore, the ECM must supply more electric current to maintain the temperature of the hot film as air flow increases. The ECM detects the air flow by means of this current change. CONSULT-II Reference Value in Data Monitor Mode NAEC1386 Specification data are reference values. MONITOR ITEM MAS A/F SE-B1 CAL/LD VALUE MASS AIRFLOW CONDITION 쐌 쐌 쐌 쐌 Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load SPECIFICATION Idle 1.0 - 1.3V 2,500 rpm 1.7 - 2.1V Idle 14.0 - 33.0% 2,500 rpm 12.0 - 25.0% Idle 2.0 - 6.0 g·m/s 2,500 rpm 7.0 - 20.0 g·m/s 51 67 OR B/P MT AT TF PD SU ditto BR ditto NAEC1387 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. WIRE COLOR CL AX ECM Terminals and Reference Value TERMINAL NO. FE ST RS BT ITEM Mass air flow sensor Mass air flow sensor ground CONDITION DATA (DC Voltage) HA [Engine is running] 쐌 Warm-up condition 쐌 Idle speed 1.0 - 1.3V [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,500 rpm. 1.7 - 2.1V [Engine is running] 쐌 Warm-up condition 쐌 Idle speed Approximately 0V EC-203 SC EL IDX DTC P0101 MAF SENSOR (TYPE II) ECM Terminals and Reference Value (Cont’d) TERMINAL NO. 111 119 120 WIRE COLOR ITEM CONDITION ECM relay (Self shutt-off) L/B B/W B/W Power supply for ECM DATA (DC Voltage) [Engine is running] [Ignition switch “OFF”] 쐌 For a few seconds after turning ignition switch “OFF” 0 - 1.5V [Ignition switch “OFF”] 쐌 A few seconds passed after turning ignition switch “OFF” BATTERY VOLTAGE (11 - 14V) [Ignition switch “ON”] BATTERY VOLTAGE (11 - 14V) On Board Diagnosis Logic NAEC1388 This self-diagnosis has the one trip detection logic. DTC No. P0101 0101 Trouble diagnosis name Mass air flow sensor circuit range/ performance problem DTC Detecting Condition Possible Cause A) A high voltage from the sensor is sent to ECM under light load driving condition. 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Mass air flow sensor B) A low voltage from the sensor is sent to ECM under heavy load driving condition. 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Intake air leaks 쐌 Mass air flow sensor DTC Confirmation Procedure NAEC1389 Perform “PROCEDURE FOR MALFUNCTION A” first. If the DTC cannot be confirmed, perform “PROCEDURE FOR MALFUNCTION B”. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. EC-204 DTC P0101 MAF SENSOR (TYPE II) DTC Confirmation Procedure (Cont’d) PROCEDURE FOR MALFUNCTION A NAEC1389S01 NOTE: If engine will not start or stops soon, wait at least 10 seconds with engine stopped (Ignition switch “ON”) instead of running engine at idle speed. With CONSULT-II SEF174Y 1) 2) 3) 4) 5) NAEC1389S0101 Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to normal operating temperature. Run engine for at least 10 seconds at idle speed. If DTC is detected, go to “Diagnostic Procedure”, EC-208. With GST GI MA EM LC NAEC1389S0102 Follow the procedure “With CONSULT-II” above. FE CL MT PROCEDURE FOR MALFUNCTION B AT NAEC1389S02 CAUTION: Always drive vehicle at a safe speed. With CONSULT-II 1) 2) 3) 4) 5) 6) 7) SEF243Y TF NAEC1389S0201 Turn ignition switch “ON”. Start engine and warm it up to normal operating temperature. If engine cannot be started, go to “Diagnostic Procedure”, EC-208. Select “DATA MONITOR” mode with CONSULT-II. Check the voltage of MAS AIR/FL SE with “DATA MONITOR”. Increases engine speed to about 4,000 rpm. Monitor the linear voltage rise in response to engine speed increases. If NG, go to “Diagnostic Procedure”, EC-208. If OK, go to following step. Maintain the following conditions for at least 10 consecutive seconds. ENG SPEED More than 2,000 rpm THRTL SEN 1 THRTL SEN 2 More than 3V Selector lever Suitable position Driving location Driving vehicle uphill (Increased engine load) will help maintain the driving conditions required for this test. 8) PD AX SU BR ST RS BT If DTC is detected, go to “Diagnostic Procedure”, EC-208. HA SC EL IDX PBIB0199E EC-205 DTC P0101 MAF SENSOR (TYPE II) Overall Function Check Overall Function Check PROCEDURE FOR MALFUNCTION B NAEC1390 NAEC1390S01 Use this procedure to check the overall function of the mass air flow sensor circuit. During this check, a DTC might not be confirmed. With GST 1) 2) 3) 4) SEF534P 5) NAEC1390S0101 Start engine and warm it up to normal operating temperature. Select “MODE 1” with GST. Check the mass air flow sensor signal with “MODE 1”. Check for linear mass air flow sensor signal value rise in response to increases to about 4,000 rpm in engine speed. If NG, go to “Diagnostic Procedure”, EC-208. EC-206 DTC P0101 MAF SENSOR (TYPE II) Wiring Diagram Wiring Diagram NAEC1391 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC515E EC-207 IDX DTC P0101 MAF SENSOR (TYPE II) Diagnostic Procedure Diagnostic Procedure 1 NAEC1392 INSPECTION START Which malfunction (A or B) is duplicated? A or B A 䊳 GO TO 3. B 䊳 GO TO 2. 2 CHECK INTAKE SYSTEM Check the following for connection. 쐌 Air duct 쐌 Vacuum hoses 쐌 Intake air passage between air duct and intake manifold collector OK or NG OK 䊳 GO TO 3. NG 䊳 Reconnect the parts. 3 RETIGHTEN GROUND SCREWS 1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. SEF959Y 䊳 GO TO 4. EC-208 DTC P0101 MAF SENSOR (TYPE II) Diagnostic Procedure (Cont’d) 4 GI CHECK MAF SENSOR POWER SUPPLY CIRCUIT 1. Disconnect mass air flow (MAF) sensor harness connector. MA EM LC SEF960YA 2. Turn ignition switch “ON”. 3. Check voltage between MAF sensor terminal 2 and ground with CONSULT-II or tester. FE CL MT AT TF PBIB1168E Voltage: Battery voltage OK or NG OK 䊳 GO TO 6. NG 䊳 GO TO 5. 5 AX DETECT MALFUNCTIONING PART SU Check the following. 쐌 Harness connector E1, M1 쐌 Harness connector M32, F23 쐌 Harness for open or short between ECM relay and mass air flow sensor 쐌 Harness for open or short between mass air flow sensor and ECM 䊳 6 Repair harness or connectors. CHECK MAF SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. 4. Turn ignition switch “OFF”. Disconnect ECM harness connector. Disconnect TCM harness connector. Check harness continuity between MAF sensor terminal 3 and ECM terminal 67, TCM terminal 42. Refer to Wiring Diagram. Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 8. NG 䊳 GO TO 7. PD BR ST RS BT HA SC EL IDX EC-209 DTC P0101 MAF SENSOR (TYPE II) Diagnostic Procedure (Cont’d) 7 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors F22, M33 쐌 Joint connector 쐌 Harness for open or short between mass air flow sensor and ECM 쐌 Harness for open or short between mass air flow sensor and TCM 䊳 8 Repair open circuit or short to gorund or short to power in harness or connectors. CHECK MAF SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between MAF sensor terminal 4 and ECM terminal 51. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 9. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. 9 CHECK MASS AIR FLOW SENSOR 1. Reconnect harness connectors disconnected. 2. Start engine and warm it up to normal operating temperature. 3. Check voltage between ECM terminal 51 (Mass air flow sensor signal) and ground. SEF100V MTBL1806 4. If the voltage is out of specification, disconnect MAF sensor harness connector and connect it again. Then repeat above check. OK or NG OK 䊳 GO TO 10. NG 䊳 Replace mass air flow sensor. 10 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-210 DTC P0102, P0103 MAF SENSOR (TYPE I) Application Notice Application Notice NAEC1394 Confirm the type of the vehicle. Refer to “How to Check Vehicle Type”, EC-9. GI MA EM LC Component Description SEC266C NAEC0746 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 film that is supplied with electric current from the ECM. The temperature of the hot film is controlled by the ECM a certain amount. The heat generated by the hot film is reduced as the intake air flows around it. The more air, the greater the heat loss. Therefore, the ECM must supply more electric current to maintain the temperature of the hot film as air flow increases. The ECM detects the air flow by means of this current change. CONSULT-II Reference Value in Data Monitor Mode NAEC0747 Specification data are reference values. MONITOR ITEM MAS A/F SE-B1 CAL/LD VALUE MASS AIRFLOW CONDITION 쐌 쐌 쐌 쐌 Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load SPECIFICATION Idle 1.2 - 1.8V 2,500 rpm 1.6 - 2.2V Idle 14.0 - 33.0% 2,500 rpm 12.0 - 25.0% Idle 2.0 - 6.0 g·m/s 2,500 rpm 7.0 - 20.0 g·m/s 48 51 P/B OR MT AT TF PD SU ditto BR ditto NAEC0748 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. WIRE COLOR CL AX ECM Terminals and Reference Value TERMINAL NO. FE ST RS BT ITEM Sensors’ power supply Mass air flow sensor CONDITION DATA (DC Voltage) [Ignition switch “ON”] Approximately 5V [Engine is running] 쐌 Warm-up condition 쐌 Idle speed 1.2 - 1.8V [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,500 rpm. 1.6 - 2.2V HA SC EL IDX EC-211 DTC P0102, P0103 MAF SENSOR (TYPE I) ECM Terminals and Reference Value (Cont’d) TERMINAL NO. 67 WIRE COLOR B/P ITEM CONDITION Mass air flow sensor ground DATA (DC Voltage) [Engine is running] 쐌 Warm-up condition 쐌 Idle speed Approximately 0V On Board Diagnosis Logic NAEC0749 These self-diagnoses have the one trip detection logic. NOTE: If DTC P0102 or P0103 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to EC-596. DTC No. Trouble diagnosis name DTC Detecting Condition Possible Cause P0102 0102 Mass air flow sensor circuit low input An excessively low voltage from the sensor is sent 쐌 Harness or connectors to ECM when engine is running. (The sensor circuit is open or shorted.) 쐌 Intake air leaks 쐌 Mass air flow sensor P0103 0103 Mass air flow sensor circuit high input An excessively high voltage from the sensor is sent to ECM. 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Mass air flow sensor FAIL-SAFE MODE NAEC0749S01 When the malfunction is detected, the ECM enters fail-safe mode and the MIL lights up. Detected items Engine operating condition in fail-safe mode Mass air flow sensor circuit Engine speed will not rise more than 2,400 rpm due to the fuel cut. DTC Confirmation Procedure NAEC0751 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. PROCEDURE FOR DTC P0103 With CONSULT-II 1) 2) 3) 4) NAEC0751S01 NAEC0751S0101 Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 6 seconds. If DTC is detected, go to “Diagnostic Procedure”, EC-215. With GST Follow the procedure “With CONSULT-II” above. SEF058Y EC-212 NAEC0751S0102 DTC P0102, P0103 MAF SENSOR (TYPE I) DTC Confirmation Procedure (Cont’d) PROCEDURE FOR DTC P0102 With CONSULT-II 1) 2) 3) 4) NAEC0751S02 NAEC0751S0201 Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and wait at least 5 seconds. If DTC is detected, go to “Diagnostic Procedure”, EC-215. With GST Follow the procedure “With CONSULT-II” above. GI MA EM NAEC0751S0202 LC SEF058Y FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-213 DTC P0102, P0103 MAF SENSOR (TYPE I) Wiring Diagram Wiring Diagram NAEC0753 MEC082E EC-214 DTC P0102, P0103 MAF SENSOR (TYPE I) Diagnostic Procedure Diagnostic Procedure 1 NAEC0754 GI INSPECTION START MA Which malfunction (P0102 or P0103) is duplicated? P0102 or P0103 P0103 䊳 GO TO 3. P0102 䊳 GO TO 2. EM LC 2 CHECK INTAKE SYSTEM Check the following for connection. 쐌 Air duct 쐌 Vacuum hoses 쐌 Intake air passage between air duct and intake manifold collector FE OK or NG OK 䊳 GO TO 3. NG 䊳 Reconnect the parts. 3 CL MT RETIGHTEN GROUND SCREWS 1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. AT TF PD AX SEF959Y 䊳 GO TO 4. SU BR ST RS BT HA SC EL IDX EC-215 DTC P0102, P0103 MAF SENSOR (TYPE I) Diagnostic Procedure (Cont’d) 4 CHECK MAF SENSOR POWER SUPPLY CIRCUIT 1. Disconnect mass air flow (MAF) sensor harness connector. SEF960YA 2. Turn ignition switch “ON”. 3. Check voltage between MAF sensor terminals 2, 4 and ground with CONSULT-II or tester. SEC428D MTBL1352 OK or NG OK 䊳 GO TO 6. NG 䊳 GO TO 5. 5 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connector E1, M1 쐌 Harness connector M32, F23 쐌 Harness for open or short between ECM relay and mass air flow sensor 쐌 Harness for open or short between mass air flow sensor and ECM 䊳 Repair harness or connectors. EC-216 DTC P0102, P0103 MAF SENSOR (TYPE I) Diagnostic Procedure (Cont’d) 6 CHECK MAF SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. 4. Turn ignition switch “OFF”. Disconnect ECM harness connector. Disconnect TCM harness connector. Check harness continuity between MAF sensor terminal 3 and ECM terminal 67, MAF sensor terminal 3 and TCM terminal 42. Refer to Wiring Diagram. Continuity should exist. 5. Also check harness for short to ground and short to power. GI MA EM LC OK or NG OK 䊳 GO TO 8. NG 䊳 GO TO 7. 7 FE DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connector F22, M33 쐌 Joint connector 쐌 Harness for open or short between mass air flow sensor and ECM 쐌 Harness for open or short between mass air flow sensor and TCM 䊳 CL MT Repair open circuit or short to ground or short to power in harness or connectors. AT 8 CHECK MAF SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between MAF sensor terminal 5 and ECM terminal 51. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. TF PD OK or NG OK 䊳 GO TO 9. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. AX SU BR ST RS BT HA SC EL IDX EC-217 DTC P0102, P0103 MAF SENSOR (TYPE I) Diagnostic Procedure (Cont’d) 9 CHECK MASS AIR FLOW SENSOR 1. Reconnect harness connectors disconnected. 2. Start engine and warm it up to normal operating temperature. 3. Check voltage between ECM terminal 51 (Mass air flow sensor signal) and ground. SEF100V MTBL1353 4. If the voltage is out of specification, disconnect MAF sensor harness connector and connect it again. Then repeat above check. OK or NG OK 䊳 GO TO 10. NG 䊳 Replace mass air flow sensor. 10 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-218 DTC P0102, P0103 MAF SENSOR (TYPE II) Application Notice Application Notice NAEC1402 Confirm the type of the vehicle. Refer to “How to Check Vehicle Type”, EC-9. GI MA EM LC Component Description PBIB1604E NAEC1395 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 film that is supplied with electric current from the ECM. The temperature of the hot film is controlled by the ECM a certain amount. The heat generated by the hot film is reduced as the intake air flows around it. The more air, the greater the heat loss. Therefore, the ECM must supply more electric current to maintain the temperature of the hot film as air flow increases. The ECM detects the air flow by means of this current change. CONSULT-II Reference Value in Data Monitor Mode NAEC1396 Specification data are reference values. MONITOR ITEM MAS A/F SE-B1 CAL/LD VALUE MASS AIRFLOW CONDITION 쐌 쐌 쐌 쐌 Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load SPECIFICATION Idle 1.0 - 1.3V 2,500 rpm 1.7 - 2.1V Idle 14.0 - 33.0% 2,500 rpm 12.0 - 25.0% Idle 2.0 - 6.0 g·m/s 2,500 rpm 7.0 - 20.0 g·m/s 51 67 OR B/P MT AT TF PD SU ditto BR ditto NAEC1397 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. WIRE COLOR CL AX ECM Terminals and Reference Value TERMINAL NO. FE ST RS BT ITEM Mass air flow sensor Mass air flow sensor ground CONDITION DATA (DC Voltage) HA [Engine is running] 쐌 Warm-up condition 쐌 Idle speed 1.0 - 1.3V [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,500 rpm. 1.7 - 2.1V [Engine is running] 쐌 Warm-up condition 쐌 Idle speed Approximately 0V EC-219 SC EL IDX DTC P0102, P0103 MAF SENSOR (TYPE II) ECM Terminals and Reference Value (Cont’d) TERMINAL NO. 111 119 120 WIRE COLOR ITEM CONDITION ECM relay (Self shutt-off) L/B B/W B/W Power supply for ECM DATA (DC Voltage) [Engine is running] [Ignition switch “OFF”] 쐌 For a few seconds after turning ignition switch “OFF” 0 - 1.5V [Ignition switch “OFF”] 쐌 A few seconds passed after turning ignition switch “OFF” BATTERY VOLTAGE (11 - 14V) [Ignition switch “ON”] BATTERY VOLTAGE (11 - 14V) On Board Diagnosis Logic NAEC1398 These self-diagnoses have the one trip detection logic. DTC No. Trouble diagnosis name DTC Detecting Condition Possible Cause P0102 0102 Mass air flow sensor circuit low input An excessively low voltage from the sensor is sent 쐌 Harness or connectors to ECM when engine is running. (The sensor circuit is open or shorted.) 쐌 Intake air leaks 쐌 Mass air flow sensor P0103 0103 Mass air flow sensor circuit high input An excessively high voltage from the sensor is sent to ECM. 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Mass air flow sensor FAIL-SAFE MODE NAEC1398S01 When the malfunction is detected, the ECM enters fail-safe mode and the MIL lights up. Detected items Engine operating condition in fail-safe mode Mass air flow sensor circuit Engine speed will not rise more than 2,400 rpm due to the fuel cut. DTC Confirmation Procedure NAEC1399 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. PROCEDURE FOR DTC P0103 With CONSULT-II 1) 2) 3) 4) NAEC1399S01 NAEC1399S0101 Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 6 seconds. If DTC is detected, go to “Diagnostic Procedure”, EC-223. With GST Follow the procedure “With CONSULT-II” above. SEF058Y EC-220 NAEC1399S0102 DTC P0102, P0103 MAF SENSOR (TYPE II) DTC Confirmation Procedure (Cont’d) PROCEDURE FOR DTC P0102 With CONSULT-II 1) 2) 3) 4) NAEC1399S02 NAEC1399S0201 Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and wait at least 5 seconds. If DTC is detected, go to “Diagnostic Procedure”, EC-223. With GST Follow the procedure “With CONSULT-II” above. GI MA EM NAEC1399S0202 LC SEF058Y FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-221 DTC P0102, P0103 MAF SENSOR (TYPE II) Wiring Diagram Wiring Diagram NAEC1400 MEC515E EC-222 DTC P0102, P0103 MAF SENSOR (TYPE II) Diagnostic Procedure Diagnostic Procedure 1 NAEC1401 GI INSPECTION START MA Which malfunction (P0102 or P0103) is duplicated? P0102 or P0103 P0103 䊳 GO TO 3. P0102 䊳 GO TO 2. EM LC 2 CHECK INTAKE SYSTEM Check the following for connection. 쐌 Air duct 쐌 Vacuum hoses 쐌 Intake air passage between air duct and intake manifold collector FE OK or NG OK 䊳 GO TO 3. NG 䊳 Reconnect the parts. 3 CL MT RETIGHTEN GROUND SCREWS 1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. AT TF PD AX SEF959Y 䊳 GO TO 4. SU BR ST RS BT HA SC EL IDX EC-223 DTC P0102, P0103 MAF SENSOR (TYPE II) Diagnostic Procedure (Cont’d) 4 CHECK MAF SENSOR POWER SUPPLY CIRCUIT 1. Disconnect mass air flow (MAF) sensor harness connector. SEF960YA 2. Turn ignition switch “ON”. 3. Check voltage between MAF sensor terminal 2 and ground with CONSULT-II or tester. PBIB1168E Voltage: Battery voltage OK or NG OK 䊳 GO TO 6. NG 䊳 GO TO 5. 5 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connector E1, M1 쐌 Harness connector M32, F23 쐌 Harness for open or short between ECM relay and mass air flow sensor 쐌 Harness for open or short between mass air flow sensor and ECM 䊳 6 Repair harness or connectors. CHECK MAF SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. 4. Turn ignition switch “OFF”. Disconnect ECM harness connector. Disconnect TCM harness connector Check harness continuity between MAF sensor terminal 3 and ECM terminal 67, TCM terminal 42. Refer to Wiring Diagram. Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 8. NG 䊳 GO TO 7. EC-224 DTC P0102, P0103 MAF SENSOR (TYPE II) Diagnostic Procedure (Cont’d) 7 GI DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connector F22, M33 쐌 Joint connector 쐌 Harness for open or short between mass air flow sensor and ECM 쐌 Harness for open or short between mass air flow sensor and TCM 䊳 8 MA EM Repair open circuit or short to ground or short to power in harness or connectors. LC CHECK MAF SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between MAF sensor terminal 4 and ECM terminal 51. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. FE OK or NG OK 䊳 GO TO 9. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. 9 CL MT CHECK MASS AIR FLOW SENSOR 1. Reconnect harness connectors disconnected. 2. Start engine and warm it up to normal operating temperature. 3. Check voltage between ECM terminal 51 (Mass air flow sensor signal) and ground. AT TF PD AX SU SEF100V BR ST RS BT MTBL1806 4. If the voltage is out of specification, disconnect MAF sensor harness connector and connect it again. Then repeat above check. HA OK or NG OK 䊳 GO TO 10. NG 䊳 Replace mass air flow sensor. 10 SC EL CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-225 IDX DTC P0112, P0113 IAT SENSOR (TYPE I) Application Notice Application Notice NAEC1403 Confirm the type of the vehicle. Refer to “How to Check Vehicle Type”, EC-9. Component Description NAEC0852 The intake air temperature sensor is mounted to the air duct housing. The sensor detects intake air temperature and transmits a signal to the ECM. The temperature sensing unit uses a thermistor which is sensitive to the change in temperature. Electrical resistance of the thermistor decreases in response to the temperature rise. Intake air temperature °C (°F) Voltage* V Resistance kΩ SEF960YA 25 (77) 3.32 1.9 - 2.1 *: These data are reference values and are measured between ECM terminal 34 (Intake air temperature sensor) and body ground. CAUTION: Do not use ECM ground terminals when measuring input/ output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. SEF012P On Board Diagnosis Logic DTC No. P0112 0112 P0113 0113 Trouble diagnosis name DTC Detecting Condition NAEC0853 Possible Cause Intake air temperature An excessively low voltage from the sensor is sent 쐌 Harness or connectors sensor circuit low to ECM. (The sensor circuit is open or input shorted.) 쐌 Intake air temperature sensor Intake air temperature An excessively high voltage from the sensor is sensor circuit high sent to ECM. input DTC Confirmation Procedure NAEC0854 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. EC-226 DTC P0112, P0113 IAT SENSOR (TYPE I) DTC Confirmation Procedure (Cont’d) WITH CONSULT-II 1) 2) 3) 4) NAEC0854S01 Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 5 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-229. WITH GST Follow the procedure “With CONSULT-II” above. GI MA EM NAEC0854S02 LC SEF058Y FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-227 DTC P0112, P0113 IAT SENSOR (TYPE I) Wiring Diagram Wiring Diagram NAEC0855 MEC083E EC-228 DTC P0112, P0113 IAT SENSOR (TYPE I) Diagnostic Procedure Diagnostic Procedure 1 NAEC0856 GI CHECK INTAKE AIR TEMPERATURE SENSOR POWER SUPPLY CIRCUIT MA 1. Turn ignition switch “OFF”. 2. Disconnect mass air flow sensor (built-in intake air temperature sensor) harness connector. EM LC FE SEF960YA 3. Turn ignition switch “ON”. 4. Check voltage between terminal 1 and ground. CL MT AT TF SEC429D PD Voltage: Approximately 5V OK or NG OK 䊳 GO TO 2. NG 䊳 Repair harness or connectors. 2 CHECK INTAKE AIR TEMPERATURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. 4. Turn ignition switch “OFF”. Disconnect ECM harness connector. Disconnect TCM harness connector. Check harness continuity between MAF sensor terminal 3 and ECM terminal 67, MAF sensor terminal 3 and TCM terminal 42. Refer to Wiring Diagram. Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 3. 3 SU BR ST RS BT HA DETECT MALFUNCTIONING PART SC Check the following. 쐌 Harness connectors F22, M33 쐌 Joint connector 쐌 Harness for open or short between mass air flow sensor and ECM 쐌 Harness for open or short between mass air flow sensor and TCM 䊳 AX Repair open circuit or short to ground or short to power in harness or connectors. EC-229 EL IDX DTC P0112, P0113 IAT SENSOR (TYPE I) Diagnostic Procedure (Cont’d) 4 CHECK INTAKE AIR TEMPERATURE SENSOR Refer to EC-230, “Component Inspection”. OK or NG OK 䊳 GO TO 5. NG 䊳 Replace mass air flow sensor (with intake air temperature sensor). 5 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END Component Inspection NAEC1193 INTAKE AIR TEMPERATURE SENSOR 1. 2. NAEC1193S01 Check resistance between intake air temperature sensor terminals 1 and 3 under the following conditions. Intake air temperature °C (°F) Resistance kΩ 25 (77) 1.9 - 2.1 If NG, replace mass air flow sensor (with intake air temperature sensor). SEC266C SEF012P EC-230 DTC P0112, P0113 IAT SENSOR (TYPE II) Application Notice Application Notice NAEC1410 Confirm the type of the vehicle. Refer to “How to Check Vehicle Type”, EC-9. GI MA EM LC Component Description NAEC1404 The intake air temperature sensor is mounted to the air duct housing. The sensor detects intake air temperature and transmits a signal to the ECM. The temperature sensing unit uses a thermistor which is sensitive to the change in temperature. Electrical resistance of the thermistor decreases in response to the temperature rise. Intake air temperature °C (°F) Voltage* V Resistance 3.32 CAUTION: Do not use ECM ground terminals when measuring input/ output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. On Board Diagnosis Logic P0112 0112 P0113 0113 TF PD AX SU SEF012P Trouble diagnosis name MT AT 1.9 - 2.1 *: These data are reference values and are measured between ECM terminal 34 (Intake air temperature sensor) and body ground. DTC No. CL kΩ SEF960YA 25 (77) FE NAEC1405 BR DTC Detecting Condition Possible Cause Intake air temperature An excessively low voltage from the sensor is sent 쐌 Harness or connectors sensor circuit low to ECM. (The sensor circuit is open or input shorted.) 쐌 Intake air temperature sensor Intake air temperature An excessively high voltage from the sensor is sensor circuit high sent to ECM. input DTC Confirmation Procedure ST RS BT NAEC1406 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. HA SC EL IDX EC-231 DTC P0112, P0113 IAT SENSOR (TYPE II) DTC Confirmation Procedure (Cont’d) WITH CONSULT-II 1) 2) 3) 4) NAEC1406S01 Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 5 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-234. WITH GST Follow the procedure “With CONSULT-II” above. SEF058Y EC-232 NAEC1406S02 DTC P0112, P0113 IAT SENSOR (TYPE II) Wiring Diagram Wiring Diagram NAEC1407 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC516E EC-233 IDX DTC P0112, P0113 IAT SENSOR (TYPE II) Diagnostic Procedure Diagnostic Procedure 1 NAEC1408 CHECK INTAKE AIR TEMPERATURE SENSOR POWER SUPPLY CIRCUIT 1. Turn ignition switch “OFF”. 2. Disconnect mass air flow sensor (built-in intake air temperature sensor) harness connector. SEF960YA 3. Turn ignition switch “ON”. 4. Check voltage between terminal 5 and ground. PBIB1169E Voltage: Approximately 5V OK or NG OK 䊳 GO TO 2. NG 䊳 Repair harness or connectors. 2 CHECK INTAKE AIR TEMPERATURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. 4. Turn ignition switch “OFF”. Disconnect ECM harness connector. Disconnect TCM harness connector. Check harness continuity between MAF sensor terminal 6 and ECM terminal 67, TCM terminal 42. Refer to Wiring Diagram. Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 3. 3 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors F22, M33 쐌 Joint connector 쐌 Harness for open or short between mass air flow sensor and ECM 쐌 Harness for open or short between mass air flow sensor and TCM 䊳 Repair open circuit or short to ground or short to power in harness or connectors. EC-234 DTC P0112, P0113 IAT SENSOR (TYPE II) Diagnostic Procedure (Cont’d) 4 GI CHECK INTAKE AIR TEMPERATURE SENSOR Refer to EC-235, “Component Inspection”. MA OK or NG OK 䊳 GO TO 5. NG 䊳 Replace mass air flow sensor (with intake air temperature sensor). 5 EM CHECK INTERMITTENT INCIDENT LC Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END FE CL MT AT Component Inspection NAEC1409 INTAKE AIR TEMPERATURE SENSOR 1. 2. NAEC1409S01 Check resistance between intake air temperature sensor terminals 1 and 3 under the following conditions. Intake air temperature °C (°F) Resistance kΩ 25 (77) 1.9 - 2.1 If NG, replace mass air flow sensor (with intake air temperature sensor). TF PD AX SU PBIB1604E BR ST RS BT SEF012P HA SC EL IDX EC-235 DTC P0117, P0118 ECT SENSOR Component Description Component Description NAEC0857 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. SEF594K Engine coolant temperature °C (°F) SEF012P Voltage* V Resistance kΩ −10 (14) 4.4 7.0 - 11.4 20 (68) 3.5 2.1 - 2.9 50 (122) 2.2 0.68 - 1.00 90 (194) 0.9 0.236 - 0.260 *: These data are reference values and are measured between ECM terminal 73 (Engine coolant temperature sensor) and ground. CAUTION: Do not use ECM ground terminals when measuring input/ output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. On Board Diagnosis Logic NAEC0858 These self-diagnoses have the one trip detection logic. DTC No. Trouble diagnosis name P0117 0117 Engine coolant temperature sensor circuit low input P0118 0118 Engine coolant temperature sensor circuit high input DTC Detecting Condition Possible Cause An excessively low voltage from the sensor is sent 쐌 Harness or connectors to ECM. (The sensor circuit is open or shorted.) 쐌 Engine coolant temperature sensor An excessively high voltage from the sensor is sent to ECM. FAIL-SAFE MODE NAEC0858S01 When this malfunction is detected, the ECM enters fail-safe mode and the MIL lights up. EC-236 DTC P0117, P0118 ECT SENSOR On Board Diagnosis Logic (Cont’d) Detected items GI 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”. CONSULT-II displays the engine coolant temperature decided by ECM. Engine coolant temperature decided (CONSULT-II display) Condition Engine coolant temperature sensor circuit Just as ignition switch is turned ON or Start 40°C (104°F) More than approx. 4 minutes after ignition ON or Start 80°C (176°F) MA EM LC 40 - 80°C (104 - 176°F) (Depends on the time) Except as shown above When the fail-safe system for engine coolant temperature is activated, the cooling fan operates while engine is running. FE CL MT DTC Confirmation Procedure AT NAEC0859 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. WITH CONSULT-II SEF058Y 1) 2) 3) 4) Follow the procedure “WITH CONSULT-II” above. PD NAEC0859S01 Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 5 seconds. If DTC is detected, go to “Diagnostic Procedure”, EC-239. WITH GST TF AX SU NAEC0859S02 BR ST RS BT HA SC EL IDX EC-237 DTC P0117, P0118 ECT SENSOR Wiring Diagram Wiring Diagram NAEC0860 MEC084E EC-238 DTC P0117, P0118 ECT SENSOR Diagnostic Procedure Diagnostic Procedure 1 NAEC0861 GI CHECK ECT SENSOR POWER SUPPLY CIRCUIT MA 1. Turn ignition switch “OFF”. 2. Disconnect engine coolant temperature (ECT) sensor connector. EM LC FE SEC426D 3. Turn ignition switch “ON”. 4. Check voltage between ECT sensor connector terminal 1 and ground with CONSULT-II or tester. CL MT AT TF SEC106D PD OK or NG OK 䊳 GO TO 3. NG 䊳 GO TO 2. AX SU 2 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors F112, F28 쐌 Harness for open or short between ECM and engine coolant temperature sensor 䊳 3 Repair harness or connectors. CHECK ECT SENSOR GROUND CIRCUIT FOR OPEN AND CIRCUIT 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECT sensor terminal 2 and ECM terminal 67. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to power. BR ST RS BT HA OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 4. SC EL IDX EC-239 DTC P0117, P0118 ECT SENSOR Diagnostic Procedure (Cont’d) 4 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors F112, F28 쐌 Joint connector F204 쐌 Harness for open between ECM and engine coolant temperature sensor 쐌 Harness for open between TCM and engine coolant temperature sensor 䊳 5 Repair open circuit or short to power in harness or connectors. CHECK ENGINE COOLANT TEMPERATURE SENSOR Check resistance between engine coolant temperature sensor terminals 1 and 2 as shown in the figure. SEF304X OK or NG OK 䊳 GO TO 6. NG 䊳 Replace engine coolant temperature sensor. 6 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-240 DTC P0122, P0123 TP SENSOR Component Description Component Description PBIB0145E =NAEC1194 Electric Throttle Control Actuator consists of throttle control motor, throttle position sensor, etc. The throttle position sensor responds to the throttle valve movement. The throttle position sensor has the two sensors. These sensors are a kind of potentiometers which transform the throttle valve position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the throttle valve and feed the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening angle properly in response to driving condition. GI MA EM LC FE CL MT CONSULT-II Reference Value in Data Monitor Mode NAEC1195 Specification data are reference values. MONITOR ITEM THRTL SEN2* CONDITION 쐌 Ignition switch: ON (Engine stopped) 쐌 Shift lever: D (A/T model) 1st (M/T model) SPECIFICATION Accelerator pedal: Fully released More than 0.36V Accelerator pedal: Fully depressed Less than 4.75V AX ECM Terminals and Reference Value SU NAEC1201 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. 47 50 WIRE COLOR L BR ITEM Sensor’s power supply (Throttle position sensor) TF PD *: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal. TERMINAL NO. AT CONDITION [Ignition switch “ON”] [Ignition switch “ON”] 쐌 Engine stopped 쐌 Shift lever position is “D” (A/T models) 쐌 Shift lever position is “1st” (M/T models) Throttle position sensor 쐌 Accelerator pedal fully released 1 [Ignition switch “ON”] 쐌 쐌 쐌 쐌 Engine stopped Shift lever position is “D” (A/T models) Shift lever position is “1st” (M/T models) Accelerator pedal fully depressed EC-241 DATA (DC Voltage) Approximately 5V BR ST RS BT HA More than 0.36V SC EL Less than 4.75V IDX DTC P0122, P0123 TP SENSOR ECM Terminals and Reference Value (Cont’d) TERMINAL NO. 66 69 WIRE COLOR BR/Y ITEM CONDITION [Engine is running] 쐌 Warm-up condition 쐌 Idle speed Sensor’s ground BR/W W/R Approximately 0V [Ignition switch “ON”] 쐌 Engine stopped 쐌 Shift lever position is “D” (A/T models) 쐌 Shift lever position is “1st” (M/T models) Throttle position sensor 쐌 Accelerator pedal fully released 2 [Ignition switch “ON”] 쐌 쐌 쐌 쐌 91 DATA (DC Voltage) Sensor’s power supply (APP sensor 2) Less than 4.75V Engine stopped Shift lever position is “D” (A/T models) Shift lever position is “1st” (M/T models) Accelerator pedal fully depressed More than 0.36V [Ignition switch “ON”] Approximately 5V On Board Diagnosis Logic NAEC1196 These self-diagnoses have the one trip detection logic. DTC No. Trouble diagnosis name DTC Detecting Condition P0122 0122 Throttle position sensor 2 circuit low input An excessively low voltage from the TP sensor 2 is sent to ECM. P0123 0123 Throttle position sensor 2 circuit high input An excessively high voltage from the TP sensor 2 is sent to ECM. Possible Cause 쐌 Harness or connectors (The TP sensor 2 circuit is open or shorted.) (APP sensor 2 circuit is shorted.) 쐌 Electric throttle control actuator (TP sensor 2) 쐌 Accelerator pedal position sensor (APP sensor 2) FAIL-SAFE MODE NAEC1196S01 When the malfunction is detected, ECM enters fail-safe mode and the MIL lights up. Engine operation condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. DTC Confirmation Procedure NAEC1197 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. EC-242 DTC P0122, P0123 TP SENSOR DTC Confirmation Procedure (Cont’d) 1) 2) 3) 4) With CONSULT-II Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to “Diagnostic Procedure”, EC-245. GI MA EM LC SEF058Y With GST Follow the procedure “With CONSULT-II” above. FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-243 DTC P0122, P0123 TP SENSOR Wiring Diagram Wiring Diagram NAEC1198 TEC846 EC-244 DTC P0122, P0123 TP SENSOR Diagnostic Procedure Diagnostic Procedure 1 NAEC1199 GI RETIGHTEN GROUND SCREWS MA 1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. EM LC FE SEF959Y 䊳 2 CL GO TO 2. MT CHECK THROTTLE POSITION SENSOR 2 POWER SUPPLY CIRCUIT-I 1. Disconnect electric throttle control actuator harness connector. 2. Turn ignition switch “ON”. AT TF PD AX SEC433D SU 3. Check voltage between electric throttle control actuator terminal 1 and ground with CONSULT-II or tester. BR ST RS BT PBIB0082E Voltage: Approximately 5V OK or NG OK 䊳 GO TO 7. NG 䊳 GO TO 3. HA SC EL IDX EC-245 DTC P0122, P0123 TP SENSOR Diagnostic Procedure (Cont’d) 3 CHECK THROTTLE POSITION SENSOR 2 POWER SUPPLY CIRCUIT-II 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between electric throttle control actuator terminal 1 and ECM terminal 47. Refer to Wiring Diagram. Continuity should exist. OK or NG OK 䊳 GO TO 4. NG 䊳 Repair or replace open circuit. 4 CHECK THROTTLE POSITION SENSOR 2 POWER SUPPLY CIRCUIT-III Check harness for short to power and short to ground, between the following terminals. 쐌 ECM terminal 47 and electric throttle control actuator terminal 1. Refer to “Wiring Diagram”, EC-244. 쐌 ECM terminal 91 and APP sensor terminal 10. Refer to “Wiring Diagram”, EC-718. OK or NG OK 䊳 GO TO 5. NG 䊳 Repair short to ground or short to power in harness or connectors. 5 CHECK APP SENSOR Refer to “Component Inspection”, EC-722. OK or NG OK 䊳 GO TO 11. NG 䊳 GO TO 6. 6 1. 2. 3. 4. REPLACE ACCELERATOR PEDAL ASSEMBLY Replace accelerator pedal assembly. Perform “Accelerator Pedal Released Position Learning”, EC-81. Perform “Throttle Valve Closed Position Learning”, EC-81. Perform “Idle Air Volume Learning”, EC-81. 䊳 7 INSPECTION END CHECK THROTTLE POSITION SENSOR 2 GROUND CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between electric throttle control actuator terminal 5 and ECM terminal 66. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 8. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. EC-246 DTC P0122, P0123 TP SENSOR Diagnostic Procedure (Cont’d) 8 GI CHECK THROTTLE POSITION SENSOR 2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 69 and electric throttle control actuator terminal 2. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. MA EM OK or NG OK 䊳 GO TO 9. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. 9 LC CHECK THROTTLE POSITION SENSOR Refer to “Component Inspection”, EC-247. OK or NG OK 䊳 GO TO 11. NG 䊳 GO TO 10. 10 FE CL REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR MT 1. Replace the electric throttle control actuator. 2. Perform “Throttle Valve Closed Position Learning”, EC-81. 3. Perform “Idle Air Volume Learning”, EC-81. 䊳 11 AT INSPECTION END TF CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 PD INSPECTION END AX SU Component Inspection SEC434D NAEC1200 THROTTLE POSITION SENSOR 1. Reconnect all harness connectors disconnected. 2. Perform “Throttle Valve Closed Position Learning”, EC-81. 3. Turn ignition switch “ON”. 4. Set selector lever to “D” position (A/T models) or “1st” position (M/T models). 5. Check voltage between ECM terminals 50 (TP sensor 1), 69 (TP sensor 2) and engine ground under the following conditions. Terminal Accelerator pedal Voltage 50 (Throttle position sensor 1) Fully released More than 0.36V Fully depressed Less than 4.75V Fully released Less than 4.75V Fully depressed More than 0.36V 69 (Throttle position sensor 2) 6. 7. If NG, replace electric throttle control actuator and go to the next step. Perform “Throttle Valve Closed Position Learning”, EC-81. EC-247 BR ST RS BT HA SC EL IDX DTC P0122, P0123 TP SENSOR Component Inspection (Cont’d) 8. Perform “Idle Air Volume Learning”, EC-81. EC-248 DTC P0125 ECT SENSOR Description Description NAEC0869 NOTE: If DTC P0125 is displayed with P0117, P0118, first perform the trouble diagnosis for DTC P0117, P0118. Refer to EC-236. GI MA EM LC COMPONENT DESCRIPTION NAEC0869S01 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. FE CL MT SEF594K AT Engine coolant temperature °C (°F) SEF012P Voltage* V Resistance kΩ −10 (14) 4.4 9.2 20 (68) 3.5 2.1 - 2.9 50 (122) 2.2 0.68 - 1.00 90 (194) 0.9 0.236 - 0.260 TF PD AX *: These data are reference values and are measured between ECM terminal 73 (Engine coolant temperature sensor) and ground. CAUTION: Do not use ECM ground terminals when measuring input/ output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. SU BR ST RS BT On Board Diagnosis Logic DTC No. P0125 0125 Trouble diagnosis name Insufficient engine coolant temperature for closed loop fuel control DTC Detecting Condition 쐌 Voltage sent to ECM from the sensor is not practical, even when some time has passed after starting the engine. 쐌 Engine coolant temperature is insufficient for closed loop fuel control. NAEC0870 HA Possible Cause 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Engine coolant temperature sensor 쐌 Thermostat SC EL IDX EC-249 DTC P0125 ECT SENSOR DTC Confirmation Procedure DTC Confirmation Procedure NAEC0871 CAUTION: Be careful not to overheat engine. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. WITH CONSULT-II SEF174Y 1) 2) 3) 4) 5) NAEC0871S01 Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Check that “COOLAN TEMP/S” is above 10°C (50°F). If it is above 10°C (50°F), the test result will be OK. If it is below 10°C (50°F), go to following step. Start engine and run it for 65 minutes at idle speed. If “COOLAN TEMP/S” increases to more than 10°C (50°F) within 65 minutes, stop engine because the test result will be OK. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-250. WITH GST NAEC0871S02 Follow the procedure “WITH CONSULT-II” above. Diagnostic Procedure 1 NAEC0872 CHECK ENGINE COOLANT TEMPERATURE SENSOR Check resistance between engine coolant temperature sensor connector terminals 1 and 2 as shown in the figure. SEF304X OK or NG OK 䊳 GO TO 2. NG 䊳 Replace engine coolant temperature sensor. EC-250 DTC P0125 ECT SENSOR Diagnostic Procedure (Cont’d) 2 GI CHECK THERMOSTAT OPERATION When the engine is cold [lower than 70°C (158°F)] condition, grasp lower radiator hose and confirm the engine coolant does not flow. MA OK or NG OK 䊳 GO TO 3. NG 䊳 Repair or replace thermostat. Refer to LC-18, “Thermostat”. 3 EM LC CHECK INTERMITTENT INCIDENT 쐌 Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 쐌 Refer to wiring diagram, EC-238. 䊳 INSPECTION END FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-251 DTC P0127 IAT SENSOR Component Description Component Description NAEC0767 The intake air temperature sensor is mounted to the air duct housing. The sensor detects intake air temperature and transmits a signal to the ECM. The temperature sensing unit uses a thermistor which is sensitive to the change in temperature. Electrical resistance of the thermistor decreases in response to the temperature rise. Intake air temperature °C (°F) Voltage* V Resistance kΩ SEF960YA 25 (77) 3.32 1.9 - 2.1 *: These data are reference values and are measured between ECM terminal 34 (Intake air temperature sensor) and body ground. CAUTION: Do not use ECM ground terminals when measuring input/ output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. SEF012P On Board Diagnosis Logic DTC No. P0127 0127 Trouble diagnosis name DTC Detecting Condition NAEC0768 Possible Cause Intake air temperature Rationally incorrect voltage from the sensor is sent 쐌 Harness or connectors too high to ECM, compared with the voltage signal from (The sensor circuit is open or engine coolant temperature sensor. shorted.) 쐌 Intake air temperature sensor DTC Confirmation Procedure NAEC0770 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. CAUTION: Always drive vehicle at a safe speed. TESTING CONDITION: This test may be conducted with the drive wheels lifted in the shop or by driving the vehicle. If a road test is expected to be easier, it is unnecessary to lift the vehicle. WITH CONSULT-II 1) a) b) c) d) 쐌 SEF176Y 2) NAEC0770S03 Wait until engine coolant temperature is less than 90°C (194°F). Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Check the engine coolant temperature. 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 temperature is above 90°C (194°F). Turn ignition switch “ON”. EC-252 DTC P0127 IAT SENSOR DTC Confirmation Procedure (Cont’d) 3) 4) 5) Select “DATA MONITOR” mode with CONSULT-II. Start engine. Hold vehicle speed at more than 70 km/h (43 MPH) for 100 consecutive seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-253. 6) WITH GST 1 CHECK INTAKE AIR TEMPERATURE SENSOR Refer to “Component Inspection”, EC-230 (Type I), 235 (Type II). OK or NG OK 䊳 GO TO 2. NG 䊳 Replace mass air flow sensor (with intake air temperature sensor). 2 MA EM NAEC0770S04 Follow the procedure “With CONSULT-II” above. Diagnostic Procedure GI LC NAEC0772 FE CL MT CHECK INTERMITTENT INCIDENT 쐌 Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 쐌 Refer to wiring diagram, EC-228 (Type I), 233 (Type II). 䊳 INSPECTION END AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-253 DTC P0128 THERMOSTAT FUNCTION On Board Diagnosis Logic On Board Diagnosis Logic NAEC1202 Engine coolant temperature has not risen enough to open the thermostat even though the engine has run long enough. This is due to a leak in the seal or the thermostat open stuck. DTC No. P0128 0128 Trouble diagnosis name Thermostat function DTC Detecting Condition Possible Cause The engine coolant temperature does not reach to 쐌 Thermostat specified temperature even though the engine has 쐌 Leakage from sealing portion of therrun long enough. mostat 쐌 Engine coolant temperature sensor DTC Confirmation Procedure NAEC1203 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: 쐌 For best results, perform at ambient temperature of –10°C (14°F) or higher. 쐌 For best results, perform at engine coolant temperature of –10°C (14°F) to 65°C (149°F). WITH CONSULT-II 1) 2) 3) 4) 5) NAEC1203S01 Replace thermostat with new one. Refer to LC-18, “Thermostat”. Use only a genuine NISSAN thermostat as a replacement. If an incorrect thermostat is used, the MIL may come on. Turn ignition switch “ON”. Select “COOLAN TEMP/S” in “DATA MONITOR” mode with CONSULT-II. Check that the “COOLAN TEMP/S” is above 60°C (140°F). If it is below 65°C (149°F), go to following step. If it is above 65°C (149°F), cool down the engine to less than 65°C (149°F), then retry from step 1. Drive vehicle for 10 consecutive minutes under the following conditions. VHCL SPEED SE 80 - 120 km/h (50 - 75 MPH) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-255. WITH GST 1) Follow the prodedure “WITH CONSULT-II” above. EC-254 NAEC1203S02 DTC P0128 THERMOSTAT FUNCTION Diagnostic Procedure Diagnostic Procedure 1 NAEC1204 GI CHECK ENGINE COOLANT TEMPERATURE SENSOR MA 1. Turn ignition switch OFF. 2. Remove engine coolant temperature sensor. 3. Check resistance between engine coolant temperature sensor terminals under the following conditions. EM LC FE CL MT AT SEF304X OK or NG OK 䊳 INSPECTION END NG 䊳 Replace engine coolant temperature sensor. TF PD AX SU BR ST RS BT HA SC EL IDX EC-255 DTC P0132, P0152 HO2S1 Component Description Component Description NAEC0873 The heated oxygen sensor 1 is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. SEF463R SEF288D CONSULT-II Reference Value in Data Monitor Mode NAEC0874 Specification data are reference values. MONITOR ITEM CONDITION SPECIFICATION HO2S1 (B1) HO2S1 (B2) HO2S1 MNTR (B1) HO2S1 MNTR (B2) 0 - 0.3V +, Approx. 0.6 - 1.0V 쐌 Engine: After warming up Maintaining engine speed at 2,000 rpm LEAN +, RICH Changes more than 5 times during 10 seconds. ECM Terminals and Reference Value NAEC0875 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) 16 G/B Heated oxygen sensor 1 (bank 2) [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm. 0 - Approximately 1.0V (Periodically change) 35 G Heated oxygen sensor 1 (bank 1) [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm. 0 - Approximately 1.0V (Periodically change) EC-256 DTC P0132, P0152 HO2S1 On Board Diagnosis Logic On Board Diagnosis Logic NAEC0876 To judge the malfunction, the diagnosis checks that the heated oxygen sensor 1 output is not inordinately high. GI MA EM LC SEF301UA DTC No. P0132 0132 (Bank 1) P0152 0152 (Bank 2) Trouble diagnosis name DTC Detecting Condition Heated oxygen senAn excessively high voltage from the sensor is sor 1 circuit high volt- sent to ECM. age Possible Cause FE 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Heated oxygen sensor 1 CL MT DTC Confirmation Procedure AT NAEC0877 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. WITH CONSULT-II SEF174Y 1) 2) 3) 4) 5) 6) PD NAEC0877S01 Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF” and wait at least 10 seconds. Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Restart engine and let it idle for 2 minutes. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-260. WITH GST 1) 2) 3) 4) 5) 6) 7) 쐌 TF NAEC0877S02 Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF” and wait at least 10 seconds. Restart engine and let it idle for 2 minutes. Turn ignition switch “OFF” and wait at least 10 seconds. Restart engine and let it idle for 2 minutes. Select “MODE 3” with GST. If DTC is detected, go to “Diagnostic Procedure”, EC-260. When using GST, “DTC Confirmation Procedure” should be performed twice as much as when using CONSULT-II because GST cannot display MODE 7 (1st trip DTC) concerning this diagnosis. Therefore, using CONSULT-II is recommended. AX SU BR ST RS BT HA SC EL IDX EC-257 DTC P0132, P0152 HO2S1 Wiring Diagram Wiring Diagram BANK 1 NAEC0878 NAEC0878S01 MEC087E EC-258 DTC P0132, P0152 HO2S1 Wiring Diagram (Cont’d) BANK 2 NAEC0878S02 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC088E EC-259 IDX DTC P0132, P0152 HO2S1 Diagnostic Procedure Diagnostic Procedure 1 NAEC0879 INSPECTION START 1. Turn ignition switch “OFF”. 2. Disconnect corresponding heated oxygen sensor 1 harness connector. SEC426D SEC427D 䊳 2 GO TO 2. RETIGHTEN HEATED OXYGEN SENSOR 1 Loosen and retighten corresponding heated oxygen sensor 1. Tightening torque: 40 - 60 N·m (4.1 - 6.1 kg-m, 30 - 44 ft-lb) 䊳 3 GO TO 3. CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between HO2S1 terminal 4 and engine ground. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to power. OK or NG OK 䊳 GO TO 4. NG 䊳 Repair open circuit or short to power in harness or connectors. EC-260 DTC P0132, P0152 HO2S1 Diagnostic Procedure (Cont’d) 4 GI CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal and HO2S1 terminal as follows. Refer to Wiring Diagram. MA EM LC MTBL1354 Continuity should exist. 3. Check harness continuity between ECM terminal or HO2S1 terminal and ground as follows. Refer to Wiring Diagram. FE CL MTBL1355 Continuity should not exist. 4. Also check harness for short to power. MT OK or NG AT OK 䊳 GO TO 5. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. TF 5 CHECK HO2S1 CONNECTOR FOR WATER 1. Disconnect heated oxygen sensor 1 harness connector. 2. Check connectors for water. Water should not exist. OK or NG PD AX OK (With CONSULT-II) 䊳 GO TO 6. OK (Without CONSULTII) 䊳 GO TO 7. SU NG 䊳 Repair or replace harness or connectors. BR ST RS BT HA SC EL IDX EC-261 DTC P0132, P0152 HO2S1 Diagnostic Procedure (Cont’d) 6 1. 2. 3. 4. 5. CHECK HEATED OXYGEN SENSOR 1 With CONSULT-II Start engine and warm it up to normal operating temperature. Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULT-II. Select “HO2S1 (B1)/(B2)” and “HO2S1 MNTR (B1)/(B2)”. Hold engine speed at 2,000 rpm under no load during the following steps. Touch “RECORD” on CONSULT-II screen. SEF967Y 6. Check the following. 쐌 “HO2S1 MNTR (B1)/(B2)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds. 5 times (cycles) are counted as shown left: SEF647Y 쐌 “HO2S1 (B1)/(B2)” voltage goes above 0.6V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage goes below 0.3V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage never exceeds 1.0V. SEF648Y CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK 䊳 GO TO 8. NG 䊳 Replace malfunctioning heated oxygen sensor 1. EC-262 DTC P0132, P0152 HO2S1 Diagnostic Procedure (Cont’d) 7 GI CHECK HEATED OXYGEN SENSOR 1 Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Set voltmeter probes between ECM terminal 35 (HO2S1 bank 1 signal) or 16 (HO2S1 bank 2 signal) and engine ground. 3. Check the following with engine speed held at 2,000 rpm constant under no load. MA EM LC FE SEC430D 쐌 쐌 쐌 쐌 The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than 5 times within 10 seconds. The maximum voltage is over 0.6V at least one time. The minimum voltage is below 0.3V at least one time. The voltage never exceeds 1.0V. 1 time: 0 - 0.3V , 0.6 - 1.0V , 0 - 0.3V 2 times: 0 - 0.3V , 0.6 - 1.0V , 0 - 0.3V , 0.6 - 1.0V , 0 - 0.3V CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK 䊳 GO TO 8. NG 䊳 Replace malfunctioning heated oxygen sensor 1. 8 CHECK INTERMITTENT INCIDENT CL MT AT TF PD AX SU Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END BR ST RS BT HA SC EL IDX EC-263 DTC P0133, P0153 HO2S1 Component Description Component Description NAEC0880 The heated oxygen sensor 1 is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. SEF463R SEF288D CONSULT-II Reference Value in Data Monitor Mode NAEC0881 Specification data are reference values. MONITOR ITEM CONDITION SPECIFICATION HO2S1 (B1) HO2S1 (B2) HO2S1 MNTR (B1) HO2S1 MNTR (B2) 0 - 0.3V +, Approx. 0.6 - 1.0V 쐌 Engine: After warming up Maintaining engine speed at 2,000 rpm LEAN +, RICH Changes more than 5 times during 10 seconds. ECM Terminals and Reference Value NAEC0882 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) 16 G/B Heated oxygen sensor 1 (bank 2) [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm. 0 - Approximately 1.0V (Periodically change) 35 G Heated oxygen sensor 1 (bank 1) [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm. 0 - Approximately 1.0V (Periodically change) EC-264 DTC P0133, P0153 HO2S1 On Board Diagnosis Logic On Board Diagnosis Logic NAEC0883 To judge the malfunction of heated oxygen sensor 1, this diagnosis measures response time of heated oxygen sensor 1 signal. The time is compensated by engine operating (speed and load), fuel feedback control constant, and heated oxygen sensor 1 temperature index. Judgment is based on whether the compensated time [heated oxygen sensor 1 cycling time index] is inordinately long or not. GI MA EM LC SEF010V DTC No. P0133 0133 (Bank 1) P0153 0153 (Bank 2) Trouble diagnosis name Heated oxygen sensor 1 circuit slow response DTC Detecting Condition The response of the voltage signal from the sensor takes more than the specified time. Possible Cause FE 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Heated oxygen sensor 1 쐌 Fuel pressure 쐌 Injectors 쐌 Intake air leaks 쐌 Exhaust gas leaks 쐌 PCV valve 쐌 Mass air flow sensor CL MT AT TF PD AX SU DTC Confirmation Procedure NAEC0884 CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: 쐌 Always perform at a temperature above −10°C (14°F). 쐌 Before performing the following procedure, confirm that battery voltage is more than 11V at idle. BR ST RS BT HA SC EL IDX EC-265 DTC P0133, P0153 HO2S1 DTC Confirmation Procedure (Cont’d) WITH CONSULT-II NAEC0884S01 1) 2) 3) SEF338Z Start engine and warm it up to normal operating temperature. Stop engine and wait at least 10 seconds. Turn ignition switch “ON” and select “HO2S1 (B1)/(B2) P0133/ P0153” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 3 minutes. NOTE: Never raise engine speed above 3,600 rpm after this step. If the engine speed limit is exceeded, return to step 5. 6) When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 40 to 50 seconds.) ENG SPEED 1,600 - 3,100 rpm Vehicle speed More than 80 km/h (50 MPH) B/FUEL SCHDL 5 - 12 msec Selector lever Suitable position SEF339Z 7) If “TESTING” is not displayed after 5 minutes, retry from step 2. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-269. SEF658Y Overall Function Check NAEC0885 Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a DTC might not be confirmed. WITH GST 1) 2) 3) SEC430D 쐌 4) NAEC0885S01 Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 35 (HO2S1 bank 1 signal) or 16 (HO2S1 bank 2 signal) and engine ground. Check the following with engine speed held at 2,000 rpm constant under no load. The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than 5 times within 10 seconds. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V If NG, go to “Diagnostic Procedure”, EC-269. EC-266 DTC P0133, P0153 HO2S1 Wiring Diagram Wiring Diagram BANK 1 NAEC0886 GI NAEC0886S01 MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC087E EC-267 IDX DTC P0133, P0153 HO2S1 Wiring Diagram (Cont’d) BANK 2 NAEC0886S02 MEC088E EC-268 DTC P0133, P0153 HO2S1 Diagnostic Procedure Diagnostic Procedure 1 NAEC0887 GI RETIGHTEN GROUND SCREWS MA 1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. EM LC FE SEF959Y 䊳 CL GO TO 2. RETIGHTEN HEATED OXYGEN SENSOR 1 MT Loosen and retighten corresponding heated oxygen sensor 1. Tightening torque: 40 - 60 N·m (4.1 - 6.1 kg-m, 30 - 44 ft-lb) AT 2 䊳 3 TF GO TO 3. PD CHECK FOR EXHAUST GAS LEAK 1. Start engine and run it at idle. 2. Listen for an exhaust gas leak before three way catalyst (manifold). AX SU BR ST SEC635D OK or NG OK 䊳 GO TO 4. NG 䊳 Repair or replace. 4 RS BT HA CHECK FOR INTAKE AIR LEAK Listen for an intake air leak after the mass air flow sensor. OK or NG OK 䊳 GO TO 5. NG 䊳 Repair or replace. SC EL IDX EC-269 DTC P0133, P0153 HO2S1 Diagnostic Procedure (Cont’d) 5 CLEAR THE SELF-LEARNING DATA With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “CLEAR”. SEF968Y 4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171, P0172, P0174 or P0175 detected? Is it difficult to start engine? 1. 2. 3. 4. 5. 6. 7. 8. Without CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF”. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 5 seconds at idle speed. Stop engine and reconnect mass air flow sensor harness connector. Make sure DTC P0102 is displayed. Erase the DTC memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-100. Make sure DTC P0000 is displayed. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171, P0172, P0174 or P0175 detected? Is it difficult to start engine? Yes or No Yes 䊳 Perform trouble diagnosis for DTC P0171, P0174 or P0172, P0175. Refer to EC-304, 312. No 䊳 GO TO 6. EC-270 DTC P0133, P0153 HO2S1 Diagnostic Procedure (Cont’d) 6 GI CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Disconnect corresponding heated oxygen sensor 1 harness connector. MA EM LC SEC426D FE CL MT AT SEC427D 3. Check harness continuity between HO2S1 terminal 4 and engine ground. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to power. OK or NG OK 䊳 GO TO 7. NG 䊳 Repair open circuit or short to power in harness or connectors. TF PD AX SU BR ST RS BT HA SC EL IDX EC-271 DTC P0133, P0153 HO2S1 Diagnostic Procedure (Cont’d) 7 CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal and HO2S1 terminal as follows. Refer to Wiring Diagram. MTBL1356 Continuity should exist. 3. Check harness continuity between ECM terminal or HO2S1 terminal and ground as follows. Refer to Wiring Diagram. MTBL1357 Continuity should not exist. 4. Also check harness for short to power. OK or NG OK 䊳 GO TO 8. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. EC-272 DTC P0133, P0153 HO2S1 Diagnostic Procedure (Cont’d) 8 GI CHECK HEATED OXYGEN SENSOR 1 HEATER Check resistance between HO2S1 terminals as follows. MA EM LC FE CL MT AT SEF249Y TF PD MTBL1782 CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK 䊳 GO TO 9. NG 䊳 GO TO 13. AX SU BR ST RS BT HA SC EL IDX EC-273 DTC P0133, P0153 HO2S1 Diagnostic Procedure (Cont’d) 9 CHECK MASS AIR FLOW SENSOR 1. Reconnect harness connectors disconnected. 2. Start engine and warm it up to normal operating temperature. 3. Check voltage between ECM terminal 51 (Mass air flow sensor signal) and ground. SEF100V MTBL1807 4. If the voltage is out of specification, disconnect mass air flow sensor harness connector and connect it again. Then repeat above check. OK or NG OK 䊳 GO TO 10. NG 䊳 Replace mass air flow sensor. EC-274 DTC P0133, P0153 HO2S1 Diagnostic Procedure (Cont’d) 10 1. 2. 3. 4. GI CHECK PCV VALVE Install all removed parts. Start engine and let it idle. Remove PCV valve ventilation hose from PCV valve. Make sure that a hissing noise will be heard as air passes through it and a strong vacuum should be felt immediately when a finger is placed over valve inlet. MA EM LC FE PBIB1589E CL OK or NG OK (With CONSULT-II) 䊳 GO TO 11. OK (Without CONSULTII) 䊳 GO TO 12. NG 䊳 Replace PCV valve. MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-275 DTC P0133, P0153 HO2S1 Diagnostic Procedure (Cont’d) 11 1. 2. 3. 4. 5. CHECK HEATED OXYGEN SENSOR 1 With CONSULT-II Start engine and warm it up to normal operating temperature. Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULT-II. Select “HO2S1 (B1)/(B2)” and “HO2S1 MNTR (B1)/(B2)”. Hold engine speed at 2,000 rpm under no load during the following steps. Touch “RECORD” on CONSULT-II screen. SEF967Y 6. Check the following. 쐌 “HO2S1 MNTR (B1)/(B2)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown below. SEF647Y 쐌 “HO2S1 (B1)/(B2)” voltage goes above 0.6V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage goes below 0.3V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage never exceeds 1.0V. SEF648Y CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK 䊳 GO TO 13. NG 䊳 Replace malfunctioning heated oxygen sensor 1. EC-276 DTC P0133, P0153 HO2S1 Diagnostic Procedure (Cont’d) 12 GI CHECK HEATED OXYGEN SENSOR 1 Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Set voltmeter probes between ECM terminal 35 (HO2S1 bank 1 signal) or 16 (HO2S1 bank 2 signal) and engine ground. 3. Check the following with engine speed held at 2,000 rpm constant under no load. MA EM LC FE SEC430D 쐌 쐌 쐌 쐌 The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than 5 times within 10 seconds. The maximum voltage is over 0.6V at least one time. The minimum voltage is below 0.3V at least one time. The voltage never exceeds 1.0V. 1 time: 0 - 0.3V , 0.6 - 1.0V , 0 - 0.3V 2 times: 0 - 0.3V , 0.6 - 1.0V , 0 - 0.3V , 0.6 - 1.0V , 0 - 0.3V CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK 䊳 GO TO 13. NG 䊳 Replace malfunctioning heated oxygen sensor 1. 13 CHECK INTERMITTENT INCIDENT CL MT AT TF PD AX SU Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END BR ST RS BT HA SC EL IDX EC-277 DTC P0134, P0154 HO2S1 Component Description Component Description NAEC0888 The heated oxygen sensor 1 is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. SEF463R SEF288D CONSULT-II Reference Value in Data Monitor Mode NAEC0889 Specification data are reference values. MONITOR ITEM CONDITION SPECIFICATION HO2S1 (B1) HO2S1 (B2) HO2S1 MNTR (B1) HO2S1 MNTR (B2) 0 - 0.3V +, Approx. 0.6 - 1.0V 쐌 Engine: After warming up Maintaining engine speed at 2,000 rpm LEAN +, RICH Changes more than 5 times during 10 seconds. ECM Terminals and Reference Value NAEC0890 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) 16 G/B Heated oxygen sensor 1 (bank 2) [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm. 0 - Approximately 1.0V (Periodically change) 35 G Heated oxygen sensor 1 (bank 1) [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm. 0 - Approximately 1.0V (Periodically change) EC-278 DTC P0134, P0154 HO2S1 On Board Diagnosis Logic On Board Diagnosis Logic NAEC0891 Under the condition in which the heated oxygen sensor 1 signal is not input, the ECM circuits will read a continuous approximately 0.3V. Therefore, for this diagnosis, the time that output voltage is within 200 to 400 mV range is monitored, and the diagnosis checks that this time is not inordinately long. GI MA EM LC SEF237U DTC No. P0134 0134 (Bank 1) P0154 0154 (Bank 2) Trouble diagnosis name Heated oxygen sensor 1 circuit no activity detected DTC Detecting Condition Possible Cause The voltage from the sensor is constantly approx. 0.3V. FE 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Heated oxygen sensor 1 CL MT DTC Confirmation Procedure AT NAEC0892 CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 11V at idle. SEC748C WITH CONSULT-II SEC750C Start engine and warm it up to normal operating temperature. Select “HO2S1 (B1)/(B2) P0134/P0154” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II. 3) Touch “START”. 4) Let it idle for at least 3 minutes. NOTE: Never raise engine speed above 3,600 rpm after this step. If the engine speed limit is exceeded, return to step 4. 5) When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 10 to 60 seconds.) ENG SPEED 1,500 - 2,800 rpm Vehicle speed More than 64 km/h (40 MPH) B/FUEL SCHDL 3.0 - 14 msec Selector lever Suitable position 6) If “TESTING” is not displayed after 5 minutes, retry from step 2. Make sure that “OK” is displayed after touching “SELF-DIAG EC-279 PD AX SU NAEC0892S01 1) 2) SEC749C TF BR ST RS BT HA SC EL IDX DTC P0134, P0154 HO2S1 DTC Confirmation Procedure (Cont’d) RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-283. During this test, P1148 and P1168 may be stored in ECM. Overall Function Check NAEC0893 Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a DTC might not be confirmed. WITH GST 1) 2) 3) SEC430D 쐌 4) NAEC0893S01 Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 35 (HO2S1 bank 1 signal) or 16 (HO2S1 bank 2 signal) and engine ground. Check the following with engine speed held at 2,000 rpm constant under no load. The voltage does not remain in the range of 0.2 to 0.4V. If NG, go to “Diagnostic Procedure”, EC-283. EC-280 DTC P0134, P0154 HO2S1 Wiring Diagram Wiring Diagram BANK 1 =NAEC0894 GI NAEC0894S01 MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC087E EC-281 IDX DTC P0134, P0154 HO2S1 Wiring Diagram (Cont’d) BANK 2 NAEC0894S02 MEC088E EC-282 DTC P0134, P0154 HO2S1 Diagnostic Procedure Diagnostic Procedure 1 NAEC0895 GI CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT MA 1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. EM LC FE SEF959Y 3. Disconnect corresponding heated oxygen sensor 1 harness connector. CL MT AT TF SEC426D PD AX SU BR SEC427D 4. Check harness continuity between HO2S1 terminal 4 and engine ground. Refer to Wiring Diagram. Continuity should exist. 5. Also check harness for short to power. ST RS OK or NG BT OK 䊳 GO TO 2. NG 䊳 Repair open circuit or short to power in harness or connectors. HA SC EL IDX EC-283 DTC P0134, P0154 HO2S1 Diagnostic Procedure (Cont’d) 2 CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal and HO2S1 terminal as follows. Refer to Wiring Diagram. MTBL1358 Continuity should exist. 3. Check harness continuity between ECM terminal or HO2S1 terminal and ground as follows. Refer to Wiring Diagram. MTBL1359 Continuity should not exist. 4. Also check harness for short to power. OK or NG OK (With CONSULT-II) 䊳 GO TO 3. OK (Without CONSULTII) 䊳 GO TO 4. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. EC-284 DTC P0134, P0154 HO2S1 Diagnostic Procedure (Cont’d) 3 1. 2. 3. 4. 5. GI CHECK HEATED OXYGEN SENSOR 1 With CONSULT-II Start engine and warm it up to normal operating temperature. Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULT-II. Select “HO2S1 (B1)/(B2)” and “HO2S1 MNTR (B1)/(B2)”. Hold engine speed at 2,000 rpm under no load during the following steps. Touch “RECORD” on CONSULT-II screen. MA EM LC FE SEF967Y 6. Check the following. 쐌 “HO2S1 MNTR (B1)/(B2)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown below. CL MT AT TF PD SEF647Y 쐌 “HO2S1 (B1)/(B2)” voltage goes above 0.6V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage goes below 0.3V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage never exceeds 1.0V. AX SU BR ST RS SEF648Y CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK 䊳 GO TO 5. NG 䊳 Replace malfunctioning heated oxygen sensor 1. BT HA SC EL IDX EC-285 DTC P0134, P0154 HO2S1 Diagnostic Procedure (Cont’d) 4 CHECK HEATED OXYGEN SENSOR 1 Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Set voltmeter probes between ECM terminal 35 (HO2S1 bank 1 signal) or 16 (HO2S1 bank 2 signal) and engine ground. 3. Check the following with engine speed held at 2,000 rpm constant under no load. SEC430D 쐌 쐌 쐌 쐌 The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than 5 times within 10 seconds. The maximum voltage is over 0.6V at least one time. The minimum voltage is below 0.3V at least one time. The voltage never exceeds 1.0V. 1 time: 0 - 0.3V , 0.6 - 1.0V , 0 - 0.3V 2 times: 0 - 0.3V , 0.6 - 1.0V , 0 - 0.3V , 0.6 - 1.0V , 0 - 0.3V CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK 䊳 GO TO 5. NG 䊳 Replace malfunctioning heated oxygen sensor 1. 5 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-286 DTC P0138, P0158 HO2S2 Component Description Component Description SEF327R NAEC0896 The heated oxygen sensor 2, after three way catalyst (manifold), monitors the oxygen level in the exhaust gas on each bank. Even if switching characteristics of the heated oxygen sensor 1 are shifted, the air-fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2. This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 is not used for engine control operation. GI MA EM LC CONSULT-II Reference Value in Data Monitor Mode NAEC0897 Specification data are reference values. MONITOR ITEM HO2S2 (B1) HO2S2 (B2) HO2S2 MNTR (B1) HO2S2 MNTR (B2) CONDITION 쐌 Engine: After warming up 쐌 After keeping engine speed between 3,500 and 4,000 rpm for one minute and at idle for one minute under no load SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V Revving engine from idle up to 3,000 rpm LEAN +, RICH AT ECM Terminals and Reference Value 55 74 WIRE COLOR OR/L OR CL MT NAEC0898 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. FE ITEM CONDITION Heated oxygen sensor 2 (bank 2) Heated oxygen sensor 2 (bank 1) [Engine is running] 쐌 Warm-up condition 쐌 Revving engine from idle up to 3,000 rpm after 0 - Approximately 1.0V the following conditions are met. 쐌 After keeping the engine speed between 3,500 and 4,000 rpm for one minute and at idle for one minute under no load On Board Diagnosis Logic PD AX DATA (DC Voltage) [Engine is running] 쐌 Warm-up condition 쐌 Revving engine from idle up to 3,000 rpm after the following conditions are met. 0 - Approximately 1.0V 쐌 After keeping the engine speed between 3,500 and 4,000 rpm for one minute and at idle for one minute under no load TF SU BR ST RS BT NAEC0899 The heated oxygen sensor 2 has a much longer switching time between rich and lean than the heated oxygen sensor 1. The oxygen storage capacity before the three way catalyst (manifold) causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2, ECM monitors whether the voltage is unusually high during the various driving condition such as fuel-cut. HA SC EL IDX SEF305UA EC-287 DTC P0138, P0158 HO2S2 On Board Diagnosis Logic (Cont’d) DTC No. P0138 0138 (Bank 1) P0158 0158 (Bank 2) Trouble diagnosis name DTC Detecting Condition Heated oxygen senAn excessively high voltage from the sensor is sor 2 circuit high volt- sent to ECM. age Possible Cause 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Heated oxygen sensor 2 DTC Confirmation Procedure NAEC0900 CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1) SEF189Y 2) 3) 4) 5) 6) WITH GST 1) 2) 3) 4) 5) 6) 7) 8) 9) 쐌 NAEC0900S01 Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to the normal operating temperature. Turn ignition switch “OFF” and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least one minute under no load. Let engine idle for two minutes. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-291. NAEC0900S02 Start engine and warm it up to the normal operating temperature. Turn ignition switch “OFF” and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least one minute under no load. Let engine idle for two minutes. Turn ignition switch “OFF” and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least one minute under no load. Let engine idle for two minutes. Select “Mode 3” with GST. If DTC is detected, go to EC-291, “Diagnostic Procedure”. When using GST, “DTC Confirmation Procedure” should be performed twice as much as when using CONSULT-II because GST cannot display MODE 7 (1st trip DTC) concerning this diagnosis. Therefore, using CONSULT-II is recommended. EC-288 DTC P0138, P0158 HO2S2 Wiring Diagram Wiring Diagram BANK 1 NAEC0902 GI NAEC0902S01 MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC089E EC-289 IDX DTC P0138, P0158 HO2S2 Wiring Diagram (Cont’d) BANK 2 NAEC0902S02 MEC090E EC-290 DTC P0138, P0158 HO2S2 Diagnostic Procedure Diagnostic Procedure 1 NAEC0903 GI INSPECTION START MA 1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. EM LC FE SEF959Y 3. Disconnect corresponding heated oxygen sensor 2 harness connector. CL MT AT TF SEC426D PD AX SU BR SEC427D 4. Disconnect ECM harness connector. 䊳 ST GO TO 2. RS BT HA SC EL IDX EC-291 DTC P0138, P0158 HO2S2 Diagnostic Procedure (Cont’d) 2 CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal and HO2S2 terminal as follows. Refer to Wiring Diagram. MTBL1360 Continuity should exist. 2. Check harness continuity between ECM terminal or HO2S2 terminal and ground as follows. Refer to Wiring Diagram. MTBL1361 Continuity should not exist. 3. Also check harness for short to power. OK or NG OK 䊳 GO TO 3. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. 3 CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between HO2S2 terminal 4 and engine ground. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to power. OK or NG OK 䊳 GO TO 4. NG 䊳 Repair open circuit or short to power in harness or connectors. 4 CHECK HO2S2 CONNECTORS FOR WATER Check heated oxygen sensor 2 connector and harness connector for water. Water should not exist. OK or NG OK (With CONSULT-II) 䊳 GO TO 5. OK (Without CONSULTII) 䊳 GO TO 6. NG 䊳 Repair or replace harness or connectors. EC-292 DTC P0138, P0158 HO2S2 Diagnostic Procedure (Cont’d) 5 GI CHECK HEATED OXYGEN SENSOR 2 With CONSULT-II Start engine and warm it up to the normal operating temperature. Turn ignition switch “ON” and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least one minute under no load. Let engine idle for one minute. Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)/(B2)” as the monitor item with CONSULTII. 6. Check “HO2S2 (B1)/(B2)” at idle speed when adjusting “FUEL INJECTION” to ±25%. 1. 2. 3. 4. 5. MA EM LC FE CL SEF972YA “HO2S2 (B1)/(B2)” should be above 0.68V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)/(B2)” should be below 0.48V at least once when the “FUEL INJECTION” is −25%. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. MT AT TF OK or NG PD OK 䊳 GO TO 8. NG 䊳 Replace malfunctioning heated oxygen sensor 2. AX SU BR ST RS BT HA SC EL IDX EC-293 DTC P0138, P0158 HO2S2 Diagnostic Procedure (Cont’d) 6 CHECK HEATED OXYGEN SENSOR 2-I Without CONSULT-II Start engine and warm it up to the normal operating temperature. Turn ignition switch “ON” and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least one minute under no load. Let engine idle for one minute. Set voltmeter probes between ECM terminal 74 (HO2S2 bank 1 signal) or 55 (HO2S2 bank 2 signal) and engine ground. 6. Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) 1. 2. 3. 4. 5. SEC432D The voltage should be above 0.68V at least once during this procedure. OK or NG OK 䊳 GO TO 8. NG 䊳 GO TO 7. 7 CHECK HEATED OXYGEN SENSOR 2-II Idle vehicle for 10 minutes, then check voltage between the same terminals as in Test No. 6; or check voltage when coasting from 80 km/h (50 MPH) in 3rd gear position (M/T), “D” position with “OD” OFF (A/T). The voltage should go below 0.48V at least once during this procedure. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK 䊳 GO TO 8. NG 䊳 Replace malfunctioning heated oxygen sensor 2. 8 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-294 DTC P0139, P0159 HO2S2 Component Description Component Description SEF327R NAEC0904 The heated oxygen sensor 2, after three way catalyst (manifold), monitors the oxygen level in the exhaust gas on each bank. Even if switching characteristics of the heated oxygen sensor 1 are shifted, the air-fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2. This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 is not used for engine control operation. GI MA EM LC CONSULT-II Reference Value in Data Monitor Mode NAEC0905 Specification data are reference values. MONITOR ITEM HO2S2 (B1) HO2S2 (B2) HO2S2 MNTR (B1) HO2S2 MNTR (B2) CONDITION 쐌 Engine: After warming up 쐌 After keeping engine speed between 3,500 and 4,000 rpm for one minute and at idle for one minute under no load SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V Revving engine from idle up to 3,000 rpm LEAN +, RICH AT ECM Terminals and Reference Value 55 74 WIRE COLOR OR/L OR CL MT NAEC0906 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. FE ITEM CONDITION Heated oxygen sensor 2 (bank 2) Heated oxygen sensor 2 (bank 1) [Engine is running] 쐌 Warm-up condition 쐌 Revving engine from idle up to 3,000 rpm after 0 - Approximately 1.0V the following conditions are met. 쐌 After keeping the engine speed between 3,500 and 4,000 rpm for one minute and at idle for one minute under no load On Board Diagnosis Logic PD AX DATA (DC Voltage) [Engine is running] 쐌 Warm-up condition 쐌 Revving engine from idle up to 3,000 rpm after the following conditions are met. 0 - Approximately 1.0V 쐌 After keeping the engine speed between 3,500 and 4,000 rpm for one minute and at idle for one minute under no load TF SU BR ST RS BT NAEC0907 The heated oxygen sensor 2 has a much longer switching time between rich and lean than the heated oxygen sensor 1. The oxygen storage capacity before the three way catalyst (manifold) causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2, ECM monitors whether the switching response of the sensor’s voltage is faster than specified during the various driving condition such as fuel-cut. HA SC EL IDX SEF302U EC-295 DTC P0139, P0159 HO2S2 On Board Diagnosis Logic (Cont’d) DTC No. P0139 0139 (Bank 1) P0159 0159 (Bank 2) Trouble diagnosis name Heated oxygen sensor 2 circuit slow response DTC Detecting Condition It takes more time for the sensor to respond between rich and lean than the specified time. Possible Cause 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Heated oxygen sensor 2 쐌 Fuel pressure 쐌 Injectors 쐌 Intake air leaks DTC Confirmation Procedure NAEC0908 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: 쐌 Open engine hood before conducting following procedure. 쐌 For the best results, perform “DTC WORK SUPPORT” at a temperature of 0 to 30°C (32 to 86°F). SEF666Y WITH CONSULT-II 1) 2) 3) 4) 5) SEF667Y 6) 7) a) b) c) d) SEF668Y NAEC0908S01 Start engine and warm it up to the normal operating temperature. Turn ignition switch “OFF” and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least one minute under no load. Let engine idle for one minute. Select “HO2S2 (B1) P0139” or “HO2S2 (B2) P0159” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II. Follow the instruction of CONSULT-II. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If NG is displayed, refer to EC-300, “Diagnostic Procedure”. If “CAN NOT BE DIAGNOSED” is displayed, perform the following. Turn ignition switch “OFF” and leave the vehicle in a cool place (soak the vehicle). Turn ignition switch “ON” and select “COOLAN TEMP/S” in “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up while monitoring “COOLAN TEMP/S” indication on CONSULT-II. When “COOLAN TEMP/S” indication reaches to 70°C (158°F), go to step 3. Overall Function Check NAEC0909 Use this procedure to check the overall function of the rear heated oxygen sensor circuit. During this check, a DTC might not be confirmed. WITH GST 1) 2) 3) SEC432D NAEC0909S01 Start engine and warm it up to the normal operating temperature. Turn ignition switch “OFF” and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least one minute under no load. EC-296 DTC P0139, P0159 HO2S2 Overall Function Check (Cont’d) 4) 5) 6) 7) 8) Let engine idle for one minute. Set voltmeter probes between ECM terminal 74 (HO2S2 bank 1 signal) or 55 (HO2S2 bank 2 signal) and engine ground. Check the voltage when racing up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) A change of voltage should be more than 0.06V for 1 second during this procedure. If the voltage can be confirmed in step 6, step 7 is not necessary. 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 (M/T), “D” position with “OD” OFF (A/T). A change of voltage should be more than 0.06V for 1 second during this procedure. If NG, go to “Diagnostic Procedure”, EC-300. GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-297 DTC P0139, P0159 HO2S2 Wiring Diagram Wiring Diagram BANK 1 =NAEC0910 NAEC0910S01 MEC089E EC-298 DTC P0139, P0159 HO2S2 Wiring Diagram (Cont’d) BANK 2 NAEC0910S02 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC090E EC-299 IDX DTC P0139, P0159 HO2S2 Diagnostic Procedure Diagnostic Procedure 1 NAEC0911 RETIGHTEN GROUND SCREWS 1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. SEF959Y 䊳 2 GO TO 2. CLEAR THE SELF-LEARNING DATA With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “CLEAR”. SEF968Y 4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171, P0172, P0174 or P0175 detected? Is it difficult to start engine? 1. 2. 3. 4. 5. 6. 7. 8. Without CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF”. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 5 seconds at idle speed. Stop engine and reconnect mass air flow sensor harness connector. Make sure DTC No. P0102 is displayed. Erase the DTC memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-100. Make sure DTC No. P0000 is displayed. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171, P0172, P0174 or P0175 detected? Is it difficult to start engine? Yes or No Yes 䊳 Perform trouble diagnosis for DTC P0171, P0174 or P0172, P0175. Refer to EC-304, 312. No 䊳 GO TO 3. EC-300 DTC P0139, P0159 HO2S2 Diagnostic Procedure (Cont’d) 3 GI CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Disconnect corresponding heated oxygen sensor 2 harness connector. MA EM LC SEC426D FE CL MT AT SEC427D 3. Disconnect ECM harness connector. 4. Check harness continuity between ECM terminal and HO2S2 terminal as follows. Refer to Wiring Diagram. TF PD AX MTBL1362 Continuity should exist. 5. Check harness continuity between ECM terminal or HO2S2 terminal and ground as follows. Refer to Wiring Diagram. SU BR ST MTBL1363 Continuity should not exist. 6. Also check harness for short to power. OK or NG OK 䊳 GO TO 4. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. RS BT HA SC EL IDX EC-301 DTC P0139, P0159 HO2S2 Diagnostic Procedure (Cont’d) 4 CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between HO2S2 terminal 4 and engine ground. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to power. OK or NG OK (With CONSULT-II) 䊳 GO TO 5. OK (Without CONSULTII) 䊳 GO TO 6. NG 䊳 Repair open circuit or short to power in harness or connectors 5 CHECK HEATED OXYGEN SENSOR 2 With CONSULT-II Start engine and warm it up to the normal operating temperature. Turn ignition switch “ON” and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least one minute under no load. Let engine idle for one minute. Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)/(B2)” as the monitor item with CONSULTII. 6. Check “HO2S2 (B1)/(B2)” at idle speed when adjusting “FUEL INJECTION” to ±25%. 1. 2. 3. 4. 5. SEF972YA “HO2S2 (B1)/(B2)” should be above 0.68V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)/(B2)” should be below 0.48V at least once when the “FUEL INJECTION” is −25%. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK 䊳 GO TO 8. NG 䊳 Replace malfunctioning heated oxygen sensor 2. EC-302 DTC P0139, P0159 HO2S2 Diagnostic Procedure (Cont’d) 6 GI CHECK HEATED OXYGEN SENSOR 2-I Without CONSULT-II Start engine and warm it up to the normal operating temperature. Turn ignition switch “ON” and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least one minute under no load. Let engine idle for one minute. Set voltmeter probes between ECM terminal 74 (HO2S2 bank 1 signal) or 55 (HO2S2 bank 2 signal) and engine ground. 6. Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) 1. 2. 3. 4. 5. MA EM LC FE CL SEC432D MT The voltage should be above 0.68V at least once during this procedure. OK or NG OK 䊳 GO TO 8. NG 䊳 GO TO 7. 7 TF CHECK HEATED OXYGEN SENSOR 2-II PD Idle vehicle for 10 minutes, then check voltage between the same terminals as in Test No. 6; or check voltage when coasting from 80 km/h (50 MPH) in 3rd gear position (M/T), “D” position with “OD” OFF (A/T). The voltage should go below 0.48V at least once during this procedure. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK 䊳 GO TO 8. NG 䊳 Replace malfunctioning heated oxygen sensor 2. 8 AT AX SU BR ST RS CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END BT HA SC EL IDX EC-303 DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION On Board Diagnosis Logic On Board Diagnosis Logic NAEC0912 With the Air/Fuel 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 heated oxygen sensors 1. The ECM calculates 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 the fuel injection system malfunction and lights up the MIL (2 trip detection logic). Sensor Heated oxygen sensors 1 DTC No. P0171 0171 (Bank 1) P0174 0174 (Bank 2) Input Signal to ECM Density of oxygen in exhaust gas (Mixture ratio feedback signal) Trouble diagnosis name Fuel injection system too lean ECM function Fuel injection control Actuator Injectors DTC Detecting Condition Fuel injection system does not operate Properly, the amount of mixture ratio compensation is too large. (The mixture ratio is too lean.) Possible Cause 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 Intake air leaks Heated oxygen sensor 1 Injectors Exhaust gas leaks Incorrect fuel pressure Lack of fuel Mass air flow sensor Incorrect PCV hose connection DTC Confirmation Procedure NAEC0913 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1) 2) 3) SEF968Y 4) 5) 6) 7) 8) NAEC0913S01 Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF” and wait at least 10 seconds. Turn ignition switch “ON” and select “SELF-LEARN CONTROL” in “WORK SUPPORT” mode with CONSULT-II. Clear the self-learning control coefficient by touching “CLEAR”. Select “DATA MONITOR” mode with CONSULT-II. Start engine again and let it idle for at least 10 minutes. The 1st trip DTC P0171 or P0174 should be detected at this stage, if a malfunction exists. If so, go to “Diagnostic Procedure”, EC-308. 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-308. If engine does not start, check exhaust and intake air leak visually. EC-304 DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION DTC Confirmation Procedure (Cont’d) WITH GST 1) 2) 3) SEF960Y NAEC0913S02 Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF” and wait at least 10 seconds. Disconnect mass air flow sensor harness connector. Then restart and run engine for at least 5 seconds at idle speed. 4) Stop engine and reconnect mass air flow sensor harness connector. 5) Select “MODE 7” with GST. Make sure DTC P0102 is detected. 6) Select “MODE 4” with GST and erase the DTC P0102. 7) Start engine again and let it idle for at least 10 minutes. 8) Select “MODE 7” with GST. The 1st trip DTC P0171 or P0174 should be detected at this stage, if a malfunction exists. If so, go to “Diagnostic Procedure”, EC-308. 9) If it is difficult to start engine at step 7, the fuel injection system has a malfunction. 10) Crank engine while depressing accelerator pedal. If engine starts, go to “Diagnostic Procedure”, EC-308. If engine does not start, check exhaust and intake air leak visually. GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-305 DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION Wiring Diagram Wiring Diagram BANK 1 NAEC0914 NAEC0914S01 MEC091E EC-306 DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION Wiring Diagram (Cont’d) BANK 2 NAEC0914S02 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC092E EC-307 IDX DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION Diagnostic Procedure Diagnostic Procedure 1 NAEC0915 CHECK EXHAUST GAS LEAK 1. Start engine and run it at idle. 2. Listen for an exhaust gas leak before three way catalyst (manifold). SEC635D OK or NG OK 䊳 GO TO 2. NG 䊳 Repair or replace. 2 CHECK FOR INTAKE AIR LEAK 1. Listen for an intake air leak after the mass air flow sensor. 2. Check PCV hose connection. OK or NG OK 䊳 GO TO 3. NG 䊳 Repair or replace. 3 1. 2. 3. 4. CHECK HEATED OXYGEN SENSOR 1 CIRCUIT FOR OPEN AND SHORT Turn ignition switch “OFF”. Disconnect corresponding heated oxygen sensor 1 harness connector. Disconnect ECM harness connector. Check harness continuity between ECM terminal and HO2S1 terminal as follows. Refer to Wiring Diagram. MTBL1364 Continuity should exist. 5. Check harness continuity between ECM terminal or HO2S1 terminal and ground as follows. Refer to Wiring Diagram. MTBL1365 Continuity should not exist. 6. Also check harness for short to power. OK or NG OK 䊳 GO TO 4. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. EC-308 DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION Diagnostic Procedure (Cont’d) 4 GI CHECK FUEL PRESSURE 1. Release fuel pressure to zero. Refer to EC-64. 2. Install fuel pressure gauge and check fuel pressure. Refer to EC-64. At idling: When fuel pressure regulator valve vacuum hose is connected. 235 kPa (2.4 kg/cm2, 34 psi) When fuel pressure regulator valve vacuum hose is disconnected. 294 kPa (3.0 kg/cm2, 43 psi) OK or NG OK 䊳 GO TO 6. NG 䊳 GO TO 5. 5 MA EM LC DETECT MALFUNCTIONING PART FE Check the following. 쐌 Fuel pump and circuit (Refer to EC-763.) 쐌 Fuel pressure regulator (Refer to EC-65.) 쐌 Fuel lines (Refer to MA-17, “Checking Fuel Lines”.) 쐌 Fuel filter for clogging CL 䊳 6 MT Repair or replace. AT CHECK MASS AIR FLOW SENSOR With CONSULT-II 1. Install all removed parts. 2. Check “MASS AIR FLOW” in “DATA MONITOR” mode with CONSULT-II. 2.0 - 6.0 g·m/sec: at idling 7.0 - 20.0 g·m/sec: at 2,500 rpm With GST 1. Install all removed parts. 2. Check mass air flow sensor signal in MODE 1 with GST. 2.0 - 6.0 g·m/sec: at idling 7.0 - 20.0 g·m/sec: at 2,500 rpm TF PD AX SU OK or NG OK 䊳 GO TO 7. NG 䊳 Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or engine grounds. Refer to EC-211 (Type I), 219 (Type II). BR ST RS BT HA SC EL IDX EC-309 DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION Diagnostic Procedure (Cont’d) 7 CHECK FUNCTION OF INJECTORS With CONSULT-II 1. Start engine. 2. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II. SEF070Y 3. Make sure that each circuit produces a momentary engine speed drop. Without CONSULT-II 1. Start engine. 2. Listen to each injector operating sound. PBIB1725E Clicking noise should be heard. OK or NG OK 䊳 GO TO 8. NG 䊳 Perform trouble diagnosis for “INJECTORS”, EC-758. EC-310 DTC P0171, P0174 FUEL INJECTION SYSTEM FUNCTION Diagnostic Procedure (Cont’d) 8 1. 2. 3. 4. 5. 6. 7. 8. GI CHECK INJECTOR Confirm that the engine is cooled down and there are no fire hazards near the vehicle. Turn ignition switch “OFF”. Disconnect injector harness connectors. Remove injector gallery assembly. Refer to EC-66. Keep fuel hose and all injectors connected to injector gallery. For DTC P0171, reconnect injector harness connectors on bank 1. For DTC P0174, reconnect injector harness connectors on bank 2. Disconnect all ignition coil harness connectors. Prepare pans or saucers under each injector. Crank engine for about 3 seconds. For DTC P0171, make sure that fuel sprays out from injectors on bank 1. For DTC P0174, make sure that fuel sprays out from injectors on bank 2. MA EM LC FE CL MT PBIB1726E AT Fuel should be sprayed evenly for each injector. OK or NG OK 䊳 GO TO 9. NG 䊳 Replace injectors from which fuel does not spray out. Always replace O-ring with new ones. 9 TF PD AX CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 SU INSPECTION END BR ST RS BT HA SC EL IDX EC-311 DTC P0172, P0175 FUEL INJECTION SYSTEM FUNCTION On Board Diagnosis Logic On Board Diagnosis Logic NAEC0916 With the Air/Fuel 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 heated oxygen sensors 1. The ECM calculates 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 judges the condition as the fuel injection system malfunction and lights up the MIL (2 trip detection logic). Sensor Heated oxygen sensors 1 DTC No. P0172 0172 (Bank 1) P0175 0175 (Bank 2) Density of oxygen in exhaust gas (Mixture ratio feedback signal) Trouble diagnosis name Fuel injection system too rich ECM function Input Signal to ECM Fuel injection control Actuator Injectors DTC Detecting Condition Fuel injection system does not operate properly, the amount of mixture ratio compensation is too large. (The mixture ratio is too rich.) Possible Cause 쐌 쐌 쐌 쐌 쐌 Heated oxygen sensor 1 Injectors Exhaust gas leaks Incorrect fuel pressure Mass air flow sensor DTC Confirmation Procedure NAEC0917 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1) 2) 3) SEF968Y 4) 5) 6) 7) 8) NAEC0917S01 Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF” and wait at least 10 seconds. Turn ignition switch “ON” and select “SELF-LEARN CONTROL” in “WORK SUPPORT” mode with CONSULT-II. Clear the self-learning control coefficient by touching “CLEAR”. Select “DATA MONITOR” mode with CONSULT-II. Start engine again and let it idle for at least 10 minutes. The 1st trip DTC P0172, P0175 should be detected at this stage, if a malfunction exists. If so, go to “Diagnostic Procedure”, EC-316. 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-316. If engine does not start, remove ignition plugs and check for fouling, etc. EC-312 DTC P0172, P0175 FUEL INJECTION SYSTEM FUNCTION DTC Confirmation Procedure (Cont’d) WITH GST 1) 2) 3) SEF960Y NAEC0917S02 Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF” and wait at least 10 seconds. Disconnect mass air flow sensor harness connector. Then restart and run engine for at least 5 seconds at idle speed. 4) Stop engine and reconnect mass air flow sensor harness connector. 5) Select “MODE 7” with GST. Make sure DTC P0102 is detected. 6) Select “MODE 4” with GST and erase the DTC P0102. 7) Start engine again and let it idle for at least 10 minutes. 8) Select “MODE 7” with GST. The 1st trip DTC P0172 or P0175 should be detected at this stage, if a malfunction exists. If so, go to “Diagnostic Procedure”, EC-316. 9) If it is difficult to start engine at step 7, the fuel injection system has a malfunction. 10) Crank engine while depressing accelerator pedal. If engine starts, go to “Diagnostic Procedure”, EC-316. If engine does not start, remove ignition plugs and check for fouling, etc. GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-313 DTC P0172, P0175 FUEL INJECTION SYSTEM FUNCTION Wiring Diagram Wiring Diagram BANK 1 NAEC0918 NAEC0918S01 MEC091E EC-314 DTC P0172, P0175 FUEL INJECTION SYSTEM FUNCTION Wiring Diagram (Cont’d) BANK 2 NAEC0918S02 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC092E EC-315 IDX DTC P0172, P0175 FUEL INJECTION SYSTEM FUNCTION Diagnostic Procedure Diagnostic Procedure 1 NAEC0919 CHECK EXHAUST GAS LEAK 1. Start engine and run it at idle. 2. Listen for an exhaust gas leak before three way catalyst (manifold). SEC635D OK or NG OK 䊳 GO TO 2. NG 䊳 Repair or replace. 2 CHECK FOR INTAKE AIR LEAK Listen for an intake air leak after the mass air flow sensor. OK or NG OK 䊳 GO TO 3. NG 䊳 Repair or replace. 3 1. 2. 3. 4. CHECK HEATED OXYGEN SENSOR 1 CIRCUIT FOR OPEN AND SHORT Turn ignition switch “OFF”. Disconnect corresponding heated oxygen sensor 1 harness connector. Disconnect ECM harness connector. Check harness continuity between ECM terminal and HO2S1 terminal as follows. Refer to Wiring Diagram. MTBL1366 Continuity should exist. 5. Check harness continuity between ECM terminal or HO2S1 terminal and ground as follows. Refer to Wiring Diagram. MTBL1367 Continuity should not exist. 6. Also check harness for short to power. OK or NG OK 䊳 GO TO 4. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. EC-316 DTC P0172, P0175 FUEL INJECTION SYSTEM FUNCTION Diagnostic Procedure (Cont’d) 4 GI CHECK FUEL PRESSURE 1. Release fuel pressure to zero. Refer to EC-64. 2. Install fuel pressure gauge and check fuel pressure. Refer to EC-64. At idling: When fuel pressure regulator valve vacuum hose is connected. 235 kPa (2.4 kg/cm2, 34 psi) When fuel pressure regulator valve vacuum hose is disconnected. 294 kPa (3.0 kg/cm2, 43 psi) OK or NG OK 䊳 GO TO 6. NG 䊳 GO TO 5. 5 DETECT MALFUNCTIONING PART EM LC FE Check the following. 쐌 Fuel pump and circuit (Refer to EC-763.) 쐌 Fuel pressure regulator (Refer to EC-65.) 䊳 MA CL Repair or replace. MT 6 CHECK MASS AIR FLOW SENSOR With CONSULT-II 1. Install all removed parts. 2. Check “MASS AIR FLOW” in “DATA MONITOR” mode with CONSULT-II. 2.0 - 6.0 g·m/sec: at idling 7.0 - 20.0 g·m/sec: at 2,500 rpm AT With GST 1. Install all removed parts. 2. Check mass air flow sensor signal in MODE 1 with GST. 2.0 - 6.0 g·m/sec: at idling 7.0 - 20.0 g·m/sec: at 2,500 rpm PD OK or NG OK 䊳 GO TO 7. NG 䊳 Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or engine grounds. Refer to EC-211 (Type I), 219 (Type II). TF AX SU BR ST RS BT HA SC EL IDX EC-317 DTC P0172, P0175 FUEL INJECTION SYSTEM FUNCTION Diagnostic Procedure (Cont’d) 7 CHECK FUNCTION OF INJECTORS With CONSULT-II 1. Start engine. 2. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II. SEF070Y 3. Make sure that each circuit produces a momentary engine speed drop. Without CONSULT-II 1. Start engine. 2. Listen to each injector operating sound. PBIB1725E Clicking noise should be heard. OK or NG OK 䊳 GO TO 8. NG 䊳 Perform trouble diagnosis for “INJECTORS”, EC-758. 8 CHECK INJECTOR 1. Remove injector assembly. Refer to EC-66. Keep fuel hose and all injectors connected to injector gallery. 2. Confirm that the engine is cooled down and there are no fire hazards near the vehicle. 3. Disconnect all injector harness connectors. 4. Disconnect all ignition coil harness connectors. 5. Prepare pans or saucers under each injectors. 6. Crank engine for about 3 seconds. Make sure fuel does not drip from injector. OK or NG OK (Does not drip.) 䊳 GO TO 9. NG (Drips.) 䊳 Replace the injectors from which fuel is dripping. Always replace O-ring with new one. 9 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-318 DTC P0181 FTT SENSOR Component Description Component Description NAEC0773 The fuel tank temperature sensor is used to detect the fuel temperature 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 thermistor decreases as temperature increases. GI MA EM LC SEF751UA Fuel temperature °C (°F) Voltage* V Resistance kΩ 20 (68) 3.5 2.3 - 2.7 50 (122) 2.2 0.79 - 0.90 CL *: These data are reference values and are measured between ECM terminal 107 (Fuel tank temperature sensor) and body ground. SEF012P FE CAUTION: Do not use ECM ground terminals when measuring input/ output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. MT AT TF PD AX SU On Board Diagnosis Logic DTC No. P0181 0181 Trouble diagnosis name NAEC0774 BR DTC Detecting Condition Possible Cause Fuel tank temperature Rationally incorrect voltage from the sensor is sent 쐌 Harness or connectors sensor circuit range/ to ECM, compared with the voltage signals from (The sensor circuit is open or performance engine coolant temperature sensor and intake air shorted.) temperature sensor. 쐌 Fuel tank temperature sensor ST RS BT DTC Confirmation Procedure NAEC0776 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. HA SC EL IDX EC-319 DTC P0181 FTT SENSOR DTC Confirmation Procedure (Cont’d) WITH CONSULT-II 1) 2) 3) 4) SEF174Y 5) 6) 7) NAEC0776S01 Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 10 seconds. If the result is NG, go to “Diagnostic Procedure”, EC-320. If the result is OK, go to following step. Check “COOLAN TEMP/S” value. If “COOLAN TEMP/S” is less than 60°C (140°F), the result will be OK. If “COOLAN TEMP/S” is above 60°C (140°F), go to the following step. Cool engine down until “COOLAN TEMP/S” is less than 60°C (140°F). Wait at least 10 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-320. WITH GST NAEC0776S02 Follow the procedure “With CONSULT-II” above. Diagnostic Procedure 1 NAEC0778 CHECK FUEL TANK TEMPERATURE SENSOR 1. Remove fuel level sensor unit. 2. Check resistance between fuel level sensor unit terminals 1 and 2 by heating with hot water or heat gun as shown in the figure. SEF974Y OK or NG OK 䊳 GO TO 2. NG 䊳 Replace fuel level sensor unit. EC-320 DTC P0181 FTT SENSOR Diagnostic Procedure (Cont’d) 2 GI CHECK INTERMITTENT INCIDENT 쐌 Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 쐌 Refer to wiring diagram, EC-324. 䊳 MA INSPECTION END EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-321 DTC P0182, P0183 FTT SENSOR Component Description Component Description NAEC0920 The fuel tank temperature sensor is used to detect the fuel temperature 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 thermistor decreases as temperature increases. SEF751UA Fuel temperature °C (°F) Voltage* V Resistance kΩ 20 (68) 3.5 2.3 - 2.7 50 (122) 2.2 0.79 - 0.90 *: These data are reference values and are measured between ECM terminal 107 (Fuel tank temperature sensor) and body ground. SEF012P CAUTION: Do not use ECM ground terminals when measuring input/ output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. On Board Diagnosis Logic DTC No. P0182 0182 P0183 0183 Trouble diagnosis name DTC Detecting Condition NAEC0921 Possible Cause Fuel tank temperature An excessively low voltage from the sensor is sent 쐌 Harness or connectors sensor circuit low to ECM. (The sensor circuit is open or input shorted.) 쐌 Fuel tank temperature sensor Fuel tank temperature An excessively high voltage from the sensor is sensor circuit high sent to ECM. input DTC Confirmation Procedure NAEC0922 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. EC-322 DTC P0182, P0183 FTT SENSOR DTC Confirmation Procedure (Cont’d) WITH CONSULT-II 1) 2) 3) 4) SEF174Y 5) 6) 7) NAEC0922S01 Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 10 seconds. If the result is NG, go to “Diagnostic Procedure”, EC-325. If the result is OK, go to following step. Check “COOLAN TEMP/S” value. If “COOLAN TEMP/S” is less than 60°C (140°F), the result will be OK. If “COOLAN TEMP/S” is above 60°C (140°F), go to the following step. Cool engine down until “COOLAN TEMP/S” is less than 60°C (140°F). Wait at least 10 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-325. GI MA EM LC FE CL MT WITH GST Follow the procedure “With CONSULT-II” above. AT NAEC0922S02 TF PD AX SU BR ST RS BT HA SC EL IDX EC-323 DTC P0182, P0183 FTT SENSOR Wiring Diagram Wiring Diagram NAEC0923 MEC093E EC-324 DTC P0182, P0183 FTT SENSOR Diagnostic Procedure Diagnostic Procedure 1 NAEC0924 GI CHECK FUEL TANK TEMPERATURE SENSOR POWER SUPPLY CIRCUIT MA 1. Turn ignition switch “OFF”. 2. Disconnect fuel level sensor unit harness connector. EM LC FE SEF751UA 3. Turn ignition switch “ON”. 4. Check voltage between fuel level sensor unit terminal 1 and ground with CONSULT-II or tester. CL MT AT TF SEF973Y PD OK or NG OK 䊳 GO TO 3. NG 䊳 GO TO 2. 2 AX SU DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors B1, M2 쐌 Harness connectors M94, F27 쐌 Harness for open or short between ECM and fuel level sensor unit 䊳 3 Repair harness or connector. CHECK FUEL TANK TEMPERATURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Check harness continuity between fuel level sensor unit terminal 2 and combination meter terminal 23. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground or short to power. BR ST RS BT HA OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 4. SC EL IDX EC-325 DTC P0182, P0183 FTT SENSOR Diagnostic Procedure (Cont’d) 4 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors B1, M2 쐌 Harness for open or short between ECM and fuel level sensor unit 䊳 5 Repair open circuit or short to ground or short to power in harness or connectors. CHECK FUEL TANK TEMPERATURE SENSOR 1. Remove fuel level sensor unit. 2. Check resistance between fuel level sensor unit terminals 1 and 2 by heating with hot water or heat gun as shown in the figure. SEF974Y OK or NG OK 䊳 GO TO 6. NG 䊳 Replace fuel level sensor unit. 6 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-326 DTC P0222, P0223 TP SENSOR Component Description Component Description PBIB0145E NAEC1205 Electric Throttle Control Actuator consists of throttle control motor, throttle position sensor, etc. The throttle position sensor responds to the throttle valve movement. The throttle position sensor has the two sensors. These sensors are a kind of potentiometers which transform the throttle valve position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the throttle valve and feed the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening angle properly in response to driving condition. GI MA EM LC FE CL MT CONSULT-II Reference Value in Data Monitor Mode NAEC1206 Specification data are reference values. MONITOR ITEM THRTL SEN1 CONDITION 쐌 Ignition switch: ON (Engine stopped) 쐌 Shift lever: D (A/T model) 1st (M/T model) SPECIFICATION Accelerator pedal: Fully released More than 0.36V Accelerator pedal: Fully depressed Less than 4.75V PD SU NAEC1212 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. 47 50 WIRE COLOR L BR TF AX ECM Terminals and Reference Value TERMINAL NO. AT ITEM CONDITION BR ST DATA (DC Voltage) RS Sensor’s power supply (Throttle position sensor) [Ignition switch “ON”] [Ignition switch “ON”] 쐌 Engine stopped 쐌 Shift lever position is “D” (A/T models) 쐌 Shift lever position is “1st” (M/T models) Throttle position sensor 쐌 Accelerator pedal fully released 1 [Ignition switch “ON”] 쐌 쐌 쐌 쐌 Engine stopped Shift lever position is “D” (A/T models) Shift lever position is “1st” (M/T models) Accelerator pedal fully depressed Approximately 5V More than 0.36V BT HA SC Less than 4.75V EL IDX EC-327 DTC P0222, P0223 TP SENSOR ECM Terminals and Reference Value (Cont’d) TERMINAL NO. 66 69 WIRE COLOR BR/Y ITEM CONDITION [Engine is running] 쐌 Warm-up condition 쐌 Idle speed Sensor’s ground BR/W W/R Approximately 0V [Ignition switch “ON”] 쐌 Engine stopped 쐌 Shift lever position is “D” (A/T models) 쐌 Shift lever position is “1st” (M/T models) Throttle position sensor 쐌 Accelerator pedal fully released 2 [Ignition switch “ON”] 쐌 쐌 쐌 쐌 91 DATA (DC Voltage) Sensor’s power supply (APP sensor 2) Less than 4.75V Engine stopped Shift lever position is “D” (A/T models) Shift lever position is “1st” (M/T models) Accelerator pedal fully depressed More than 0.36V [Ignition switch “ON”] Approximately 5V On Board Diagnosis Logic NAEC1207 These self-diagnoses have the one trip detection logic. DTC No. Trouble diagnosis name DTC Detecting Condition P0222 0222 Throttle position sensor 1 circuit low input An excessively low voltage from the TP sensor 1 is sent to ECM. P0223 0223 Throttle position sensor 1 circuit high input An excessively high voltage from the TP sensor 1 is sent to ECM. Possible Cause 쐌 Harness or connectors (The TP sensor 1 circuit is open or shorted.) (APP sensor 2 circuit is shorted.) 쐌 Electric throttle control actuator (TP sensor 1) 쐌 Accelerator pedal position sensor (APP sensor 2) FAIL-SAFE MODE NAEC1207S01 When the malfunction is detected, ECM enters fail-safe mode and the MIL lights up. Engine operation condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. DTC Confirmation Procedure NAEC1208 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. EC-328 DTC P0222, P0223 TP SENSOR DTC Confirmation Procedure (Cont’d) 1. 2. 3. 4. With CONSULT-II Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to “Diagnostic Procedure”, EC-331. GI MA EM LC SEF058Y With GST Follow the procedure “WITH CONSULT-II” above. FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-329 DTC P0222, P0223 TP SENSOR Wiring Diagram Wiring Diagram NAEC1209 TEC845 EC-330 DTC P0222, P0223 TP SENSOR Diagnostic Procedure Diagnostic Procedure 1 NAEC1210 GI RETIGHTEN GROUND SCREWS MA 1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. EM LC FE SEF959Y 䊳 2 CL GO TO 2. MT CHECK THROTTLE POSITION SENSOR 1 POWER SUPPLY CIRCUIT-I 1. Disconnect electric throttle control actuator harness connector. 2. Turn ignition switch “ON”. AT TF PD AX SEC433D SU 3. Check voltage between electric throttle control actuator terminal 1 and ground with CONSULT-II or tester. BR ST RS BT PBIB0082E Voltage: Approximately 5V OK or NG OK 䊳 GO TO 7. NG 䊳 GO TO 3. HA SC EL IDX EC-331 DTC P0222, P0223 TP SENSOR Diagnostic Procedure (Cont’d) 3 CHECK THROTTLE POSITION SENSOR 2 POWER SUPPLY CIRCUIT-II 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between electric throttle control actuator terminal 1 and ECM terminal 47. Refer to Wiring Diagram. Continuity should exist. OK or NG OK 䊳 GO TO 4. NG 䊳 Repair or replace open circuit. 4 CHECK THROTTLE POSITION SENSOR 2 POWER SUPPLY CIRCUIT-III Check harness for short to power and short to ground, between the following terminals. 쐌 ECM terminal 47 and electric throttle control actuator terminal 1. Refer to “Wiring Diagram”, EC-330. 쐌 ECM terminal 91 and APP sensor terminal 10. Refer to “Wiring Diagram”, EC-718. OK or NG OK 䊳 GO TO 5. NG 䊳 Repair short to ground or short to power in harness or connectors. 5 CHECK APP SENSOR Refer to “Component Inspection”, EC-722. OK or NG OK 䊳 GO TO 11. NG 䊳 GO TO 6. 6 1. 2. 3. 4. REPLACE ACCELERATOR PEDAL ASSEMBLY Replace accelerator pedal assembly. Perform “Accelerator Pedal Released Position Learning”, EC-81. Perform “Throttle Valve Closed Position Learning”, EC-81. Perform “Idle Air Volume Learning”, EC-81. 䊳 7 INSPECTION END CHECK THROTTLE POSITION SENSOR 1 GROUND CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between electric throttle control actuator terminal 5 and ECM terminal 66. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 8. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. EC-332 DTC P0222, P0223 TP SENSOR Diagnostic Procedure (Cont’d) 8 GI CHECK THROTTLE POSITION SENSOR 1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 50 and electric throttle control actuator terminal 4. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. MA EM OK or NG OK 䊳 GO TO 9. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. 9 LC CHECK THROTTLE POSITION SENSOR Refer to “Component Inspection”, EC-333. OK or NG OK 䊳 GO TO 11. NG 䊳 GO TO 10. 10 FE CL REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR MT 1. Replace the electric throttle control actuator. 2. Perform “Throttle Valve Closed Position Learning”, EC-81. 3. Perform “Idle Air Volume Learning”, EC-81. 䊳 11 AT INSPECTION END TF CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 PD INSPECTION END AX SU Component Inspection SEC434D NAEC1211 THROTTLE POSITION SENSOR 1. Reconnect all harness connectors disconnected. 2. Perform “Throttle Valve Closed Position Learning”, EC-81. 3. Turn ignition switch “ON”. 4. Set selector lever to “D” position (A/T models) or “1st” position (M/T models). 5. Check voltage between ECM terminals 50 (TP sensor 1), 69 (TP sensor 2) and engine ground under the following conditions. Terminal Accelerator pedal Voltage 50 (Throttle position sensor 1) Fully released More than 0.36V Fully depressed Less than 4.75V Fully released Less than 4.75V Fully depressed More than 0.36V 69 (Throttle position sensor 2) 6. 7. If NG, replace electric throttle control actuator and go to the next step. Perform “Throttle Valve Closed Position Learning”, EC-81. EC-333 BR ST RS BT HA SC EL IDX DTC P0222, P0223 TP SENSOR Component Inspection (Cont’d) 8. Perform “Idle Air Volume Learning”, EC-81. EC-334 DTC P0300 - P0306 MULTIPLE CYLINDER MISFIRE, NO. 1 - 6 CYLINDER MISFIRE On Board Diagnosis Logic On Board Diagnosis Logic NAEC0929 When a misfire occurs, engine speed will fluctuate. If the engine speed fluctuates enough to cause the CKP sensor signal to vary, ECM can determine that a misfire is occurring. Sensor Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Input Signal to ECM DTC No. P0300 0300 MA ECM function EM Engine speed On board diagnosis of misfire The misfire detection logic consists of the following two conditions. 1. One Trip Detection Logic (Three Way Catalyst Damage) On the first trip that a misfire condition occurs that can damage the three way catalyst (TWC) due to overheating, the MIL will blink. When a misfire condition occurs, the ECM monitors the CKP sensor signal every 200 engine revolutions for a change. When the misfire condition decreases to a level that will not damage the TWC, the MIL will turn off. If another misfire condition occurs that can damage the TWC on a second trip, the MIL will blink. When the misfire condition decreases to a level that will not damage the TWC, the MIL will remain on. If another misfire condition occurs that can damage the TWC, the MIL will begin to blink again. 2. Two Trip Detection Logic (Exhaust quality deterioration) For misfire conditions that will not damage the TWC (but will affect vehicle emissions), the MIL will only light when the misfire is detected on a second trip. During this condition, the ECM monitors the CKP sensor signal every 1,000 engine revolutions. A misfire malfunction can be detected on any one cylinder or on multiple cylinders. Trouble diagnosis name GI DTC Detecting Condition P0301 0301 Multiple cylinder mis- Multiple cylinders misfire, No. 1 cylinder misfires, fire detected No. 2 cylinder misfires, No. 3 cylinder misfires, No. 4 cylinder misfires, No. 5 cylinder misfires and No. No. 1 cylinder misfire 6 cylinder misfires. detected P0302 0302 No. 2 cylinder misfire detected P0303 0303 No. 3 cylinder misfire detected P0304 0304 No. 4 cylinder misfire detected P0305 0305 No. 5 cylinder misfire detected P0306 0306 No. 6 cylinder misfire detected LC FE CL MT AT TF PD AX Possible Cause 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 Improper spark plug Insufficient compression Incorrect fuel pressure The injector circuit is open or shorted Injectors Intake air leak The ignition secondary circuit is open or shorted Lack of fuel Drive plate or flywheel Heated oxygen sensor 1 Incorrect PCV hose connection SU BR ST RS BT HA SC EL IDX EC-335 DTC P0300 - P0306 MULTIPLE CYLINDER MISFIRE, NO. 1 - 6 CYLINDER MISFIRE DTC Confirmation Procedure DTC Confirmation Procedure NAEC0930 CAUTION: Always drive vehicle in safe manner according to traffic conditions and obey all traffic laws when driving. NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II SEF213Y NAEC0930S01 1) Turn ignition switch ON, and select “DATA MONITOR” mode with CONSULT-II. 2) Start engine and warm it up to normal operating temperature. 3) Turn ignition switch OFF and wait at least 10 seconds. 4) Restart engine and let it idle for about 15 minutes. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-337. NOTE: If 1st trip DTC is not detected during above procedure, performing the following procedure is advised. 1) Turn ignition switch OFF and wait at least 10 seconds. 2) Start engine and drive the vehicle under the similar conditions to (1st trip) Freeze Frame Data for a certain time. Refer to the table below. Hold the accelerator pedal as steady as possible. The similar conditions to (1st trip) Freeze Frame Data means the vehicle operation that the following conditions should be satisfied at the same time. Engine speed Engine speed in the freeze frame data ±400 rpm Vehicle speed Vehicle speed in the freeze frame data ±10 km/h (5 MPH) When the freeze frame data shows lower than 70°C (158°F), T should be lower than 70°C (158°F). 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). The time to driving varies according to the engine speed in the freeze frame data. Engine speed Time Around 1,000 rpm Approximately 10 minutes Around 2,000 rpm Approximately 5 minutes More than 3,000 rpm Approximately 3.5 minutes WITH GST Follow the procedure “With CONSULT-II” above. EC-336 NAEC0930S02 DTC P0300 - P0306 MULTIPLE CYLINDER MISFIRE, NO. 1 - 6 CYLINDER MISFIRE Diagnostic Procedure Diagnostic Procedure 1 GI CHECK FOR INTAKE AIR LEAK MA 1. Start engine and run it at idle speed. 2. Listen for the sound of the intake air leak. 3. Check PCV hose connection. OK or NG OK 䊳 GO TO 2. NG 䊳 Discover air leak location and repair. 2 NAEC0931 EM LC CHECK FOR EXHAUST SYSTEM CLOGGING 1. Stop engine and visually check exhaust tube, three way catalyst and muffler for dents. OK or NG OK 䊳 GO TO 3. NG 䊳 Repair or replace it. FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-337 DTC P0300 - P0306 MULTIPLE CYLINDER MISFIRE, NO. 1 - 6 CYLINDER MISFIRE Diagnostic Procedure (Cont’d) 3 PERFORM POWER BALANCE TEST With CONSULT-II 1. Perform “POWER BALANCE” in “ACTIVE TEST” mode. SEF190Y 2. Is there any cylinder which does not produce a momentary engine speed drop? Without CONSULT-II When disconnecting each ignition coil harness connector one at a time, is there any cylinder which does not produce a momentary engine speed drop? SEC435D SEC436D Yes or No Yes 䊳 GO TO 5. No 䊳 GO TO 4. EC-338 DTC P0300 - P0306 MULTIPLE CYLINDER MISFIRE, NO. 1 - 6 CYLINDER MISFIRE Diagnostic Procedure (Cont’d) 4 GI CHECK INJECTOR Does each injector make an operating sound at idle? MA EM LC PBIB1725E FE Yes or No Yes 䊳 GO TO 5. No 䊳 Check injector(s) and circuit(s). Refer to EC-758. 5 1. 2. 3. 4. CL CHECK IGNITION SPARK MT Disconnect ignition wire from spark plug. Connect a known good spark plug to the ignition wire. Place end of spark plug against a suitable ground and crank engine. Check for spark. AT TF PD AX SU SEC437D OK or NG OK 䊳 GO TO 6. NG 䊳 Check ignition coil, power transistor and their circuits. Refer to “IGNITION SIGNAL”, EC-748. BR ST RS BT HA SC EL IDX EC-339 DTC P0300 - P0306 MULTIPLE CYLINDER MISFIRE, NO. 1 - 6 CYLINDER MISFIRE Diagnostic Procedure (Cont’d) 6 CHECK SPARK PLUGS Remove the spark plugs and check for fouling, etc. SEF156I OK or NG OK 䊳 GO TO 7. NG 䊳 Repair or replace spark plug(s) with standard type one(s). For spark plug type, refer to MA-32, “ENGINE MAINTENANCE”. 7 CHECK COMPRESSION PRESSURE Check compression pressure. Refer to EM-14, “Measurement of Compression Pressure”. Standard: 1,275 kPa (13.0 kg/cm2, 185 psi)/300 rpm Minimum: 981 kPa (10.0 kg/cm2, 142 psi)/300 rpm Difference between each cylinder: 98 kPa (1.0 kg/cm2, 14 psi)/300 rpm OK or NG OK 䊳 GO TO 8. NG 䊳 Check pistons, piston rings, valves, valve seats and cylinder head gaskets. 8 CHECK FUEL PRESSURE 1. Install all removed parts. 2. Release fuel pressure to zero. Refer to EC-64. 3. Install fuel pressure gauge and check fuel pressure. Refer to EC-64. At idling: With vacuum hose connected Approximately 235 kPa (2.4 kg/cm2, 34 psi) With vacuum hose disconnected Approximately 294 kPa (3.0 kg/cm2, 43 psi) OK or NG OK 䊳 GO TO 10. NG 䊳 GO TO 9. 9 DETECT MALFUNCTIONING PART Check the following. 쐌 Fuel pump and circuit (Refer to EC-763.) 쐌 Fuel pressure regulator (Refer to EC-65.) 쐌 Fuel lines (Refer to MA-17, “Checking Fuel Lines”.) 쐌 Fuel filter for clogging 䊳 Repair or replace. EC-340 DTC P0300 - P0306 MULTIPLE CYLINDER MISFIRE, NO. 1 - 6 CYLINDER MISFIRE Diagnostic Procedure (Cont’d) 10 GI CHECK IGNITION TIMING Check the following items. Refer to “Basic Inspection”, EC-131. MA EM MTBL1368 OK or NG OK (With CONSULT-II) 䊳 GO TO 11. OK (Without CONSULTII) 䊳 GO TO 12. NG 䊳 Follow the “Basic Inspection”. LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-341 DTC P0300 - P0306 MULTIPLE CYLINDER MISFIRE, NO. 1 - 6 CYLINDER MISFIRE Diagnostic Procedure (Cont’d) 11 CHECK HEATED OXYGEN SENSOR 1 With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “MANU TRIG” and “HI SPEED” in “DATA MONITOR” mode with CONSULT-II, and select “HO2S1 (B1)/(B2)” and “HO2S1 MNTR (B1)/(B2)”. 3. Hold engine speed at 2,000 rpm under no load during the following steps. 4. Touch “RECORD” on CONSULT-II screen. SEF967Y 5. Check the following. 쐌 “HO2S1 MNTR (B1)/(B2)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown left: SEF647Y 쐌 “HO2S1 (B1)/(B2)” voltage goes above 0.6V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage goes below 0.3V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage never exceeds 1.0V. SEF648Y CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK 䊳 GO TO 13. NG 䊳 Replace malfunctioning heated oxygen sensor 1. EC-342 DTC P0300 - P0306 MULTIPLE CYLINDER MISFIRE, NO. 1 - 6 CYLINDER MISFIRE Diagnostic Procedure (Cont’d) 12 GI CHECK HEATED OXYGEN SENSOR 1 Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Set voltmeter probes between ECM terminal 35 (HO2S1 bank 1 signal) or 16 (HO2S1 bank 2 signal) and engine ground. 3. Check the following with engine speed held at 2,000 rpm constant under no load. MA EM LC FE SEC430D 쐌 쐌 쐌 쐌 The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than 5 times within 10 seconds. The maximum voltage is over 0.6V at least one time. The minimum voltage is below 0.3V at least one time. The voltage never exceeds 1.0V. 1 time: 0 - 0.3V , 0.6 - 1.0V , 0 - 0.3V 2 times: 0 - 0.3V , 0.6 - 1.0V , 0 - 0.3V , 0.6 - 1.0V , 0 - 0.3V CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK 䊳 GO TO 13. NG 䊳 Replace malfunctioning heated oxygen sensor 1. 13 CHECK MASS AIR FLOW SENSOR CL MT AT TF PD AX SU With CONSULT-II Check mass air flow sensor signal in “DATA MONITOR” mode with CONSULT-II. 2.0 - 6.0 g·m/sec: at idling 7.0 - 20.0 g·m/sec: at 2,500 rpm With GST Check mass air flow sensor signal in MODE 1 with GST. 2.0 - 6.0 g·m/sec: at idling 7.0 - 20.0 g·m/sec: at 2,500 rpm BR ST RS OK or NG BT OK 䊳 GO TO 14. NG 䊳 Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or engine grounds. Refer to EC-211 (Type I), 219 (Type II). 14 CHECK SYMPTOM MATRIX CHART Check items on the rough idle symptom in “Symptom Matrix Chart”, EC-139. OK or NG OK 䊳 GO TO 15. NG 䊳 Repair or replace. HA SC EL IDX EC-343 DTC P0300 - P0306 MULTIPLE CYLINDER MISFIRE, NO. 1 - 6 CYLINDER MISFIRE Diagnostic Procedure (Cont’d) 15 ERASE THE 1ST TRIP DTC Erase the 1st trip DTC from the ECM memory after performing the tests. Refer to EC-100. Some tests may cause a 1st trip DTC to be set. 䊳 16 GO TO 16. CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-344 DTC P0327, P0328 KS Component Description Component Description NAEC0932 The knock sensor is attached to the cylinder block. It senses engine knocking using a piezoelectric element. A knocking vibration from the cylinder block is sensed as vibrational pressure. This pressure is converted into a voltage signal and sent to the ECM. GI MA EM LC SEF332I ECM Terminals and Reference Value NAEC0933 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 15 WIRE COLOR W ITEM CONDITION CL DATA (DC Voltage) MT Knock sensor [Engine is running] 쐌 Idle speed Approximately 2.5V AT On Board Diagnosis Logic NAEC0934 The MIL will not light up for these self-diagnoses. DTC No. FE Trouble diagnosis name P0327 0327 Knock sensor circuit low input P0328 0328 Knock sensor circuit high input DTC Detecting Condition TF Possible Cause PD An excessively low voltage from the sensor is sent 쐌 Harness or connectors to ECM. (The sensor circuit is open or shorted.) An excessively high voltage from the sensor is 쐌 Knock sensor sent to ECM. AX SU DTC Confirmation Procedure NAEC0935 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II SEF058Y 1) 2) 3) NAEC0935S01 Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II Start engine and run it for at least 5 seconds at idle speed. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-347. WITH GST NAEC0935S03 BR ST RS BT HA SC Follow the procedure “WITH CONSULT-II” above. EL IDX EC-345 DTC P0327, P0328 KS Wiring Diagram Wiring Diagram NAEC0936 MEC094E EC-346 DTC P0327, P0328 KS Diagnostic Procedure Diagnostic Procedure 1 NAEC0937 GI CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT-I MA 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check resistance between ECM terminal 15 and engine ground. NOTE: It is necessary to use an ohmmeter which can measure more than 10 MΩ. EM LC FE CL SEC438D Resistance: Approximately 500 - 620 kΩ [at 25°C (77°F)] 4. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 2. 2 MT AT TF CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT-II 1. Disconnect knock sensor harness connector. 2. Check harness continuity between ECM terminal 15 and knock sensor terminal 1. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. PD AX OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 3. SU BR 3 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors F19, F116 쐌 Harness for open or short between ECM and knock sensor 䊳 Repair open circuit or short to ground or short to power in harness or connectors. ST RS BT HA SC EL IDX EC-347 DTC P0327, P0328 KS Diagnostic Procedure (Cont’d) 4 CHECK KNOCK SENSOR Check resistance between knock sensor terminal 1 and ground. NOTE: It is necessary to use an ohmmeter which can measure more than 10 MΩ. SEC439D Resistance: 500 - 620 kΩ [at 25°C (77°F)] CAUTION: Do not use any knock sensors that have been dropped or physically damaged. Use only new ones. OK or NG OK 䊳 GO TO 8. NG 䊳 Replace knock sensor. 5 RETIGHTEN GROUND SCREWS Loose and retighten engine ground screws. SEF959Y 䊳 6 GO TO 6. CHECK KNOCK SENSOR SHIELD CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between knock sensor terminal 2 and engine ground. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to power. OK or NG OK 䊳 GO TO 8. NG 䊳 GO TO 7. 7 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors F19, F116 쐌 Harness connectors F22, M33 쐌 Harness for open between harness connector knock sensor and engine ground 䊳 Repair open circuit or short to power in harness or connectors. EC-348 DTC P0327, P0328 KS Diagnostic Procedure (Cont’d) 8 GI CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 MA INSPECTION END EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-349 DTC P0335 CKP SENSOR (POS) Component Description Component Description PBIB0562E NAEC1213 The crankshaft position sensor (POS) is located on the oil pan facing the gear teeth (cogs) of the signal plate. It detects the fluctuation of the engine revolution. The sensor consists of a permanent magnet and Hall IC. When the engine is running, the high and low parts of the teeth cause the gap with the sensor to change. 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. CONSULT-II Reference Value in Data Monitor Mode NAEC1214 Specification data are reference values. MONITOR ITEM ENG SPEED CONDITION 쐌 Tachometer: Connect 쐌 Run engine and compare tachometer indication with the CONSULT-II value. SPECIFICATION Almost the same speed as the CONSULT-II value. On Board Diagnosis Logic DTC No. P0335 0335 Trouble diagnosis name Crankshaft position sensor (POS) circuit DTC Detecting Condition NAEC1215 Possible Cause 쐌 Harness or connectors 쐌 The crankshaft position sensor signal is not detected by the ECM during the first [The crankshaft position sensor (POS) circuit is open or shorted.] few seconds of engine cranking. 쐌 The proper pulse signal from the crank쐌 Crankshaft position sensor (POS) shaft position sensor (POS) is not sent to 쐌 Signal plate ECM while the engine is running. 쐌 The crankshaft position sensor signal is not in the normal pattern during engine running. EC-350 DTC P0335 CKP SENSOR (POS) DTC Confirmation Procedure DTC Confirmation Procedure SEF058Y =NAEC1216 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10.5V with ignition switch “ON”. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 2) Crank engine for at least 2 seconds and run it for at least 5 seconds at idle speed. 3) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-353. If 1st trip DTC is not detected, go to next step. 4) Maintaining engine speed at more than 1,000 rpm for at least 5 seconds. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-353 With GST Follow the procedure “With CONSULT-II” above. GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-351 DTC P0335 CKP SENSOR (POS) Wiring Diagram Wiring Diagram NAEC1217 MEC095E EC-352 DTC P0335 CKP SENSOR (POS) Wiring Diagram (Cont’d) Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION GI MA EM DATA (DC Voltage) LC Approximately 1.6V★ [Engine is running] 쐌 Idle speed FE PBIB1041E 13 Y Crankshaft position sensor (POS) CL Approximately 1.5V★ MT [Engine is running] 쐌 Engine speed is 2,000 rpm. AT PBIB1042E TF ★: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) PD AX SU Diagnostic Procedure 1 NAEC1218 BR RETIGHTEN GROUND SCREWS 1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. ST RS BT HA SEF959Y 䊳 GO TO 2. SC EL IDX EC-353 DTC P0335 CKP SENSOR (POS) Diagnostic Procedure (Cont’d) 2 CHECK CKP SENSOR (POS) POWER SUPPLY CIRCUIT 1. Disconnect crankshaft position sensor (POS) harness connector. SEC440D 2. Turn ignition switch “ON”. 3. Check voltage between crankshaft position sensor (POS) terminal 1 and ground with CONSULT-II or tester. PBIB0664E Voltage: Battery voltage 4. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 3. 3 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors E132, E135 쐌 Harness for open or short between ECM relay and crankshaft position sensor (POS) 쐌 Harness for open or short between ECM and crankshaft position sensor (POS) 䊳 4 Repair open circuit or short to ground or short to power in harness or connectors. CHECK CKP SENSOR (POS) GROUND CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Check harness continuity between crankshaft position sensor (POS) terminal 3 and engine ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK 䊳 GO TO 6. NG 䊳 GO TO 5. EC-354 DTC P0335 CKP SENSOR (POS) Diagnostic Procedure (Cont’d) 5 GI DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors E132, E135 쐌 Harness connectors E116, M114 쐌 Harness connectors M32, F23 쐌 Joint connector F204 쐌 Harness connectors F22, M33 쐌 Harness for open between crankshaft position sensor (POS) and ground 䊳 6 Repair open circuit or short to power in harness or connectors. OK or NG OK 䊳 GO TO 8. NG 䊳 GO TO 7. FE CL AT DETECT MALFUNCTIONING PART 䊳 TF PD Repair open circuit or short to ground or short to power in harness or connectors. CHECK CRANKSHAFT POSITION SENSOR (POS) Refer to “Component Inspection”, EC-356. OK or NG OK 䊳 GO TO 9. NG 䊳 Replace crankshaft position sensor (POS). 9 LC MT Check the following. 쐌 Harness connectors E132, E135 쐌 Harness connectors E116, M114 쐌 Harness connectors M32, F23 쐌 Harness for open or short between ECM and crankshaft position sensor (POS) 8 EM CHECK CKP SENSOR (POS) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 13 and crankshaft position sensor (POS) terminal 2. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. 7 MA AX SU BR ST CHECK GEAR TOOTH Visually check for chipping signal plate gear tooth. OK or NG OK 䊳 GO TO 10. NG 䊳 Replace the signal plate. 10 CHECK INTERMITTENT INCIDENT RS BT HA Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END SC EL IDX EC-355 DTC P0335 CKP SENSOR (POS) Component Inspection Component Inspection NAEC1219 CRANKSHAFT POSITION SENSOR (POS) 1. 2. NAEC1219S01 3. 4. Loosen the fixing bolt of the sensor. Disconnect crankshaft position sensor (POS) harness connector. Remove the sensor. Visually check the sensor for chipping. 5. Check resistance as shown in the figure. SEC420D Terminal No. (Polarity) Resistance Ω [at 25°C (77°F)] 1 (+) - 2 (−) 1 (+) - 3 (−) 2 (+) - 3 (−) SEC421D EC-356 Except 0 or ∞ DTC P0340, P0345 CMP SENSOR (PHASE) Component Description Component Description PBIB0562E NAEC1220 The camshaft position sensor (PHASE) senses the retraction of intake valve camshaft to identify a particular cylinder. The crankshaft position sensor (POS) senses the piston position. When the crankshaft position sensor (POS) system becomes inoperative, the camshaft position sensor (PHASE) provides various controls of engine parts instead, utilizing timing of cylinder identification signals. The sensor consists of a permanent magnet and Hall IC. When engine is running, the high and low parts of the teeth cause the gap with the sensor to change. The changing gap causes the magnetic field near the sensor to change. Due to the changing magnetic field, the voltage from the sensor changes. GI MA EM LC FE CL MT AT On Board Diagnosis Logic DTC No. P0340 0340 (Bank 1) P0345 0345 (Bank 2) Trouble diagnosis name DTC Detecting Condition Camshaft position sen- 쐌 The cylinder No. signal is not sent to ECM sor (PHASE) circuit for the first few seconds during engine cranking. 쐌 The cylinder No. signal is not sent to ECM during engine running. 쐌 The cylinder No. signal is not in the normal pattern during engine running. NAEC1221 TF Possible Cause 쐌 Harness or connectors [The camshaft position sensor (PHASE) circuit is open or shorted.] 쐌 Camshaft position sensor (PHASE) 쐌 Camshaft (Intake) 쐌 Starter motor (Refer to SC section.) 쐌 Starting system circuit (Refer to SC section.) 쐌 Dead (Weak) battery PD AX SU BR ST RS BT DTC Confirmation Procedure NAEC1222 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10.5V with ignition switch “ON”. HA SC EL IDX EC-357 DTC P0340, P0345 CMP SENSOR (PHASE) DTC Confirmation Procedure (Cont’d) WITH CONSULT-II 1) 2) 3) 4) 5) 6) SEF058Y NAEC1222S01 Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Crank engine for at least 2 seconds and run it for at least 5 seconds at idle speed. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-361. If 1st trip DTC is not detected, go to next step. Maintaining engine speed at more than 1,000 rpm for at least 5 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-361. WITH GST Follow the procedure “With CONSULT-II” above. EC-358 NAEC1222S02 DTC P0340, P0345 CMP SENSOR (PHASE) Wiring Diagram Wiring Diagram BANK 1 NAEC1223 GI NAEC1223S01 MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC102E EC-359 IDX DTC P0340, P0345 CMP SENSOR (PHASE) Wiring Diagram (Cont’d) BANK 2 NAEC1223S02 MEC103E EC-360 DTC P0340, P0345 CMP SENSOR (PHASE) Wiring Diagram (Cont’d) Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION GI MA EM DATA (DC Voltage) LC 1.0 - 4.0V★ [Engine is running] 쐌 Warm-up condition 쐌 Idle speed FE 33 Y/G Camshaft position sensor (PHASE) (Bank 1) PBIB1039E CL 1.0 - 4.0V★ MT [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm. AT PBIB1040E TF 1.0 - 4.0V★ PD [Engine is running] 쐌 Warm-up condition 쐌 Idle speed 14 OR AX PBIB1039E Camshaft position sensor (PHASE) (Bank 2) SU 1.0 - 4.0V★ BR [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm. ST PBIB1040E RS ★: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) BT Diagnostic Procedure 1 CHECK STARTING SYSTEM Turn ignition switch to “START” position. Does the engine turn over? Does the starter motor operate? NAEC1224 HA SC Yes or No Yes 䊳 GO TO 2. No 䊳 Check starting system. (Refer to SC-10, “STARTING SYSTEM”.) EC-361 EL IDX DTC P0340, P0345 CMP SENSOR (PHASE) Diagnostic Procedure (Cont’d) 2 RETIGHTEN GROUND SCREWS 1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. SEF959Y 䊳 GO TO 3. EC-362 DTC P0340, P0345 CMP SENSOR (PHASE) Diagnostic Procedure (Cont’d) 3 GI CHECK CMP SENSOR (PHASE) POWER SUPPLY CIRCUIT 1. Disconnect CMP sensor (PHASE) harness connector (bank 1) or (bank 2). MA EM LC SEC452D FE CL MT AT SEC477D 2. Turn ignition switch “ON”. 3. Check voltage between CMP sensor (PHASE) terminal 3 and ground with CONSULT-II or tester. TF PD AX SU SEF479Y Voltage: Battery voltage 4. Also check harness for short to ground and short to power. BR ST OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 4. 4 RS BT DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors E1, M1 쐌 Harness connectors M32, F23 쐌 Harness for open or short between ECM and camshaft position sensor (PHASE) 쐌 Harness for open or short between ECM relay and camshaft position sensor (PHASE) 䊳 HA SC Repair open circuit or short to ground or short to power in harness or connectors. EL IDX EC-363 DTC P0340, P0345 CMP SENSOR (PHASE) Diagnostic Procedure (Cont’d) 5 CHECK CMP SENSOR (PHASE) GROUND CIRCUIT FOR OPEN AND SHORT 1. Check CMP sensor (PHASE) terminal 1 and engine ground. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to power. OK or NG OK 䊳 GO TO 7. NG 䊳 GO TO 6. 6 DETECT MALFUNCTIONING PART Check the following. 쐌 Joint connector F204 쐌 Harness connectors F22, M33 쐌 Harness for open between camshaft position sensor (PHASE) and ground 䊳 7 Repair open circuit or short to ground or short to power in harness or connectors. CHECK CMP SENSOR (PHASE) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 33 and CMP sensor (PHASE) (Bank 1) terminal 2. 3. Check harness continuity between ECM terminal 14 and CMP sensor (PHASE) (Bank 2) terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 8. NG 䊳 Repair harness or connectors. 8 CHECK CAMSHAFT POSITION SENSOR (PHASE) Refer to “Component Inspection”, EC-365. OK or NG OK 䊳 GO TO 9. NG 䊳 Replace camshaft position sensor (PHASE). 9 CHECK CAMSHAFT (INTAKE) Visually check for chipped signal plate at camshaft. SEC578D OK or NG OK 䊳 GO TO 10. NG 䊳 Replace camshaft. EC-364 DTC P0340, P0345 CMP SENSOR (PHASE) Diagnostic Procedure (Cont’d) 10 GI CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 MA INSPECTION END EM LC Component Inspection NAEC1225 CAMSHAFT POSITION SENSOR (PHASE) 1. 2. 3. 4. NAEC1225S01 Loosen the fixing bolt of the sensor. Disconnect camshaft position sensor (PHASE) harness connector. Remove the sensor. Visually check the sensor for chipping. FE CL MT PBIB0563E 5. Check resistance as shown inthe figure. Terminal No. (Polarity) Resistance Ω [at 25°C (77°F)] AT TF 1 (+) - 2 (−) 1 (+) - 3 (−) Except 0 or ∞ PD 2 (+) - 3 (−) AX SU PBIB0564E BR ST RS BT HA SC EL IDX EC-365 DTC P0420, P0430 THREE WAY CATALYST FUNCTION On Board Diagnosis Logic On Board Diagnosis Logic NAEC0951 The ECM monitors the switching frequency ratio of heated oxygen sensors 1 and 2. A three way catalyst (manifold) with high oxygen storage capacity will indicate a low switching frequency of heated oxygen sensor 2. As oxygen storage capacity decreases, the heated oxygen sensor 2 switching frequency will increase. When the frequency ratio of heated oxygen sensors 1 and 2 approaches a specified limit value, the three way catalyst (manifold) malfunction is diagnosed. SEF484YF DTC No. P0420 0420 (Bank 1) P0430 0430 (Bank 2) Trouble diagnosis name Catalyst system efficiency below threshold DTC Detecting Condition Three way catalyst (manifold) does not operate properly, three way catalyst (manifold) does not have enough oxygen storage capacity. Possible Cause 쐌 쐌 쐌 쐌 쐌 쐌 쐌 Three way catalyst (manifold) Exhaust tube Intake air leaks Injectors Injector leaks Spark plug Improper ignition timing DTC Confirmation Procedure NAEC0952 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. WITH CONSULT-II SEC138D SEC139D SEF560X NAEC0952S01 TESTING CONDITION: 쐌 Open engine hood before conducting the following procedure. 쐌 Do not hold engine speed for more than the specified minutes below. 1) Start engine and warm it up to the normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 10 seconds. 3) Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least one minute under no load. 4) Let engine idle for one minute. 5) Open engine hood. 6) Select “DTC & SRT CONFIRMATION” then “SRT WORK SUPPORT” mode with CONSULT-II. 7) Rev engine up to 2,000 to 3,000 rpm and hold it for 3 consecutive minutes then release the accelerator pedal completely. If “INCMP” of “CATALYST” changed to “COMPLT”, go to step 10. 8) Wait 5 seconds at idle. 9) Rev engine up to 2,000 to 3,000 rpm and maintain it until “INCMP” of “CATALYST” changes to “CMPLT” (It will take approximately 5 minutes). If not “CMPLT”, perform the following. a) Turn ignition switch “OFF” and leave the vehicle in a cool place (soak the vehicle). b) Turn ignition switch “ON” and select “COOLAN TEMP/S” in “DATA MONITOR” mode with CONSULT-II. c) Start engine and warm it up while monitoring “COOLAN EC-366 DTC P0420, P0430 THREE WAY CATALYST FUNCTION DTC Confirmation Procedure (Cont’d) TEMP/S” indication on CONSULT-II. When “COOLAN TEMP/S” indication reaches to 70°C (158°F), go to step 3. 10) Select “SELF-DIAG RESULTS” mode with CONSULT-II. 11) Confirm that the 1st trip DTC is not detected. If the 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-367. GI d) MA EM LC Overall Function Check NAEC0953 Use this procedure to check the overall function of the warm-up three way catalyst. During this check, a DTC might not be confirmed. CAUTION: Always drive vehicle at a safe speed. WITH GST NAEC0953S01 1) SEC430D SEC431D Start engine and warm it up to the normal operating temperature. 2) Turn ignition switch “OFF” and wait at least 10 seconds. 3) Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least one minute under no load. 4) Let engine idle for one minute. 5) Set voltmeters probes between ECM terminals 35 [heated oxygen sensor 1 bank 1 signal], 16 [heated oxygen sensor 1 bank 2 signal] and engine ground, and ECM terminals 74 [heated oxygen sensor 2 bank 1 signal], 55 [heated oxygen sensor 2 bank 2 signal] and engine ground. 6) Keep engine speed at 2,000 rpm constant under no load. 7) Make sure that the voltage switching frequency (high & low) between ECM terminals 74 and engine ground, or 55 and engine ground is very less than that of ECM terminals 35 and engine ground, or 16 and engine ground. Switching frequency ratio = A/B A: Heated oxygen sensor 2 voltage switching frequency B: Heated oxygen sensor 1 voltage switching frequency This ratio should be less than 0.75. If the ratio is greater than above, it means warm-up three way catalyst does not operate properly. Go to “Diagnostic Procedure”, EC-367. NOTE: If the voltage at terminal 16 or 35 does not switch periodically more than 5 times within 10 seconds at step 5, perform trouble diagnosis for “DTC P0133, P0153” first. (See EC-264.) Diagnostic Procedure 1 CHECK EXHAUST SYSTEM Visually check exhaust tubes and muffler for dent. OK or NG OK 䊳 GO TO 2. NG 䊳 Repair or replace. NAEC0954 FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-367 DTC P0420, P0430 THREE WAY CATALYST FUNCTION Diagnostic Procedure (Cont’d) 2 CHECK EXHAUST GAS LEAK 1. Start engine and run it at idle. 2. Listen for an exhaust gas leak before the three way catalyst (manifold). SEC635D OK or NG OK 䊳 GO TO 3. NG 䊳 Repair or replace. 3 CHECK INTAKE AIR LEAK Listen for an intake air leak after the mass air flow sensor. OK or NG OK 䊳 GO TO 4. NG 䊳 Repair or replace. 4 CHECK IGNITION TIMING Check the following items. Refer to “Basic Inspection”, EC-131. MTBL1368 OK or NG OK 䊳 GO TO 5. NG 䊳 Follow the “Basic Inspection”. EC-368 DTC P0420, P0430 THREE WAY CATALYST FUNCTION Diagnostic Procedure (Cont’d) 5 GI CHECK INJECTORS 1. Refer to WIRING DIAGRAM for Injectors, EC-759. 2. Stop engine and then turn ignition switch “ON”. 3. Check voltage between ECM terminals 21, 22, 23, 40, 41, 42 and ground with CONSULT-II or tester. MA EM LC SEC516D FE Voltage: Battery voltage OK or NG CL MT OK 䊳 GO TO 6. NG 䊳 Perform “Diagnostic Procedure”, “INJECTOR”, EC-760. 6 1. 2. 3. 4. 5. CHECK IGNITION SPARK AT Turn ignition switch “OFF”. Disconnect ignition coil assembly from rocker cover. Connect a known-good spark plug to the ignition coil assembly. Place end of spark plug against a suitable ground and crank engine. Check for spark. TF PD AX SU BR SEC437D OK or NG OK 䊳 GO TO 7. NG 䊳 Check ignition coil with power transistor and their circuit. Refer to EC-748. 7 ST RS BT CHECK INJECTOR 1. Turn ignition switch “OFF”. 2. Remove injector assembly. Refer to EC-66. Keep fuel hose and all injectors connected to injector gallery. 3. Disconnect all ignition coil harness connectors. 4. Turn ignition switch “ON”. Make sure fuel does not drip from injector. OK or NG OK (Does not drip.) 䊳 GO TO 8. NG (Drips.) 䊳 Replace the injector(s) from which fuel is dripping. EC-369 HA SC EL IDX DTC P0420, P0430 THREE WAY CATALYST FUNCTION Diagnostic Procedure (Cont’d) 8 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. Trouble is fixed. 䊳 INSPECTION END Trouble is not fixed. 䊳 Replace three way catalyst (manifold). EC-370 DTC P0441 EVAP CONTROL SYSTEM System Description System Description NAEC0955 NOTE: If DTC P0441 is displayed with other DTC such as P2122, P2123, P2127, P2128 or P2138, first perform trouble diagnosis for other DTC. GI MA EM LC SEF323U 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 solenoid valve is open to admit purge flow. Purge flow exposes the EVAP control system pressure sensor to intake manifold vacuum. P0441 0441 EVAP control system incorrect purge flow DTC Detecting Condition EVAP control system does not operate properly, EVAP control system has a leak between intake manifold and EVAP control system pressure sensor. MT NAEC0956 Under normal conditions (non-closed throttle), sensor output voltage indicates if pressure drop and purge flow are adequate. If not, a fault is determined. Trouble diagnosis name CL AT On Board Diagnosis Logic DTC No. FE Possible Cause 쐌 EVAP canister purge volume control solenoid valve stuck closed 쐌 EVAP control system pressure sensor and the circuit 쐌 Loose, disconnected or improper connection of rubber tube 쐌 Blocked rubber tube 쐌 Cracked EVAP canister 쐌 EVAP canister purge volume control solenoid valve circuit 쐌 Accelerator pedal position sensor 쐌 Blocked purge port 쐌 EVAP canister vent control valve TF PD AX SU BR ST RS BT HA SC EL IDX EC-371 DTC P0441 EVAP CONTROL SYSTEM DTC Confirmation Procedure DTC Confirmation Procedure NAEC0957 CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Always perform test at a temperature of 5°C (41°F) or more. WITH CONSULT-II SEC757C 1) 2) 3) 4) 5) 6) SEC758C NAEC0957S01 Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF” and wait at least 10 seconds. Start engine and let it idle for at least 70 seconds. Select “PURG FLOW P0441” of “EVAPORATIVE SYSTEM” in “DTC CONFIRMATION” mode with CONSULT-II. Touch “START”. If “COMPLETED” is displayed, go to step 7. When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take at least 35 seconds.) Selector lever Suitable position Vehicle speed 32 - 120 km/h (20 - 75 MPH) ENG SPEED 500 - 3,000 rpm B/FUEL SCHDL 1.0 - 10 msec Engine coolant temperature More than 20°C (68°F) 7) SEC759C If “TESTING” is not changed for a long time, retry from step 2. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-374. Overall Function Check NAEC0958 Use this procedure to check the overall monitoring function of the EVAP control system purge flow monitoring. During this check, a DTC might not be confirmed. WITH GST 1) 2) SEC523D 3) 4) NAEC0958S01 Lift up drive wheels. Start engine (TCS switch “OFF”) and warm it up to normal operating temperature. Turn ignition switch “OFF”, wait at least 10 seconds. Start engine and wait at least 70 seconds. EC-372 DTC P0441 EVAP CONTROL SYSTEM Overall Function Check (Cont’d) 5) 6) 7) Set voltmeter probes to ECM terminals 32 (EVAP control system pressure sensor signal) and ground. Check EVAP control system pressure sensor value at idle speed and note it. Establish and maintain the following conditions for at least 1 minute. Air conditioner switch ON Headlamp switch ON Rear window defogger switch ON Engine speed Approx. 3,000 rpm Gear position Any position other than “P”, “N” or “R” 8) 9) Verify that EVAP control system pressure sensor value stays 0.1V less than the value at idle speed (measured at step 6) for at least 1 second. If NG, go to “Diagnostic Procedure”, EC-374. GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-373 DTC P0441 EVAP CONTROL SYSTEM Diagnostic Procedure Diagnostic Procedure 1 =NAEC0959 CHECK EVAP CANISTER 1. Turn ignition switch “OFF”. 2. Check EVAP canister for cracks. OK or NG OK (With CONSULT-II) 䊳 GO TO 2. OK (Without CONSULTII) 䊳 GO TO 3. NG 䊳 Replace EVAP canister. 2 CHECK PURGE FLOW With CONSULT-II 1. Disconnect vacuum hose connected to EVAP canister purge volume control solenoid valve at EVAP service port and install vacuum gauge. SEF983Y 2. 3. 4. 5. Start engine and let it idle. Select “PURG VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Rev engine up to 2,000 rpm. Touch “Qd” and “Qu” on CONSULT-II screen to adjust “PURG VOL CONT/V” opening and check vacuum existence. PBIB1678E MTBL1805 OK or NG OK 䊳 GO TO 7. NG 䊳 GO TO 4. EC-374 DTC P0441 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 3 GI CHECK PURGE FLOW Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Stop engine. 3. Disconnect vacuum hose connected to EVAP canister purge volume control solenoid valve at EVAP service port and install vacuum gauge. MA EM LC FE SEF983Y 4. Start engine and let it idle for at least 80 seconds. 5. Check vacuum gauge indication when revving engine up to 2,000 rpm. Vacuum should exist. 6. Release the accelerator pedal fully and let idle. Vacuum should not exist. OK or NG OK 䊳 GO TO 7. NG 䊳 GO TO 4. 4 CL MT AT TF CHECK EVAP PURGE LINE PD 1. Turn ignition switch “OFF”. 2. Check EVAP purge line for improper connection or disconnection. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-45. AX OK or NG OK 䊳 GO TO 5. NG 䊳 Repair it. SU BR ST RS BT HA SC EL IDX EC-375 DTC P0441 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 5 CHECK EVAP PURGE HOSE AND PURGE PORT 1. Disconnect purge hoses connected to EVAP service port A and EVAP canister purge volume control solenoid valve B. SEF367U 2. Blow air into each hose and EVAP purge port C. 3. Check that air flows freely. SEF368U OK or NG OK (With CONSULT-II) 䊳 GO TO 6. OK (Without CONSULTII) 䊳 GO TO 7. NG 䊳 Repair or clean hoses and/or purge port. 6 CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE With CONSULT-II 1. Start engine. 2. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Check that engine speed varies according to the valve opening. PBIB1678E OK or NG OK 䊳 GO TO 8. NG 䊳 GO TO 7. EC-376 DTC P0441 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 7 GI CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE With CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions. MA EM LC SEF334XA Without CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions. FE CL MT AT TF SEF335X PD OK or NG OK 䊳 GO TO 8. NG 䊳 Replace EVAP canister purge volume control solenoid valve. 8 AX CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR HOSE 1. Turn ignition switch “OFF”. 2. Check disconnection or improper connection of hose connected to EVAP control system pressure sensor. SU BR OK or NG OK 䊳 GO TO 9. NG 䊳 Repair it. ST RS BT HA SC EL IDX EC-377 DTC P0441 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 9 CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR CONNECTOR 1. Disconnect EVAP control system pressure sensor harness connector. SEC931C 2. Check connectors for water. Water should not exist. OK or NG OK 䊳 GO TO 10. NG 䊳 Replace EVAP control system pressure sensor. 10 CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR FUNCTION Refer to “DTC Confirmation Procedure” for DTC P0452, EC-410 and P0453, EC-416. OK or NG OK 䊳 GO TO 11. NG 䊳 Replace EVAP control system pressure sensor. 11 CHECK RUBBER TUBE FOR CLOGGING 1. Disconnect rubber tube connected to EVAP canister vent control valve. 2. Check the rubber tube for clogging. OK or NG OK 䊳 GO TO 12. NG 䊳 Clean the rubber tube using an air blower. 12 CHECK EVAP CANISTER VENT CONTROL VALVE-I 1. Remove EVAP canister vent control valve from EVAP canister. 2. Check portion B of EVAP canister vent control valve for being rusted. SEF376Z OK or NG OK 䊳 GO TO 13. NG 䊳 Replace EVAP canister vent control valve. EC-378 DTC P0441 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 13 1. 2. 3. 4. GI CHECK EVAP CANISTER VENT CONTROL VALVE-II With CONSULT-II Reconnect harness connectors disconnected. Turn ignition switch “ON”. Perform “VENT CONTROL/V” in “ACTIVE TEST” mode. Check air passage continuity and operation delay time. MA EM LC FE SEC158D Without CONSULT-II Check air passage continuity and operation delay time under the following conditions. CL MT AT TF PD SEF378Z AX Make sure new O-ring is installed properly. OK or NG OK 䊳 GO TO 15. NG 䊳 GO TO 14. 14 BR CHECK EVAP CANISTER VENT CONTROL VALVE-III 1. Clean the air passage (Portion A to B) of EVAP canister vent control valve using an air blower. 2. Perform Test No. 13 again. OK or NG OK 䊳 GO TO 15. NG 䊳 Replace EVAP canister vent control valve. 15 SU CHECK EVAP PURGE LINE ST RS BT HA Inspect EVAP purge line (pipe and rubber tube). Check for evidence of leaks. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-45. OK or NG OK 䊳 GO TO 16. NG 䊳 Replace it. SC EL IDX EC-379 DTC P0441 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 16 CLEAN EVAP PURGE LINE Clean EVAP purge line (pipe and rubber tube) using air blower. 䊳 17 GO TO 17. CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-380 DTC P0442 EVAP CONTROL SYSTEM On Board Diagnosis Logic On Board Diagnosis Logic NAEC0960 NOTE: If DTC P0442 is displayed with P1448, first perform trouble diagnosis for DTC P1448. (See EC-636.) This diagnosis detects leaks in the EVAP purge line using engine intake manifold vacuum. If pressure does not increase, the ECM will check for leaks in the line between the fuel tank and EVAP canister purge volume control solenoid 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 purge volume control solenoid valve. The EVAP canister vent control valve will then be closed to shut the EVAP purge line off. The EVAP canister purge volume control solenoid valve is opened to depressurize the EVAP purge line using intake manifold vacuum. After this occurs, the EVAP canister purge volume control solenoid valve will be closed. GI MA EM LC FE CL MT AT SEF323U DTC No. P0442 0442 Trouble diagnosis name EVAP control system small leak detected (negative pressure) DTC Detecting Condition EVAP control system has a leak, EVAP control system does not operate properly. EC-381 Possible Cause 쐌 Incorrect fuel tank vacuum relief valve 쐌 Incorrect fuel filler cap used 쐌 Fuel filler cap remains open or fails to close. 쐌 Foreign matter caught in fuel filler cap 쐌 Leak is in line between intake manifold and EVAP canister purge volume control solenoid valve. 쐌 Foreign matter caught in EVAP canister vent control valve 쐌 EVAP canister or fuel tank leaks 쐌 EVAP purge line (pipe and rubber tube) leaks 쐌 EVAP purge line rubber tube bent 쐌 Blocked or bent rubber tube to EVAP control system pressure sensor 쐌 Loose or disconnected rubber tube 쐌 EVAP canister vent control valve and the circuit 쐌 EVAP canister purge volume control solenoid valve and the circuit 쐌 Fuel tank temperature sensor 쐌 O-ring of EVAP canister vent control valve is missing or damaged. 쐌 Water separator 쐌 EVAP canister is saturated with water. 쐌 EVAP control system pressure sensor 쐌 Fuel level sensor and the circuit 쐌 Refueling control valve 쐌 ORVR system leaks TF PD AX SU BR ST RS BT HA SC EL IDX DTC P0442 EVAP CONTROL SYSTEM On Board Diagnosis Logic (Cont’d) CAUTION: 쐌 Use only a genuine NISSAN fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. 쐌 If the fuel filler cap is not tightened properly, the MIL may come on. 쐌 Use only a genuine NISSAN rubber tube as a replacement. DTC Confirmation Procedure SEC760C NAEC0961 NOTE: 쐌 If DTC P0442 is displayed with P1448, first perform trouble diagnosis for DTC P1448 (See EC-636). 쐌 If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: 쐌 Perform “DTC WORK SUPPORT” when the fuel level is between 1/4 and 3/4 full, and vehicle is placed on flat level surface. 쐌 Open engine hood before conducting the following procedure. WITH CONSULT-II NAEC0961S01 1) 2) 3) SEC761C SEC762C Turn ignition switch “ON”. Turn ignition switch “OFF” and wait at least 10 seconds. Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 4) Make sure that the following conditions are met. COOLAN TEMP/S: 0 - 70°C (32 - 158°F) INT/A TEMP SE: 0 - 30°C (32 - 86°F) 5) Select “EVP SML LEAK P0442/P1442” of “EVAPORATIVE SYSTEM” in “DTC WORK SUPPORT” mode with CONSULTII. Follow the instruction displayed. NOTE: If the engine speed cannot be maintained within the range displayed on the CONSULT-II screen, go to “Basic Inspection”, EC-131. 6) Make sure that “OK” is displayed. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-383. NOTE: Make sure that EVAP hoses are connected to EVAP canister purge volume control solenoid valve properly. WITH GST SEC763C NAEC0961S02 NOTE: Be sure to read the explanation of “Driving Pattern” on EC-92 before driving vehicle. 1) Start engine. 2) Drive vehicle according to “Driving Pattern”, EC-92. 3) Stop vehicle. 4) Select “MODE 1” with GST. 쐌 If SRT of EVAP system is not set yet, go to the following step. EC-382 DTC P0442 EVAP CONTROL SYSTEM DTC Confirmation Procedure (Cont’d) 쐌 5) 6) If SRT of EVAP system is set, the result will be OK. Turn ignition switch “OFF” and wait at least 10 seconds. Start engine. It is not necessary to cool engine down before driving. 7) Drive vehicle again according to the “Driving Pattern”, EC-92. 8) Stop vehicle. 9) Select “MODE 3” with GST. 쐌 If P0442 is displayed on the screen, go to “Diagnostic Procedure”, EC-383. 쐌 If P0441 is displayed on the screen, go to “Diagnostic Procedure” for DTC P0441, EC-374. 쐌 If P0441 and P0442 are not displayed on the screen, go to the following step. 10) Select “MODE 1” with GST. 쐌 If SRT of EVAP system is set, the result will be OK. 쐌 If SRT of EVAP system is not set, go to step 6. GI MA EM LC FE CL MT AT Diagnostic Procedure 1 NAEC0962 CHECK FUEL FILLER CAP DESIGN TF 1. Turn ignition switch “OFF”. 2. Check for genuine NISSAN fuel filler cap design. PD AX SU SEF915U BR OK or NG ST OK 䊳 GO TO 2. NG 䊳 Replace with genuine NISSAN fuel filler cap. RS 2 CHECK FUEL FILLER CAP INSTALLATION Check that the cap is tightened properly by rotating the cap clockwise. BT OK or NG OK 䊳 GO TO 3. NG 䊳 쐌 Open fuel filler cap, then clean cap and fuel filler neck threads using air blower. 쐌 Retighten until ratcheting sound is heard. HA SC EL IDX EC-383 DTC P0442 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 3 CHECK FUEL FILLER CAP FUNCTION Check for air releasing sound while opening the fuel filler cap. OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 4. 4 CHECK FUEL TANK VACUUM RELIEF VALVE 1. Wipe clean valve housing. 2. Check valve opening pressure and vacuum. SEF445Y SEF943S Pressure: 15.3 - 20.0 kPa (0.156 - 0.204 kg/cm2, 2.22 - 2.90 psi) Vacuum: −6.0 to −3.3 kPa (−0.061 to −0.034 kg/cm2, −0.87 to −0.48 psi) CAUTION: Use only a genuine fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. OK or NG OK 䊳 GO TO 5. NG 䊳 Replace fuel filler cap with a genuine one. EC-384 DTC P0442 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 5 GI INSTALL THE PRESSURE PUMP To locate the EVAP leak, install EVAP service port adapter and pressure pump to EVAP service port securely. MA EM LC SEF983Y FE CL MT AT SEF916U NOTE: Improper installation of the EVAP service port adapter to the EVAP service port may cause leaking. With CONSULT-II 䊳 GO TO 6. Without CONSULT-II 䊳 GO TO 7. TF PD AX SU BR ST RS BT HA SC EL IDX EC-385 DTC P0442 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 6 CHECK FOR EVAP LEAK With CONSULT-II 1. Turn ignition switch “ON”. 2. Select “EVAP SYSTEM CLOSE” of “WORK SUPPORT” mode with CONSULT-II. 3. Touch “START” and apply pressure into the EVAP line until the pressure indicator reaches the middle of the bar graph. NOTE: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in the system. PEF917U 4. Using EVAP leak detector, locate the EVAP leak. For the leak detector, refer to the instruction manual for more details. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-45. SEF200U OK or NG OK 䊳 GO TO 8. NG 䊳 Repair or replace. EC-386 DTC P0442 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 7 GI CHECK FOR EVAP LEAK Without CONSULT-II 1. Turn ignition switch “OFF”. 2. Apply 12 volts DC to EVAP canister vent control valve. The valve will close. (Continue to apply 12 volts until the end of test.) MA EM LC FE SEC930C 3. Apply 12 volts DC to vacuum cut valve bypass valve. The valve will open. (Continue to apply 12V until the end of test.) CL MT AT TF SEC932C 4. Pressurize the EVAP line using pressure pump with 1.3 to 2.7 kPa (10 to 20 mmHg, 0.39 to 0.79 inHg), then remove pump and EVAP service port adapter. NOTE: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in the system. 5. Using EVAP leak detector, locate the EVAP leak. For the leak detector, refer to the instruction manual for more details. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-45. PD AX SU BR ST RS BT SEF200U OK or NG OK 䊳 GO TO 8. NG 䊳 Repair or replace. HA SC EL IDX EC-387 DTC P0442 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 8 1. 2. 3. 4. CHECK WATER SEPARATOR Check Check Check Check visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged. PBIB1032E 5. In case of NG in items 2 - 4, replace the parts. NOTE: 쐌 Do not disassemble water separator. OK or NG OK 䊳 GO TO 9. NG 䊳 Replace water separator. 9 CHECK EVAP CANISTER VENT CONTROL VALVE, O-RING AND CIRCUIT Refer to “DTC Confirmation Procedure”, EC-404. OK or NG OK 䊳 GO TO 10. NG 䊳 Repair or replace EVAP canister vent control valve and O-ring or harness/connector. 10 CHECK IF EVAP CANISTER SATURATED WITH WATER 1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Does water drain from the EVAP canister? SEF596U Yes or No Yes 䊳 GO TO 11. No (With CONSULT-II) 䊳 GO TO 13. No (Without CONSULTII) 䊳 GO TO 14. EC-388 DTC P0442 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 11 GI CHECK EVAP CANISTER Weigh the EVAP canister with the EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb). MA OK or NG OK (With CONSULT-II) 䊳 GO TO 13. OK (Without CONSULTII) 䊳 GO TO 14. NG 䊳 GO TO 12. 12 EM LC DETECT MALFUNCTIONING PART Check the following. 쐌 EVAP canister for damage 쐌 EVAP hose between EVAP canister and water separator for clogging or poor connection 䊳 13 1. 2. 3. 4. 5. FE Repair hose or replace EVAP canister. CL CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION MT With CONSULT-II Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port. Start engine. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode. Touch “Qu” on CONSULT-II screen to increase “PURG VOL CONT/V” opening to 100%. Check vacuum hose for vacuum when revving engine up to 2,000 rpm. AT TF PD AX SU PBIB1678E BR Vacuum should exist. OK or NG OK 䊳 GO TO 16. NG 䊳 GO TO 15. ST RS 14 1. 2. 3. 4. 5. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION Without CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine. Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port. Start engine and let it idle for at least 80 seconds. Check vacuum hose for vacuum when revving engine up to 2,000 rpm. Vacuum should exist. BT HA SC OK or NG OK 䊳 GO TO 17. NG 䊳 GO TO 15. EL IDX EC-389 DTC P0442 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 15 CHECK VACUUM HOSE Check vacuum hoses for clogging or disconnection. Refer to “Vacuum Hose Drawing”, EC-35. OK or NG OK (With CONSULT-II) 䊳 GO TO 16. OK (Without CONSULTII) 䊳 GO TO 17. NG 䊳 Repair or reconnect the hose. 16 CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE With CONSULT-II 1. Start engine. 2. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Check that engine speed varies according to the valve opening. PBIB1678E OK or NG OK 䊳 GO TO 18. NG 䊳 GO TO 17. EC-390 DTC P0442 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 17 GI CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE With CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions. MA EM LC SEC524D FE CL MT AT SEF334XA TF Without CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions. PD AX SU BR SEC524D ST RS BT HA SEF335X OK or NG OK 䊳 GO TO 18. NG 䊳 Replace EVAP canister purge volume control solenoid valve. SC EL IDX EC-391 DTC P0442 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 18 CHECK FUEL TANK TEMPERATURE SENSOR 1. Remove fuel level sensor unit. 2. Check resistance between fuel level sensor unit terminals 1 and 2 by heating with hot water or heat gun as shown in the figure. SEF974Y OK or NG OK 䊳 GO TO 19. NG 䊳 Replace fuel level sensor unit. EC-392 DTC P0442 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 19 GI CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR 1. Remove EVAP control system pressure sensor with its harness connector connected. 쐌 Never apply force to the air hole protector of the sensor if equipped. MA EM LC SEF799W 2. Remove EVAP control system pressure sensor from EVAP canister. Do not reuse the O-ring, replace it with a new one. 3. Install a vacuum pump to EVAP control system pressure sensor. 4. Turn ignition switch “ON” and check output voltage between ECM terminal 32 and ground under the following conditions. FE CL MT AT TF PD SEC422D CAUTION: 쐌 Always calibrate the vacuum pump gauge when using it. 쐌 Do not apply below −93.3 kPa (−700 mmHg, −27.56 inHg) or pressure over 101.3 kPa (760 mmHg, 29.92 inHg). 쐌 Discard and EVAP control system pressure 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. AX SU OK or NG BR OK 䊳 GO TO 20. NG 䊳 Replace EVAP control system pressure sensor. ST 20 CHECK EVAP PURGE LINE Check EVAP purge line (pipe, rubber tube, fuel tank and EVAP canister) for cracks or improper connection. Refer to “Evaporative Emission System”, EC-41. OK or NG OK 䊳 GO TO 21. NG 䊳 Repair or reconnect the hose. 21 CLEAN EVAP PURGE LINE Clean EVAP purge line (pipe and rubber tube) using air blower. 䊳 RS BT HA SC GO TO 22. EL IDX EC-393 DTC P0442 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 22 CHECK REFUELING EVAP VAPOR LINE 쐌 Check refueling EVAP vapor line between EVAP canister and fuel tank for clogging, kink, looseness and improper connection. For location, refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-45. OK or NG OK 䊳 GO TO 23. NG 䊳 Repair or replace hoses and tubes. 23 CHECK SIGNAL LINE AND RECIRCULATION LINE 쐌 Check signal line and recirculation line between filler neck tube and fuel tank for clogging, kink, cracks, looseness and improper connection. OK or NG OK 䊳 GO TO 24. NG 䊳 Repair or replace hoses, tubes or filler neck tube. 24 CHECK REFUELING CONTROL VALVE 1. Remove fuel filler cap. 2. Check air continuity between hose ends A and B. Blow air into hose end B. Air should flow freely into the fuel tank. 3. Blow air into hose end A and check that there is no leakage. 4. Apply pressure to both hose ends A and B [20 kPa (150 mmHg, 5.91 inHg)] using a pressure pump and a suitable 3-way connector. Check that there is no leakage. SEC883C OK or NG OK 䊳 GO TO 25. NG 䊳 Replace or refueling control valve with fuel tank. 25 CHECK FUEL LEVEL SENSOR Refer to EL-124, “Fuel Level Sensor Unit Check”. OK or NG OK 䊳 GO TO 26. NG 䊳 Replace fuel level sensor unit. EC-394 DTC P0442 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 26 GI CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 MA INSPECTION END EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-395 DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE Description Description NAEC0963 SYSTEM DESCRIPTION Sensor Input Signal to ECM Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed*2 and piston position Mass air flow sensor Amount of intake air Engine coolant temperature sensor Engine coolant temperature Battery Battery voltage*2 Throttle position sensor Throttle position Accelerator pedal position sensor Accelerator pedal position Heated oxygen sensor 1 Density of oxygen in exhaust gas (Mixture ratio feedback signal) Fuel tank temperature sensor Fuel temperature in fuel tank Vehicle speed signal*1 Vehicle speed NAEC0963S01 ECM function Actuator EVAP canEVAP canister purge volume ister purge control solenoid valve flow control *1: This signal is sent to the ECM through CAN communication line. *2: ECM determines the start signal status by the signals of engine speed and battery voltage. This system controls flow rate of fuel vapor from the EVAP canister. The opening of the vapor by-pass passage in the EVAP canister purge volume control solenoid valve changes to control the flow rate. The EVAP canister purge volume control solenoid valve repeats ON/OFF operation according to the signal sent from the ECM. The opening of the valve varies for optimum engine control. The optimum value stored in the ECM is determined by considering various engine conditions. When the engine is operating, the flow rate of fuel vapor from the EVAP canister is regulated as the air flow changes. COMPONENT DESCRIPTION NAEC0963S02 The EVAP canister purge volume control solenoid valve uses a ON/OFF duty to control the flow rate of fuel vapor from the EVAP canister. The EVAP canister purge volume control solenoid valve is moved by ON/OFF pulses from the ECM. The longer the ON pulse, the greater the amount of fuel vapor that will flow through the valve. SEF337U CONSULT-II Reference Value in Data Monitor Mode NAEC0964 Specification data are reference values. MONITOR ITEM PURG VOL C/V CONDITION 쐌 쐌 쐌 쐌 Engine: After warming up Air conditioner switch “OFF” Shift lever: “N” No-load SPECIFICATION Idle (Vehicle stopped) 0% 2,000 rpm — EC-396 DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE ECM Terminals and Reference Value ECM Terminals and Reference Value NAEC0965 Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) GI MA EM LC BATTERY VOLTAGE (11 - 14V)★ [Engine is running] 쐌 Idle speed FE CL 45 L/Y SEC990C EVAP canister purge volume control solenoid valve BATTERY VOLTAGE (11 - 14V)★ MT AT [Engine is running] 쐌 Engine speed is about 2,000 rpm (More than 100 seconds after starting engine). TF SEC991C PD ★: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) AX SU On Board Diagnosis Logic DTC No. P0444 0444 P0445 0445 Trouble diagnosis name NAEC0966 BR DTC Detecting Condition EVAP canister purge volume control solenoid valve circuit open An excessively low voltage signal is sent to ECM through the valve. EVAP canister purge volume control solenoid valve circuit shorted An excessively high voltage signal is sent to ECM through the valve. Possible Cause 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 EVAP canister purge volume control solenoid valve 쐌 Harness or connectors (The sensor circuit is shorted.) 쐌 EVAP canister purge volume control solenoid valve ST RS BT HA SC EL IDX EC-397 DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE DTC Confirmation Procedure DTC Confirmation Procedure NAEC0967 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm battery voltage is more than 11V at idle. WITH CONSULT-II SEF058Y 1) 2) 3) 4) NAEC0967S01 Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for at least 13 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-400. WITH GST Follow the proocedure “WITH CONSULT-II” above. EC-398 NAEC0967S02 DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE Wiring Diagram Wiring Diagram NAEC0968 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC096E EC-399 IDX DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE Diagnostic Procedure Diagnostic Procedure 1 NAEC0969 CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT 1. Turn ignition switch “OFF”. 2. Disconnect EVAP canister purge volume control solenoid valve harness connector. SEC524D 3. Turn ignition switch “ON”. 4. Check voltage between EVAP canister purge volume control solenoid valve terminal 1 and ground with CONSULT-II or tester. SEF988Y OK or NG OK 䊳 GO TO 3. NG 䊳 GO TO 2. 2 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors E1, M1 쐌 Harness connectors M32, F23 쐌 Harness for open or short between EVAP canister purge volume control solenoid valve and ECM 쐌 Harness for open or short between EVAP canister purge volume control solenoid valve and ECM relay 䊳 Repair open circuit or short to ground and short to power in harness or connectors. EC-400 DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE Diagnostic Procedure (Cont’d) 3 CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT GI 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 45 and EVAP canister purge volume control solenoid valve terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. MA OK or NG LC OK (With CONSULT-II) 䊳 GO TO 4. OK (Without CONSULTII) 䊳 GO TO 5. NG 䊳 Repair open circuit or short to ground and short to power in harness or connetors. 4 EM FE CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION With CONSULT-II 1. Start engine. 2. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Check that engine speed varies according to the valve opening. CL MT AT TF PD PBIB1678E AX OK or NG OK 䊳 GO TO 6. NG 䊳 GO TO 5. SU BR ST RS BT HA SC EL IDX EC-401 DTC P0444, P0445 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE Diagnostic Procedure (Cont’d) 5 CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE With CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions. SEF334XA Without CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions. SEF335X OK or NG OK 䊳 GO TO 6. NG 䊳 Replace EVAP canister purge volume control solenoid valve. 6 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-402 DTC P0447 EVAP CANISTER VENT CONTROL VALVE Component Description Component Description SEF381Z NAEC0970 The EVAP canister vent control valve is located on the EVAP canister and is used to seal the canister vent. This solenoid valve responds to 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 evaporative emission control system components. This solenoid valve is used only for diagnosis, and usually remains opened. When the vent is closed, under normal purge conditions, the evaporative emission control system is depressurized and allows “EVAP Control System (Small Leak)” diagnosis. GI MA EM LC FE CL MT SEC928C CONSULT-II Reference Value in Data Monitor Mode NAEC0971 Specification data are reference values. MONITOR ITEM CONDITION SPECIFICATION 쐌 Ignition switch: ON VENT CONT/V NAEC0972 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 117 WIRE COLOR G/R P0447 0447 AX SU BR ITEM CONDITION EVAP canister vent control valve [Ignition switch “ON”] DATA (DC Voltage) Trouble diagnosis name EVAP canister vent control valve circuit open DTC Detecting Condition ST BATTERY VOLTAGE (11 - 14V) RS On Board Diagnosis Logic DTC No. TF PD OFF ECM Terminals and Reference Value AT NAEC0973 Possible Cause An improper voltage signal is sent to ECM through Harness or connectors EVAP canister vent control valve. (The valve circuit is open or shorted.) 쐌 EVAP canister vent control valve BT HA SC EL IDX EC-403 DTC P0447 EVAP CANISTER VENT CONTROL VALVE DTC Confirmation Procedure DTC Confirmation Procedure NAEC0974 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm battery voltage is more than 11V at idle. WITH CONSULT-II 1) 2) 3) 4) NAEC0974S01 Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and wait at least 8 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-406. WITH GST Follow the procedure “WITH CONSULT-II” above. SEF058Y EC-404 NAEC0974S02 DTC P0447 EVAP CANISTER VENT CONTROL VALVE Wiring Diagram Wiring Diagram NAEC0975 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC097E EC-405 IDX DTC P0447 EVAP CANISTER VENT CONTROL VALVE Diagnostic Procedure Diagnostic Procedure 1 NAEC0976 INSPECTION START 1. Do you have CONSULT-II? Yes or No Yes 䊳 GO TO 2. No 䊳 GO TO 3. 2 CHECK EVAP CANISTER VENT CONTROL VALVE CIRCUIT With CONSULT-II 1. Turn ignition switch “OFF” and then turn “ON”. 2. Select “VENT CONTROL/V” in “ACTIVE TEST” mode with CONSULT-II. 3. Touch “ON/OFF” on CONSULT-II screen. PBIB0151E 4. Check for operating sound of the valve. Clicking noise should be heard. OK or NG OK 䊳 GO TO 7. NG 䊳 GO TO 3. EC-406 DTC P0447 EVAP CANISTER VENT CONTROL VALVE Diagnostic Procedure (Cont’d) 3 GI CHECK EVAP CANISTER VENT CONTROL VALVE POWER SUPPLY CIRCUIT 1. Turn ignition switch “OFF”. 2. Disconnect EVAP canister vent control valve harness connector. MA EM LC SEC928C 3. Turn ignition switch “ON”. 4. Check voltage between EVAP canister vent control valve terminal 2 and ground with CONSULT-II or tester. FE CL MT AT TF SEF990Y OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 4. 4 AX DETECT MALFUNCTIONING PART SU Check the following. 쐌 Harness connectors E1, M1 쐌 Harness connectors M33, F22 쐌 Harness connectors F27, M94 쐌 Harness connectors M2, B1 쐌 Harness connectors B43, M101 쐌 Harness for open or short between EVAP canister vent control valve and ECM relay 䊳 5 PD Repair open circuit or short to ground or short to power in harness or connectors. BR ST RS CHECK EVAP CANISTER VENT CONTROL VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 117 and EVAP canister vent control valve terminal 1. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 7. NG 䊳 GO TO 6. BT HA SC EL IDX EC-407 DTC P0447 EVAP CANISTER VENT CONTROL VALVE Diagnostic Procedure (Cont’d) 6 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors B101, B43 쐌 Harness connectors B1, M2 쐌 Harness connectors M94, F27 쐌 Harness for open or short between EVAP canister vent control valve and ECM 䊳 7 Repair open circuit or short to ground or short to power in harness or connectors. CHECK RUBBER TUBE FOR CLOGGING 1. Disconnect rubber tube connected to EVAP canister vent control valve. 2. Check the rubber tube for clogging. OK or NG OK 䊳 GO TO 8. NG 䊳 Clean the rubber tube using an air blower. 8 CHECK EVAP CANISTER VENT CONTROL VALVE-I 1. Remove EVAP canister vent control valve from EVAP canister. 2. Check portion B of EVAP canister vent control valve for being rusted. SEF376Z OK or NG OK 䊳 GO TO 9. NG 䊳 Replace EVAP canister vent control valve. EC-408 DTC P0447 EVAP CANISTER VENT CONTROL VALVE Diagnostic Procedure (Cont’d) 9 1. 2. 3. 4. GI CHECK EVAP CANISTER VENT CONTROL VALVE-II With CONSULT-II Reconnect harness connectors disconnected. Turn ignition switch “ON”. Perform “VENT CONTROL/V” in “ACTIVE TEST” mode. Check air passage continuity and operation delay time. MA EM LC FE SEC158D Without CONSULT-II Check air passage continuity and operation delay time under the following conditions. CL MT AT TF PD SEF378Z AX Make sure new O-ring is installed properly. OK or NG OK 䊳 GO TO 11. NG 䊳 GO TO 10. 10 BR CHECK EVAP CANISTER VENT CONTROL VALVE-III 1. Clean the air passage (Portion A to B) of EVAP canister vent control valve using an air blower. 2. Perform Test No. 9 again. OK or NG OK 䊳 GO TO 11. NG 䊳 Replace EVAP canister vent control valve. 11 SU CHECK INTERMITTENT INCIDENT ST RS BT HA Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END SC EL IDX EC-409 DTC P0452 EVAP SYSTEM PRESSURE SENSOR Component Description Component Description NAEC0779 The EVAP control system pressure sensor detects pressure in the purge line. The sensor output voltage to the ECM increases as pressure increases. SEF053V PBIB1207E CONSULT-II Reference Value in Data Monitor Mode NAEC0780 Specification data are reference values. MONITOR ITEM CONDITION SPECIFICATION EVAP SYS PRES 쐌 Ignition switch: ON 1.8 - 4.8V ECM Terminals and Reference Value NAEC0781 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) 32 L/G EVAP control system pressure sensor [Ignition switch “ON”] 1.8 - 4.8V 48 P/B Sensor’s power supply [Ignition switch “ON”] Approximately 5V 67 B/P Sensor’s ground [Engine is running] 쐌 Warm-up condition 쐌 Idle speed Approximately 0V EC-410 DTC P0452 EVAP SYSTEM PRESSURE SENSOR On Board Diagnosis Logic On Board Diagnosis Logic =NAEC0782 NOTE: If DTC P0452 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to EC-596. DTC No. P0452 0452 Trouble diagnosis name EVAP control system pressure sensor low input DTC Detecting Condition Possible Cause MA EM An excessively low voltage from the sensor is sent 쐌 Harness or connectors to ECM. (The sensor circuit is open or shorted.) 쐌 EVAP control system pressure sensor DTC Confirmation Procedure GI LC NAEC0784 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Always perform test at a temperature of 5°C (41°F) or more. FE CL MT WITH CONSULT-II AT NAEC0784S01 1) 2) 3) 4) 5) 6) 7) SEF194Y Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF” and wait at least 10 seconds. Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Make sure that “FUEL T/TEMP SE” is more than 0°C (32°F). Start engine and wait at least 20 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-413. If 1st trip DTC is not detected, go to next step. 8) Stop engine and install EVAP service port adapter and pressure pump to EVAP service port securely. 9) Pressurize the EVAP line using pressure pump. 10) Confirm the pressure does not go up. 11) If pressure go up, go to “Diagnostic Procedure”, EC-413. WITH GST 1) 2) SEC525D 3) 4) 5) 6) TF PD AX SU BR ST NAEC0784S02 Start engine and warm it up to normal operating temperature. Check that voltage between ECM terminal 107 (Fuel tank temperature sensor signal) and ground is less than 4.2V. Turn ignition switch “OFF” and wait at least 10 seconds. Start engine and wait at least 20 seconds. Select “MODE 7” with GST. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-413. RS BT HA SC EL IDX EC-411 DTC P0452 EVAP SYSTEM PRESSURE SENSOR Wiring Diagram Wiring Diagram NAEC0785 MEC098E EC-412 DTC P0452 EVAP SYSTEM PRESSURE SENSOR Diagnostic Procedure Diagnostic Procedure 1 NAEC0786 GI RETIGHTEN GROUND SCREWS MA Loosen and retighten engine ground screws. EM LC SEF959Y 䊳 2 GO TO 2. FE CL CHECK CONNECTOR MT 1. Disconnect EVAP control system pressure sensor harness connector. 2. Check sensor harness connector for water. Water should not exist. AT OK or NG OK 䊳 GO TO 3. NG 䊳 Repair or replace harness connector. 3 TF PD CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR POWER SUPPLY CIRCUIT 1. Turn ignition switch “ON”. 2. Check voltage between EVAP control system pressure sensor terminal 3 and ground with CONSULT-II or tester. AX SU BR ST SEF992Y RS OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 4. BT HA 4 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors B101, B43 쐌 Harness connectors B1, M2 쐌 Harness connectors M94, F27 쐌 Harness for open or short between EVAP control system pressure sensor and ECM 䊳 SC EL Repair harness or connectors. IDX EC-413 DTC P0452 EVAP SYSTEM PRESSURE SENSOR Diagnostic Procedure (Cont’d) 5 CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Check harness continuity between EVAP control system pressure sensor terminal 1 and engine ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK 䊳 GO TO 7. NG 䊳 GO TO 6. 6 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors B101, B43 쐌 Harness connectors B1, M2 쐌 Harness connectors M94, F27 쐌 Harness connectors F22, M23 쐌 Joint connector F204 쐌 Harness for open between EVAP control system pressure sensor and ECM 쐌 Harness for open between EVAP control system pressure sensor and TCM 䊳 7 Repair open circuit or short to power in harness or connectors. CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 32 and EVAP control system pressure sensor terminal 2. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 9. NG 䊳 GO TO 8. 8 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors B101, B43 쐌 Harness connectors B1, M2 쐌 Harness connectors M94, F27 쐌 Harness for open or short between ECM and EVAP control system pressure sensor 䊳 Repair open circuit or short to ground or short to power in harness or connectors. EC-414 DTC P0452 EVAP SYSTEM PRESSURE SENSOR Diagnostic Procedure (Cont’d) 9 GI CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR 1. Remove EVAP control system pressure sensor with its harness connector connected. 쐌 Never apply force to the air hole protector of the sensor if equipped. MA EM LC SEF799W 2. Remove EVAP control system pressure sensor from EVAP canister. Do not reuse the O-ring, replace it with a new one. 3. Install a vacuum pump to EVAP control system pressure sensor. 4. Turn ignition switch “ON” and check output voltage between ECM terminal 32 and ground under the following conditions. FE CL MT AT TF PD SEC422D CAUTION: 쐌 Always calibrate the vacuum pump gauge when using it. 쐌 Do not apply below −93.3 kPa (−700 mmHg, −27.56 inHg) or pressure over 101.3 kPa (760 mmHg, 29.92 inHg). 쐌 Discard and EVAP control system pressure 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. AX SU OK or NG BR OK 䊳 GO TO 10. NG 䊳 Replace EVAP control system pressure sensor. ST 10 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 RS INSPECTION END BT HA SC EL IDX EC-415 DTC P0453 EVAP SYSTEM PRESSURE SENSOR Component Description Component Description NAEC0977 The EVAP control system pressure sensor detects pressure in the purge line. The sensor output voltage to the ECM increases as pressure increases. SEF053V PBIB1207E CONSULT-II Reference Value in Data Monitor Mode NAEC0978 Specification data are reference values. MONITOR ITEM EVAP SYS PRES CONDITION SPECIFICATION 쐌 Ignition switch: ON 1.8 - 4.8V ECM Terminals and Reference Value NAEC0979 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) 32 L/G EVAP control system pressure sensor [Ignition switch “ON”] 1.8 - 4.8V 48 P/B Sensors’ power supply [Ignition switch “ON”] Approximately 5V 67 B/P Sensors’ ground [Engine is running] 쐌 Warm-up condition 쐌 Idle speed Approximately 0V EC-416 DTC P0453 EVAP SYSTEM PRESSURE SENSOR On Board Diagnosis Logic On Board Diagnosis Logic NAEC0980 NOTE: If DTC P0453 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to EC-596. DTC No. P0453 0453 Trouble diagnosis name EVAP control system pressure sensor high input DTC Detecting Condition An excessively high voltage from the sensor is sent to ECM. Possible Cause GI MA EM 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 EVAP control system pressure sensor 쐌 EVAP canister vent control valve 쐌 EVAP canister 쐌 Water separator 쐌 Rubber hose from EVAP canister vent control valve to water separator LC FE CL MT DTC Confirmation Procedure AT NAEC0981 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Always perform test at a temperature of 5°C (41°F) or more. TF PD AX SU WITH CONSULT-II 1) 2) 3) 4) 5) 6) 7) NAEC0981S01 Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF” and wait at least 10 seconds. Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Make sure that “FUEL T/TEMP SE” is more than 0°C (32°F). Start engine and wait at least 20 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-419. BR ST RS BT SEF194Y WITH GST 1) 2) 3) 4) 5) 6) NAEC0981S02 Start engine and warm it up to normal operating temperature. Check that voltage between ECM terminal 107 (Fuel tank temperature sensor signal) and ground is less than 4.2V. Turn ignition switch “OFF” and wait at least 10 seconds. Start engine and wait at least 20 seconds. Select “MODE 7” with GST. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-419. SEC525D EC-417 HA SC EL IDX DTC P0453 EVAP SYSTEM PRESSURE SENSOR Wiring Diagram Wiring Diagram NAEC0982 MEC098E EC-418 DTC P0453 EVAP SYSTEM PRESSURE SENSOR Diagnostic Procedure Diagnostic Procedure 1 NAEC0983 GI RETIGHTEN GROUND SCREWS MA Loosen and retighten engine ground screws. EM LC SEF959Y 䊳 2 GO TO 2. FE CL CHECK CONNECTOR MT 1. Disconnect EVAP control system pressure sensor harness connector. 2. Check sensor harness connector for water. Water should not exist. AT OK or NG OK 䊳 GO TO 3. NG 䊳 Repair or replace harness connector. 3 TF PD CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR POWER SUPPLY CIRCUIT 1. Turn ignition switch “ON”. 2. Check voltage between EVAP control system pressure sensor terminal 3 and ground with CONSULT-II or tester. AX SU BR ST SEF992Y RS OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 4. BT HA 4 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors B101, B43 쐌 Harness connectors B1, M2 쐌 Harness connectors M94, F27 쐌 Harness for open or short between EVAP control system pressure sensor and ECM 䊳 SC EL Repair open circuit or short to ground or short to power in harness or connectors. IDX EC-419 DTC P0453 EVAP SYSTEM PRESSURE SENSOR Diagnostic Procedure (Cont’d) 5 CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Check harness continuity between EVAP control system pressure sensor terminal 1 and engine ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK 䊳 GO TO 7. NG 䊳 GO TO 6. 6 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors B101, B43 쐌 Harness connectors B1, M2 쐌 Harness connectors M94, F27 쐌 Harness connectors F22, M33 쐌 Joint connector F204 쐌 Harness for open between EVAP control system pressure sensor and ECM 쐌 Harness for open between EVAP control system pressure sensor and TCM 䊳 7 Repair open circuit or short to power in harness or connectors. CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 32 and EVAP control system pressure sensor terminal 2. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 9. NG 䊳 GO TO 8. 8 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors B101, B43 쐌 Harness connectors B1, M2 쐌 Harness connectors M94, F27 쐌 Harness for open or short between ECM and EVAP control system pressure sensor 䊳 9 Repair open circuit or short to ground or short to power in harness or connectors. CHECK RUBBER TUBE FOR CLOGGING 1. Disconnect rubber tube connected to EVAP canister vent control valve. 2. Check the rubber tube for clogging. OK or NG OK 䊳 GO TO 10. NG 䊳 Clean the rubber tube using an air blower. EC-420 DTC P0453 EVAP SYSTEM PRESSURE SENSOR Diagnostic Procedure (Cont’d) CHECK EVAP CANISTER VENT CONTROL VALVE-I GI 1. Remove EVAP canister vent control valve from EVAP canister. 2. Check portion B of EVAP canister vent control valve for being rusted. MA 10 EM LC SEF376Z FE OK or NG OK 䊳 GO TO 11. NG 䊳 Replace EVAP canister vent control valve. 11 CL MT CHECK EVAP CANISTER VENT CONTROL VALVE With CONSULT-II 1. Perform “VENT CONTROL/V” in “ACTIVE TEST” mode. 2. Check air passage continuity and operation delay time under the following conditions. AT TF PD AX SU SEC158D BR Without CONSULT-II Check air passage continuity and operation delay time under the following conditions. ST RS BT HA SEF378Z Make sure new O-ring is installed properly. SC OK or NG OK 䊳 GO TO 13. NG 䊳 GO TO 12. EL IDX EC-421 DTC P0453 EVAP SYSTEM PRESSURE SENSOR Diagnostic Procedure (Cont’d) 12 CHECK EVAP CANISTER VENT CONTROL VALVE-III 1. Clean the air passage (portion A to B) of EVAP canister vent control valve using an air blower. 2. Perform Test No. 14 again. OK or NG OK 䊳 GO TO 13. NG 䊳 Replace EVAP canister vent control valve. 13 CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR 1. Remove EVAP control system pressure sensor with its harness connector connected. 쐌 Never apply force to the air hole protector of the sensor if equipped. SEF799W 2. Remove EVAP control system pressure sensor from EVAP canister. Do not reuse the O-ring, replace it with a new one. 3. Install a vacuum pump to EVAP control system pressure sensor. 4. Turn ignition switch “ON” and check output voltage between ECM terminal 32 and ground under the following conditions. SEC422D CAUTION: 쐌 Always calibrate the vacuum pump gauge when using it. 쐌 Do not apply below −93.3 kPa (−700 mmHg, −27.56 inHg) or pressure over 101.3 kPa (760 mmHg, 29.92 inHg). 쐌 Discard and EVAP control system pressure sensor which has been dropped from a height of more than 0.5m (19.7in) onto a hard surface such as a concrete floor; use a new one. OK or NG OK 䊳 GO TO 14. NG 䊳 Replace EVAP control system pressure sensor. 14 CHECK RUBBER TUBE Check obstructed rubber tube connected to EVAP canister vent control valve. OK or NG OK 䊳 GO TO 15. NG 䊳 Clean rubber tube using an air blower, repair or replace rubber tube. EC-422 DTC P0453 EVAP SYSTEM PRESSURE SENSOR Diagnostic Procedure (Cont’d) 15 1. 2. 3. 4. GI CHECK WATER SEPARATOR Check Check Check Check visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged. MA EM LC FE PBIB1032E 5. In case of NG in items 2 - 4, replace the parts. NOTE: 쐌 Do not disassemble water separator. CL MT OK or NG OK 䊳 GO TO 16. NG 䊳 Replace water separator. 16 AT CHECK IF EVAP CANISTER SATURATED WITH WATER TF 1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Check if water will drain from the EVAP canister. PD AX SU BR SEF596U ST Yes or No Yes 䊳 GO TO 17. No 䊳 GO TO 19. 17 RS BT CHECK EVAP CANISTER Weigh the EVAP canister with the EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb). HA OK or NG OK 䊳 GO TO 19. NG 䊳 GO TO 18. SC EL IDX EC-423 DTC P0453 EVAP SYSTEM PRESSURE SENSOR Diagnostic Procedure (Cont’d) 18 DETECT MALFUNCTIONING PART Check the following. 쐌 EVAP canister for damage 쐌 EVAP hose between EVAP canister and water separator for clogging or poor connection 䊳 19 Repair hose or replace EVAP canister. CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-424 DTC P0455 EVAP CONTROL SYSTEM On Board Diagnosis Logic On Board Diagnosis Logic NAEC0984 NOTE: If DTC P0455 is displayed with P1448, first perform trouble diagnosis for DTC P1448. (See EC-636.) This diagnosis detects a very large leak (fuel filler cap fell off etc.) in EVAP system between the fuel tank and EVAP canister purge volume control solenoid valve. GI MA EM LC FE SEF323U DTC No. P0455 0455 Trouble diagnosis name EVAP control system gross leak detected DTC Detecting Condition Possible Cause EVAP control system has a very large leak such 쐌 Fuel filler cap remains open or fails to as fuel filler cap fell off, EVAP control system does close. not operate properly. 쐌 Incorrect fuel tank vacuum relief valve 쐌 Incorrect fuel filler cap used 쐌 Foreign matter caught in fuel filler cap 쐌 Leak is in line between intake manifold and EVAP canister purge volume control solenoid valve. 쐌 Foreign matter caught in EVAP canister vent control valve 쐌 EVAP canister or fuel tank leaks 쐌 EVAP purge line (pipe and rubber tube) leaks 쐌 EVAP purge line rubber tube bent 쐌 Blocked or bent rubber tube to EVAP control system pressure sensor 쐌 Loose or disconnected rubber tube 쐌 EVAP canister vent control valve and the circuit 쐌 EVAP canister purge volume control solenoid valve and the circuit 쐌 Fuel tank temperature sensor 쐌 O-ring of EVAP canister vent control valve is missing or damaged. 쐌 EVAP control system pressure sensor 쐌 Refueling control valve 쐌 ORVR system leaks CAUTION: 쐌 Use only a genuine NISSAN fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. 쐌 If the fuel filler cap is not tightened properly, the MIL may come on. 쐌 Use only a genuine NISSAN rubber tube as a replacement. CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-425 DTC P0455 EVAP CONTROL SYSTEM DTC Confirmation Procedure DTC Confirmation Procedure SEC760C WITH CONSULT-II SEC761C SEC762C NAEC0985S01 1) 2) 3) 4) Tighten fuel filler cap securely until ratcheting sound is heard. Turn ignition switch “ON”. Turn ignition switch “OFF” and wait at least 10 seconds. Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 5) Make sure that the following conditions are met. COOLAN TEMP/S: 0 - 70°C (32 - 158°F) INT/A TEMP SE: 0 - 60°C (32 - 140°F) 6) Select “EVP SML LEAK P0442/P1442” of “EVAPORATIVE SYSTEM” in “DTC WORK SUPPORT” mode with CONSULTII. Follow the instruction displayed. NOTE: If the engine speed cannot be maintained within the range displayed on the CONSULT-II screen, go to “Basic Inspection”, EC-131. 7) Make sure that “OK” is displayed. If “NG” is displayed, select “SELF-DIAG RESULTS” mode and make sure that “EVAP GROSS LEAK [P0455]” is displayed. If it is displayed, refer to “Diagnostic Procedure”, EC-427. If P0442 is displayed, perform “Diagnostic Procedure” for DTC P0442. WITH GST SEC763C NAEC0985 CAUTION: Never remove fuel filler cap during the DTC Confirmation Procedure. NOTE: 쐌 If DTC P0455 is displayed with P1448, first perform trouble diagnosis for DTC P1448. (See EC-636.) 쐌 Make sure that EVAP hoses are connected to EVAP canister purge volume control solenoid valve properly. 쐌 If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: 쐌 Perform “DTC WORK SUPPORT” when the fuel level is between 1/4 and 3/4 full, and vehicle is placed on flat level surface. 쐌 Open engine hood before conducting the following procedures. NAEC0985S02 NOTE: Be sure to read the explanation of “Driving Pattern” on EC-92 before driving vehicle. 1) Start engine. 2) Drive vehicle according to “Driving Pattern”, EC-92. 3) Stop vehicle. 4) Select “MODE 1” with GST. 쐌 If SRT of EVAP system is not set yet, go to the following step. 쐌 If SRT of EVAP system is set, the result will be OK. 5) Turn ignition switch “OFF” and wait at least 10 seconds. 6) Start engine. It is not necessary to cool engine down before driving. 7) Drive vehicle again according to the “Driving Pattern”, EC-92. EC-426 DTC P0455 EVAP CONTROL SYSTEM DTC Confirmation Procedure (Cont’d) 8) 9) 쐌 Stop vehicle. Select “MODE 3” with GST. If P0455 is displayed on the screen, go to “Diagnostic Procedure”, EC-427. 쐌 If P0442 is displayed on the screen, go to “Diagnostic Procedure”, for DTC P0442, EC-381. 쐌 If P0441 is displayed on the screen, go to “Diagnostic Procedure” for DTC P0441, EC-371. 쐌 If P0441, P0442 and P0455 are not displayed on the screen, go to the following step. 10) Select “MODE 1” with GST. 쐌 If SRT of EVAP system is set, the result will be OK. 쐌 If SRT of EVAP system is not set, go to step 6. GI MA EM LC FE CL MT AT Diagnostic Procedure 1 NAEC0986 CHECK FUEL FILLER CAP DESIGN TF 1. Turn ignition switch “OFF”. 2. Check for genuine NISSAN fuel filler cap design. PD AX SU SEF915U BR OK or NG ST OK 䊳 GO TO 2. NG 䊳 Replace with genuine NISSAN fuel filler cap. RS 2 CHECK FUEL FILLER CAP INSTALLATION Check that the cap is tightened properly by rotating the cap clockwise. BT OK or NG OK 䊳 GO TO 3. NG 䊳 쐌 Open fuel filler cap, then clean cap and fuel filler neck threads using air blower. 쐌 Retighten until ratcheting sound is heard. HA SC EL IDX EC-427 DTC P0455 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 3 CHECK FUEL FILLER CAP FUNCTION Check for air releasing sound while opening the fuel filler cap. OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 4. 4 CHECK FUEL TANK VACUUM RELIEF VALVE 1. Wipe clean valve housing. 2. Check valve opening pressure and vacuum. SEF445Y SEF943S Pressure: 15.3 - 20.0 kPa (0.156 - 0.204 kg/cm2, 2.22 - 2.90 psi) Vacuum: −6.0 to −3.3 kPa (−0.061 to −0.034 kg/cm2, −0.87 to −0.48 psi) CAUTION: Use only a genuine fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. OK or NG OK 䊳 GO TO 5. NG 䊳 Replace fuel filler cap with a genuine one. 5 CHECK EVAP PURGE LINE Check EVAP purge line (pipe, rubber tube, fuel tank and EVAP canister) for cracks, improper connection or disconnection. Refer to “Evaporative Emission System”, EC-41. OK or NG OK 䊳 GO TO 6. NG 䊳 Repair or reconnect the hose. 6 CLEAN EVAP PURGE LINE Clean EVAP purge line (pipe and rubber tube) using air blower. 䊳 GO TO 7. EC-428 DTC P0455 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 7 GI CHECK EVAP CANISTER VENT CONTROL VALVE, O-RING AND CIRCUIT Refer to “DTC Confirmation Procedure”, EC-404. MA OK or NG OK 䊳 GO TO 8. NG 䊳 Repair or replace EVAP canister vent control valve and O-ring or harness/connector. 8 INSTALL THE PRESSURE PUMP EM LC To locate the EVAP leak, install EVAP service port adapter and pressure pump to EVAP service port securely. FE CL MT SEF983Y AT TF PD AX SEF916U NOTE: Improper installation of the EVAP service port adapter to the EVAP service port may cause leaking. With CONSULT-II 䊳 GO TO 9. Without CONSULT-II 䊳 GO TO 10. SU BR ST RS BT HA SC EL IDX EC-429 DTC P0455 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 9 CHECK FOR EVAP LEAK With CONSULT-II 1. Turn ignition switch “ON”. 2. Select “EVAP SYSTEM CLOSE” of “WORK SUPPORT” mode with CONSULT-II. 3. Touch “START” and apply pressure into the EVAP line until the pressure indicator reaches the middle of the bar graph. NOTE: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in the system. PEF917U 4. Using EVAP leak detector, locate the EVAP leak. For the leak detector, refer to the instruction manual for more details. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-45. SEF200U OK or NG OK 䊳 GO TO 11. NG 䊳 Repair or replace. EC-430 DTC P0455 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 10 GI CHECK FOR EVAP LEAK Without CONSULT-II 1. Turn ignition switch “OFF”. 2. Apply 12 volts DC to EVAP canister vent control valve. The valve will close. (Continue to apply 12 volts until the end of test.) MA EM LC FE SEC930C 3. Apply 12 volts DC to vacuum cut valve bypass valve. The valve will open. (Continue to apply 12V until the end of test.) CL MT AT TF SEC932C 4. Pressurize the EVAP line using pressure pump with 1.3 to 2.7 kPa (10 to 20 mmHg, 0.39 to 0.79 inHg), then remove pump and EVAP service port adapter. NOTE: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in the system. 5. Using EVAP leak detector, locate the EVAP leak. For the leak detector, refer to the instruction manual for more details. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-45. PD AX SU BR ST RS BT SEF200U OK or NG OK 䊳 GO TO 12. NG 䊳 Repair or replace. HA SC EL IDX EC-431 DTC P0455 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 11 1. 2. 3. 4. 5. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION With CONSULT-II Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port. Start engine. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode. Touch “Qu” on CONSULT-II screen to increase “PURG VOL CONT/V” opening to 100%. Check vacuum hose for vacuum when revving engine up to 2,000 rpm. PBIB1678E Vacuum should exist. OK or NG OK 䊳 GO TO 14. NG 䊳 GO TO 13. 12 1. 2. 3. 4. 5. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION Without CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine. Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port. Start engine and let it idle for at least 80 seconds. Check vacuum hose for vacuum when revving engine up to 2,000 rpm. Vacuum should exist. OK or NG OK 䊳 GO TO 15. NG 䊳 GO TO 13. 13 CHECK VACUUM HOSE Check vacuum hoses for clogging or disconnection. Refer to “Vacuum Hose Drawing”, EC-35. OK or NG OK (With CONSULT-II) 䊳 GO TO 14. OK (Without CONSULTII) 䊳 GO TO 15. NG 䊳 Repair or reconnect the hose. EC-432 DTC P0455 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 14 GI CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE With CONSULT-II 1. Start engine. 2. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Check that engine speed varies according to the valve opening. MA EM LC FE PBIB1678E OK or NG OK 䊳 GO TO 16. NG 䊳 GO TO 15. CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-433 DTC P0455 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 15 CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE With CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions. SEC524D SEF334XA Without CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions. SEC524D SEF335X OK or NG OK 䊳 GO TO 16. NG 䊳 Replace EVAP canister purge volume control solenoid valve. EC-434 DTC P0455 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 16 GI CHECK FUEL TANK TEMPERATURE SENSOR 1. Remove fuel level sensor unit. 2. Check resistance between fuel level sensor unit terminals 1 and 2 by heating with hot water or heat gun as shown in the figure. MA EM LC SEF974Y FE OK or NG CL OK 䊳 GO TO 17. NG 䊳 Replace fuel level sensor unit. MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-435 DTC P0455 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 17 CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR 1. Remove EVAP control system pressure sensor with its harness connector connected. 쐌 Never apply force to the air hole protector of the sensor if equipped. SEF799W 2. Remove EVAP control system pressure sensor from EVAP canister. Do not reuse the O-ring, replace it with a new one. 3. Install a vacuum pump to EVAP control system pressure sensor. 4. Turn ignition switch “ON” and check output voltage between ECM terminal 32 and ground under the following conditions. SEC422D CAUTION: 쐌 Always calibrate the vacuum pump gauge when using it. 쐌 Do not apply below −93.3 kPa (−700 mmHg, −27.56 inHg) or pressure over 101.3 kPa (760 mmHg, 29.92 inHg). 쐌 Discard and EVAP control system pressure 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. OK or NG OK 䊳 GO TO 18. NG 䊳 Replace EVAP control system pressure sensor. 18 CHECK REFUELING EVAP VAPOR LINE 쐌 Check refueling EVAP vapor line between EVAP canister and fuel tank for clogging, kink, looseness and improper connection. For location, refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-45. OK or NG OK 䊳 GO TO 19. NG 䊳 Repair or replace hoses and tubes. 19 CHECK SIGNAL LINE AND RECIRCULATION LINE 쐌 Check signal line and recirculation line between filler neck tube and fuel tank for clogging, kink, cracks, looseness and improper connection. OK or NG OK 䊳 GO TO 20. NG 䊳 Repair or replace hoses, tubes or filler neck tube. EC-436 DTC P0455 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 20 GI CHECK REFUELING CONTROL VALVE 1. Remove fuel filler cap. 2. Check air continuity between hose ends A and B. Blow air into hose end B. Air should flow freely into the fuel tank. 3. Blow air into hose end A and check that there is no leakage. 4. Apply pressure to both hose ends A and B [20 kPa (150 mmHg, 5.91 inHg)] using a pressure pump and a suitable 3-way connector. Check that there is no leakage. MA EM LC FE CL MT AT TF SEC883C OK or NG OK 䊳 GO TO 21. NG 䊳 Replace or refueling control valve with fuel tank. 21 PD AX CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 SU INSPECTION END BR ST RS BT HA SC EL IDX EC-437 DTC P0456 EVAP CONTROL SYSTEM On Board Diagnosis Logic On Board Diagnosis Logic NAEC0987 SEF323U This diagnosis detects very small leaks in the EVAP line between fuel tank and EVAP canister purge volume control solenoid valve, using the intake manifold same as a conventional EVAP small leak diagnosis. If ECM judges a leak which corresponds to a very small leak, the very small leak P0456 will be detected. If ECM judges a leak equivalent to a small leak, EVAP small leak P0442 will be detected. If ECM judges there are no leaks, the diagnosis will be OK. DTC No. P0456 0456 Trouble diagnosis name Evaporative emission control system very small leak (negative pressure check) DTC Detecting Condition 쐌 EVAP system has a very small leak. 쐌 EVAP system does not operate properly. Possible Cause 쐌 Incorrect fuel tank vacuum relief valve 쐌 Incorrect fuel filler cap used 쐌 Fuel filler cap remains open or fails to close. 쐌 Foreign matter caught in fuel filler cap 쐌 Leak is in line between intake manifold and EVAP canister purge volume control solenoid valve. 쐌 Foreign matter caught in EVAP canister vent control valve 쐌 EVAP canister or fuel tank leaks 쐌 EVAP purge line (Pipe and rubber tube) leaks 쐌 EVAP purge line rubber tube bent 쐌 Blocked or bent rubber tube to EVAP control system pressure sensor 쐌 Loose or disconnected rubber tube 쐌 EVAP canister vent control valve and the circuit 쐌 EVAP canister purge volume control solenoid valve and the circuit 쐌 Fuel tank temperature sensor 쐌 O-ring of EVAP canister vent control valve is missing or damaged. 쐌 Water separator 쐌 EVAP canister saturated with water 쐌 EVAP control system pressure sensor 쐌 Refueling control valve 쐌 ORVR system leaks 쐌 Fuel level sensor and the circuit 쐌 Foreign matter caught in EVAP canister purge volume control solenoid valve CAUTION: 쐌 Use only a genuine NISSAN fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. 쐌 If the fuel filler cap is not tightened properly, the MIL may come on. 쐌 Use only a genuine NISSAN rubber tube as a replacement. EC-438 DTC P0456 EVAP CONTROL SYSTEM DTC Confirmation Procedure DTC Confirmation Procedure SEC764C SEC765C SEC766C NAEC0988 CAUTION: Never remove fuel filler cap during the DTC confirmation procedure. NOTE: 쐌 If DTC P0456 is displayed with P0442, first perform trouble diagnosis for DTC P0456. 쐌 If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. 쐌 After repair, make sure that the hoses and clips are installed properly. TESTING CONDITION: 쐌 Open engine hood before conducting following procedure. 쐌 If any of following condition is met just before the DTC confirmation procedure, leave the vehicle for more than 1 hour. a) Fuel filler cap is removed. b) Refilled or drained the fuel. c) EVAP component parts is/are removed. 쐌 Before performing the following procedure, confirm that battery voltage is more than 11V at idle. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 2) Make sure the following conditions are met. FUEL LEVEL SE: 1.08 - 0.2V COOLAN TEMP/S: 0 - 32°C (32 - 90°F) FUEL T/TMP SE: 0 - 35°C (32 - 95°F) INT A/TEMP SE: More than 0°C (32°F) If NG, turn ignition switch “OFF” and leave the vehicle in a cool place (soak the vehicle) or refilling/draining fuel until the output voltage condition of the “FUEL LEVEL SE” meets within the range above and leave the vehicle for more than 1 hour. Then start from step 1). 3) Turn ignition switch “OFF” and wait at least 5 seconds. 4) Turn ignition switch “ON”. 5) Select “EVP V/S LEAK P0456/P1456” of “EVAPORATIVE SYSTEM” in “DTC WORK SUPPORT” mode with CONSULTII. Follow the instruction displayed. 6) Make sure that “OK” is displayed. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-441. NOTE: 쐌 If the engine speed cannot be maintained within the range displayed on CONSULT-II screen, go to “Basic inspection”, EC-131. 쐌 Make sure that EVAP hoses are connected to EVAP canister purge volume control solenoid valve properly. GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-439 DTC P0456 EVAP CONTROL SYSTEM Overall Function Check Overall Function Check WITH GST SEF983Y SEF462UA NAEC0989 NAEC0989S01 Use this procedure to check the overall function of the EVAP very small leak function. During this check, a DTC might not be confirmed. CAUTION: 쐌 Never use compressed air, doing so may damage the EVAP system. 쐌 Do not start engine. 쐌 Do not exceeded 4.12 kPa (0.042 kg/cm2, 0.6 psi). 1) Attach the EVAP service port adapter securely to the EVAP service port. 2) Set the pressure pump and a hose. 3) Also set a vacuum gauge via 3-way connector and a hose. 4) Turn ignition switch “ON”. 5) Connect GST and select mode 8. 6) Using mode 8 control the EVAP canister vent control valve (close) and vacuum cut valve bypass valve (open). 7) Apply pressure and make sure the following conditions are satisfied. Pressure to be applied: 2.7 kPa (20 mmHg, 0.79 inHg) Time to be waited after the pressure drawn in to the EVAP system and the pressure to be dropped: 60 seconds and the pressure should not be dropped more than 0.4 kPa (3 mmHg, 0.12 inHg) If NG, go to diagnostic procedure, EC-441. If OK, go to next step. 8) Disconnect GST. 9) Start engine and warm it up to normal operating temperature. 10) Turn ignition switch “OFF” and wait at least 10 seconds. 11) Restart engine and let it idle for 90 seconds. 12) Keep engine speed at 2,000 rpm for 30 seconds. 13) Turn ignition switch “OFF”. NOTE: For more information, refer to GST instruction manual. EC-440 DTC P0456 EVAP CONTROL SYSTEM Diagnostic Procedure Diagnostic Procedure 1 NAEC0990 GI CHECK FUEL FILLER CAP DESIGN MA 1. Turn ignition switch “OFF”. 2. Check for genuine NISSAN fuel filler cap design. EM LC SEF915U FE OK or NG OK 䊳 GO TO 2. NG 䊳 Replace with genuine NISSAN fuel filler cap. 2 CL MT CHECK FUEL FILLER CAP INSTALLATION Check that the cap is tightened properly by rotating the cap clockwise. OK or NG OK 䊳 GO TO 3. NG 䊳 쐌 Open fuel filler cap, then clean cap and fuel filler neck threads using air blower. 쐌 Retighten until ratcheting sound is heard. AT TF PD 3 CHECK FUEL FILLER CAP FUNCTION Check for air releasing sound while opening the fuel filler cap. AX OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 4. SU BR ST RS BT HA SC EL IDX EC-441 DTC P0456 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 4 CHECK FUEL TANK VACUUM RELIEF VALVE 1. Wipe clean valve housing. 2. Check valve opening pressure and vacuum. SEF445Y SEF943S Pressure: 15.3 - 20.0 kPa (0.156 - 0.204 kg/cm2, 2.22 - 2.90 psi) Vacuum: −6.0 to −3.3 kPa (−0.061 to −0.034 kg/cm2, −0.87 to −0.48 psi) CAUTION: Use only a genuine fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. OK or NG OK 䊳 GO TO 5. NG 䊳 Replace fuel filler cap with a genuine one. EC-442 DTC P0456 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 5 GI INSTALL THE PRESSURE PUMP To locate the EVAP leak, install EVAP service port adapter and pressure pump to EVAP service port securely. MA EM LC SEF983Y FE CL MT AT SEF916U NOTE: Improper installation of the EVAP service port adapter to the EVAP service port may cause leaking. With CONSULT-II 䊳 GO TO 6. Without CONSULT-II 䊳 GO TO 7. TF PD AX SU BR ST RS BT HA SC EL IDX EC-443 DTC P0456 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 6 CHECK FOR EVAP LEAK With CONSULT-II 1. Turn ignition switch “ON”. 2. Select “EVAP SYSTEM CLOSE” of “WORK SUPPORT” mode with CONSULT-II. 3. Touch “START” and apply pressure into the EVAP line until the pressure indicator reaches the middle of the bar graph. NOTE: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in the system. PEF917U 4. Using EVAP leak detector, locate the EVAP leak. For the leak detector, refer to the instruction manual for more details. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-45. SEF200U OK or NG OK 䊳 GO TO 8. NG 䊳 Repair or replace. EC-444 DTC P0456 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 7 GI CHECK FOR EVAP LEAK Without CONSULT-II 1. Turn ignition switch “OFF”. 2. Apply 12 volts DC to EVAP canister vent control valve. The valve will close. (Continue to apply 12 volts until the end of test.) MA EM LC FE SEC930C 3. Apply 12 volts DC to vacuum cut valve bypass valve. The valve will open. (Continue to apply 12V until the end of test.) CL MT AT TF SEC932C 4. Pressurize the EVAP line using pressure pump with 1.3 to 2.7 kPa (10 to 20 mmHg, 0.39 to 0.79 inHg), then remove pump and EVAP service port adapter. NOTE: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in the system. 5. Using EVAP leak detector, locate the EVAP leak. For the leak detector, refer to the instruction manual for more details. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-45. PD AX SU BR ST RS BT SEF200U OK or NG OK 䊳 GO TO 8. NG 䊳 Repair or replace. HA SC EL IDX EC-445 DTC P0456 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 8 1. 2. 3. 4. CHECK WATER SEPARATOR Check Check Check Check visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged. PBIB1032E 5. In case of NG in items 2 - 4, replace the parts. NOTE: 쐌 Do not disassemble water separator. OK or NG OK 䊳 GO TO 9. NG 䊳 Replace water separator. 9 CHECK EVAP CANISTER VENT CONTROL VALVE, O-RING AND CIRCUIT Refer to “DTC Confirmation Procedure”, EC-404. OK or NG OK 䊳 GO TO 10. NG 䊳 Repair or replace EVAP canister vent control valve and O-ring or harness/connector. 10 CHECK IF EVAP CANISTER SATURATED WITH WATER 1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Does water drain from the EVAP canister? SEF596U Yes or No Yes 䊳 GO TO 11. No (With CONSULT-II) 䊳 GO TO 13. No (Without CONSULTII) 䊳 GO TO 14. EC-446 DTC P0456 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 11 GI CHECK EVAP CANISTER Weigh the EVAP canister with the EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb). MA OK or NG OK (With CONSULT-II) 䊳 GO TO 13. OK (Without CONSULTII) 䊳 GO TO 14. NG 䊳 GO TO 12. 12 EM LC DETECT MALFUNCTIONING PART Check the following. 쐌 EVAP canister for damage 쐌 EVAP hose between EVAP canister and water separator for clogging or poor connection 䊳 13 1. 2. 3. 4. 5. FE Repair hose or replace EVAP canister. CL CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION MT With CONSULT-II Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port. Start engine. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode. Touch “Qu” on CONSULT-II screen to increase “PURG VOL CONT/V” opening to 100%. Check vacuum hose for vacuum when revving engine up to 2,000 rpm. AT TF PD AX SU PBIB1678E BR Vacuum should exist. OK or NG OK 䊳 GO TO 16. NG 䊳 GO TO 15. ST RS 14 1. 2. 3. 4. 5. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION Without CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine. Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port. Start engine and let it idle for at least 80 seconds. Check vacuum hose for vacuum when revving engine up to 2,000 rpm. Vacuum should exist. BT HA SC OK or NG OK 䊳 GO TO 17. NG 䊳 GO TO 15. EL IDX EC-447 DTC P0456 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 15 CHECK VACUUM HOSE Check vacuum hoses for clogging or disconnection. Refer to “Vacuum Hose Drawing”, EC-35. OK or NG OK (With CONSULT-II) 䊳 GO TO 16. OK (Without CONSULTII) 䊳 GO TO 17. NG 䊳 Repair or reconnect the hose. 16 CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE With CONSULT-II 1. Start engine. 2. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Check that engine speed varies according to the valve opening. PBIB1678E OK or NG OK 䊳 GO TO 18. NG 䊳 GO TO 17. EC-448 DTC P0456 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 17 GI CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE With CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions. MA EM LC SEC524D FE CL MT AT SEF334XA TF Without CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions. PD AX SU BR SEC524D ST RS BT HA SEF335X OK or NG OK 䊳 GO TO 18. NG 䊳 Replace EVAP canister purge volume control solenoid valve. SC EL IDX EC-449 DTC P0456 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 18 CHECK FUEL TANK TEMPERATURE SENSOR 1. Remove fuel level sensor unit. 2. Check resistance between fuel level sensor unit terminals 1 and 2 by heating with hot water or heat gun as shown in the figure. SEF974Y OK or NG OK 䊳 GO TO 19. NG 䊳 Replace fuel level sensor unit. EC-450 DTC P0456 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 19 GI CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR 1. Remove EVAP control system pressure sensor with its harness connector connected. 쐌 Never apply force to the air hole protector of the sensor if equipped. MA EM LC SEF799W 2. Remove EVAP control system pressure sensor from EVAP canister. Do not reuse the O-ring, replace it with a new one. 3. Install a vacuum pump to EVAP control system pressure sensor. 4. Turn ignition switch “ON” and check output voltage between ECM terminal 32 and ground under the following conditions. FE CL MT AT TF PD SEC422D CAUTION: 쐌 Always calibrate the vacuum pump gauge when using it. 쐌 Do not apply below −93.3 kPa (−700 mmHg, −27.56 inHg) or pressure over 101.3 kPa (760 mmHg, 29.92 inHg). 쐌 Discard and EVAP control system pressure 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. AX SU OK or NG BR OK 䊳 GO TO 20. NG 䊳 Replace EVAP control system pressure sensor. ST 20 CHECK EVAP PURGE LINE Check EVAP purge line (pipe, rubber tube, fuel tank and EVAP canister) for cracks or improper connection. Refer to “Evaporative Emission System”, EC-41. OK or NG OK 䊳 GO TO 21. NG 䊳 Repair or reconnect the hose. 21 CLEAN EVAP PURGE LINE Clean EVAP purge line (pipe and rubber tube) using air blower. 䊳 RS BT HA SC GO TO 22. EL IDX EC-451 DTC P0456 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 22 CHECK REFUELING EVAP VAPOR LINE 쐌 Check refueling EVAP vapor line between EVAP canister and fuel tank for clogging, kink, looseness and improper connection. For location, refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-45. OK or NG OK 䊳 GO TO 23. NG 䊳 Repair or replace hoses and tubes. 23 CHECK SIGNAL LINE AND RECIRCULATION LINE 쐌 Check signal line and recirculation line between filler neck tube and fuel tank for clogging, kink, cracks, looseness and improper connection. OK or NG OK 䊳 GO TO 24. NG 䊳 Repair or replace hoses, tubes or filler neck tube. 24 CHECK REFUELING CONTROL VALVE 1. Remove fuel filler cap. 2. Check air continuity between hose ends A and B. Blow air into hose end B. Air should flow freely into the fuel tank. 3. Blow air into hose end A and check that there is no leakage. 4. Apply pressure to both hose ends A and B [20 kPa (150 mmHg, 5.91 inHg)] using a pressure pump and a suitable 3-way connector. Check that there is no leakage. SEC883C OK or NG OK 䊳 GO TO 25. NG 䊳 Replace or refueling control valve with fuel tank. 25 CHECK FUEL LEVEL SENSOR Refer to EL-134, “Fuel Level Sensor Unit Check”. OK or NG OK 䊳 GO TO 26. NG 䊳 Replace fuel level sensor unit. EC-452 DTC P0456 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 26 GI CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 MA INSPECTION END EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-453 DTC P0460 FUEL LEVEL SENSOR Component Description Component Description NAEC0991 The fuel level sensor is mounted in the fuel level sensor unit. The sensor detects a fuel level in the fuel tank and transmits a signal to the combination meter. The combination meter sends the fuel level sensor signal to the ECM through CAN communication line. It consists of two parts, one is mechanical float and the other is variable resistor. Fuel level sensor output voltage changes depending on the movement of the fuel mechanical float. SEF018S On Board Diagnostic Logic NAEC0992 NOTE: If DTC P0460 is displayed with DTC U1000, U1001, first perform the trouble diagnosis for DTC U1000, U1001. Refer to “DTC U1000, U1001 CAN COMMUNICATION LINE”, EC-172. When the vehicle is parked, naturally the fuel level in the fuel tank is stable. It means that output signal of the fuel level sensor does not change. If ECM senses sloshing signal from the sensor, fuel level sensor malfunction is detected. DTC No. P0460 0460 Trouble diagnosis name Fuel level sensor circuit noise DTC Detecting Condition Even though the vehicle is parked, a signal being varied is sent from the fuel level sensor to ECM. Possible Cause 쐌 Fuel level sensor circuit (The fuel level sensor circuit is open or shorted.) 쐌 Fuel level sensor DTC Confirmation Procedure NAEC0993 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. WITH CONSULT-II SEF195Y 1) 2) 3) 4) NAEC0993S01 Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and wait maximum of 2 consecutive minutes. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-455. WITH GST Follow the procedure “WITH CONSULT-II” above. EC-454 NAEC0993S02 DTC P0460 FUEL LEVEL SENSOR Diagnostic Procedure Diagnostic Procedure 1 =NAEC0995 GI CHECK FUEL GAUGE OPERATION Refer to EL-129, “Meter/Gauge Operation and Odo/Trip Meter Segment Check in Diagnosis Mode”. MA OK or NG EM OK 䊳 GO TO 2. NG 䊳 Follow the instruction of “Meter/Gauge Operation and Odo/Trip Meter Segment Check in Diagnosis Mode”, Refer to EL-129. 2 LC CHECK FUEL LEVEL SENSOR AND CIRCUIT Refer to EL-133, “INSPECTION/FUEL LEVEL SENSOR”. OK or NG OK 䊳 GO TO 3. NG 䊳 Repair or replace malfunctioning parts. 3 FE CL CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 MT INSPECTION END AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-455 DTC P0461 FUEL LEVEL SENSOR Component Description Component Description =NAEC0996 The fuel level sensor is mounted in the fuel level sensor unit. The sensor detects a fuel level in the fuel tank and transmits a signal to the combination meter. The combination meter sends the fuel level sensor signal to the ECM through CAN communication line. It consists of two parts, one is mechanical float and the other is variable resistor. Fuel level sensor output voltage changes depending on the movement of the fuel mechanical float. SEF018S On Board Diagnostic Logic NAEC0997 NOTE: If DTC P0461 is displayed with DTC U1000, U1001, first perform the trouble diagnosis for DTC U1000, U1001. Refer to “DTC U1000, U1001 CAN COMMUNICATION LINE”, EC-172. Driving long distances naturally affect fuel gauge level. This diagnosis detects the fuel gauge malfunction of the gauge not moving even after a long distance has been driven. DTC No. P0461 0461 Trouble diagnosis name Fuel level sensor circuit range/ performance DTC Detecting Condition Possible Cause The output signal of the fuel level sensor does not 쐌 Harness or connectors change within the specified range even though the (The level sensor circuit is open or vehicle has been driven a long distance. shorted.) 쐌 Fuel level sensor Overall Function Check NAEC0998 Use this procedure to check the overall function of the fuel level sensor function. During this check, a 1st trip DTC might not be confirmed. WARNING: When performing following procedure, be sure to observe the handling of the fuel. Refer to FE-5, “Fuel Tank”. TESTING CONDITION: Before starting overall function check, preparation of draining fuel and refilling fuel is required. WITH CONSULT-II SEF195Y NAEC0998S01 NOTE: Start from step 11, if it is possible to confirm that the fuel cannot be drained by 30 (7-7/8 US gal, 6-5/8 Imp gal) in advance. 1) Prepare a fuel container and a spare hose. 2) Release fuel pressure from fuel line, refer to “Fuel Pressure Release”, EC-64. 3) Remove the fuel feed hose on the fuel level sensor unit. 4) Connect a spare fuel hose where the fuel feed hose was removed. EC-456 DTC P0461 FUEL LEVEL SENSOR Overall Function Check (Cont’d) 5) Turn ignition switch “OFF” and wait at least 10 seconds then turn “ON”. 6) Select “FUEL LEVEL SE” in “DATA MONITOR” mode with CONSULT-II. 7) Check “FUEL LEVEL SE” output voltage and note it. 8) Select “FUEL PUMP” in “ACTIVE TEST” mode with CONSULT-II. 9) Touch “ON” and drain fuel approximately 30 (7-7/8 US gal, 6-5/8 Imp gal) and stop it. 10) Fill fuel into the fuel tank for 30 (7-7/8 US gal, 6-5/8 Imp gal). 11) Check “FUEL LEVEL SE” output voltage and note it. 12) Check “FUEL LEVEL SE” output voltage and confirm whether the voltage changes more than 0.03V during step 7 to 11. If NG, go to “Diagnostic Procedure”, EC-457. WITH GST 1 MA EM LC FE NAEC0998S02 NOTE: Start from step 11, if it is possible to confirm that the fuel cannot be drained by 30 (7-7/8 US gal, 6-5/8 Imp gal) in advance. 1) Prepare a fuel container and a spare hose. 2) Release fuel pressure from fuel line, refer to “Fuel Pressure Release”, EC-64. 3) Remove the fuel feed hose on the fuel level sensor unit. 4) Connect a spare fuel hose where the fuel feed hose was removed. 5) Turn ignition switch “ON”. 6) Drain fuel by 30 (7-7/8 US gal, 6-5/8 Imp gal) from the fuel tank using proper equipment. 7) Confirm that the fuel gauge indication varies. 8) Fill fuel into the fuel tank for 30 (7-7/8 US gal, 6-5/8 Imp gal). 9) Confirm that the fuel gauge indication varies. 10) If NG, go to “Diagnostic Procedure”, EC-457. Diagnostic Procedure GI CL MT AT TF PD AX SU NAEC1226 BR CHECK FUEL GAUGE OPERATION Refer to EL-129, “Meter/Gauge Operation and Odo/Trip Meter Segment Check in Diagnosis Mode”. OK or NG OK 䊳 GO TO 2. NG 䊳 Follow the instruction of “Meter/Gauge Operation and Odo/Trip Meter Segment Check in Diagnosis Mode”. Refer to EL-129. 2 CHECK FUEL LEVEL SENSOR AND CIRCUIT Refer to EL-133, “INSPECTION/FUEL LEVEL SENSOR”. OK or NG OK 䊳 GO TO 3. NG 䊳 Repair or replace malfunctioning parts. 3 ST RS BT HA SC EL CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 IDX INSPECTION END EC-457 DTC P0462, P0463 FUEL LEVEL SENSOR Component Description Component Description NAEC0999 The fuel level sensor is mounted in the fuel level sensor unit. The sensor detects a fuel level in the fuel tank and transmits a signal to the combination meter. The combination meter sends the fuel level sensor signal to the ECM through CAN communication line. It consists of two parts, one is mechanical float and the other is variable resistor. Fuel level sensor output voltage changes depending on the movement of the fuel mechanical float. SEF018S On Board Diagnostic Logic NAEC1000 NOTE: If DTC P0462, P0463 is displayed with DTC U1000, U1001, first perform the trouble diagnosis for DTC U1000, U1001. Refer to “DTC U1000, U1001 CAN COMMUNICATION LINE”, EC-172. ECM receives two signals from the fuel level sensor circuit. One is fuel level sensor power supply circuit, and the other is fuel level sensor ground circuit. This diagnosis indicates the former, to detect open or short circuit malfunction. DTC No. Trouble diagnosis name P0462 0462 Fuel level sensor circuit low input P0463 0463 Fuel level sensor circuit high input DTC Detecting Condition Possible Cause An excessively low voltage from the sensor is sent 쐌 Harness or connectors to ECM. (The sensor circuit is open or shorted.) An excessively high voltage from the sensor is 쐌 Fuel level sensor sent to ECM. DTC Confirmation Procedure NAEC1001 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 11V at ignition switch “ON”. WITH CONSULT-II 1) 2) 3) 4) NAEC1001S01 Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 5 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-459. WITH GST Follow the procedure “WITH CONSULT-II” above. SEF195Y EC-458 NAEC1001S02 DTC P0462, P0463 FUEL LEVEL SENSOR Diagnostic Procedure Diagnostic Procedure 1 =NAEC1003 GI CHECK FUEL GAUGE OPERATION Refer to EL-129, “Meter/Gauge Operation and Odo/Trip Meter Segment Check in Diagnosis Mode”. MA OK or NG EM OK 䊳 GO TO 2. NG 䊳 Follow the instruction of “Meter/Gauge Operation and Odo/Trip Meter Segment Check in Diagnosis Mode”. Refer to EL-129. 2 LC CHECK FUEL LEVEL SENSOR AND CIRCUIT Refer to EL-133, “INSPECTION/FUEL LEVEL SENSOR”. OK or NG OK 䊳 GO TO 3. NG 䊳 Repair or replace malfunctioning parts. 3 FE CL CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 MT INSPECTION END AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-459 DTC P0500 VSS Description Description =NAEC1004 NOTE: If DTC P0500 is displayed with DTC U1000 or U1001, first perform the trouble diagnosis for DTC U1000, U1001. Refer to EC-172. The vehicle speed sensor is installed in the transmission. It contains a pulse generator which provides a vehicle speed signal to the combination meter. The combination meter then sends a signal to the ECM through CAN communication line. On Board Diagnosis Logic DTC No. P0500 0500 Trouble diagnosis name DTC Detecting Condition NAEC1006 Possible Cause Vehicle speed sensor The almost 0 km/h (0 MPH) signal from vehicle 쐌 Harness or connectors speed sensor is sent to ECM even when vehicle is (The CAN communication line is open being driven. or shorted) 쐌 Harness or connectors (The vehicle speed sensor circuit is open or shorted) 쐌 Vehicle speed sensor 쐌 Combination meter DTC Confirmation Procedure NAEC1007 CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Steps 1 and 2 may be conducted with the drive wheels lifted in the shop or by driving the vehicle. If a road test is expected to be easier, it is unnecessary to lift the vehicle. WITH CONSULT-II 1) 2) 3) 4) 5) NAEC1007S01 Start engine. Read “VHCL SPEED SE” in “DATA MONITOR” mode with CONSULT-II. The vehicle speed on CONSULT-II should exceed 10 km/h (6 MPH) when rotating wheels with suitable gear position. If NG, go to “Diagnostic Procedure”, EC-461. If OK, go to following step. Select “DATA MONITOR” mode with CONSULT-II. Warm engine up to normal operating temperature. Maintain the following conditions for at least 60 consecutive seconds. ENG SPEED More than 1,800 rpm (A/T models) More than 2,000 rpm (M/T models) COOLAN TEMP/S More than 70°C (158°F) B/FUEL SCHDL More than 5.5 msec Selector lever Except “P” or “N” position PW/ST SIGNAL OFF SEF196Y EC-460 DTC P0500 VSS DTC Confirmation Procedure (Cont’d) 6) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-461. GI MA EM LC Overall Function Check NAEC1008 Use this procedure to check the overall function of the vehicle speed sensor signal circuit. During this check, a 1st trip DTC might not be confirmed. WITH GST 1) 2) 3) 4) NAEC1008S01 Lift up drive wheels. Start engine. Read vehicle speed sensor signal in “MODE 1” with GST. The vehicle speed sensor signal on GST should be able to exceed 10 km/h (6 MPH) when rotating wheels with suitable gear position. If NG, go to “Diagnostic Procedure”, EC-461. FE CL MT AT TF PD AX SU Diagnostic Procedure 1 CHECK VEHICLE SPEED SENSOR CIRCUIT NAEC1010 BR Refer to EL-130, “Trouble Diagnosis”. OK or NG OK 䊳 GO TO 2. NG 䊳 Repair or replace. 2 RS CHECK COMBINATION METER BT Check combination meter function. Refer to EL-125, “COMBINATION METERS”. 䊳 ST HA INSPECTION END SC EL IDX EC-461 DTC P0506 ISC SYSTEM Description Description NAEC1227 NOTE: If DTC P0506 is displayed with other DTC, first perform the trouble diagnosis for the other DTC. The ECM controls the engine idle speed to a specified level through the fine adjustment of the air, which is let into the intake manifold, by operating the electric throttle control actuator. The operating of the throttle valve is varied to allow for optimum control of the engine idling speed. The crankshaft position sensor (POS) detects the actual engine speed and sends a signal to the ECM. The ECM controls the electric throttle control actuator so that the engine speed coincides with the target value memorized in the ECM. The target engine speed is the lowest speed at which the engine can operate steadly. The optimum value stored in the ECM is determined by taking into consideration various engine conditions, such as during warming up, deceleration, and engine load (air conditioner and power steering operation, etc.). On Board Diagnosis Logic DTC No. P0506 0506 Trouble diagnosis name Idle speed control system RPM lower than expected DTC Detecting Condition The idle speed is not in the specified range. NAEC1228 Possible Cause 쐌 Electric throttle control actuator 쐌 Intake air leak DTC Confirmation Procedure NAEC1229 NOTE: 쐌 If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. 쐌 If the target idle speed is out of the specified value, perform “Idle Air Volume Learning” before conducting “DTC Confirmation Procedure”. For the target idle speed, refer to the “Service Data and Specifications (SDS)”, EC-792. TESTING CONDITION: 쐌 Before performing the following procedure, confirm that battery voltage is more than 11V at idle. 쐌 Always perform the test at a temperature above −10°C (14°F). WITH CONSULT-II 1) 2) 3) 4) 5) 6) NAEC1229S01 Open engine hood. Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF” and wait at least 10 seconds. Turn ignition switch “ON” again and select “DATA MONITOR” mode with CONSULT-II. Start engine and run it for at least 1 minute at idle speed. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-463. SEF174Y EC-462 DTC P0506 ISC SYSTEM DTC Confirmation Procedure (Cont’d) WITH GST NAEC1229S02 GI Follow the procedure “With CONSULT-II” above. MA EM LC Diagnostic Procedure 1 NAEC1230 CHECK INTAKE AIR LEAK 1. Start engine and let it idle. 2. Listen for an intake air leak after the mass air flow sensor. OK or NG OK 䊳 GO TO 2. NG 䊳 Discover air leak location and repair. 2 REPLACE ECM FE CL MT AT 1. Stop engine. 2. Replace ECM. 3. Perform initialization of NVIS (NATS) system and registration of all NVIS (NATS) ignition key IDs. Refer to “NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS)”, EC-101. 4. Perform “Accelerator Pedal Released Position Learning”, EC-81. 5. Perform “Throttle Valve Closed Position Learning”, EC-81. 6. Perform “Idle Air Volume Learning”, EC-81. 䊳 INSPECTION END TF PD AX SU BR ST RS BT HA SC EL IDX EC-463 DTC P0507 ISC SYSTEM Description Description NAEC1231 NOTE: If DTC P0507 is displayed with other DTC, first perform the trouble diagnosis for the other DTC. The ECM controls the engine idle speed to a specified level through the fine adjustment of the air, which is let into the intake manifold, by operating the electric throttle control actuator. The operating of the throttle valve is varied to allow for optimum control of the engine idling speed. The crankshaft position sensor (POS) detects the actual engine speed and sends a signal to the ECM. The ECM controls the electric throttle control actuator so that the engine speed coincides with the target value memorized in the ECM. The target engine speed is the lowest speed at which the engine can operate steadly. The optimum value stored in the ECM is determined by taking into consideration various engine conditions, such as during warming up, deceleration, and engine load (air conditioner and power steering operation, etc.). On Board Diagnosis Logic DTC No. P0507 0507 Trouble diagnosis name Idle speed control system RPM higher than expected DTC Detecting Condition The idle speed is not in the specified range. NAEC1232 Possible Cause 쐌 Electric throttle control actuator 쐌 Intake air leak 쐌 PCV system DTC Confirmation Procedure NAEC1233 NOTE: 쐌 If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. 쐌 If the target idle speed is out of the specified value, perform “Idle Air Volume Learning” before conducting “DTC Confirmation Procedure”. For the target idle speed, refer to the “Service Data and Specifications (SDS)”, EC-792. TESTING CONDITION: 쐌 Before performing the following procedure, confirm that battery voltage is more than 11V at idle. 쐌 Always perform the test at a temperature above −10°C (14°F). WITH CONSULT-II 1) 2) 3) 4) 5) 6) NAEC1233S01 Open engine hood. Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF” and wait at least 10 seconds. Turn ignition switch “ON” again and select “DATA MONITOR” mode with CONSULT-II. Start engine and run it for at least 1 minute at idle speed. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-465. SEF174Y EC-464 DTC P0507 ISC SYSTEM DTC Confirmation Procedure (Cont’d) WITH GST NAEC1233S02 GI Follow the procedure “With CONSULT-II” above. MA EM LC Diagnostic Procedure 1 NAEC1234 CHECK INTAKE AIR LEAK 1. Start engine and let it idle. 2. Listen for an intake air leak after the mass air flow sensor. OK or NG OK 䊳 GO TO 2. NG 䊳 Discover air leak location and repair. 2 REPLACE ECM FE CL MT AT 1. Stop engine. 2. Replace ECM. 3. Perform initialization of NVIS (NATS) system and registration of all NVIS (NATS) ignition key IDs. Refer to “NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS)”, EC-101. 4. Perform “Accelerator Pedal Released Position Learning”, EC-81. 5. Perform “Throttle Valve Closed Position Learning”, EC-81. 6. Perform “Idle Air Volume Learning”, EC-81. 䊳 INSPECTION END TF PD AX SU BR ST RS BT HA SC EL IDX EC-465 DTC P0550 PSP SENSOR Component Description Component Description NAEC1359 Power steering pressure (PSP) sensor is installed to the power steering high-pressure tube and detects a power steering load. This sensor is a potentiometer which transforms the power steering load into output voltage, and emits the voltage signal to the ECM. The ECM controls the electric throttle control actuator and adjusts the throttle valve opening angle to increase the engine speed and adjusts the idle speed for the increased load. SEC526D CONSULT-II Reference Value in Data Monitor Mode NAEC1360 Specification data are reference values. MONITOR ITEM PW/ST SIGNAL CONDITION SPECIFICATION Steering wheel is in neutral position. OFF 쐌 Engine: After warming up, idle the (Forward direction) engine Steering wheel is turned. ON On Board Diagnosis Logic NAEC1361 The MIL will not light up for this self-diagnosis. NOTE: If DTC P0550 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to EC-596. DTC No. P0550 0550 Trouble diagnosis name Power steering pressure sensor circuit DTC detecting condition An excessively low or high voltage from the sensor is sent to ECM. Possible cause 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Power steering pressure sensor DTC Confirmation Procedure NAEC1362 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. With CONSULT-II 1. Turn ignition switch “ON”. 2. Select “DATA MONITOR” mode with CONSULT-II. 3. Start engine and let it idle for at least 5 seconds. 4. If 1st trip DTC is detected, go to EC-468, “Diagnostic Procedure”. With GST Follow the procedure “WITH CONSULT-II” above. EC-466 DTC P0550 PSP SENSOR Wiring Diagram Wiring Diagram NAEC1363 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC113E EC-467 IDX DTC P0550 PSP SENSOR Wiring Diagram (Cont’d) Specification data are reference values and are measured between each terminal and body ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 12 WIRE COLOR R/B 67 B/P 68 L ITEM Power steering pressure sensor Sensors’ ground CONDITION [Engine is running] 쐌 Steering wheel is being turned. 0.5 - 4.0V [Engine is running] 쐌 Steering wheel is not being turned. 0.4 - 0.8V [Engine is running] 쐌 Warm-up condition 쐌 Idle speed Approximately 0V Sensors’ power supply [Ignition switch “ON”] Diagnostic Procedure 1 DATA (DC Voltage) Approximately 5V NAEC1364 RETIGHTEN GROUND SCREWS 1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. SEF959Y 䊳 GO TO 2. EC-468 DTC P0550 PSP SENSOR Diagnostic Procedure (Cont’d) 2 GI CHECK PSP SENSOR POWER SUPPLY CIRCUIT 1. Disconnect PSP sensor harness connector. 2. Turn ignition switch “ON”. MA EM LC SEC526D 3. Check voltage between PSP sensor terminal 1 and ground with CONSULT-II or tester. FE CL MT AT TF SEC048D Voltage: Approximately 5V OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 3. 3 AX DETECT MALFUNCTIONING PART SU Check the following. 쐌 Harness connectors E132, E135 쐌 Harness connectors E116, M114 쐌 Harness connectors M32, F23 쐌 Harness for open or short between ECM and power steering pressure sensor 䊳 4 PD Repair open circuit or short to ground or short to power in harness or connectors. CHECK PSP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Check harness continuity between PSP sensor terminal 3 and engine ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. BR ST RS BT HA OK or NG OK 䊳 GO TO 6. NG 䊳 GO TO 5. SC EL IDX EC-469 DTC P0550 PSP SENSOR Diagnostic Procedure (Cont’d) 5 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors E102, E48 쐌 Harness connectors E1, M1 쐌 Harness connectors M32, F23 쐌 Harness connectors F22, M33 쐌 Joint connector F204 쐌 Harness for open or short between ECM and PSP sensor 쐌 Harness for open or short between TCM and PSP sensor. 䊳 6 Repair open circuit or short to ground or short to power in harness or connectors. CHECK PSP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 12 and PSP sensor terminal 2. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 8. NG 䊳 GO TO 7. 7 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors E102, E48 쐌 Harness connectors E1, M1 쐌 Harness connectors M32, F23 쐌 Harness for open or short between ECM and power steering pressure sensor 䊳 8 Repair open circuit or short to ground or short to power in harness or connectors. CHECK PSP SENSOR Refer to “Component Inspection”, EC-470. OK or NG OK 䊳 GO TO 9. NG 䊳 Replace PSP sensor. 9 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END Component Inspection NAEC1365 POWER STEERING PRESSURE SENSOR 1. Reconnect all harness connectors disconnected. 2. Start engine and let it idle. 3. Check voltage between ECM terminal 12 and ground under the following conditions. Condition MBIB0025E Voltage Steering wheel is turned fully. Approximately 0.5 - 4.0V Steering wheel is not turned. Approximately 0.4 - 0.8V EC-470 DTC P0605 ECM Component Description Component Description NAEC1235 The ECM consists of a microcomputer and connectors for signal input and output and for power supply. The unit controls the engine. GI MA EM LC SEC405D On Board Diagnosis Logic NAEC1236 This self-diagnosis has one or two trip detection logic. P0605 0605 FE Trouble diagnosis name DTC No. Engine control module DTC Detecting Condition A) ECM calculation function is malfunctioning. B) ECM EEP-ROM system is malfunctioning. C) ECM self shut-off function is malfunctioning. Possible Cause CL 쐌 ECM MT FAIL-SAFE MODE ECM enters fail-safe mode when the malfunction A is detected. Detected items Malfunction A AT Engine operation condition in fail-safe mode 쐌 ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. 쐌 ECM deactivates ASCD operation. TF PD AX SU DTC Confirmation Procedure NAEC1237 Perform “PROCEDURE FOR MALFUNCTION A” first. If the 1st trip DTC cannot be confirmed, perform “PROCEDURE FOR MALFUNCTION B”. If there is no malfunction on “PROCEDURE FOR MALFUNCTION B”, perform “PROCEDURE FOR MALFUNCTION C”. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. PROCEDURE FOR MALFUNCTION A With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) If 1st trip DTC is detected, go to EC-472, “Diagnostic Procedure”. With GST Follow the procedure “With CONSULT-II” above. BR ST RS BT HA SC EL IDX SEF058Y EC-471 DTC P0605 ECM DTC Confirmation Procedure (Cont’d) PROCEDURE FOR MALFUNCTION B With CONSULT-II 1) Turn ignition switch “ON” and wait at least 1 second. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Turn ignition switch “OFF”, wait at least 10 seconds, and then turn “ON”. 4) If 1st trip DTC is detected, go to EC-472, “Diagnostic Procedure”. With GST Follow the procedure “With CONSULT-II” above. SEF058Y SEF058Y PROCEDURE FOR MALFUNCTION C With CONSULT-II 1) Turn ignition switch “ON” and wait at least 1 second. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Turn ignition switch “OFF”, wait at least 10 seconds, and then turn “ON”. 4) Repeat “step 3” 32 times. 5) If 1st trip DTC is detected, go to EC-472, “Diagnostic Procedure”. With GST Follow the procedure “With CONSULT-II” above. Diagnostic Procedure 1 NAEC1238 INSPECTION START With CONSULT-II Turn ignition switch “ON”. Select “SELF DIAG RESULTS” mode with CONSULT-II. Touch “ERASE”. Perform “DTC Confirmation Procedure”. See EC-471. 5. Is the 1st trip DTC P0605 displayed again? 1. 2. 3. 4. With GST Turn ignition switch “ON”. Select MODE 4 with GST. Touch “ERASE”. Perform “DTC Confirmation Procedure”. See EC-471. 5. Is the 1st trip DTC P0605 displayed again? 1. 2. 3. 4. Yes or No Yes 䊳 GO TO 2. No 䊳 INSPECTION END 2 REPLACE ECM 1. Replace ECM. 2. Perform initialization of NVIS (NATS) system and registration of all NVIS (NATS) ignition key IDs. Refer to “NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS)”, EC-101. 3. Perform “Accelerator Pedal Released Position Learning”, EC-81. 4. Perform “Throttle Valve Closed Position Learning”, EC-81. 5. Perform “Idle Air Volume Learning”, EC-81. 䊳 INSPECTION END EC-472 DTC P1065 ECM POWER SUPPLY (BACK UP) Component Description Component Description NAEC1239 Battery voltage is supplied to the ECM even when the ignition switch is turned OFF for the ECM memory function of the DTC memory, the air-fuel ratio feedback compensation value memory, the idle air volume learning value memory, etc. GI MA EM LC PBIB1164E ECM Terminals and Reference Value NAEC1244 Specification data are reference values and are measured between each terminal and body ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 121 WIRE COLOR W/R ITEM CONDITION P1065 1065 CL DATA (DC Voltage) MT Power supply for ECM (Back-up) BATTERY VOLTAGE (11 - 14V) [Ignition switch “OFF”] On Board Diagnosis Logic DTC No. FE Trouble diagnosis name ECM power supply circuit DTC detecting condition ECM back-up RAM system does not function properly. AT NAEC1240 TF Possible cause 쐌 Harness or connectors [ECM power supply (back-up) circuit is open or shorted.] 쐌 ECM PD AX SU DTC Confirmation Procedure NAEC1241 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. BR ST RS BT 1. 2. 3. 4. 5. 6. With CONSULT-II Turn ignition switch “ON” and wait at least 1 second. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. Turn ignition switch “OFF”, wait at least 10 seconds, and then turn “ON”. Repeat steps 3 and 4 four times. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-476. HA SC EL IDX SEF058Y EC-473 DTC P1065 ECM POWER SUPPLY (BACK UP) DTC Confirmation Procedure (Cont’d) With GST Follow the procedure “WITH CONSULT-II” above. EC-474 DTC P1065 ECM POWER SUPPLY (BACK UP) Wiring Diagram Wiring Diagram NAEC1242 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC345E EC-475 IDX DTC P1065 ECM POWER SUPPLY (BACK UP) Diagnostic Procedure Diagnostic Procedure 1 NAEC1243 CHECK ECM POWER SUPPLY 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check voltage between ECM terminal 121 and ground with CONSULT-II or tester. MBIB0026E Voltage: Battery voltage OK or NG OK 䊳 GO TO 3. NG 䊳 GO TO 2. 2 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors E1, M1 쐌 Harness connectors M32, F23 쐌 7.5A fuse 쐌 Harness for open or short between ECM and fuse 䊳 3 Repair or replace harness or connectors. CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. OK or NG OK 䊳 GO TO 4. NG 䊳 Repair or replace harness or connectors. EC-476 DTC P1065 ECM POWER SUPPLY (BACK UP) Diagnostic Procedure (Cont’d) 4 PERFORM DTC CONFIRMATION PROCEDURE With CONSULT-II Turn ignition switch “ON”. Select “SELF DIAG RESULTS” mode with CONSULT-II. Touch “ERASE”. Perform “DTC Confirmation Procedure”. See EC-473. 5. Is the 1st trip DTC P1065 displayed again? GI 1. 2. 3. 4. MA With GST Turn ignition switch “ON”. Select MODE 4 with GST. Touch “ERASE”. Perform “DTC Confirmation Procedure”. See EC-473. 5. Is the 1st trip DTC P1065 displayed again? LC EM 1. 2. 3. 4. FE Yes or No Yes 䊳 GO TO 5. No 䊳 INSPECTION END CL MT 5 REPLACE ECM 1. Replace ECM. 2. Perform initialization of NVIS (NATS) system and registration of all NVIS (NATS) ignition key IDs. Refer to “NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM — NATS)”, EC-101. 3. Perform “Accelerator Pedal Released Position Learning”, EC-81. 4. Perform “Throttle Valve Closed Position Learning”, EC-81. 5. Perform “Idle Air Volume Learning”, EC-81. 䊳 INSPECTION END AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-477 DTC P1102 MAF SENSOR (TYPE I) Application Notice Application Notice NAEC1411 Confirm the type of the vehicle. Refer to “How to Check Vehicle Type”, EC-9. Component Description SEC266C NAEC0803 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 film that is supplied with electric current from the ECM. The temperature of the hot film is controlled by the ECM a certain amount. The heat generated by the hot film is reduced as the intake air flows around it. The more air, the greater the heat loss. Therefore, the ECM must supply more electric current to maintain the temperature of the hot film as air flow increases. The ECM detects the air flow by means of this current change. CONSULT-II Reference Value in Data Monitor Mode NAEC0804 Specification data are reference values. MONITOR ITEM MAS A/F SE-B1 CAL/LD VALUE MASS AIRFLOW CONDITION 쐌 쐌 쐌 쐌 Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load SPECIFICATION Idle 1.2 - 1.8V 2,500 rpm 1.6 - 2.2V Idle 14.0 - 33.0% 2,500 rpm 12.0 - 25.0% Idle 2.0 - 6.0 g·m/s 2,500 rpm 7.0 - 20.0 g·m/s ditto ditto ECM Terminals and Reference Value NAEC0805 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 48 51 WIRE COLOR P/B OR ITEM Sensors’ power supply Mass air flow sensor CONDITION DATA (DC Voltage) [Ignition switch “ON”] Approximately 5V [Engine is running] 쐌 Warm-up condition 쐌 Idle speed 1.2 - 1.8V [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,500 rpm. 1.6 - 2.2V EC-478 DTC P1102 MAF SENSOR (TYPE I) ECM Terminals and Reference Value (Cont’d) GI TERMINAL NO. 67 WIRE COLOR B/P ITEM CONDITION Mass air flow sensor ground DATA (DC Voltage) MA [Engine is running] 쐌 Warm-up condition 쐌 Idle speed Approximately 0V EM On Board Diagnosis Logic NAEC0806 This self-diagnosis has the one trip detection logic. NOTE: If DTC P1102 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to EC-596. DTC No. P1102 1102 Trouble diagnosis name Mass air flow sensor circuit range/ performance problem DTC Detecting Condition A voltage from the sensor is constantly approx. 1.0V when engine is running. Possible Cause LC FE 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Mass air flow sensor CL MT FAIL-SAFE MODE NAEC0806S01 When the malfunction is detected, the ECM enters fail-safe mode and the MIL lights up. Detected items AT Engine operating condition in fail-safe mode Mass air flow sensor circuit Engine speed will not rise more than 2,400 rpm due to the fuel cut. TF PD AX SU DTC Confirmation Procedure NAEC0808 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. BR ST RS BT WITH CONSULT-II 1) 2) 3) 4) NAEC0808S06 Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and wait at least 5 seconds. If DTC is detected, go to “Diagnostic Procedure”, EC-481. WITH GST Follow the procedure “With CONSULT-II” above. NAEC0808S07 HA SC EL IDX SEF058Y EC-479 DTC P1102 MAF SENSOR (TYPE I) Wiring Diagram Wiring Diagram NAEC0810 MEC082E EC-480 DTC P1102 MAF SENSOR (TYPE I) Diagnostic Procedure Diagnostic Procedure 1 NAEC0811 CHECK INTAKE SYSTEM MA Check the following for connection. 쐌 Air duct 쐌 Vacuum hoses EM OK or NG OK 䊳 GO TO 2. NG 䊳 Reconnect the parts. 2 GI LC RETIGHTEN GROUND SCREWS 1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. FE CL MT AT SEF959Y 䊳 TF GO TO 3. PD AX SU BR ST RS BT HA SC EL IDX EC-481 DTC P1102 MAF SENSOR (TYPE I) Diagnostic Procedure (Cont’d) 3 CHECK MAF SENSOR POWER SUPPLY CIRCUIT 1. Disconnect mass air flow (MAF) sensor harness connector. SEF960Y 2. Turn ignition switch “ON”. 3. Check voltage between MAF sensor terminals 2, 4 and ground with CONSULT-II or tester. SEC428D MTBL1352 OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 4. 4 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors E1, M1 쐌 Harness connectors M32, F23 쐌 Harness for open or short between ECM relay and mass air flow sensor 쐌 Harness for open or short between mass air flow sensor and ECM 䊳 Repair open circuit or short to ground or short to power in harness or connectors. EC-482 DTC P1102 MAF SENSOR (TYPE I) Diagnostic Procedure (Cont’d) 5 CHECK MAF SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. 4. Turn ignition switch “OFF”. Disconnect ECM harness connector. Disconnect TCM harness connector. Check harness continuity between MAF sensor terminal 3 and ECM terminal 67, MAF sensor terminal 3 and TCM terminal 42. Refer to Wiring Diagram. Continuity should exist. 5. Also check harness for short to ground and short to power. GI MA EM LC OK or NG OK 䊳 GO TO 7. NG 䊳 GO TO 6. 6 FE DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors F22, M33 쐌 Joint connector 쐌 Harness for open or short between mass air flow sensor and ECM 쐌 Harness for open or short between mass air flow sensor and TCM 䊳 CL MT Repair open circuit or short to ground or short to power in harness or connectors. AT 7 CHECK MAF SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between MAF sensor terminal 5 and ECM terminal 51. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. TF PD OK or NG OK 䊳 GO TO 8. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. AX SU BR ST RS BT HA SC EL IDX EC-483 DTC P1102 MAF SENSOR (TYPE I) Diagnostic Procedure (Cont’d) 8 CHECK MASS AIR FLOW SENSOR 1. Reconnect harness connectors disconnected. 2. Start engine and warm it up to normal operating temperature. 3. Check voltage between ECM terminal 51 (Mass air flow sensor signal) and ground. SEF100V MTBL1353 4. If the voltage is out of specification, disconnect MAF sensor harness connector and connect it again. Then repeat above check. OK or NG OK 䊳 GO TO 9. NG 䊳 Replace mass air flow sensor. 9 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-484 DTC P1110, P1135 IVT CONTROL Description Description NAEC1371 SYSTEM DESCRIPTION GI NAEC1371S01 Sensor Input signal to ECM function ECM MA Actuator Crankshaft position sensor (POS) Engine speed and piston position Camshaft position sensor (PHASE) Engine coolant temperature sensor Engine coolant temperature Vehicle speed signal*1 Vehicle speed Intake valve timing control Intake valve timing control solenoid valve EM LC *1: This signal is sent to the ECM through CAN communication line. FE CL MT AT TF PD SEC419D This mechanism hydraulically controls cam phases continuously with the fixed operating angle of the intake valve. The ECM receives signals such as crankshaft position, camshaft position, engine speed, and engine coolant temperature. Then, the ECM sends ON/OFF pulse duty signals to the camshaft timing control valve depending on driving status. This makes it possible to control the shut/open timing of the intake valve to increase engine torque in low/mid speed range and output in high-speed range. CONSULT-II Reference Value in Data Monitor Mode AX SU BR ST NAEC1372 Specification data are reference values. MONITOR ITEM INT/V TIM (B1) INT/V TIM (B2) INT/V SOL (B1) INT/V SOL (B2) CONDITION 쐌 Engine: After warming up 쐌 Shift lever “N” 쐌 Quickly depressed accelerator pedal 쐌 No-load 쐌 Engine: After warming up 쐌 Shift lever “N” 쐌 Quickly depressed accelerator pedal 쐌 No-load SPECIFICATION Idle 0° CA 2,000 rpm Approximately 12 - 18° CA Idle 0% RS BT HA SC 2,000 rpm Approximately 40% EL IDX EC-485 DTC P1110, P1135 IVT CONTROL On Board Diagnosis Logic On Board Diagnosis Logic DTC No. P1110 1110 (Bank 1) P1135 1135 (Bank 2) Trouble diagnosis name Intake valve timing control performance DTC Detecting Condition The alignment of the intake valve timing control has been misregistered. =NAEC1373 Possible Cause 쐌 Crankshaft position sensor (POS) 쐌 Camshaft position sensor (PHASE) 쐌 Accumulation of debris to the signal pick-up portion of the camshaft FAIL-SAFE MODE NAEC1373S01 When malfunction is detected, the ECM enters fail-safe mode. Detected items Intake valve timing control Engine operating condition in fail-safe mode The signal is not energized to the solenoid valve and the valve control does not function. DTC Confirmation Procedure NAEC1374 CAUTION: Always drive at a safe speed. NOTE: 쐌 If DTC P1110 or P1135 is displayed with DTC P1111 or P1136, first perform trouble diagnosis for DTC P1111 or P1136, EC-488. 쐌 If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1) 2) 3) NAEC1374S01 Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Maintain the following conditions for at least 10 conecutive seconds. ENG SPEED 1,200 - 2,000 rpm (A constant rotation is maintained.) COOLANT TEMPS More than 60°C (140°F) Selector lever 1st position Driving location Driving vehicle uphill (Increased engine load will help maintain the driving conditions required for this test.) SEF353Z 4) Maintain the following conditions for at least 20 conecutive seconds. ENG SPEED Idle COOLANT TEMPS More than 60°C (140°F) Selector lever “P” or “N” position EC-486 DTC P1110, P1135 IVT CONTROL DTC Confirmation Procedure (Cont’d) 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-487. WITH GST NAEC1374S02 Follow the procedure “With CONSULT-II” above. GI MA EM LC Diagnostic Procedure 1 NAEC1375 CHECK CRANKSHAFT POSITION SENSOR (POS) FE Refer to “Component Inspection”, EC-356. OK or NG OK 䊳 GO TO 2. NG 䊳 Replace crankshaft position sensor (POS). 2 CL MT CHECK CAMSHAFT POSITION SENSOR (PHASE) AT Refer to “Component Inspection”, EC-365. OK or NG OK 䊳 GO TO 3. NG 䊳 Replace. TF PD 3 CHECK CAMSHAFT (INTAKE) Visually check for chipped signal plate at camshaft. AX SU BR ST SEC578D RS OK or NG OK 䊳 GO TO 4. NG 䊳 Replace camshaft. 4 BT HA CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. For Wiring Diagram, refer to EC-352 CKP sensor (POS), and EC-359 for CMP sensor (PHASE). SC OK or NG 䊳 EL INSPECTION END IDX EC-487 DTC P1111, P1136 IVT CONTROL SOLENOID VALVE Component Description Component Description PBIB1842E NAEC1036 Intake valve timing control solenoid valve is activated by ON/OFF pulse duty (ratio) signals from the ECM. The intake valve timing control solenoid valve changes the oil amount and direction of flow through intake valve timing control unit or stops oil flow. The longer pulse width advances valve angle. The shorter pulse width retards valve angle. When ON and OFF pulse widths become equal, the solenoid valve stops oil pressure flow to fix the intake valve angle at the control position. CONSULT-II Reference Value in Data Monitor Mode NAEC1037 Specification data are reference values. MONITOR ITEM INT/V SOL (B1) INT/V SOL (B2) CONDITION 쐌 Engine: After warming up 쐌 Shift lever “N” 쐌 Quickly depressed accelerator pedal 쐌 No-load SPECIFICATION Idle 0% 2,000 rpm Approximately 40% ECM Terminals and Reference Value NAEC1038 Specification data are reference values, and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than the ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION [Engine is running] 쐌 Warm-up condition 쐌 Idle speed DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V) 7 - 8V★ 10 P/L Intake valve timing control solenoid valves (bank 2) [Engine is running] 쐌 Warm-up condition 쐌 When revving engine up to 2,000 rpm quickly. PBIB1790E [Engine is running] 쐌 Warm-up condition 쐌 Idle speed BATTERY VOLTAGE (11 - 14V) 7 - 8V★ 11 OR/B Intake valve timing control solenoid valves (bank 1) [Engine is running] 쐌 Warm-up condition 쐌 When revving engine up to 2,000 rpm quickly. PBIB1790E ★: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) EC-488 DTC P1111, P1136 IVT CONTROL SOLENOID VALVE On Board Diagnosis Logic On Board Diagnosis Logic DTC No. P1111 1111 (Bank 1) P1136 1136 (Bank 2) Trouble diagnosis name DTC Detecting Condition Intake valve timing An improper voltage is sent to the ECM through control solenoid valve intake valve timing control solenoid valve. circuit NAEC1039 Possible Cause MA 쐌 Harness or connectors (Intake valve timing control solenoid valve circuit is open or shorted.) 쐌 Intake valve timing control solenoid valve DTC Confirmation Procedure SEF353Z 1) 2) 3) 4) WITH GST LC FE CL NAEC1040S01 Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 5 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-492. Follow the procedure “With CONSULT-II” above. EM NAEC1040 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. WITH CONSULT-II GI NAEC1040S02 MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-489 DTC P1111, P1136 IVT CONTROL SOLENOID VALVE Wiring Diagram Wiring Diagram BANK 1 NAEC1041 NAEC1041S01 MEC099E EC-490 DTC P1111, P1136 IVT CONTROL SOLENOID VALVE Wiring Diagram (Cont’d) BANK 2 NAEC1041S02 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC100E EC-491 IDX DTC P1111, P1136 IVT CONTROL SOLENOID VALVE Diagnostic Procedure Diagnostic Procedure 1 NAEC1042 INTAKE VALVE TIMING CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT 1. Turn ignition switch “OFF”. 2. Disconnect intake valve timing control solenoid valve harness connector. SEC572D SEC573D 3. Turn ignition switch “ON”. 4. Check voltage between intake valve timing control solenoid valve terminal 1 and ground with CONSULT-II or tester. SEC556D Voltage: Battery voltage OK or NG OK 䊳 GO TO 3. NG 䊳 GO TO 2. 2 DETECT MALFUNCTION PART Check the following. 쐌 Harness connectors E1, M1 쐌 Harness connectors M33, F22 쐌 Harness continuity between intake valve timing control solenoid valve and ECM relay 䊳 Repair harness or connectors. EC-492 DTC P1111, P1136 IVT CONTROL SOLENOID VALVE Diagnostic Procedure (Cont’d) 3 CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE OUTPUT CIRCUIT FOR OPEN AND SHORT GI 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness connectors continuity between ECM terminal 11 (bank 1) or 10 (bank 2) and intake valve timing control solenoid valve terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. MA OK or NG LC OK 䊳 GO TO 4. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. 4 CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE EM FE Check resistance between intake valve timing control solenoid valve terminals as follows. CL MT AT TF SEC555D OK or NG OK 䊳 GO TO 5. NG 䊳 Repair intake valve timing control solenoid valve. 5 PD AX CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 SU INSPECTION END BR ST RS BT HA SC EL IDX EC-493 DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR Component Description Component Description NAEC1245 Electric Throttle Control Actuator consists of throttle control motor, throttle position sensor, etc. The throttle control motor is operated by the ECM and it opens and closes the throttle valve. The throttle position sensor detects the throttle valve position, and the opening and closing speed of the throttle valve and feeds the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening angle properly in response to driving condition. On Board Diagnosis Logic Trouble diagnosis name DTC No. P1121 1121 Electric throttle control actuator DTC detecting condition A) Electric throttle control actuator does not function properly due to the return spring malfunction. B) Throttle valve opening angle in fail-safe mode is not in specified range. C) ECM detects that the throttle valve is stuck open. NAEC1246 Possible cause 쐌 Electric throttle control actuator FAIL-SAFE MODE When the malfunction is detected, ECM enters fail-safe mode and the MIL lights up. Detected items Engine operating condition in fail-safe mode Malfunction A The ECM controls the electric throttle throttle actuator by regulating the throttle opening around the idle position. The engine speed will not rise more than 2,000 rpm. Malfunction B ECM controls the electric throttle control actuator by regulating the throttle opening to 20 degrees or less. Malfunction C While the vehicle is driving, it slows down gradually by fuel cut. After the vehicle stops, the engine stalls. The engine can restart in “N” or “P” position, and engine speed will not exceed 1,000 rpm or more. DTC Confirmation Procedure NAEC1247 NOTE: 쐌 Perform “PROCEDURE FOR MALFUNCTION A AND B” first. If the 1st trip DTC cannot be confirmed, perform “PROCEDURE FOR MALFUNCTION C”. If there is no malfunction on “PROCEDURE FOR MALFUNCTION A AND B”, perform “PROCEDURE FOR MALFUNCTION C”. 쐌 If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. PROCEDURE FOR MALFUNCTION A AND B With CONSULT-II 1) Turn ignition switch “ON” and wait at least 1 second. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Shift selector lever to “D” position and wait at least 2 seconds. 4) Turn ignition switch “OFF” and wait at least 10 seconds. 5) Turn ignition switch “ON” and wait at least 1 second. 6) Shift selector lever to “D” position and wait at least 2 seconds. 7) Turn ignition switch “OFF”, wait at least 10 seconds, and then turn “ON”. SEF058Y EC-494 DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR DTC Confirmation Procedure (Cont’d) 8) If DTC is detected, go to “Diagnostic Procedure”, EC-495. With GST Follow the procedure “WITH CONSULT-II” above. GI MA EM LC SEF058Y PROCEDURE FOR MALFUNCTION C With CONSULT-II 1) Turn ignition switch “ON” and wait at least 1 second. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Shift selector lever to “D” position and wait at least 2 seconds. 4) Shift selector lever to “N” or “P” position. 5) Start engine and let it idle for 3 seconds. 6) If DTC is detected, go to “Diagnostic Procedure”, EC-495. With GST Follow the procedure “WITH CONSULT-II” above. Diagnostic Procedure 1 FE CL MT AT NAEC1248 CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY TF 1. Remove the intake air duct. 2. Check if a foreign matter is caught between the throttle valve and the housing. PD AX SU BR SEC513D OK or NG OK 䊳 GO TO 2. NG 䊳 Remove the foreign matter and clean the electric throttle control actuator inside. 2 REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. Replace the electric throttle control actuator. 2. Perform “Throttle Valve Closed Position Learning”, EC-81. 3. Perform “Idle Air Volume Learning”, EC-81. 䊳 ST RS BT HA INSPECTION END SC EL IDX EC-495 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION Description Description NAEC1249 NOTE: If DTC P1122 is displayed with DTC P1121 or P1126, first perform the trouble diagnosis for DTC P1121 or P1126. Refer to EC-494, 504. Electric Throttle Control Actuator consists of throttle control motor, throttle position sensor, etc. The throttle control motor is operated by the ECM and it opens and closes the throttle valve. The current opening angle of the throttle valve is detected by the throttle position sensor and it provides the feedback to the ECM to control the throttle control motor to make the throttle valve opening angle properly in response to driving condition. ECM Terminals and Reference Value NAEC1268 Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 3 WIRE COLOR OR ITEM Throttle control motor relay power supply CONDITION [Ignition switch “ON”] DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V) 0 - 14V★ 4 L/W Throttle control motor (Close) [Ignition switch “ON”] 쐌 Engine stopped 쐌 Shift lever position is “D” (A/T models) 쐌 Shift lever position is “1st” (M/T models) 쐌 Accelerator pedal is releasing PBIB1104E 0 - 14V★ 5 L/B Throttle control motor (Open) [Ignition switch “ON”] 쐌 Engine stopped 쐌 Shift lever position is “D” (A/T models) 쐌 Shift lever position is “1st” (M/T models) 쐌 Accelerator pedal is depressing PBIB1105E 104 L Throttle control motor relay [Ignition switch “OFF”] BATTERY VOLTAGE (11 - 14V) [Ignition switch “ON”] 0 - 1.0V ★: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) EC-496 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION On Board Diagnosis Logic On Board Diagnosis Logic =NAEC1250 GI This self-diagnosis has the one trip detection logic. DTC No. P1122 1122 Trouble diagnosis name Electric throttle control performance problem DTC Detecting Condition Electric throttle control function does not operate properly. MA Possible Cause 쐌 Harness or connectors (Throttle control motor circuit is open or shorted.) 쐌 Electric throttle control actuator EM LC FAIL-SAFE MODE When the malfunction is detected, the ECM enters fail-safe mode and the MIL lights up. Engine operating condition in fail-safe mode ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. FE CL MT DTC Confirmation Procedure AT NAEC1251 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TF PD AX SU 1) 2) 3) 4) With CONSULT-II Turn ignition switch “ON” and wait at least 2 seconds. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 5 seconds. If DTC is detected, go to “Diagnostic Procedure”, EC-499. BR ST RS BT SEF058Y With GST Follow the procedure “WITH CONSULT-II” above. HA SC EL IDX EC-497 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION Wiring Diagram Wiring Diagram NAEC1252 MEC121E EC-498 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION Diagnostic Procedure Diagnostic Procedure 1 NAEC1253 GI RETIGHTEN GROUND SCREWS MA 1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. EM LC FE SEF959Y 䊳 2 CL GO TO 2. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT-I MT Check voltage between ECM terminal 3 and ground under the following conditions with CONSULT-II or tester. AT TF PD AX MBIB0028E SU BR MTBL1168 OK or NG OK 䊳 GO TO 11. NG 䊳 GO TO 3. ST RS BT HA SC EL IDX EC-499 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION Diagnostic Procedure (Cont’d) 3 CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT 1. Turn ignition switch “OFF”. 2. Disconnect throttle control motor relay. SEC425D 3. Check voltage between throttle control motor relay terminals 1, 3 and ground with CONSULT-II or tester. SEC538D Voltage: Battery voltage OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 4. 4 DETECT MALFUNCTIONING PART Check the following. 쐌 15A fuse 쐌 Harness for open and short between throttle control motor relay and battery 䊳 5 Repair open circuit or short to ground or short to power in harness or connectors. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT-II 1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 3 and throttle control motor relay terminal 5. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 7. NG 䊳 GO TO 6. EC-500 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION Diagnostic Procedure (Cont’d) 6 GI DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connector E1, M11 쐌 Harness connector M33, F22 쐌 Harness for open and short between throttle control motor relay and ECM 䊳 7 Repair open circuit or short to ground or short to power in harness or connectors. CHECK THROTTLE CONTROL MOTOR RELAY OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT MA EM LC 1. Check harness continuity between ECM terminal 104 and throttle control motor relay terminal 2. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 9. NG 䊳 GO TO 8. 8 CL DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connector E1, M1 쐌 Harness connectors M33, F22 쐌 Harness for open and short between throttle control motor relay and ECM 䊳 9 FE MT AT Repair open circuit or short to ground or short to power in harness or connectors. TF CHECK THROTTLE CONTROL MOTOR RELAY PD Refer to “Component Inspection”, EC-503. OK or NG AX OK 䊳 GO TO 10. NG 䊳 Replace throttle control motor relay. SU 10 CHECK INTERMITTENT INCIDENT Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 BR INSPECTION END ST RS BT HA SC EL IDX EC-501 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION Diagnostic Procedure (Cont’d) 11 CHECK THROTTLE CONTROL MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN OR SHORT 1. Turn ignition switch “OFF”. 2. Disconnect electric throttle control actuator harness connector. SEC433D 3. Disconnect ECM harness connector. 4. Check harness continuity between the following terminals. Refer to Wiring Diagram. MTBL1377 5. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 12. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. 12 CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY 1. Remove the intake air duct. 2. Check if foreign matter is caught between the throttle valve and the housing. SEC513D OK or NG OK 䊳 GO TO 13. NG 䊳 Remove the foreign matter and clean the electric throttle control actuator inside. EC-502 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION Diagnostic Procedure (Cont’d) 13 GI CHECK THROTTLE CONTROL MOTOR Refer to “Component Inspection”, EC-503. MA OK or NG OK 䊳 GO TO 14. NG 䊳 GO TO 15. 14 EM CHECK INTERMITTENT INCIDENT LC Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. OK or NG OK 䊳 GO TO 15. NG 䊳 Repair or replace harness or connectors. 15 FE REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR CL 1. Replace the electric throttle control actuator. 2. Perform “Throttle Valve Closed Position Learning”, EC-81. 3. Perform “Idle Air Volume Learning”, EC-81. 䊳 MT INSPECTION END AT Component Inspection NAEC1254 THROTTLE CONTROL MOTOR 1. 2. 3. 4. 5. NAEC1254S01 Disconnect electric throttle control actuator harness connector. Check resistance between terminals 3 and 6. Resistance: Approximately 1 - 15Ω [at 25°C (77°F)] If NG, replace electric throttle control actuator and go to next step. Perform “Throttle Valve Closed Position Learning”, EC-81. Perform “Idle Air Volume Learning”, EC-81. TF PD AX SU PBIB0095E THROTTLE CONTROL MOTOR RELAY 1. 2. NAEC1254S02 Apply 12V direct current between relay terminals 1 and 2. Check continuity between relay terminals 3 and 5. Conditions Continuity 12V direct current supply between terminals 1 and 2 Yes No current supply No 3. If NG, replace throttle control motor relay. PBIB0098E BR ST RS BT HA SC EL IDX EC-503 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY Component Description Component Description NAEC1255 Power supply for the Throttle Control motor is provided to the ECM via throttle control motor relay. The throttle control motor relay is ON/OFF controlled by the ECM. When the ignition switch is turned ON, the ECM sends an ON signal to throttle control motor relay and battery voltage is provided to the ECM. When the ignition switch is turned OFF, the ECM sends an OFF signal to throttle control motor relay and battery voltage is not provided to the ECM. CONSULT-II Reference Value in Data Monitor Mode NAEC1256 Specification data are reference values. MONITOR ITEM CONDITION SPECIFICATION 쐌 Ignition switch: ON THRTL RELAY ON ECM Terminals and Reference Value NAEC1269 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 3 104 WIRE COLOR ITEM OR Throttle control motor relay power supply L Throttle control motor relay CONDITION DATA (DC Voltage) [Ignition switch “ON”] BATTERY VOLTAGE (11 - 14V) [Ignition switch “OFF”] BATTERY VOLTAGE (11 - 14V) [Ignition switch “ON”] 0 - 1.0V On Board Diagnosis Logic NAEC1257 These self-diagnoses have the one trip detection logic. DTC No. Trouble diagnosis name DTC Detecting Condition Possible Cause P1124 1124 Throttle control motor ECM detects that the throttle control motor relay is 쐌 Harness or connectors relay circuit short stuck ON. (Throttle control motor relay circuit is shorted) 쐌 Throttle control motor relay P1126 1126 Throttle control motor ECM detects that a voltage of power source for relay circuit open throttle control motor is excessively low. 쐌 Harness or connectors (Throttle control motor relay circuit is open) 쐌 Throttle control motor relay FAIL-SAFE MODE NAEC1257S01 When the malfunction is detected, ECM enters fail-safe mode and the MIL lights up. Engine operating condition in fail-safe mode ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. EC-504 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY DTC Confirmation Procedure DTC Confirmation Procedure NAEC1258 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. PROCEDURE FOR DTC P1124 TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. With CONSULT-II Turn ignition switch “ON” and wait at least 1 second. Select “DATA MONITOR” mode with CONSULT-II. If DTC is detected, go to “Diagnostic Procedure”, EC-507. With GST Follow the procedure “With CONSULT-II” above. 1) 2) 3) GI MA EM LC FE CL MT SEF058Y PROCEDURE FOR DTC P1126 With CONSULT-II 1) Turn ignition switch “ON” and wait at least 2 seconds. 2) Select “DATA MONITOR” mode with CONSULT-II. 3) Start engine and let it idle for 5 seconds. 4) If DTC is detected, go to “Diagnostic Procedure”, EC-507. With GST Follow the procedure “With CONSULT-II” above. AT TF PD AX SU SEF058Y BR ST RS BT HA SC EL IDX EC-505 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY Wiring Diagram Wiring Diagram NAEC1259 MEC122E EC-506 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY Diagnostic Procedure Diagnostic Procedure 1 NAEC1260 GI CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT MA 1. Turn ignition switch “OFF”. 2. Disconnect throttle control motor relay. EM LC FE SEC425D 3. Check voltage between throttle control motor relay terminals 1, 3 and ground with CONSULT-II or tester. CL MT AT TF SEC538D Voltage: Battery voltage PD OK or NG OK 䊳 GO TO 3. NG 䊳 GO TO 2. AX SU 2 DETECT MALFUNCTIONING PART Check the following. 쐌 15A fuse 쐌 Harness for open and short between throttle control motor relay and battery Repair open circuit or short to ground or short to power in harness or connectors. ST CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT RS 䊳 3 BR 1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 3 and throttle control motor relay terminal 5. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 4. BT HA SC EL IDX EC-507 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY Diagnostic Procedure (Cont’d) 4 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connector E1, M1 쐌 Harness connector M33, F22 쐌 Harness for open and short between throttle control motor relay and ECM 䊳 5 Repair open circuit or short to ground or short to power in harness or connectors. CHECK THROTTLE CONTROL MOTOR RELAY OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 104 and throttle control motor relay terminal 2. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 7. NG 䊳 GO TO 6. 6 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connector E1, M1 쐌 Harness connectors M33, F22 쐌 Harness for open and short between throttle control motor relay and ECM 䊳 7 Repair open circuit or short to ground or short to power in harness or connectors. CHECK THROTTLE CONTROL MOTOR RELAY Refer to “Component Inspection”, EC-508. OK or NG OK 䊳 GO TO 8. NG 䊳 Replace throttle control motor relay. 8 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END Component Inspection NAEC1261 THROTTLE CONTROL MOTOR RELAY 1. Apply 12V direct current between relay terminals 1 and 2. 2. Check continuity between relay terminals 3 and 5. PBIB0098E Conditions Continuity 12V direct current supply between terminals 1 and 2 Yes No current supply No 3. If NG, replace throttle control motor relay. EC-508 DTC P1128 THROTTLE CONTROL MOTOR Component Description Component Description NAEC1262 The throttle control motor is operated by the ECM and it opens and closes the throttle valve. The current opening angle of the throttle valve is detected by the throttle position sensor and it provides feedback to the ECM to control the throttle control motor to make the throttle valve opening angle properly in response to driving condition. ECM Terminals and Reference Value NAEC1270 Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) GI MA EM LC FE 0 - 14V★ 4 L/W Throttle control motor (Close) CL [Ignition switch “ON”] 쐌 Engine stopped 쐌 Shift lever position is “D” (A/T models) 쐌 Shift lever position is “1st” (M/T models) 쐌 Accelerator pedal is releasing MT PBIB1104E AT 0 - 14V★ TF 5 L/B Throttle control motor (Open) [Ignition switch “ON”] 쐌 Engine stopped 쐌 Shift lever position is “D” (A/T models) 쐌 Shift lever position is “1st” (M/T models) 쐌 Accelerator pedal is depressing PD PBIB1105E ★: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) SU On Board Diagnosis Logic NAEC1263 This self-diagnosis has the one trip detection logic. DTC No. P1128 1128 Trouble diagnosis name BR DTC Detecting Condition Throttle control motor ECM detects short in both circuits between ECM circuit short and throttle control motor. AX Possible Cause ST 쐌 Harness or connectors (Throttle control motor circuit is shorted.) 쐌 Electric throttle control actuator (Throttle control motor) RS BT DTC Confirmation Procedure NAEC1264 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. HA SC EL IDX EC-509 DTC P1128 THROTTLE CONTROL MOTOR DTC Confirmation Procedure (Cont’d) 1) 2) 3) 4) With CONSULT-II Turn ignition switch “ON” and wait at least 2 seconds. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 5 seconds. If DTC is detected, go to “Diagnostic Procedure”, EC-512. SEF058Y With GST Follow the procedure “With CONSULT-II” above. EC-510 DTC P1128 THROTTLE CONTROL MOTOR Wiring Diagram Wiring Diagram NAEC1265 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC123E EC-511 IDX DTC P1128 THROTTLE CONTROL MOTOR Diagnostic Procedure Diagnostic Procedure 1 NAEC1266 RETIGHTEN GROUND SCREWS 1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. SEF959Y 䊳 2 1. 2. 3. 4. GO TO 2. CHECK THROTTLE CONTROL MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN OR SHORT Turn ignition switch “OFF”. Disconnect electric throttle control actuator harness connector. Disconnect ECM harness connector. Check harness continuity between the following terminals. Refer to Wiring Diagram. SEC433D MTBL1377 5. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 3. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. EC-512 DTC P1128 THROTTLE CONTROL MOTOR Diagnostic Procedure (Cont’d) 3 GI CHECK THROTTLE CONTROL MOTOR Refer to “Component Inspection”, EC-513. MA OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 5. 4 EM CHECK INTERMITTENT INCIDENT LC Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. OK or NG OK 䊳 GO TO 5. NG 䊳 Repair or replace harness or connectors. 5 FE REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR CL 1. Replace the electric throttle control actuator. 2. Perform “Throttle Valve Closed Position Learning”, EC-81. 3. Perform “Idle Air Volume Learning”, EC-81. 䊳 MT INSPECTION END Component Inspection AT NAEC1267 THROTTLE CONTROL MOTOR 1. Disconnect electric throttle control actuator harness connector. 2. Check resistance between terminals 3 and 6. Resistance: Approximately 1 - 15Ω [at 25°C (77°F)] 3. If NG, replace electric throttle control actuator and go to next step. 4. Perform “Throttle Valve Closed Position Learning”, EC-81. 5. Perform “Idle Air Volume Learning”, EC-81. TF PD AX SU PBIB0095E BR ST RS BT HA SC EL IDX EC-513 DTC P1130 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE Description Description NAEC1043 If DTC P1130 is displayed with P1165, first perform trouble diagnosis for DTC P1165, EC-577. SYSTEM DESCRIPTION Sensor Input Signal to ECM Throttle position sensor Throttle position Accelerator pedal position sensor Accelerator pedal position Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed Mass air flow sensor Amount of intake air Engine coolant temperature sensor Engine coolant temperature NAEC1043S01 ECM function Swirl control valve control Actuator Swirl control valve control solenoid valve " Vacuum signal Swirl control valve actuator " Swirl control valve This system has a swirl control valve in the intake passage of each cylinder. While idling and during low engine speed operation, the swirl control valve closes. Thus the velocity of the air in the intake passage increases, promoting the vaporization of the fuel and producing a swirl in the combustion chamber. Because of this operation, this system tends to increase the burning speed of the gas mixture, improve fuel consumption, and increase the stability in running conditions. Also, except when idling and during low engine speed operation, this system opens the swirl control valve. In this condition, this system tends to increase power by improving intake efficiency via reduction of intake flow resistance, intake flow. The solenoid valve controls swirl control valve’s shut/open condition. This solenoid valve is operated by the ECM. Accelerator pedal position sensor (Idle position) Engine speed (A/T) Engine speed (M/T) Swirl control valve control solenoid valve Swirl control valve ON Below 3,200 rpm Below 2,400 rpm ON Closed Less than 3,200 rpm Less than 2,400 rpm ON Closed More than 3,600 rpm More than 2,800 rpm OFF Open OFF When engine coolant temperature is below 10°C (50°F) and above 55°C (131°F), swirl control valve is kept open regardless of above condition. SEF446Z EC-514 DTC P1130 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE Description (Cont’d) COMPONENT DESCRIPTION Swirl Control Valve Control Solenoid Valve NAEC1043S02 GI NAEC1043S0201 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. MA EM LC SEC539D CONSULT-II Reference Value in Data Monitor Mode NAEC1044 Specification data are reference values. MONITOR ITEM SWRL CONT S/V CONDITION 쐌 Engine speed: Idle SPECIFICATION CL Engine coolant temperature is between 15°C (59°F) to 50°C (122°F). ON Engine coolant temperature is above 55°C (131°F). OFF MT ECM Terminals and Reference Value AT NAEC1045 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 27 WIRE COLOR G ITEM FE CONDITION TF PD DATA (DC Voltage) AX [Engine is running] 쐌 Idle speed 쐌 Engine coolant temperature is between 15 to 50°C (59 to 122°F). Swirl control valve control solenoid valve [Engine is running] 쐌 Idle speed 쐌 Engine coolant temperature is above 55°C (131°F). 0 - 1.0V SU BR BATTERY VOLTAGE (11 - 14V) ST RS BT HA SC EL IDX EC-515 DTC P1130 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE On Board Diagnosis Logic On Board Diagnosis Logic DTC No. P1130 1130 Trouble diagnosis name DTC Detecting Condition Swirl control valve A) control solenoid valve An improper voltage signal is sent to ECM through swirl control valve control solenoid valve. NAEC1046 Possible Cause 쐌 Harness or connectors (The swirl control valve control solenoid valve circuit is open or shorted.) 쐌 Swirl control valve control solenoid valve B) The vacuum signal is not sent to swirl con- 쐌 Harness or connector trol valve under specified driving conditions, (The swirl control valve control soleeven though swirl control valve control solenoid valve circuit is open.) noid valve is ON. 쐌 Swirl control valve control solenoid valve 쐌 Intake system (Intake air leaks) 쐌 Hoses and tubes between intake manifold, vacuum tank and swirl control valve actuator 쐌 Swirl control valve actuator 쐌 Swirl control valve control vacuum check switch 쐌 Mass air flow sensor 쐌 Camshaft position sensor (PHASE) 쐌 Throttle position sensor 쐌 Accelerator pedal position sensor C) The vacuum signal is sent to swirl control valve even though swirl control valve control solenoid valve is OFF. 쐌 Harness or connector (The swirl control valve control solenoid valve circuit is shorted.) 쐌 Swirl control valve control vacuum check switch 쐌 Camshaft position sensor (PHASE) 쐌 Throttle position sensor 쐌 Accelerator pedal position sensor 쐌 Hoses and tubes between air cleaner and swirl control valve vacuum check switch 쐌 Swirl control valve control solenoid valve DTC Confirmation Procedure NAEC1047 Perform “Procedure for malfunction A” first. If the 1st trip DTC cannot be confirmed, perform “Procedure for malfunction B”. If the 1st trip DTC is not confirmed on “Procedure for malfunction B”, perform “Procedure for malfunction C”. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. EC-516 DTC P1130 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE DTC Confirmation Procedure (Cont’d) PROCEDURE FOR MALFUNCTION A With CONSULT-II 1) 2) 3) NAEC1047S01 NAEC1047S0101 Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 5 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-519. With GST GI NAEC1047S0102 Follow the procedure “With CONSULT-II” above. MA EM LC SEF058Y PROCEDURE FOR MALFUNCTION B NAEC1047S02 TESTING CONDITION: 쐌 For best results, perform the test at a temperature above 5°C (41°F). 쐌 Before performing the following procedure, confirm that battery voltage is more than 10V at idle, then stop engine immediately. With CONSULT-II SEF174Y 1) 2) 3) 4) 5) NAEC1047S0201 Turn ignition switch “OFF” and wait at least 10 seconds. Turn ignition switch “ON”. Check “COOLAN TEMP/S” in “DATA MONITOR” mode with CONSULT-II. Confirm COOLAN TEMP/S value is 40°C (104°F) or less. If the value is more than 40°C (104°F), park the vehicle in a cool place and retry from step 1. Start engine and wait until COOLAN TEMP/S value increases to more than 55°C (131°F). If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-519. With GST With CONSULT-II SEF174Y 4) With GST AT TF PD AX NAEC1047S03 NAEC1047S0301 Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF” and wait at least 10 seconds. Turn ignition switch “ON” again and select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for at least 20 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-519. Follow the procedure “With CONSULT-II” above. MT SU TESTING CONDITION: 쐌 For best results, perform the test at a temperature above 5°C (41°F). 쐌 Before performing the following procedure, confirm that battery voltage is more than 10V at idle. 1) 2) 3) CL NAEC1047S0202 Follow the procedure “With CONSULT-II” above. PROCEDURE FOR MALFUNCTION C FE NAEC1047S0302 BR ST RS BT HA SC EL IDX EC-517 DTC P1130 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE Wiring Diagram Wiring Diagram NAEC1048 MEC101E EC-518 DTC P1130 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE Diagnostic Procedure Diagnostic Procedure PROCEDURE A 1 NAEC1049 GI NAEC1049S01 MA INSPECTION START Do you have CONSULT-II? EM Yes or No Yes 䊳 GO TO 2. No 䊳 GO TO 3. 2 LC CHECK SWIRL CONTROL VALVE CONTROL SOLENOID VALVE CIRCUIT With CONSULT-II 1. Turn ignition switch “ON”. 2. Select “SWIRL CONT SOL VALVE” in “ACTIVE TEST” mode with CONSULT-II. 3. Touch “ON” and “OFF” on CONSULT-II screen. FE CL MT AT TF SEF003Z 4. Make sure that clicking sound is heard from the swirl control valve control solenoid valve. OK or NG OK 䊳 GO TO 6. NG 䊳 GO TO 3. PD AX SU BR ST RS BT HA SC EL IDX EC-519 DTC P1130 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE Diagnostic Procedure (Cont’d) 3 CHECK SWIRL CONTROL VALVE CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT 1. Turn ignition switch “OFF”. 2. Disconnect swirl control valve control solenoid valve harness connector. SEC539D 3. Turn ignition switch “ON”. 4. Check voltage between swirl control valve control solenoid valve terminal 1 and ground with CONSULT-II or tester. SEF619X OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 4. 4 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors E1, M1 쐌 Harness connectors M33, F22 쐌 Harness for open or short between swirl control valve control solenoid valve and ECM relay 䊳 5 Repair open circuit or short to ground or short to power in harness connectors. CHECK SWIRL CONTROL VALVE CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 27 and swirl control valve control solenoid valve terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 6. NG 䊳 Repair open circuit or short to ground or short to power in harness connectors. EC-520 DTC P1130 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE Diagnostic Procedure (Cont’d) 6 1. 2. 3. 4. 5. 6. GI CHECK SWIRL CONTROL VALVE CONTROL SOLENOID VALVE With CONSULT-II Reconnect the disconnected harness connectors. Start engine and let it idle. Remove vacuum hose connected to swirl control valve actuator. Select “SWIRL CONT SOL VALVE” in “ACTIVE TEST” mode with CONSULT-II. Touch “ON” and “OFF” on CONSULT-II screen. Check vacuum existence and operation delay time under the following conditions. MA EM LC FE CL SEC540D MT 1. 2. 3. 4. 5. Without CONSULT-II Reconnect ECM harness connector. Remove vacuum hose connected to swirl control valve actuator. Start engine and let it idle. Apply 12V of direct current between swirl control valve control solenoid valve terminals 1 and 2. Check vacuum existence and operation delay time under the following conditions. AT TF PD AX SU SEC541D BR OK or NG OK 䊳 GO TO 7. NG 䊳 Replace intake manifold collector assembly. ST RS 7 CHECK INTERMITTENT INCIDENT Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END BT HA SC EL IDX EC-521 DTC P1130 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE Diagnostic Procedure (Cont’d) PROCEDURE B 1 NAEC1049S02 CHECK INTAKE SYSTEM 1. Start engine and let it idle. 2. Check intake air system for air leaks. OK or NG OK (With CONSULT-II) 䊳 GO TO 2. OK (Without CONSULTII) 䊳 GO TO 3. NG 䊳 Repair intake system. 2 CHECK SWIRL CONTROL VALVE CONTROL SOLENOID VALVE CIRCUIT With CONSULT-II 1. Select “SWIRL CONT SOL VALVE” in “ACTIVE TEST” mode with CONSULT-II. 2. Touch “ON” and “OFF” on CONSULT-II screen. SEF003Z 3. Make sure that clicking sound is heard from the swirl control valve control solenoid valve. OK or NG OK 䊳 GO TO 6. NG 䊳 GO TO 3. EC-522 DTC P1130 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE Diagnostic Procedure (Cont’d) 3 GI CHECK SWIRL CONTROL VALVE CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT 1. Turn ignition switch “OFF”. 2. Disconnect swirl control valve control solenoid valve harness connector. MA EM LC SEC539D 3. Turn ignition switch “ON”. 4. Check voltage between swirl control valve control solenoid valve terminal 1 and ground with CONSULT-II or tester. FE CL MT AT TF SEF619X OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 4. 4 AX DETECT MALFUNCTIONING PART SU Check the following. 쐌 Harness connectors E1, M1 쐌 Harness connectors M33, F22 쐌 Harness for open or short between swirl control valve control solenoid valve and ECM relay 䊳 5 PD Repair open circuit or short to ground or short to power in harness connectors. CHECK SWIRL CONTROL VALVE CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 27 and swirl control valve control solenoid valve terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. BR ST RS BT HA OK or NG SC OK 䊳 GO TO 6. NG 䊳 Repair open circuit or short to ground or short to power in harness connectors. EL IDX EC-523 DTC P1130 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE Diagnostic Procedure (Cont’d) 6 CHECK HOSES Check hoses and tubes between intake manifold, and swirl control valve actuator for crack, clogging, improper connection or disconnection. SEF109L OK or NG OK 䊳 GO TO 7. NG 䊳 Repair hoses or tubes. EC-524 DTC P1130 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE Diagnostic Procedure (Cont’d) 7 1. 2. 3. 4. 5. 6. GI CHECK SWIRL CONTROL VALVE CONTROL SOLENOID VALVE With CONSULT-II Reconnect the disconnected harness connectors. Start engine and let it idle. Remove vacuum hose connected to swirl control valve actuator. Select “SWIRL CONT SOL/V” in “ACTIVE TEST” mode with CONSULT-II. Touch “ON” and “OFF” on CONSULT-II screen. Check vacuum existence and operation delay time under the following conditions. MA EM LC FE CL SEC540D MT 1. 2. 3. 4. 5. Without CONSULT-II Reconnect ECM harness connector. Remove vacuum hose connected to swirl control valve actuator. Start engine and let it idle. Apply 12V of direct current between swirl control valve control solenoid valve terminals 1 and 2. Check vacuum existence and operation delay time under the following conditions. AT TF PD AX SU SEC541D BR OK or NG OK 䊳 GO TO 8. NG 䊳 Replace intake manifold collector assembly. ST RS BT HA SC EL IDX EC-525 DTC P1130 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE Diagnostic Procedure (Cont’d) 8 1. 2. 3. 4. 5. CHECK SWIRL CONTROL VALVE ACTUATOR With CONSULT-II Reconnect vacuum hose between swirl control valve actuator and swirl control valve control solenoid valve. Start engine and let it idle. Select “SWIRL CONT SOL/V” in “ACTIVE TEST” mode. Touch “ON” and “OFF” on CONSULT-II screen. Make sure that swirl control valve actuator rod moves according to “SWIRL CONT SOL/V indication. SEF006ZA 1. 2. 3. 4. Without CONSULT-II Reconnect vacuum hose between swirl control valve actuator and swirl control valve control solenoid valve. Start engine and let it idle. Apply 12V direct current between swirl control valve control solenoid valve terminals 1 and 2. Make sure that swirl control valve actuator rod moves according to 12V direct current being applied. SEF006ZA OK or NG OK 䊳 GO TO 9. NG 䊳 Replace swirl control valve actuator. EC-526 DTC P1130 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE Diagnostic Procedure (Cont’d) 9 CHECK SWIRL CONTROL VALVE CONTROL VACUUM CHECK SWITCH 1. 2. 3. 4. 5. Turn ignition switch “OFF”. Disconnect vacuum hose connected to swirl control valve control vacuum check switch. Attach vacuum pump to swirl control valve control vacuum check switch. Turn ignition switch “ON”. Check voltage between ECM terminal 59 and ground under the following conditions. GI MA EM LC FE SEC542D CL MT AT TF MTBL1369 OK or NG OK 䊳 GO TO 10. NG 䊳 Replace swirl control valve control vacuum check switch. PD AX SU BR ST RS BT HA SC EL IDX EC-527 DTC P1130 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE Diagnostic Procedure (Cont’d) 10 CHECK MASS AIR FLOW SENSOR 1. Reconnect harness connectors disconnected. 2. Start engine and warm it up to normal operating temperature. 3. Check voltage between ECM terminal 51 (Mass air flow sensor signal) and ground. SEC543D MTBL1807 4. If the voltage is out of specification, disconnect MAF sensor harness connector and connect it again. Then repeat above check. OK or NG OK 䊳 GO TO 11. NG 䊳 Replace mass air flow sensor. 11 CHECK ACCELERATOR PEDAL POSITION SENSOR Refer to EC-737, “Component Inspection”. OK or NG OK 䊳 GO TO 12. NG 䊳 Replace accelerator pedal assembly. 12 CHECK THROTTLE POSITION SENSOR Refer to EC-729, “Component Inspection”. OK or NG OK 䊳 GO TO 13. NG 䊳 Replace electric throttle control actuator. 13 CHECK CAMSHAFT POSITION SENSOR (PHASE) Refer to EC-365, “Component Inspection”. OK or NG OK 䊳 GO TO 14. NG 䊳 Replace crankshaft position sensor (PHASE). EC-528 DTC P1130 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE Diagnostic Procedure (Cont’d) 14 GI CHECK INTERMITTENT INCIDENT Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 MA INSPECTION END PROCEDURE C 1 NAEC1049S03 INSPECTION START Do you have CONSULT-II? LC Yes or No Yes 䊳 GO TO 2. No 䊳 GO TO 3. 2 EM FE CHECK SWIRL CONTROL VALVE CONTROL SOLENOID VALVE CIRCUIT With CONSULT-II 1. Turn ignition switch “OFF”. 2. Select “SWIRL CONT SOL VALVE” in “ACTIVE TEST” mode with CONSULT-II. 3. Touch “ON” and “OFF” on CONSULT-II screen. CL MT AT TF PD SEF003Z 4. Make sure that clicking sound is heard from the swirl control valve control solenoid valve. AX OK or NG OK 䊳 GO TO 6. NG 䊳 GO TO 3. SU BR ST RS BT HA SC EL IDX EC-529 DTC P1130 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE Diagnostic Procedure (Cont’d) 3 CHECK SWIRL CONTROL VALVE CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT 1. Turn ignition switch “OFF”. 2. Disconnect swirl control valve control solenoid valve harness connector. SEC539D 3. Turn ignition switch “ON”. 4. Check voltage between swirl control valve control solenoid valve terminal 1 and ground with CONSULT-II or tester. SEF619X OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 4. 4 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors E1, M1 쐌 Harness connectors M33, F22 쐌 Harness for open or short between swirl control valve control solenoid valve and ECM relay 䊳 5 Repair open circuit or short to ground or short to power in harness connectors. CHECK SWIRL CONTROL VALVE CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 27 and swirl control valve control solenoid valve terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also, check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 6. NG 䊳 Repair open circuit or short to ground or short to power in harness connectors. EC-530 DTC P1130 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE Diagnostic Procedure (Cont’d) 6 GI CHECK HOSES Check hoses and tubes between air cleaner and swirl control valve vacuum check switch for clogging or improper connection. MA EM LC SEF109L FE OK or NG OK 䊳 GO TO 7. NG 䊳 Repair hoses or tubes. CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-531 DTC P1130 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE Diagnostic Procedure (Cont’d) 7 1. 2. 3. 4. 5. 6. CHECK SWIRL CONTROL VALVE CONTROL SOLENOID VALVE With CONSULT-II Reconnect the disconnected harness connectors. Start engine and let it idle. Remove vacuum hose connected to swirl control valve actuator. Select “SWIRL CONT SOL/V” in “ACTIVE TEST” mode with CONSULT-II. Touch “ON” and “OFF” on CONSULT-II screen. Check vacuum existence and operation delay time under the following conditions. SEC540D 1. 2. 3. 4. 5. Without CONSULT-II Reconnect ECM harness connector. Remove vacuum hose connected to swirl control valve actuator. Start engine and let it idle. Apply 12V of direct current between swirl control valve control solenoid valve terminals 1 and 2. Check vacuum existence and operation delay time under the following conditions. SEC541D OK or NG OK 䊳 GO TO 8. NG 䊳 Replace intake manifold collector assembly. EC-532 DTC P1130 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE Diagnostic Procedure (Cont’d) 8 CHECK SWIRL CONTROL VALVE CONTROL VACUUM CHECK SWITCH 1. 2. 3. 4. 5. Turn ignition switch “OFF”. Disconnect vacuum hose connected to swirl control valve control vacuum check switch. Attach vacuum pump to swirl control valve control vacuum check switch. Turn ignition switch “ON”. Check voltage between ECM terminal 59 and ground under the following conditions. GI MA EM LC FE SEC542D CL MT AT TF MTBL1369 OK or NG OK 䊳 GO TO 9. NG 䊳 Replace swirl control valve control vacuum check switch. 9 CHECK CAMSHAFT POSITION SENSOR (PHASE) PD AX SU Refer to EC-365, “Component Inspection”. OK or NG OK 䊳 GO TO 10. NG 䊳 Replace camshaft position sensor (PHASE). 10 CHECK THROTTLE POSITION SENSOR BR ST RS Refer to EC-729, “Component Inspection”. OK or NG OK 䊳 GO TO 11. NG 䊳 Replace electric throttle control actuator. 11 CHECK ACCELERATOR PEDAL POSITION SENSOR Refer to EC-737, “Component Inspection”. OK or NG OK 䊳 GO TO 12. NG 䊳 Replace accelerator pedal assembly. BT HA SC EL IDX EC-533 DTC P1130 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE Diagnostic Procedure (Cont’d) 12 CHECK INTERMITTENT INCIDENT Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-534 DTC P1131 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE Component Description Component Description NAEC1050 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. GI MA EM LC SEC539D CONSULT-II Reference Value in Data Monitor Mode NAEC1051 Specification data are reference values. MONITOR ITEM SWRL CONT S/V CONDITION 쐌 Engine speed: Idle SPECIFICATION CL Engine coolant temperature is between 15°C (59°F) to 50°C (122°F). ON Engine coolant temperature is above 55°C (131°F). OFF MT ECM Terminals and Reference Value AT NAEC1052 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 27 WIRE COLOR G ITEM CONDITION PD DATA (DC Voltage) [Engine is running] 쐌 Idle speed 쐌 Engine coolant temperature is between 15 to 50°C (59 to 122°F). Swirl control valve control solenoid valve [Engine is running] Trouble diagnosis name DTC Detecting Condition SU 0 - 1.0V BR BATTERY VOLTAGE (11 - 14V) ST On Board Diagnosis Logic P1131 1131 TF AX 쐌 Idle speed 쐌 Engine coolant temperature is above 55°C (131°F). DTC No. FE NAEC1053 RS Possible Cause Swirl control valve An improper voltage signal is sent to ECM through 쐌 Harness or connectors (The swirl control solenoid valve swirl control valve control solenoid valve. control valve control solenoid valve circuit circuit is open or shorted.) 쐌 Swirl control valve control solenoid valve BT HA SC EL IDX EC-535 DTC P1131 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE DTC Confirmation Procedure DTC Confirmation Procedure NAEC1054 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1) 2) 3) SEF058Y NAEC1054S01 Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 5 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-538. WITH GST Follow the procedure “With CONSULT-II” above. EC-536 NAEC1054S02 DTC P1131 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE Wiring Diagram Wiring Diagram =NAEC1055 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC101E EC-537 IDX DTC P1131 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE Diagnostic Procedure Diagnostic Procedure 1 NAEC1056 INSPECTION START Do you have CONSULT-II? Yes or No Yes 䊳 GO TO 2. No 䊳 GO TO 3. 2 CHECK SWIRL CONTROL VALVE CONTROL SOLENOID VALVE CIRCUIT With CONSULT-II 1. Turn ignition switch “ON”. 2. Select “SWIRL CONT SOL VALVE” in “ACTIVE TEST” mode with CONSULT-II. 3. Touch “ON” and “OFF” on CONSULT-II screen. SEF003Z 4. Make sure that clicking sound is heard from the swirl control valve control solenoid valve. OK or NG OK 䊳 GO TO 6. NG 䊳 GO TO 3. EC-538 DTC P1131 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE Diagnostic Procedure (Cont’d) 3 GI CHECK SWIRL CONTROL VALVE CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT 1. Turn ignition switch “OFF”. 2. Disconnect swirl control valve control solenoid valve harness connector. MA EM LC SEC539D 3. Turn ignition switch “ON”. 4. Check voltage between swirl control valve control solenoid valve terminal 1 and ground with CONSULT-II or tester. FE CL MT AT TF SEF619X OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 4. 4 AX DETECT MALFUNCTIONING PART SU Check the following. 쐌 Harness connectors E1, M1 쐌 Harness connectors M33, F22 쐌 Harness for open or short between swirl control valve control solenoid valve and ECM relay 䊳 5 PD Repair open circuit or short to ground or short to power in harness connectors. CHECK SWIRL CONTROL VALVE CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 27 and swirl control valve control solenoid valve terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. BR ST RS BT HA OK or NG SC OK 䊳 GO TO 6. NG 䊳 Repair open circuit or short to ground or short to power in harness connectors. EL IDX EC-539 DTC P1131 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE Diagnostic Procedure (Cont’d) 6 1. 2. 3. 4. 5. 6. CHECK SWIRL CONTROL VALVE CONTROL SOLENOID VALVE With CONSULT-II Reconnect the disconnected harness connectors. Start engine and let it idle. Remove vacuum hose connected to swirl control valve actuator. Select “SWIRL CONT SOL VALVE” in “ACTIVE TEST” mode with CONSULT-II. Touch “ON” and “OFF” on CONSULT-II screen. Check vacuum existence and operation delay time under the following conditions. SEC540D 1. 2. 3. 4. 5. Without CONSULT-II Reconnect ECM harness connector. Remove vacuum hose connected to swirl control valve actuator. Start engine and let it idle. Apply 12V of direct current between swirl control valve control solenoid valve terminals 1 and 2. Check vacuum existence and operation delay time under the following conditions. SEC541D OK or NG OK 䊳 GO TO 7. NG 䊳 Replace intake manifold collector assembly. 7 CHECK INTERMITTENT INCIDENT Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-540 DTC P1143, P1163 HO2S1 Component Description Component Description NAEC1147 The heated oxygen sensor 1 is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. GI MA EM LC SEF463R FE CL MT SEF288D CONSULT-II Reference Value in Data Monitor Mode NAEC1148 Specification data are reference values. MONITOR ITEM CONDITION SPECIFICATION HO2S1 (B1) HO2S1 (B2) HO2S1 MNTR (B1) HO2S1 MNTR (B2) 쐌 Engine: After warming up Maintaining engine speed at 2,000 rpm PD LEAN +, RICH Changes more than 5 times during 10 seconds. ECM Terminals and Reference Value WIRE COLOR TF 0 - 0.3V +, Approx. 0.6 - 1.0V NAEC1149 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. AT ITEM CONDITION DATA (DC Voltage) 16 G/B Heated oxygen sensor 1 (bank 2) [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm. 0 - Approximately 1.0V (Periodically change) 35 G Heated oxygen sensor 1 (bank 1) [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm. 0 - Approximately 1.0V (Periodically change) AX SU BR ST RS BT HA SC EL IDX EC-541 DTC P1143, P1163 HO2S1 On Board Diagnosis Logic On Board Diagnosis Logic NAEC1150 To judge the malfunction, the output from the heated oxygen sensor 1 is monitored to determine whether the “rich” output is sufficiently high and whether the “lean” output is sufficiently low. When both the outputs are shifting to the lean side, the malfunction will be detected. SEF300U DTC No. P1143 1143 (Bank 1) P1163 1163 (Bank 2) Trouble diagnosis name Heated oxygen sensor 1 lean shift monitoring DTC Detecting Condition The maximum and minimum voltage from the sen- 쐌 sor are not reached to the specified voltages. 쐌 쐌 쐌 쐌 Possible Cause Heated oxygen sensor 1 Heated oxygen sensor 1 heater Fuel pressure Injectors Intake air leaks DTC Confirmation Procedure NAEC1151 CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: 쐌 Always perform at a temperature above −10°C (14°F). 쐌 Before performing following procedure, confirm that battery voltage is more than 11V at idle. EC-542 DTC P1143, P1163 HO2S1 DTC Confirmation Procedure (Cont’d) WITH CONSULT-II NAEC1151S01 1) 2) 3) SEC767C Start engine and warm it up to normal operating temperature. Stop engine and wait at least 10 seconds. Turn ignition switch “ON” and select “HO2S1 (B1)/(B2) P1143/ P0154” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 3 minutes. NOTE: Never raise engine speed above 3,600 rpm after this step. If the engine speed limit is exceeded, return to step 5. 6) When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 50 seconds or more.) ENG SPEED 1,300 - 2,800 rpm Vehicle speed Less than 100 km/h (62 MPH) B/FUEL SCHDL 3 - 14 msec Selector lever Suitable position SEC768C 7) GI MA EM LC FE CL MT If “TESTING” is not displayed after 5 minutes, retry from step 2. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-544. AT TF PD AX SU SEC769C Overall Function Check NAEC1152 Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a DTC might not be confirmed. WITH GST 1) 2) 3) SEC430D 쐌 쐌 4) BR ST NAEC1152S01 Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 35 (HO2S1 bank 1 signal) or 16 (HO2S1 bank 2 signal) and engine ground. Check one of the following with engine speed held at 2,000 rpm constant under no load. The maximum voltage is over 0.6V at least one time. The minimum voltage is over 0.1V at least one time. If NG, go to “Diagnostic Procedure”, EC-544. RS BT HA SC EL IDX EC-543 DTC P1143, P1163 HO2S1 Diagnostic Procedure Diagnostic Procedure 1 NAEC1153 RETIGHTEN GROUND SCREWS 1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. SEF959Y 䊳 2 GO TO 2. RETIGHTEN HEATED OXYGEN SENSOR 1 Loosen and retighten corresponding heated oxygen sensor 1. Tightening torque: 40 - 60 N·m (4.1 - 6.1 kg-m, 30 - 44 ft-lb) 䊳 GO TO 3. EC-544 DTC P1143, P1163 HO2S1 Diagnostic Procedure (Cont’d) 3 GI CLEAR THE SELF-LEARNING DATA With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “CLEAR”. MA EM LC FE SEF968Y 4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 or P0174 detected? Is it difficult to start engine? 1. 2. 3. 4. 5. 6. 7. 8. CL Without CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF”. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 5 seconds at idle speed. Stop engine and reconnect mass air flow sensor harness connector. Make sure DTC P0102 is displayed. Erase the DTC memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-100. Make sure DTC P0000 is displayed. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 or P0174 detected? Is it difficult to start engine? Yes or No Yes 䊳 Perform trouble diagnosis for DTC P0171, P0174. Refer to EC-304. No 䊳 GO TO 4. MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-545 DTC P1143, P1163 HO2S1 Diagnostic Procedure (Cont’d) 4 CHECK HEATED OXYGEN SENSOR HEATER 1 1. Stop engine. 2. Disconnect HO2S1 harness connector. 3. Check resistance between HO2S1 terminals as follows. SEF249Y MTBL1782 CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK (With CONSULT-II) 䊳 GO TO 5. OK (Without CONSULTII) 䊳 GO TO 6. NG 䊳 Replace malfunctioning heated oxygen sensor 1. EC-546 DTC P1143, P1163 HO2S1 Diagnostic Procedure (Cont’d) 5 1. 2. 3. 4. 5. GI CHECK HEATED OXYGEN SENSOR 1 With CONSULT-II Start engine and warm it up to normal operating temperature. Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULT-II. Select “HO2S1 (B1)/(B2)” and “HO2S1 MNTR (B1)/(B2)”. Hold engine speed at 2,000 rpm under no load during the following steps. Touch “RECORD” on CONSULT-II screen. MA EM LC FE SEF967Y 6. Check the following. 쐌 “HO2S1 MNTR (B1)/(B2)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown below. CL MT AT TF PD SEF647Y 쐌 “HO2S1 (B1)/(B2)” voltage goes above 0.6V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage goes below 0.3V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage never exceeds 1.0V. AX SU BR ST RS SEF648Y CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK 䊳 GO TO 7. NG 䊳 Replace malfunctioning heated oxygen sensor 1. BT HA SC EL IDX EC-547 DTC P1143, P1163 HO2S1 Diagnostic Procedure (Cont’d) 6 CHECK HEATED OXYGEN SENSOR 1 Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Set voltmeter probes between ECM terminal 35 (HO2S1 bank 1 signal) or 16 (HO2S1 bank 2 signal) and engine ground. 3. Check the following with engine speed held at 2,000 rpm constant under no load. SEC430D 쐌 쐌 쐌 쐌 The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than 5 times within 10 seconds. The maximum voltage is over 0.6V at least one time. The minimum voltage is below 0.3V at least one time. The voltage never exceeds 1.0V. 1 time: 0 - 0.3V , 0.6 - 1.0V , 0 - 0.3V 2 times: 0 - 0.3V , 0.6 - 1.0V , 0 - 0.3V , 0.6 - 1.0V , 0 - 0.3V CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK 䊳 GO TO 7. NG 䊳 Replace malfunctioning heated oxygen sensor 1. 7 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. For circuit, refer to “Wiring Diagram”, EC-278. 䊳 INSPECTION END EC-548 DTC P1144, P1164 HO2S1 Component Description Component Description NAEC1154 The heated oxygen sensor 1 is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. GI MA EM LC SEF463R FE CL MT SEF288D CONSULT-II Reference Value in Data Monitor Mode NAEC1155 Specification data are reference values. MONITOR ITEM CONDITION SPECIFICATION HO2S1 (B1) HO2S1 (B2) HO2S1 MNTR (B1) HO2S1 MNTR (B2) 쐌 Engine: After warming up Maintaining engine speed at 2,000 rpm PD LEAN +, RICH Changes more than 5 times during 10 seconds. ECM Terminals and Reference Value WIRE COLOR TF 0 - 0.3V +, Approx. 0.6 - 1.0V NAEC1156 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. AT ITEM CONDITION DATA (DC Voltage) 16 G/B Heated oxygen sensor 1 (bank 2) [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm. 0 - Approximately 1.0V (Periodically change) 35 G Heated oxygen sensor 1 (bank 1) [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm. 0 - Approximately 1.0V (Periodically change) AX SU BR ST RS BT HA SC EL IDX EC-549 DTC P1144, P1164 HO2S1 On Board Diagnosis Logic On Board Diagnosis Logic NAEC1157 To judge the malfunction, the output from the heated oxygen sensor 1 is monitored to determine whether the “rich” output is sufficiently high and “lean” output is sufficiently low. When both the outputs are shifting to the rich side, the malfunction will be detected. SEF299U DTC No. P1144 1144 (Bank 1) P1164 1164 (Bank 2) Trouble diagnosis name Heated oxygen sensor 1 rich shift monitoring DTC Detecting Condition The maximum and minimum voltages from the sensor are outside the specified voltages. Possible Cause 쐌 쐌 쐌 쐌 Heated oxygen sensor 1 Fuel pressure Injectors Heated oxygen sensor 1 heater DTC Confirmation Procedure NAEC1158 CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: 쐌 Always perform at a temperature above −10°C (14°F). 쐌 Before performing the following procedure, confirm that battery voltage is more than 11V at idle. EC-550 DTC P1144, P1164 HO2S1 DTC Confirmation Procedure (Cont’d) WITH CONSULT-II NAEC1158S01 1) 2) 3) SEC770C Start engine and warm it up to normal operating temperature. Stop engine and wait at least 5 seconds. Turn ignition switch “ON” and select “HO2S1 (B1)/(B2) P1144/ P1164” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II. 4) Touch “START”. 5) Start engine and let it idle for at least 3 minutes. NOTE: Never raise engine speed above 3,600 rpm after this step. If the engine speed limit is exceeded, return to step 5. 6) When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 50 seconds or more.) ENG SPEED 1,300 - 2,800 rpm Vehicle speed Less than 100 km/h (62 MPH) B/FUEL SCHDL 3 - 14 msec Selector lever Suitable position SEC771C 7) GI MA EM LC FE CL MT If “TESTING” is not displayed after 5 minutes, retry from step 2. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-552. AT TF PD AX SU SEC772C Overall Function Check NAEC1159 Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a DTC might not be confirmed. WITH GST 1) 2) 3) SEC430D 쐌 쐌 4) BR ST NAEC1159S01 Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 35 (HO2S1 bank 1 signal) or 16 (HO2S1 bank 2 signal) and engine ground. Check one of the following with engine speed held at 2,000 rpm constant under no load. The maximum voltage is below 0.8V at least one time. The minimum voltage is below 0.35V at least one time. If NG, go to “Diagnostic Procedure”, EC-552. RS BT HA SC EL IDX EC-551 DTC P1144, P1164 HO2S1 Diagnostic Procedure Diagnostic Procedure 1 NAEC1160 RETIGHTEN GROUND SCREWS 1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. SEF959Y 䊳 2 GO TO 2. RETIGHTEN HEATED OXYGEN SENSOR 1 Loosen and retighten corresponding heated oxygen sensor 1. Tightening torque: 40 - 60 N·m (4.1 - 6.1 kg-m, 30 - 44 ft-lb) 䊳 GO TO 3. EC-552 DTC P1144, P1164 HO2S1 Diagnostic Procedure (Cont’d) 3 GI CLEAR THE SELF-LEARNING DATA With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “CLEAR”. MA EM LC FE SEF968Y 4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 or P0175 detected? Is it difficult to start engine? 1. 2. 3. 4. 5. 6. 7. 8. CL Without CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF”. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 5 seconds at idle speed. Stop engine and reconnect mass air flow sensor harness connector. Make sure DTC P0102 is displayed. Erase the DTC memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-100. Make sure DTC P0000 is displayed. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 or P0175 detected? Is it difficult to start engine? Yes or No Yes 䊳 Perform trouble diagnosis for DTC P0172, P0175. Refer to EC-312. No 䊳 GO TO 4. 4 MT AT TF PD AX SU CHECK HO2S 1 CONNECTOR FOR WATER 1. Turn ignition switch “OFF”. 2. Disconnect heated oxygen sensor 1 harness connector. 3. Check connectors for water. Water should not exist. BR ST OK or NG RS OK 䊳 GO TO 5. NG 䊳 Repair or replace harness or connectors. BT HA SC EL IDX EC-553 DTC P1144, P1164 HO2S1 Diagnostic Procedure (Cont’d) 5 CHECK HEATED OXYGEN SENSOR 1 HEATER Check resistance between HO2S1 terminals as follows. SEF249Y MTBL1782 CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK (With CONSULT-II) 䊳 GO TO 6. OK (Without CONSULTII) 䊳 GO TO 7. NG 䊳 Replace malfunctioning heated oxygen sensor 1. EC-554 DTC P1144, P1164 HO2S1 Diagnostic Procedure (Cont’d) 6 1. 2. 3. 4. 5. GI CHECK HEATED OXYGEN SENSOR 1 With CONSULT-II Start engine and warm it up to normal operating temperature. Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULT-II. Select “HO2S1 (B1)/(B2)” and “HO2S1 MNTR (B1)/(B2)”. Hold engine speed at 2,000 rpm under no load during the following steps. Touch “RECORD” on CONSULT-II screen. MA EM LC FE SEF967Y 6. Check the following. 쐌 “HO2S1 MNTR (B1)/(B2)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” 5 times in 10 seconds. 5 times (cycles) are counted as shown below. CL MT AT TF PD SEF647Y 쐌 “HO2S1 (B1)/(B2)” voltage goes above 0.6V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage goes below 0.3V at least once. 쐌 “HO2S1 (B1)/(B2)” voltage never exceeds 1.0V. AX SU BR ST RS SEF648Y CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK 䊳 GO TO 8. NG 䊳 Replace malfunctioning heated oxygen sensor 1. BT HA SC EL IDX EC-555 DTC P1144, P1164 HO2S1 Diagnostic Procedure (Cont’d) 7 CHECK HEATED OXYGEN SENSOR 1 Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Set voltmeter probes between ECM terminal 35 (HO2S1 bank 1 signal) or 16 (HO2S1 bank 2 signal) and engine ground. 3. Check the following with engine speed held at 2,000 rpm constant under no load. SEC430D 쐌 쐌 쐌 쐌 The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than 5 times within 10 seconds. The maximum voltage is over 0.6V at least one time. The minimum voltage is below 0.3V at least one time. The voltage never exceeds 1.0V. 1 time: 0 - 0.3V , 0.6 - 1.0V , 0 - 0.3V 2 times: 0 - 0.3V , 0.6 - 1.0V , 0 - 0.3V , 0.6 - 1.0V , 0 - 0.3V CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK 䊳 GO TO 8. NG 䊳 Replace malfunctioning heated oxygen sensor 1. 8 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. For circuit, refer to “Wiring Diagram”, EC-278. 䊳 INSPECTION END EC-556 DTC P1146, P1166 HO2S2 Component Description Component Description SEF327R NAEC1161 The heated oxygen sensor 2, after three way catalyst (manifold), monitors the oxygen level in the exhaust gas on each bank. Even if switching characteristics of the heated oxygen sensor 1 are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2. This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 is not used for engine control operation. GI MA EM LC CONSULT-II Reference Value in Data Monitor Mode NAEC1162 Specification data are reference values. MONITOR ITEM HO2S2 (B1) HO2S2 (B2) HO2S2 MNTR (B1) HO2S2 MNTR (B2) CONDITION 쐌 Engine: After warming up 쐌 After keeping engine speed between 3,500 and 4,000 rpm for one minute and at idle for one minute under no load SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V Revving engine from idle up to 3,000 rpm LEAN +, RICH AT ECM Terminals and Reference Value 55 74 WIRE COLOR OR/L OR CL MT NAEC1163 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. FE ITEM CONDITION Heated oxygen sensor 2 (bank 2) Heated oxygen sensor 2 (bank 1) [Engine is running] 쐌 Warm-up condition 쐌 Revving engine from idle up to 3,000 rpm after 0 - Approximately 1.0V the following conditions are met. 쐌 After keeping the engine speed between 3,500 and 4,000 rpm for one minute and at idle for one minute under no load On Board Diagnosis Logic PD AX DATA (DC Voltage) [Engine is running] 쐌 Warm-up condition 쐌 Revving engine from idle up to 3,000 rpm after the following conditions are met. 0 - Approximately 1.0V 쐌 After keeping the engine speed between 3,500 and 4,000 rpm for one minute and at idle for one minute under no load TF SU BR ST RS BT NAEC1164 The heated oxygen sensor 2 has a much longer switching time between rich and lean than the heated oxygen sensor 1. The oxygen storage capacity of the three way catalyst (manifold) causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2, ECM monitors whether the minimum voltage of sensor is sufficiently low during the various driving condition such as fuel-cut. HA SC EL IDX SEF972Z EC-557 DTC P1146, P1166 HO2S2 On Board Diagnosis Logic (Cont’d) DTC No. P1146 1146 (Bank 1) P1166 1166 (Bank 2) Trouble diagnosis name Heated oxygen sensor 2 minimum voltage monitoring DTC Detecting Condition The minimum voltage from the sensor is not reached to the specified voltage. Possible Cause 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Heated oxygen sensor 2 쐌 Fuel pressure 쐌 Injectors DTC Confirmation Procedure NAEC1165 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: 쐌 Open engine hood before conducting following procedure. 쐌 For the best results, perform “DTC WORK SUPPORT” at a temperature of 0 to 30°C (32 to 86°F). SEC773C WITH CONSULT-II 1) 2) 3) 4) 5) SEC774C 6) 7) a) b) c) d) SEC775C NAEC1165S01 Start engine and warm it up to the normal operating temperature. Turn ignition switch “OFF” and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least one minute under no load. Let engine idle for one minute. Select “HO2S2 (B1) P1146” or “HO2S2 (B2) P1166” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II. Follow the instruction of CONSULT-II. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If NG is displayed, refer to EC-562, “Diagnostic Procedure”. If “CAN NOT BE DIAGNOSED” is displayed, perform the following. Turn ignition switch “OFF” and leave the vehicle in a cool place (soak the vehicle). Turn ignition switch “ON” and select “COOLAN TEMP/S” in “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up while monitoring “COOLAN TEMP/S” indication on CONSULT-II. When “COOLAN TEMP/S” indication reaches to 70°C (158°F), go to step 3. Overall Function Check NAEC1166 Use this procedure to check the overall function of the heated oxygen sensor 2 circuit. During this check, a DTC might not be confirmed. WITH GST 1) 2) 3) SEC432D NAEC1166S01 Start engine and warm it up to the normal operating temperature. Turn ignition switch “OFF” and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least one minute under no load. EC-558 DTC P1146, P1166 HO2S2 Overall Function Check (Cont’d) 4) 5) 6) 7) 8) Let engine idle for one minute. Set voltmeter probes between ECM terminal 74 (HO2S2 bank 1 signal) or 55 (HO2S2 bank 2 signal) and engine ground. Check the voltage when racing up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be below 0.48V at least once during this procedure. If the voltage can be confirmed in step 6, step 7 is not necessary. 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 (M/T), “D” position with “OD” OFF (A/T). The voltage should be below 0.48V at least once during this procedure. If NG, go to “Diagnostic Procedure”, EC-562. GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-559 DTC P1146, P1166 HO2S2 Wiring Diagram Wiring Diagram BANK 1 =NAEC1167 NAEC1167S01 MEC089E EC-560 DTC P1146, P1166 HO2S2 Wiring Diagram (Cont’d) BANK 2 NAEC1167S02 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC090E EC-561 IDX DTC P1146, P1166 HO2S2 Diagnostic Procedure Diagnostic Procedure 1 NAEC1168 RETIGHTEN GROUND SCREWS 1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. SEF959Y 䊳 2 GO TO 2. CLEAR THE SELF-LEARNING DATA With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “CLEAR”. SEF968Y 4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 or P0175 detected? Is it difficult to start engine? 1. 2. 3. 4. 5. 6. 7. 8. Without CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF”. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 5 seconds at idle speed. Stop engine and reconnect mass air flow sensor harness connector. Make sure DTC P0102 is displayed. Erase the DTC memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-100. Make sure DTC P0000 is displayed. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 or P0175 detected? Is it difficult to start engine? Yes or No Yes 䊳 Perform trouble diagnosis for DTC P0172, P0175. Refer to EC-312. No 䊳 GO TO 3. EC-562 DTC P1146, P1166 HO2S2 Diagnostic Procedure (Cont’d) 3 GI CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Disconnect corresponding heated oxygen sensor 2 harness connector. MA EM LC SEC426D FE CL MT AT SEC427D 3. Disconnect ECM harness connector. 4. Check harness continuity between ECM terminal and rear HO2S terminal as follows. Refer to Wiring Diagram. TF PD AX MTBL1371 Continuity should exist. 5. Check harness continuity between ECM terminal or HO2S2 terminal and ground as follows. Refer to Wiring Diagram. SU BR ST MTBL1372 Continuity should not exist. 6. Also check harness for short to power. OK or NG OK 䊳 GO TO 4. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. RS BT HA SC EL IDX EC-563 DTC P1146, P1166 HO2S2 Diagnostic Procedure (Cont’d) 4 CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between HO2S2 terminal 4 and engine ground. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to power. OK or NG OK (With CONSULT-II) 䊳 GO TO 5. OK (Without CONSULTII) 䊳 GO TO 6. NG 䊳 Repair open circuit or short to power in harness or connectors. 5 CHECK HEATED OXYGEN SENSOR 2 With CONSULT-II Start engine and warm it up to the normal operating temperature. Turn ignition switch “ON” and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least one minute under no load. Let engine idle for one minute. Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)/(B2)” as the monitor item with CONSULTII. 6. Check “HO2S2 (B1)/(B2)” at idle speed when adjusting “FUEL INJECTION” to ±25%. 1. 2. 3. 4. 5. SEF972YA “HO2S2 (B1)/(B2)” should be above 0.68V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)/(B2)” should be below 0.48V at least once when the “FUEL INJECTION” is −25%. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK 䊳 GO TO 8. NG 䊳 Replace malfunctioning heated oxygen sensor 2. EC-564 DTC P1146, P1166 HO2S2 Diagnostic Procedure (Cont’d) 6 GI CHECK HEATED OXYGEN SENSOR 2-I Without CONSULT-II Start engine and warm it up to the normal operating temperature. Turn ignition switch “ON” and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least one minute under no load. Let engine idle for one minute. Set voltmeter probes between ECM terminal 74 (HO2S2 bank 1 signal) or 55 (HO2S2 bank 2 signal) and engine ground. 6. Check the voltage when rewing up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) 1. 2. 3. 4. 5. MA EM LC FE CL SEC432D MT The voltage should be above 0.68V at least once during this procedure. OK or NG OK 䊳 GO TO 8. NG 䊳 GO TO 7. 7 TF CHECK HEATED OXYGEN SENSOR 2-II PD Idle vehicle for 10 minutes, then check voltage between the same terminals as in Test No. 6; or check voltage when coasting from 80 km/h (50 MPH) in 3rd gear position (M/T), “D” position with “OD” OFF (A/T). The voltage should go below 0.48V at least once during this procedure. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK 䊳 GO TO 8. NG 䊳 Replace malfunctioning heated oxygen sensor 2. 8 AT AX SU BR ST RS CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END BT HA SC EL IDX EC-565 DTC P1147, P1167 HO2S2 Component Description Component Description SEF327R NAEC1169 The heated oxygen sensor 2, after three way catalyst (manifold), monitors the oxygen level in the exhaust gas on each bank. Even if switching characteristics of the heated oxygen sensor 1 are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2. This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 is not used for engine control operation. CONSULT-II Reference Value in Data Monitor Mode NAEC1170 Specification data are reference values. MONITOR ITEM HO2S2 (B1) HO2S2 (B2) HO2S2 MNTR (B1) HO2S2 MNTR (B2) CONDITION 쐌 Engine: After warming up 쐌 After keeping engine speed between 3,500 and 4,000 rpm for one minute and at idle for one minute under no load SPECIFICATION 0 - 0.3V +, Approx. 0.6 - 1.0V Revving engine from idle up to 3,000 rpm LEAN +, RICH ECM Terminals and Reference Value NAEC1171 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 55 74 WIRE COLOR OR/L OR ITEM CONDITION DATA (DC Voltage) Heated oxygen sensor 2 (bank 2) [Engine is running] 쐌 Warm-up condition 쐌 Revving engine from idle up to 3,000 rpm after the following conditions are met. 0 - Approximately 1.0V 쐌 After keeping the engine speed between 3,500 and 4,000 rpm for one minute and at idle for one minute under no load Heated oxygen sensor 2 (bank 1) [Engine is running] 쐌 Warm-up condition 쐌 Revving engine from idle up to 3,000 rpm after 0 - Approximately 1.0V the following conditions are met. 쐌 After keeping the engine speed between 3,500 and 4,000 rpm for one minute and at idle for one minute under no load On Board Diagnosis Logic NAEC1172 The heated oxygen sensor 2 has a much longer switching time between rich and lean than the heated oxygen sensor 1. The oxygen storage capacity before the three way catalyst (manifold) causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2, ECM monitors whether the maximum voltage of the sensor is sufficiently high during the various driving condition such as fuel-cut. SEF259VA EC-566 DTC P1147, P1167 HO2S2 On Board Diagnosis Logic (Cont’d) DTC No. P1147 1147 (Bank 1) P1167 1167 (Bank 2) GI Trouble diagnosis name Heated oxygen sensor 2 maximum voltage monitoring DTC Detecting Condition The maximum voltage from the sensor is not reached to the specified voltage. Possible Cause 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Heated oxygen sensor 2 쐌 Fuel pressure 쐌 Injectors 쐌 Intake air leaks DTC Confirmation Procedure MA EM LC NAEC1173 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: 쐌 Open engine hood before conducting following procedure. 쐌 For the best results, perform “DTC WORK SUPPORT” at a temperature of 0 to 30°C (32 to 86°F). SEC776C WITH CONSULT-II 1) 2) 3) 4) 5) SEC777C 6) 7) a) b) c) d) SEC778C NAEC1173S01 Start engine and warm it up to the normal operating temperature. Turn ignition switch “OFF” and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least one minute under no load. Let engine idle for one minute. Select “HO2S2 (B1) P1147” or “HO2S2 (B2) P1167” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II. Start engine and follow the instruction of CONSULT-II. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to EC-571, “Diagnostic Procedure”. If “CAN NOT BE DIAGNOSED” is displayed, perform the following. Turn ignition switch “OFF” and leave the vehicle in a cool place (soak the vehicle). Turn ignition switch “ON” and select “COOLAN TEMP/S” in “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up while monitoring “COOLAN TEMP/S” indication on CONSULT-II. When “COOLAN TEMP/S” indication reaches to 70°C (158°F), go to step 3. Overall Function Check NAEC1174 Use this procedure to check the overall function of the heated oxygen sensor 2 circuit. During this check, a DTC might not be confirmed. WITH GST 1) 2) 3) SEC432D CL MT AT TF PD AX SU BR ST RS BT HA SC NAEC1174S01 Start engine and warm it up to the normal operating temperature. Turn ignition switch “OFF” and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least one minute under no load. EC-567 FE EL IDX DTC P1147, P1167 HO2S2 Overall Function Check (Cont’d) 4) 5) 6) 7) 8) Let engine idle for one minute. Set voltmeter probes between ECM terminal 74 (HO2S2 bank 1 signal) or 55 (HO2S2 bank 2 signal) and engine ground. Check the voltage when racing up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be above 0.68V at least once during this procedure. If the voltage can be confirmed in step 6, step 7 is not necessary. 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 (M/T), “D” position with “OD” OFF (A/T). The voltage should be above 0.68V at least once during this procedure. If NG, go to “Diagnostic Procedure”, EC-571. EC-568 DTC P1147, P1167 HO2S2 Wiring Diagram Wiring Diagram BANK 1 =NAEC1175 GI NAEC1175S01 MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC089E EC-569 IDX DTC P1147, P1167 HO2S2 Wiring Diagram (Cont’d) BANK 2 NAEC1175S02 MEC090E EC-570 DTC P1147, P1167 HO2S2 Diagnostic Procedure Diagnostic Procedure 1 NAEC1176 GI RETIGHTEN GROUND SCREWS MA 1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. EM LC FE SEF959Y 䊳 2 CL GO TO 2. MT CLEAR THE SELF-LEARNING DATA With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “CLEAR”. AT TF PD AX SU SEF968Y 4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 or P0174 detected? Is it difficult to start engine? 1. 2. 3. 4. 5. 6. 7. 8. BR Without CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF”. Disconnect mass air flow sensor harness connector, and restart and run engine for at least 5 seconds at idle speed. Stop engine and reconnect mass air flow sensor harness connector. Make sure DTC P0102 is displayed. Erase the DTC memory. Refer to “HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”, EC-100. Make sure DTC P0000 is displayed. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 or P0174 detected? Is it difficult to start engine? Yes or No Yes 䊳 Perform trouble diagnosis for DTC P0171, P0174. Refer to EC-304. No 䊳 GO TO 3. ST RS BT HA SC EL IDX EC-571 DTC P1147, P1167 HO2S2 Diagnostic Procedure (Cont’d) 3 CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Disconnect corresponding heated oxygen sensor 2 harness connector. SEC426D SEC427D 3. Disconnect ECM harness connector. 4. Check harness continuity between ECM terminal and HO2S2 terminal as follows. Refer to Wiring Diagram. MTBL1379 Continuity should exist. 5. Check harness continuity between ECM terminal or HO2S2 terminal and ground as follows. Refer to Wiring Diagram. MTBL1380 Continuity should not exist. 6. Also check harness for short to power. OK or NG OK 䊳 GO TO 4. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. EC-572 DTC P1147, P1167 HO2S2 Diagnostic Procedure (Cont’d) 4 GI CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between HO2S2 terminal 4 and engine ground. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to power. MA EM OK or NG OK (With CONSULT-II) 䊳 GO TO 5. OK (Without CONSULTII) 䊳 GO TO 6. NG 䊳 Repair open circuit or short to power in harness or connectors. 5 1. 2. 3. 4. 5. 6. LC CHECK HEATED OXYGEN SENSOR 2 With CONSULT-II Start engine and warm it up to the normal operating temperature. Turn ignition switch “ON” and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least one minute under no load. Let engine idle for one minute. Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)/(B2)” as the monitor item with CONSULTII. Check “HO2S2 (B1)/(B2)” at idle speed when adjusting “FUEL INJECTION” to ±25%. FE CL MT AT TF PD AX SEF972YA “HO2S2 (B1)/(B2)” should be above 0.68V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)/(B2)” should be below 0.48V at least once when the “FUEL INJECTION” is −25%. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK 䊳 GO TO 8. NG 䊳 Replace malfunctioning heated oxygen sensor 2. SU BR ST RS BT HA SC EL IDX EC-573 DTC P1147, P1167 HO2S2 Diagnostic Procedure (Cont’d) 6 1. 2. 3. 4. 5. 6. CHECK HEATED OXYGEN SENSOR 2-I Without CONSULT-II Start engine and warm it up to the normal operating temperature. Turn ignition switch “ON” and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least one minute under no load. Let engine idle for one minute. Set voltmeter probes between ECM terminal 74 (HO2S2 bank 1 signal) or 55 (HO2S bank 2 signal) and engine ground. Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) SEC432D The voltage should be above 0.68V at least once during this procedure. OK or NG OK 䊳 GO TO 8. NG 䊳 GO TO 7. 7 CHECK HEATED OXYGEN SENSOR 2-II Idle vehicle for 10 minutes, then check voltage between the same terminals as in Test No. 6; or check voltage when coasting from 80 km/h (50 MPH) in 3rd gear position (M/T), “D” position with “OD” OFF (A/T). The voltage should go below 0.48V at least once during this procedure. CAUTION: 쐌 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. 쐌 Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool J-43897-18 or J-43897-12 and approved anti-seize lubricant. OK or NG OK 䊳 GO TO 8. NG 䊳 Replace malfunctioning heated oxygen sensor 2. 8 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-574 DTC P1148, P1168 CLOSED LOOP CONTROL On Board Diagnosis Logic On Board Diagnosis Logic NAEC1064 GI ★ The closed loop control has the one trip detection logic. DTC No. P1148 1148 (Bank 1) P1168 1168 (Bank 2) Trouble diagnosis name Closed loop control DTC Detecting Condition The closed loop control function for right bank does not operate even when vehicle is driving in the specified condition, the closed loop control function for left bank does not operate even when vehicle is driving in the specified condition. MA Possible Cause 쐌 The front heated oxygen sensor circuit is open or shorted. 쐌 Heated oxygen sensor 1 쐌 Heated oxygen sensor 1 heater DTC Confirmation Procedure EM LC NAEC1065 CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: 쐌 Never raise engine speed above 3,600 rpm during the “DTC Confirmation Procedure”. If the engine speed limit is exceeded, retry the procedure from step 2. 쐌 Before performing the following procedure, confirm that battery voltage is more than 11V at idle. FE CL MT AT TF PD AX SU WITH CONSULT-II 1) 2) 3) 4) 5) 6) SEF063Y 쐌 쐌 7) 8) NAEC1065S01 Start engine and warm it up to the normal operating temperature. Turn ignition switch “OFF” and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least one minute under no load. Let engine idle for one minute. Select “DATA MONITOR” mode with CONSULT-II. Hold engine speed at 2,000 rpm and check one of the following. “HO2S1 (B1)/(B2)” voltage should go above 0.70V at least once. “HO2S1 (B1)/(B2)” voltage should go below 0.21V at least once. If the check result is NG, perform “Diagnosis Procedure”, EC-576. If the check result is OK, perform the following step. Let engine idle at least 5 minutes. Maintain the following condition at least 50 consecutive seconds. BR ST RS BT HA SC EL IDX EC-575 DTC P1148, P1168 CLOSED LOOP CONTROL DTC Confirmation Procedure (Cont’d) B/FUEL SCHDL 3.6 msec or more (A/T) 3.0 msec or more (M/T) ENG SPEED 1,500 rpm or more Selector lever Suitable position VHCL SPEED SE More than 70 km/h (43 MPH) 9) During this test, P0134 and/or P0154 may be displayed on CONSULT-II screen. If DTC is detected, go to “Diagnostic Procedure”, EC-576. Overall Function Check NAEC1066 Use this procedure to check the overall function of the closed loop control. During this check, a DTC might not be confirmed. WITH GST 1) 2) 3) SEC430D 4) 5) 6) 쐌 쐌 7) NAEC1066S01 Start engine and warm it up to the normal operating temperature. Turn ignition switch “OFF” and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least one minute under no load. Let engine idle for one minute. Set voltmeter probes between ECM terminal 35 [Heated oxygen sensor 1 bank 1 signal] or 16 [Heated oxygen sensor 1 bank 2 signal] and engine ground. Check the following with engine speed held at 2,000 rpm constant under no-load. The voltage should go above 0.70V at least once. The voltage should go below 0.21V at least once. If NG, go to “Diagnostic Procedure”, EC-576. Diagnostic Procedure NAEC1067 Perform trouble diagnosis for “DTC P0133, P0153”, EC-264. EC-576 DTC P1165 SWIRL CONTROL VALVE CONTROL VACUUM CHECK SWITCH Component Description Component Description NAEC1068 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 control vacuum check switch sends “OFF” signal to the ECM. The swirl control valve control vacuum check switch is not used to control the engine system, it is used for on board diagnosis. GI MA EM LC SEF999Y FE CL MT SEF446Z CONSULT-II Reference Value in Data Monitor Mode NAEC1069 Specification data are reference values. MONITOR ITEM SWL CON VC SW CONDITION SPECIFICATION AX ON ECM Terminals and Reference Value SU NAEC1070 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 59 TF PD 쐌 Engine speed: Idle OFF 쐌 Engine coolant temperature is between 15°C (59°F) to 50°C (122°F). 쐌 Engine speed: Idle 쐌 Engine coolant temperature is above 55°C (131°F). AT BR ST WIRE COLOR ITEM CONDITION DATA (DC Voltage) RS W/B [Engine is running] 쐌 Idle speed 쐌 Engine coolant temperature is between 15 to Swirl control valve con50°C (59 to 122°F). trol vacuum check [Engine is running] switch 쐌 Idle speed 쐌 Engine coolant temperature is above 55°C (131°F). Approximately 5V BT HA 0 - 1.0V SC EL IDX EC-577 DTC P1165 SWIRL CONTROL VALVE CONTROL VACUUM CHECK SWITCH On Board Diagnosis Logic On Board Diagnosis Logic DTC No. P1165 1165 Trouble diagnosis name DTC Detecting Condition Swirl control valve The swirl control valve control vacuum check control vacuum check switch remains “OFF” under specified engine conswitch ditions. NAEC1071 Possible Cause 쐌 Harness or connectors (Swirl control valve control vacuum check switch circuit is open.) 쐌 Hoses (Hoses are clogged or connected incorrectly.) 쐌 Swirl control valve control solenoid valve 쐌 Swirl control valve control vacuum check switch DTC Confirmation Procedure NAEC1072 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: For best results, perform the test at a temperature above 5°C (41°F). WITH CONSULT-II SEF058Y 1) 2) 3) NAEC1072S01 Turn ignition switch “OFF” and wait at least 10 seconds. Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II and wait at least 5 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-580. WITH GST Follow the procedure “WITH CONSULT-II” above. EC-578 NAEC1072S02 DTC P1165 SWIRL CONTROL VALVE CONTROL VACUUM CHECK SWITCH Wiring Diagram Wiring Diagram NAEC1073 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC104E EC-579 IDX DTC P1165 SWIRL CONTROL VALVE CONTROL VACUUM CHECK SWITCH Diagnostic Procedure Diagnostic Procedure 1 NAEC1074 CHECK HOSES 1. Turn ignition switch “OFF”. 2. Check hose for clogging or improper connection. SEF109L OK or NG OK 䊳 GO TO 2. NG 䊳 Repair or reconnect the hose. 2 CHECK SWIRL CONTROL VALVE CONTROL VACUUM CHECK SWITCH GROUND CIRCUIT FOR OPEN AND SHORT 1. Disconnect swirl control valve control vacuum check switch harness connector. SEF999Y 2. Check harness continuity between terminal 2 and ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 3. 3 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors E1, M1 쐌 Harness connectors M32, F23 쐌 Harness connectors F22, M33 (A/T models) 쐌 Joint connector F204 쐌 Harness for open or short between swirl control valve control vacuum check switch and ECM 쐌 Harness for open or short between swirl control valve control vacuum check switch and TCM 䊳 Repair open circuit or short to ground or short to power in harness or connectors. EC-580 DTC P1165 SWIRL CONTROL VALVE CONTROL VACUUM CHECK SWITCH Diagnostic Procedure (Cont’d) 4 CHECK SWIRL CONTROL VALVE CONTROL VACUUM CHECK SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 59 and swirl control valve control vacuum check switch terminal 1. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. GI MA EM OK or NG OK 䊳 GO TO 6. NG 䊳 GO TO 5. 5 LC DETECT MALFUNCTIONING PART FE Check the following. 쐌 Harness connectors E1, M1 쐌 Harness connectors M94, F27 쐌 Harness for open or short between swirl control valve control vacuum check switch and ECM 䊳 CL Repair open circuit or short to ground or short to power in harness connectors. MT 6 CHECK SWIRL CONTROL VALVE CONTROL VACUUM CHECK SWITCH 1. 2. 3. 4. 5. Turn ignition switch “OFF”. Disconnect vacuum hose connected to swirl control valve control vacuum check switch. Attach vacuum pump to swirl control valve control vacuum check switch. Turn ignition switch “ON”. Check voltage between ECM terminal 59 and ground under the following conditions. AT TF PD AX SU SEC542D BR ST RS BT MTBL1369 HA OK or NG OK 䊳 GO TO 7. NG 䊳 Replace swirl control valve control vacuum check switch. SC EL IDX EC-581 DTC P1165 SWIRL CONTROL VALVE CONTROL VACUUM CHECK SWITCH Diagnostic Procedure (Cont’d) 7 1. 2. 3. 4. 5. 6. CHECK SWIRL CONTROL VALVE CONTROL SOLENOID VALVE With CONSULT-II Reconnect the disconnected harness connectors. Start engine and let it idle. Remove vacuum hose connected to swirl control valve actuator. Select “SWIRL CONT SOL VALVE” in “ACTIVE TEST” mode with CONSULT-II. Touch “ON” and “OFF” on CONSULT-II screen. Check vacuum existence and operation delay time under the following conditions. SEC540D 1. 2. 3. 4. 5. Without CONSULT-II Reconnect ECM harness connector. Remove vacuum hose connected to swirl control valve actuator. Start engine and let it idle. Apply 12V of direct current between swirl control valve control solenoid valve terminals and 2. Check vacuum existence and operation delay time under the following conditions. SEC541D OK or NG OK 䊳 GO TO 8. NG 䊳 Replace intake manifold collector assembly. 8 CHECK INTERMITTENT INCIDENT Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-582 DTC P1211 ABS/TCS CONTROL UNIT Description Description NAEC1271 The malfunction information related to TCS is transferred through the CAN communication line from ABS actuator and electric unit (control unit) to ECM. Be sure to erase the malfunction information such as DTC not only for ABS actuator and electric unit (control unit) but also for ECM after TCS related repair. On Board Diagnosis Logic NAEC1272 Freeze frame data is not stored in the ECM for this self-diagnosis. The MIL will not light up for this self-diagnosis. DTC No. P1211 1211 Trouble diagnosis name TCS control unit DTC detecting condition Possible cause ECM receives a malfunction information from ABS actuator and electric unit (Control unit). 쐌 ABS actuator and electric unit (control unit) 쐌 TCS related parts GI MA EM LC FE CL MT DTC Confirmation Procedure AT NAEC1273 TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. TF PD AX SU 1. 2. 3. 4. With CONSULT-II Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for at least 60 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-584. BR ST RS BT SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. HA SC EL IDX EC-583 DTC P1211 ABS/TCS CONTROL UNIT Diagnostic Procedure Diagnostic Procedure Go to BR-94, “TROUBLE DIAGNOSIS”. EC-584 NAEC1274 DTC P1212 ABS/TCS COMMUNICATION LINE Description Description NAEC1275 NOTE: If DTC P1212 is displayed with DTC U1000, U1001, first perform the trouble diagnosis for DTC U1000, U1001. Refer to “DTC U1000, U1001 CAN COMMUNICATION LINE”, EC-172. This CAN communication line is used to control the smooth engine operation during the TCS operation. Pulse signals are exchanged between ECM and ABS actuator and electric unit (control unit). Be sure to erase the malfunction information such as DTC not only in ABS actuator and electric unit (control unit) but also ECM after the ABS related repair. GI MA EM LC On Board Diagnosis Logic NAEC1276 Freeze frame data is not stored in the ECM for this self-diagnosis. The MIL will not light up for this self-diagnosis. DTC No. P1212 1212 Trouble diagnosis name TCS communication line DTC detecting condition ECM cannot receive the information from ABS actuator and electric unit (control unit) continuously. Possible cause 쐌 Harness or connectors (The CAN communication line is open or shorted.) 쐌 ABS actuator and electric unit (control unit) 쐌 Dead (Weak) battery FE CL MT DTC Confirmation Procedure AT NAEC1277 TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. TF PD AX SU 1. 2. 3. 4. WITH CONSULT-II Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for at least 10 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-586. BR ST RS BT SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. HA SC EL IDX EC-585 DTC P1212 ABS/TCS COMMUNICATION LINE Diagnostic Procedure Diagnostic Procedure Go to BR-94, “TROUBLE DIAGNOSIS”. EC-586 NAEC1278 DTC P1217 ENGINE OVER TEMPERATURE On Board Diagnosis Logic On Board Diagnosis Logic NAEC1177 If the cooling fan or another component in the cooling system malfunctions, engine coolant temperature will rise. When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction is indicated. This self-diagnosis has the one trip detection logic. DTC No. P1217 1217 Trouble diagnosis name DTC Detecting Condition Engine over tempera- 쐌 Cooling fan does not operate properly (Overture heat). 쐌 Cooling fan system does not operate properly (Overheat). 쐌 Engine coolant was not added to the system using the proper filling method. 쐌 Engine coolant is not within the specified range. GI MA EM Possible Cause 쐌 쐌 쐌 쐌 쐌 쐌 Cooling fan (Crankshaft driven) Thermostat Radiator hose Radiator Radiator cap Water pump For more information, refer to “MAIN 12 CAUSES OF OVERHEATING”, EC-591. LC FE CL CAUTION: When a malfunction is indicated be sure to replace the coolant, follow the procedure in “Changing Engine Coolant”, “ENGINE MAINTENANCE”, MA-15. Also, replace the engine oil. 1) Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute like pouring coolant by kettle. Be sure to use coolant with the proper mixture ratio. Refer to “Anti-freeze Coolant Mixture Ratio”, “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-13. 2) After refilling coolant, run engine to ensure that no water-flow noise is emitted. MT AT TF PD AX SU Overall Function Check NAEC1178 Use this procedure to check the overall function of the coolant overtemperature enrichment protection check, a DTC might not be confirmed. WARNING: Never remove the radiator cap when the engine is hot. Serious burns could be caused by high-pressure fluid escaping from the radiator. Wrap a thick cloth around the 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. WITH CONSULT-II 1) 2) WITH GST 1) SEF621W NAEC1178S01 Check the coolant level in the reservoir tank and radiator. Allow engine to cool before checking coolant level. If the coolant level in the reservoir and/or radiator is below the proper range, go to “Diagnostic Procedure”, EC-588. Confirm whether customer filled the coolant or not. If customer filled the coolant, go to “Diagnostic Procedure”, EC-588. ST RS BT HA SC EL NAEC1178S02 Check the coolant level in the reservoir tank and radiator. Allow engine to cool before checking coolant level. If the coolant level in the reservoir and/or radiator is below the EC-587 BR IDX DTC P1217 ENGINE OVER TEMPERATURE Overall Function Check (Cont’d) 2) proper range, and go to “Diagnostic Procedure”, EC-588. Confirm whether customer filled the coolant or not. If customer filled the coolant, go to “Diagnostic Procedure”, EC-588. Diagnostic Procedure 1 NAEC1179 CHECK COOLING FAN (CRANKSHAFT DRIVEN) OPERATION Start engine and make sure that cooling fan (crankshaft driven) operates. OK or NG OK 䊳 GO TO 2. NG 䊳 Check cooling fan (crankshaft driven). Refer to LC-22, “Cooling Fan (Crankshaft driven)”. 2 CHECK COOLING SYSTEM FOR LEAK Apply pressure to the cooling system with a tester, and check if the pressure drops. CAUTION: Higher than the specified pressure may cause radiator damage. Testing pressure: 157 kPa (1.6 kg/cm2, 23 psi) SLC754A Pressure should not drop. OK or NG OK 䊳 GO TO 3. NG 䊳 Check the following for leak 쐌 Hose 쐌 Radiator 쐌 Water pump Refer to “Water Pump”, LC-13. EC-588 DTC P1217 ENGINE OVER TEMPERATURE Diagnostic Procedure (Cont’d) 3 GI CHECK RADIATOR CAP Apply pressure to cap with a tester and check radiator cap relief pressure. MA EM LC SLC755A FE Radiator cap relief pressure: 59 - 98 kPa (0.6 - 1.0 kg/cm2, 9 - 14 psi) OK or NG OK 䊳 GO TO 4. NG 䊳 Replace radiator cap. 4 CL MT CHECK THERMOSTAT AT 1. Check valve seating condition at normal room temperatures. It should seat tightly. 2. Check valve opening temperature and valve lift. TF PD AX SU SLC949A Valve opening temperature: 76.5°C (170°F) [standard] Valve lift: More than 8 mm/108°C (0.315 in/226°F) 3. Check if valve is closed at 5°C (9°F) below valve opening temperature. For details, refer to “Thermostat”, LC-18. BR ST RS OK or NG OK 䊳 GO TO 5. NG 䊳 Replace thermostat BT HA SC EL IDX EC-589 DTC P1217 ENGINE OVER TEMPERATURE Diagnostic Procedure (Cont’d) 5 CHECK ENGINE COOLANT TEMPERATURE SENSOR Check resistance as shown in the figure. SEF152P MTBL0229 SEF012P OK or NG OK 䊳 GO TO 6. NG 䊳 Replace engine coolant temperature sensor. 6 CHECK MAIN 12 CAUSES If the cause cannot be isolated, go to “MAIN 12 CAUSES OF OVERHEATING”, EC-591. 䊳 INSPECTION END EC-590 DTC P1217 ENGINE OVER TEMPERATURE Main 12 Causes of Overheating Main 12 Causes of Overheating Engine Step OFF 1 2 Inspection item 쐌 쐌 쐌 쐌 Blocked Blocked Blocked Blocked radiator condenser radiator grille bumper 쐌 Coolant mixture Equipment 쐌 Visual Standard No blocking NAEC1180 Reference page — 쐌 Coolant tester 50 - 50% coolant mixture See “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-12. 쐌 Coolant level 쐌 Visual Coolant up to MAX level in reservoir tank and radiator filler neck See “Changing Engine Coolant”, “ENGINE MAINTENANCE”, MA-15. 4 쐌 Radiator cap 쐌 Pressure tester 59 - 98 kPa (0.6 - 1.0 kg/cm2, 9 - 14 psi) (Limit) See “System Check”, “ENGINE COOLING SYSTEM”, LC-12. ON*1 5 쐌 Coolant leaks 쐌 Visual No leaks See “System Check”, “ENGINE COOLING SYSTEM”, LC-12. ON*1 6 쐌 Thermostat 쐌 Touch the upper and lower radiator hoses Both hoses should be hot See “Thermostat” and “Radiator”, “ENGINE COOLING SYSTEM”, LC-18, LC-21. OFF ON*2 OFF*3 OFF 7 8 9 MA EM 3 ON*1 GI 쐌 Cooling fan (Crankshaft driven) 쐌 Visual Operating 쐌 Combustion gas leak 쐌 Color checker chemical tester 4 Gas analyzer Negative 쐌 Coolant temperature gauge 쐌 Visual Gauge less than 3/4 when driving 쐌 Coolant overflow to reservoir tank 쐌 Visual See LC-22, “Cooling Fan (Crankshaft driven)”. LC FE CL MT AT TF — PD — AX No overflow during driving and idling See “Changing Engine Coolant”, “ENGINE MAINTENANCE”, MA-15. SU 쐌 Coolant return from 쐌 Visual reservoir tank to radiator Should be initial level in reservoir tank See “ENGINE MAINTENANCE”, MA-14. BR 11 쐌 Cylinder head 0.1 mm (0.004 in) Maximum distortion (warping) See “Inspection”, “CYLINDER HEAD DISTORTION”, EM-44. 12 쐌 Cylinder block and pis- 쐌 Visual tons No scuffing on cylinder walls or piston See “Inspection”, “CYLINDER BLOCK DISTORTION AND WEAR”, EM-67. 10 쐌 Straight gauge feeler gauge *1: Engine running at 3,000 rpm for 10 minutes. *2: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes. *3: After 60 minutes of cool down time. For more information, refer to “Engine Cooling System”, “OVERHEATING CAUSE ANALYSIS”, LC-26. ST RS BT HA SC EL IDX EC-591 DTC P1225 TP SENSOR Component Description Component Description PBIB0145E NAEC1279 Electric Throttle Control Actuator consists of throttle control motor, throttle position sensor, etc. The throttle position sensor responds to the throttle valve movement. The throttle position sensor has the two sensors. These sensors are a kind of potentiometers which transform the throttle valve position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the throttle valve and feed the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening angle properly in response to driving condition. On Board Diagnosis Logic NAEC1280 The MIL will not light up for this self-diagnosis. DTC No. P1225 1225 Trouble diagnosis name Closed throttle position learning performance problem DTC Detecting Condition Closed throttle position learning value is excessively low. Possible Cause 쐌 Electric throttle control actuator (TP sensor 1 and 2) DTC Confirmation Procedure NAEC1281 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. 1) 2) 3) 4) 5) With CONSULT-II Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Turn ignition switch “OFF”, wait at least 10 seconds. Turn ignition switch “ON”. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-593. SEF058Y EC-592 DTC P1225 TP SENSOR DTC Confirmation Procedure (Cont’d) With GST Follow the procedure “With CONSULT-II” above. GI MA EM LC Diagnostic Procedure 1 NAEC1282 CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY FE 1. Turn ignition switch “OFF”. 2. Remove the intake air duct. 3. Check if foreign matter is caught between the throttle valve and the housing. CL MT AT TF SEC513D PD OK or NG OK 䊳 GO TO 2. NG 䊳 Remove the foreign matter and clean the electric throttle control actuator inside. 2 AX REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. Replace the electric throttle control actuator. 2. Perform “Throttle Valve Closed Position Learning”, EC-81. 3. Perform “Idle Air Volume Learning”, EC-81. 䊳 INSPECTION END SU BR ST RS BT HA SC EL IDX EC-593 DTC P1226 TP SENSOR Component Description Component Description PBIB0145E NAEC1283 Electric Throttle Control Actuator consists of throttle control motor, throttle position sensor, etc. The throttle position sensor responds to the throttle valve movement. The throttle position sensor has the two sensors. These sensors are a kind of potentiometers which transform the throttle valve position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the throttle valve and feed the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening angle properly in response to driving condition. On Board Diagnosis Logic NAEC1284 The MIL will not light up for this self-diagnosis. DTC No. P1226 1226 Trouble diagnosis name Closed throttle position learning performance problem DTC Detecting Condition Closed throttle position learning is not performed successfully, repeatedly. Possible Cause 쐌 Electric throttle control actuator (TP sensor 1 and 2) DTC Confirmation Procedure NAEC1285 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. 1) 2) 3) 4) 5) 6) With CONSULT-II Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Turn ignition switch “OFF”, wait at least 10 seconds. Turn ignition switch “ON”. Repeat steps 3 and 4, 32 times. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-595. SEF058Y EC-594 DTC P1226 TP SENSOR DTC Confirmation Procedure (Cont’d) With GST Follow the procedure “With CONSULT-II” above. GI MA EM LC Diagnostic Procedure 1 NAEC1286 CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY FE 1. Turn ignition switch “OFF”. 2. Remove the intake air duct. 3. Check if foreign matter is caught between the throttle valve and the housing. CL MT AT TF SEC513D PD OK or NG OK 䊳 GO TO 2. NG 䊳 Remove the foreign matter and clean the electric throttle control actuator inside. 2 AX REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. Replace the electric throttle control actuator. 2. Perform “Throttle Valve Closed Position Learning”, EC-81. 3. Perform “Idle Air Volume Learning”, EC-81. 䊳 INSPECTION END SU BR ST RS BT HA SC EL IDX EC-595 DTC P1229 SENSOR POWER SUPPLY ECM Terminals and Reference Value ECM Terminals and Reference Value NAEC1291 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) 48 P/B Sensor’s power supply [Ignition switch “ON”] Approximately 5V 49 P/B Sensor’s power supply (Refrigerant pressure sensor) [Ignition switch “ON”] Approximately 5V 68 L Sensor’s power supply (Power steering pressure sensor) [Ignition switch “ON”] Approximately 5V 90 L Sensor’s power supply (APP sensor 1) [Ignition switch “ON”] Approximately 5V On Board Diagnosis Logic NAEC1287 This self-diagnosis has the one trip detection logic. DTC No. P1229 1229 Trouble diagnosis name Sensor power supply circuit short DTC Detecting Condition Possible Cause ECM detects a voltage of power source for sensor 쐌 Harness or connectors is excessively low or high. (APP sensor 1 circuit is shorted.) (PSP sensor circuit is shorted.) (Refrigerant pressure sensor circuit is shorted.) [MAF sensor (TYPE I) circuit is shorted.] (EVAP control system pressure sensor circuit is shorted.) 쐌 Accelerator pedal position sensor 쐌 Power steering pressure sensor 쐌 EVAP control system pressure sensor 쐌 Refrigerant pressure sensor 쐌 MAF sensor (TYPE I) FAIL-SAFE MODE NAEC1287S01 When the malfunction is detected, ECM enters fail-safe mode and the MIL lights up. Engine operation condition in fail-safe mode ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. DTC Confirmation Procedure NAEC1288 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. EC-596 DTC P1229 SENSOR POWER SUPPLY DTC Confirmation Procedure (Cont’d) 1) 2) 3) 4) With CONSULT-II Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to “Diagnostic Procedure”, EC-599. GI MA EM LC SEF058Y With GST Follow the procedure “With CONSULT-II” above. FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-597 DTC P1229 SENSOR POWER SUPPLY Wiring Diagram Wiring Diagram NAEC1289 TEC847 EC-598 DTC P1229 SENSOR POWER SUPPLY Diagnostic Procedure Diagnostic Procedure 1 NAEC1290 GI RETIGHTEN GROUND SCREWS MA 1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. EM LC FE SEF959Y 䊳 2 CL GO TO 2. MT CHECK ACCELERATOR PEDAL POSITION SENSOR 1 POWER SUPPLY CIRCUIT 1. Disconnect accelerator pedal position (APP) sensor harness connector. 2. Turn ignition switch “ON”. AT TF PD AX SEC550D 3. Check voltage between APP sensor terminal 12 and ground with CONSULT-II or tester. SU BR ST RS BT SEC551D Voltage: Approximately 5V OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 3. HA SC EL IDX EC-599 DTC P1229 SENSOR POWER SUPPLY Diagnostic Procedure (Cont’d) 3 CHECK SENSOR POWER SUPPLY CIRCUITS Check harness for short to power and short to ground, between the following terminals. 쐌 ECM terminal 48 and EVAP control system pressure sensor terminal 3. Refer to “Wiring Diagram”, EC-412. 쐌 ECM terminal 48 and mass air flow sensor (TYPE I) terminal 4. Refer to “Wiring Diagram”, EC-198. 쐌 ECM terminal 68 and power steering pressure sensor terminal 1. Refer to “Wiring Diagram”, EC-467. 쐌 ECM terminal 49 and refrigerant pressure sensor terminal 3. Refer to “Wiring Diagram”, EC-771. 쐌 ECM terminal 90 and APP sensor terminal 12. Refer to “Wiring Diagram”, EC-598. OK or NG OK 䊳 GO TO 4. NG 䊳 Repair short to ground or short to power in harness or connectors. 4 CHECK COMPONENTS Check the following. 쐌 Refrigerant pressure sensor (Refer to “COMPONENT INSPECTION”, HA-132.) 쐌 Power steering pressure sensor (Refer to “Component Inspection”, EC-466.) 쐌 EVAP control system pressure sensor (Refer to “Diagnostic Procedure”, EC-410.) 쐌 Mass air flow sensor (TYPE I) (Refer to “Diagnostic Procedure”, EC-194.) OK or NG OK 䊳 GO TO 7. NG 䊳 Replace malfunctioning component. 5 CHECK APP SENSOR Refer to “Component Inspection”, EC-714. OK or NG OK 䊳 GO TO 7. NG 䊳 GO TO 6. 6 1. 2. 3. 4. REPLACE ACCELERATOR PEDAL ASSEMBLY Replace accelerator pedal assembly. Perform “Accelerator Pedal Released Position Learning”, EC-81. Perform “Throttle Valve Closed Position Learning”, EC-81. Perform “Idle Air Volume Learning”, EC-81. 䊳 7 INSPECTION END REPLACE ACCELERATOR PEDAL ASSEMBLY Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-600 DTC P1442 EVAP CONTROL SYSTEM On Board Diagnosis Logic On Board Diagnosis Logic NAEC1377 NOTE: If DTC P0442 is displayed with P1448, perform trouble diagnosis for DTC P1448 first. (See EC-636.) This diagnosis detects leaks in the EVAP purge line using the vapor pressure in the fuel tank. 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 volume control solenoid 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 canister purge volume control solenoid valve. GI MA EM LC FE CL MT AT SEF323U DTC No. P1442 1442 Trouble diagnosis name EVAP control system small leak detected (positive pressure) TF DTC Detecting Condition EVAP control system has a leak, EVAP control system does not operate properly. Possible Cause 쐌 Incorrect fuel tank vacuum relief valve 쐌 Incorrect fuel filler cap used 쐌 Fuel filler cap remains open or fails to close. 쐌 Foreign matter caught in fuel filler cap 쐌 Leak is in line between intake manifold and EVAP canister purge volume control solenoid valve. 쐌 Foreign matter caught in EVAP canister vent control valve 쐌 EVAP canister or fuel tank leaks 쐌 EVAP purge line (pipe and rubber tube) leaks 쐌 EVAP purge line rubber tube bent 쐌 Blocked or bent rubber tube to EVAP control system pressure sensor 쐌 Loose or disconnected rubber tube 쐌 EVAP canister vent control valve and the circuit 쐌 EVAP canister purge volume control solenoid valve and the circuit 쐌 Fuel tank temperature sensor 쐌 O-ring of EVAP canister vent control valve is missing or damaged. 쐌 Water separator 쐌 EVAP canister is saturated with water. 쐌 EVAP control system pressure sensor 쐌 Fuel level sensor and the circuit 쐌 Refueling control valve 쐌 ORVR system leaks PD AX SU BR ST RS BT HA SC EL IDX EC-601 DTC P1442 EVAP CONTROL SYSTEM On Board Diagnosis Logic (Cont’d) CAUTION: 쐌 Use only a genuine NISSAN fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. 쐌 If the fuel filler cap is not tightened properly, the MIL may come on. 쐌 Use only a genuine NISSAN rubber tube as a replacement. DTC Confirmation Procedure SEC760C NAEC1378 NOTE: 쐌 If DTC P1442 is displayed with P1448, first perform trouble diagnosis for DTC P1448 (See EC-636). 쐌 If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: 쐌 Perform “DTC WORK SUPPORT” when the fuel level is between 1/4 to 3/4 full and vehicle is placed on flat level surface. 쐌 Open engine hood before conducting the following procedure. WITH CONSULT-II NAEC1378S01 1) 2) 3) SEC761C SEC762C Turn ignition switch “ON”. Turn ignition switch “OFF” and wait at least 10 seconds. Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 4) Make sure that the following conditions are met. COOLAN TEMP/S: 0 - 70°C (32 - 158°F) INT/A TEMP SE: 0 - 30°C (32 - 86°F) 5) Select “EVP SML LEAK P0442/P1442” of “EVAPORATIVE SYSTEM” in “DTC WORK SUPPORT” mode with CONSULTII. Follow the instruction displayed. NOTE: If the engine speed cannot be maintained within the range displayed on the CONSULT-II screen, go to “Basic Inspection”, EC-131. 6) Make sure that “OK” is displayed. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-603. NOTE: Make sure that EVAP hoses are connected to EVAP canister purge volume control solenoid valve properly. WITH GST SEC763C NAEC1378S02 NOTE: Be sure to read the explanation of “Driving Pattern” on EC-92 before driving vehicle. 1) Start engine. 2) Drive vehicle according to “Driving Pattern”, EC-92. 3) Stop vehicle. 4) Select “MODE 1” with GST. 쐌 If SRT of EVAP system is not set yet, go to the following step. EC-602 DTC P1442 EVAP CONTROL SYSTEM DTC Confirmation Procedure (Cont’d) 쐌 5) 6) If SRT of EVAP system is set, the result will be OK. Turn ignition switch “OFF” and wait at least 10 seconds. Start engine. It is not necessary to cool engine down before driving. 7) Drive vehicle again according to the “Driving Pattern”, EC-92. 8) Stop vehicle. 9) Select “MODE 3” with GST. 쐌 If P1442 is displayed on the screen, go to “Diagnostic Procedure”, EC-603. 쐌 If P0442 is displayed on the screen, go to “Diagnostic Procedure”, EC-383. 쐌 If P0441 is displayed on the screen, go to “Diagnostic Procedure” for DTC P0441, EC-374. 쐌 If P0441, P0442 and P1442 are not displayed on the screen, go to the following step. 10) Select “MODE 1” with GST. 쐌 If SRT of EVAP system is set, the result will be OK. 쐌 If SRT of EVAP system is not set, go to step 6. GI MA EM LC FE CL MT AT Diagnostic Procedure 1 NAEC1379 CHECK FUEL FILLER CAP DESIGN TF 1. Turn ignition switch “OFF”. 2. Check for genuine NISSAN fuel filler cap design. PD AX SU SEF915U BR OK or NG ST OK 䊳 GO TO 2. NG 䊳 Replace with genuine NISSAN fuel filler cap. RS 2 CHECK FUEL FILLER CAP INSTALLATION Check that the cap is tightened properly by rotating the cap clockwise. BT OK or NG OK 䊳 GO TO 3. NG 䊳 쐌 Open fuel filler cap, then clean cap and fuel filler neck threads using air blower. 쐌 Retighten until ratcheting sound is heard. HA SC EL IDX EC-603 DTC P1442 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 3 CHECK FUEL FILLER CAP FUNCTION Check for air releasing sound while opening the fuel filler cap. OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 4. 4 CHECK FUEL TANK VACUUM RELIEF VALVE 1. Wipe clean valve housing. 2. Check valve opening pressure and vacuum. SEF445Y SEF943S Pressure: 15.3 - 20.0 kPa (0.156 - 0.204 kg/cm2, 2.22 - 2.90 psi) Vacuum: −6.0 to −3.3 kPa (−0.061 to −0.034 kg/cm2, −0.87 to −0.48 psi) CAUTION: Use only a genuine fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. OK or NG OK 䊳 GO TO 5. NG 䊳 Replace fuel filler cap with a genuine one. EC-604 DTC P1442 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 5 GI INSTALL THE PRESSURE PUMP To locate the EVAP leak, install EVAP service port adapter and pressure pump to EVAP service port securely. MA EM LC SEF983Y FE CL MT AT SEF916U NOTE: Improper installation of the EVAP service port adapter to the EVAP service port may cause leaking. With CONSULT-II 䊳 GO TO 6. Without CONSULT-II 䊳 GO TO 7. TF PD AX SU BR ST RS BT HA SC EL IDX EC-605 DTC P1442 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 6 CHECK FOR EVAP LEAK With CONSULT-II 1. Turn ignition switch “ON”. 2. Select “EVAP SYSTEM CLOSE” of “WORK SUPPORT” mode with CONSULT-II. 3. Touch “START” and apply pressure into the EVAP line until the pressure indicator reaches the middle of the bar graph. NOTE: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in the system. PEF917U 4. Using EVAP leak detector, locate the EVAP leak. For the leak detector, refer to the instruction manual for more details. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-45. SEF200U OK or NG OK 䊳 GO TO 8. NG 䊳 Repair or replace. EC-606 DTC P1442 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 7 GI CHECK FOR EVAP LEAK Without CONSULT-II 1. Turn ignition switch “OFF”. 2. Apply 12 volts DC to EVAP canister vent control valve. The valve will close. (Continue to apply 12 volts until the end of test.) MA EM LC FE SEC930C 3. Apply 12 volts DC to vacuum cut valve bypass valve. The valve will open. (Continue to apply 12V until the end of test.) CL MT AT TF SEC932C 4. Pressurize the EVAP line using pressure pump with 1.3 to 2.7 kPa (10 to 20 mmHg, 0.39 to 0.79 inHg), then remove pump and EVAP service port adapter. NOTE: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in the system. 5. Using EVAP leak detector, locate the EVAP leak. For the leak detector, refer to the instruction manual for more details. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-45. PD AX SU BR ST RS BT SEF200U OK or NG OK 䊳 GO TO 8. NG 䊳 Repair or replace. HA SC EL IDX EC-607 DTC P1442 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 8 1. 2. 3. 4. CHECK WATER SEPARATOR Check Check Check Check visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged. PBIB1032E 5. In case of NG in items 2 - 4, replace the parts. NOTE: 쐌 Do not disassemble water separator. OK or NG OK 䊳 GO TO 9. NG 䊳 Replace water separator. 9 CHECK EVAP CANISTER VENT CONTROL VALVE, O-RING AND CIRCUIT Refer to “DTC Confirmation Procedure”, EC-404. OK or NG OK 䊳 GO TO 10. NG 䊳 Repair or replace EVAP canister vent control valve and O-ring or harness/connector. 10 CHECK IF EVAP CANISTER SATURATED WITH WATER 1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Does water drain from the EVAP canister? SEF596U Yes or No Yes 䊳 GO TO 11. No (With CONSULT-II) 䊳 GO TO 13. No (Without CONSULTII) 䊳 GO TO 14. EC-608 DTC P1442 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 11 GI CHECK EVAP CANISTER Weigh the EVAP canister with the EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb). MA OK or NG OK (With CONSULT-II) 䊳 GO TO 13. OK (Without CONSULTII) 䊳 GO TO 14. NG 䊳 GO TO 12. 12 EM LC DETECT MALFUNCTIONING PART Check the following. 쐌 EVAP canister for damage 쐌 EVAP hose between EVAP canister and water separator for clogging or poor connection 䊳 13 1. 2. 3. 4. 5. FE Repair hose or replace EVAP canister. CL CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION MT With CONSULT-II Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port. Start engine. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode. Touch “Qu” on CONSULT-II screen to increase “PURG VOL CONT/V” opening to 100%. Check vacuum hose for vacuum when revving engine up to 2,000 rpm. AT TF PD AX SU PBIB1678E BR Vacuum should exist. OK or NG OK 䊳 GO TO 16. NG 䊳 GO TO 15. ST RS 14 1. 2. 3. 4. 5. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION Without CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine. Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port. Start engine and let it idle for at least 80 seconds. Check vacuum hose for vacuum when revving engine up to 2,000 rpm. Vacuum should exist. BT HA SC OK or NG OK 䊳 GO TO 17. NG 䊳 GO TO 15. EL IDX EC-609 DTC P1442 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 15 CHECK VACUUM HOSE Check vacuum hoses for clogging or disconnection. Refer to “Vacuum Hose Drawing”, EC-35. OK or NG OK (With CONSULT-II) 䊳 GO TO 16. OK (Without CONSULTII) 䊳 GO TO 17. NG 䊳 Repair or reconnect the hose. 16 CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE With CONSULT-II 1. Start engine. 2. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Check that engine speed varies according to the valve opening. PBIB1678E OK or NG OK 䊳 GO TO 18. NG 䊳 GO TO 17. EC-610 DTC P1442 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 17 GI CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE With CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions. MA EM LC SEC524D FE CL MT AT SEF334XA TF Without CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions. PD AX SU BR SEC524D ST RS BT HA SEF335X OK or NG OK 䊳 GO TO 18. NG 䊳 Replace EVAP canister purge volume control solenoid valve. SC EL IDX EC-611 DTC P1442 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 18 CHECK FUEL TANK TEMPERATURE SENSOR 1. Remove fuel level sensor unit. 2. Check resistance between fuel level sensor unit terminals 1 and 2 by heating with hot water or heat gun as shown in the figure. SEF974Y OK or NG OK 䊳 GO TO 19. NG 䊳 Replace fuel level sensor unit. EC-612 DTC P1442 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 19 GI CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR 1. Remove EVAP control system pressure sensor with its harness connector connected. 쐌 Never apply force to the air hole protector of the sensor if equipped. MA EM LC SEF799W 2. Remove EVAP control system pressure sensor from EVAP canister. Do not reuse the O-ring, replace it with a new one. 3. Install a vacuum pump to EVAP control system pressure sensor. 4. Turn ignition switch “ON” and check output voltage between ECM terminal 32 and ground under the following conditions. FE CL MT AT TF PD SEC422D CAUTION: 쐌 Always calibrate the vacuum pump gauge when using it. 쐌 Do not apply below −93.3 kPa (−700 mmHg, −27.56 inHg) or pressure over 101.3 kPa (760 mmHg, 29.92 inHg). 쐌 Discard and EVAP control system pressure 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. AX SU OK or NG BR OK 䊳 GO TO 20. NG 䊳 Replace EVAP control system pressure sensor. ST 20 CHECK EVAP PURGE LINE Check EVAP purge line (pipe, rubber tube, fuel tank and EVAP canister) for cracks or improper connection. Refer to “Evaporative Emission System”, EC-41. OK or NG OK 䊳 GO TO 21. NG 䊳 Repair or reconnect the hose. 21 CLEAN EVAP PURGE LINE Clean EVAP purge line (pipe and rubber tube) using air blower. 䊳 RS BT HA SC GO TO 22. EL IDX EC-613 DTC P1442 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 22 CHECK REFUELING EVAP VAPOR LINE 쐌 Check refueling EVAP vapor line between EVAP canister and fuel tank for clogging, kink, looseness and improper connection. For location, refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-45. OK or NG OK 䊳 GO TO 23. NG 䊳 Repair or replace hoses and tubes. 23 CHECK SIGNAL LINE AND RECIRCULATION LINE 쐌 Check signal line and recirculation line between filler neck tube and fuel tank for clogging, kink, cracks, looseness and improper connection. OK or NG OK 䊳 GO TO 24. NG 䊳 Repair or replace hoses, tubes or filler neck tube. 24 CHECK REFUELING CONTROL VALVE 1. Remove fuel filler cap. 2. Check air continuity between hose ends A and B. Blow air into hose end B. Air should flow freely into the fuel tank. 3. Blow air into hose end A and check that there is no leakage. 4. Apply pressure to both hose ends A and B [20 kPa (150 mmHg, 5.91 inHg)] using a pressure pump and a suitable 3-way connector. Check that there is no leakage. SEC883C OK or NG OK 䊳 GO TO 25. NG 䊳 Replace or refueling control valve with fuel tank. 25 CHECK FUEL LEVEL SENSOR Refer to EL-124, “Fuel Level Sensor Unit Check”. OK or NG OK 䊳 GO TO 26. NG 䊳 Replace fuel level sensor unit. EC-614 DTC P1442 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 26 GI CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 MA INSPECTION END EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-615 DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE Description Description NAEC1089 SYSTEM DESCRIPTION Sensor Input Signal to ECM Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed*2 and piston position Mass air flow sensor Amount of intake air Engine coolant temperature sensor Engine coolant temperature Throttle position sensor Throttle position Accelerator pedal position sensor Accelerator pedal position Heated oxygen sensor 1 Density of oxygen in exhaust gas (Mixture ratio feedback signal) Fuel tank temperature sensor Fuel temperature in fuel tank Vehicle speed signal*1 Vehicle speed Battery Battery voltage*2 NAEC1089S01 ECM function Actuator EVAP canEVAP canister purge volume ister purge control solenoid valve flow control *1: This signal is sent to the ECM through CAN communication line. *2: ECM determines the start signal status by the signals of engine speed and battery voltage. This system controls flow rate of fuel vapor from the EVAP canister. The opening of the vapor by-pass passage in the EVAP canister purge volume control solenoid valve changes to control the flow rate. The EVAP canister purge volume control solenoid valve repeats ON/OFF operation according to the signal sent from the ECM. The opening of the valve varies for optimum engine control. The optimum value stored in the ECM is determined by considering various engine conditions. When the engine is operating, the flow rate of fuel vapor from the EVAP canister is regulated as the air flow changes. COMPONENT DESCRIPTION NAEC1089S02 The EVAP canister purge volume control solenoid valve uses a ON/OFF duty to control the flow rate of fuel vapor from the EVAP canister. The EVAP canister purge volume control solenoid valve is moved by ON/OFF pulses from the ECM. The longer the ON pulse, the greater the amount of fuel vapor that will flow through the valve. SEF337U CONSULT-II Reference Value in Data Monitor Mode NAEC1090 Specification data are reference values. MONITOR ITEM PURG VOL C/V CONDITION 쐌 쐌 쐌 쐌 Engine: After warming up Air conditioner switch “OFF” Shift lever: “N” No-load SPECIFICATION Idle (Vehicle stopped) 0% 2,000 rpm — EC-616 DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE ECM Terminals and Reference Value ECM Terminals and Reference Value NAEC1091 Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) GI MA EM LC BATTERY VOLTAGE (11 - 14V)★ [Engine is running] 쐌 Idle speed FE CL 45 L/Y SEC990C EVAP canister purge volume control solenoid valve BATTERY VOLTAGE (11 - 14V)★ MT AT [Engine is running] 쐌 Engine speed is about 2,000 rpm (More than 100 seconds after starting engine). TF SEC991C PD ★: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) AX On Board Diagnosis Logic DTC No. P1444 1444 Trouble diagnosis name EVAP canister purge volume control solenoid valve DTC Detecting Condition NAEC1092 Possible Cause SU The canister purge flow is detected during the 쐌 EVAP control system pressure sensor specified driving conditions, even when EVAP can- 쐌 EVAP canister purge volume control ister purge volume control solenoid valve is comsolenoid valve (The valve is stuck pletely closed. open.) 쐌 EVAP canister vent control valve 쐌 EVAP canister 쐌 Hoses (Hoses are connected incorrectly or clogged.) BR ST RS BT DTC Confirmation Procedure NAEC1093 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Always perform test at a temperature of 0°C (32°F) or more. HA SC EL IDX EC-617 DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE DTC Confirmation Procedure (Cont’d) WITH CONSULT-II 1) 2) 3) 4) 5) 6) SEC143D 7) WITH GST SEC144D 1) 2) 3) 4) 5) NAEC1093S01 Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF” and wait at least 10 seconds. Turn ignition switch “ON”. Select “PURG VOL CN/V P1444” of “EVAPORATIVE SYSTEM” in “DTC WORK SUPPORT” mode with CONSULT-II. Touch “START”. Start engine and let it idle until “TESTING” on CONSULT-II changes to “COMPLETED”. (It will take for approximately 10 seconds.) If “TESTING” is not displayed after 5 minutes, retry from step 2. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-620. NAEC1093S02 Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF” and wait at least 10 seconds. Start engine and let it idle for at least 20 seconds. Select “MODE 7” with GST. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-620. SEF237Y EC-618 DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE Wiring Diagram Wiring Diagram NAEC1094 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC096E EC-619 IDX DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE Diagnostic Procedure Diagnostic Procedure 1 NAEC1095 CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT 1. Turn ignition switch “OFF”. 2. Disconnect EVAP canister purge volume control solenoid valve harness connector. SEC524D 3. Turn ignition switch “ON”. 4. Check voltage between EVAP canister purge volume control solenoid valve terminal 1 and engine ground with CONSULT-II or tester. PBIB0080E Voltage: Battery voltage OK or NG OK 䊳 GO TO 3. NG 䊳 GO TO 2. 2 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors E1, M1 쐌 Harness connectors M32, F23 쐌 Harness for open or short between EVAP canister purge volume control solenoid valve and ECM 쐌 Harness for open or short between EVAP canister purge volume control solenoid valve and ECM relay 䊳 3 Repair open circuit or short to ground or short to power in harness or connectors. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 45 and EVAP canister purge volume control solenoid valve terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 4. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. EC-620 DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE Diagnostic Procedure (Cont’d) 4 GI CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR HOSE Check disconnection or improper connection of hose connected to EVAP control system pressure sensor. MA EM LC SEC931C OK or NG OK 䊳 GO TO 5. NG 䊳 Repair it. 5 FE CL CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR CONNECTOR 1. Disconnect EVAP control system pressure sensor harness connector. 2. Check connectors for water. Water should not exist. MT AT OK or NG TF OK 䊳 GO TO 6. NG 䊳 Replace EVAP control system pressure sensor. PD AX SU BR ST RS BT HA SC EL IDX EC-621 DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE Diagnostic Procedure (Cont’d) 6 CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR 1. Remove EVAP control system pressure sensor with its harness connector connected. 쐌 Never apply force to the air hole protector of the sensor if equipped. SEF799W 2. Remove EVAP control system pressure sensor from EVAP canister. Do not reuse the O-ring, replace it with a new one. 3. Install a vacuum pump to EVAP control system pressure sensor. 4. Turn ignition switch “ON” and check output voltage between ECM terminal 32 and ground under the following conditions. SEC422D CAUTION: 쐌 Always calibrate the vacuum pump gauge when using it. 쐌 Do not apply below −93.3 kPa (−700 mmHg, −27.56 inHg) or pressure over 101.3 kPa (760 mmHg, 29.92 inHg). 쐌 Discard and EVAP control system pressure 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. OK or NG OK (With CONSULT-II) 䊳 GO TO 7. OK (Without CONSULTII) 䊳 GO TO 8. NG 䊳 Replace EVAP control system pressure sensor. EC-622 DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE Diagnostic Procedure (Cont’d) 7 1. 2. 3. 4. GI CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE With CONSULT-II Turn ignition switch “OFF”. Reconnect harness connectors disconnected. Start engine. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Check that engine speed varies according to the valve opening. MA EM LC FE PBIB1678E OK or NG OK 䊳 GO TO 9. NG 䊳 GO TO 8. CL MT AT 8 CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE TF With CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions. PD AX SU BR SEF334XA ST Without CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions. RS BT HA SC SEF335X OK or NG OK 䊳 GO TO 9. NG 䊳 Replace EVAP canister purge volume control solenoid valve. EC-623 EL IDX DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE Diagnostic Procedure (Cont’d) 9 CHECK RUBBER TUBE FOR CLOGGING 1. Disconnect rubber tube connected to EVAP canister vent control valve. 2. Check the rubber tube for clogging. OK or NG OK 䊳 GO TO 10. NG 䊳 Clean the rubber tube using an air blower. 10 CHECK EVAP CANISTER VENT CONTROL VALVE-I 1. Remove EVAP canister vent control valve from EVAP canister. 2. Check portion B of EVAP canister vent control valve for being rusted. SEF376Z OK or NG OK 䊳 GO TO 11. NG 䊳 Replace EVAP canister vent control valve. EC-624 DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE Diagnostic Procedure (Cont’d) 11 1. 2. 3. 4. GI CHECK EVAP CANISTER VENT CONTROL VALVE-II With CONSULT-II Reconnect harness connectors disconnected. Turn ignition switch “ON”. Perform “VENT CONTROL/V” in “ACTIVE TEST” mode. Check air passage continuity and operation delay time. MA EM LC FE SEC158D Without CONSULT-II Check air passage continuity and operation delay time under the following conditions. CL MT AT TF PD SEF378Z AX Make sure new O-ring is installed properly. OK or NG OK 䊳 GO TO 13. NG 䊳 GO TO 12. 12 SU BR CHECK EVAP CANISTER VENT CONTROL VALVE-III 1. Clean the air passage (Portion A to B) of EVAP canister vent control valve using an air blower. 2. Perform procedure 9 again. OK or NG OK 䊳 GO TO 13. NG 䊳 Replace EVAP canister vent control valve. ST RS BT HA SC EL IDX EC-625 DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE Diagnostic Procedure (Cont’d) 13 CHECK IF EVAP CANISTER SATURATED WITH WATER 1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Check if water will drain from the EVAP canister. SEF596U Yes or No Yes 䊳 GO TO 14. No 䊳 GO TO 17. 14 CHECK EVAP CANISTER Weigh the EVAP canister with the EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb). OK or NG OK 䊳 GO TO 16. NG 䊳 GO TO 15. 15 DETECT MALFUNCTIONING PART Check the following. 쐌 EVAP canister for damage 쐌 EVAP hose between EVAP canister and water separater for clogging or poor connection 䊳 Repair hose or replace EVAP canister. EC-626 DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE Diagnostic Procedure (Cont’d) 16 1. 2. 3. 4. GI CHECK WATER SEPARATOR Check Check Check Check visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged. MA EM LC FE PBIB1032E 5. In case of NG in items 2 - 4, replace the parts. NOTE: 쐌 Do not disassemble water separator. CL OK or NG OK 䊳 GO TO 17. NG 䊳 Clean or replace water separator. 17 CHECK INTERMITTENT INCIDENT MT AT TF Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END PD AX SU BR ST RS BT HA SC EL IDX EC-627 DTC P1446 EVAP CANISTER VENT CONTROL VALVE Component Description Component Description SEF381Z NAEC1096 The EVAP canister vent control valve is located on the EVAP canister and is used to seal the canister vent. This solenoid valve responds to 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 evaporative emission control system components. This solenoid valve is used only for diagnosis, and usually remains opened. When the vent is closed, under normal purge conditions, the evaporative emission control system is depressurized and allows “EVAP Control System (Small Leak)” diagnosis. SEC928C CONSULT-II Reference Value in Data Monitor Mode NAEC1097 Specification data are reference values. MONITOR ITEM CONDITION SPECIFICATION 쐌 Ignition switch: ON VENT CONT/V OFF ECM Terminals and Reference Value NAEC1098 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 117 WIRE COLOR G/R ITEM CONDITION EVAP canister vent control valve DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V) [Ignition switch “ON”] On Board Diagnosis Logic DTC No. P1446 1446 Trouble diagnosis name EVAP canister vent control valve closed DTC Detecting Condition EVAP canister vent control valve remains closed under specified driving conditions. EC-628 NAEC1099 Possible Cause 쐌 EVAP canister vent control valve 쐌 EVAP control system pressure sensor and the circuit 쐌 Blocked rubber tube to EVAP canister vent control valve 쐌 Water separator 쐌 EVAP canister is saturated with water. DTC P1446 EVAP CANISTER VENT CONTROL VALVE DTC Confirmation Procedure DTC Confirmation Procedure NAEC1100 CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. WITH CONSULT-II PBIB0164E NAEC1100S01 1) 2) 3) 4) Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine. Drive vehicle at a speed of approximately 80 km/h (50 MPH) for a maximum of 15 minutes. NOTE: If a malfunction exists, NG result may be displayed quicker. 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-631. WITH GST Follow the procedure “WITH CONSULT-II” above. NAEC1100S02 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-629 DTC P1446 EVAP CANISTER VENT CONTROL VALVE Wiring Diagram Wiring Diagram NAEC1101 MEC097E EC-630 DTC P1446 EVAP CANISTER VENT CONTROL VALVE Diagnostic Procedure Diagnostic Procedure 1 NAEC1102 GI CHECK RUBBER TUBE MA 1. Turn ignition switch “OFF”. 2. Disconnect rubber tube connected to EVAP canister vent control valve. 3. Check the rubber tube for clogging. EM LC FE SEC928C OK or NG OK 䊳 GO TO 2. NG 䊳 Clean rubber tube using an air blower. 2 1. 2. 3. 4. MT AT CHECK WATER SEPARATOR Check Check Check Check CL visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged. TF PD AX SU BR PBIB1032E 5. In case of NG in items 2 - 4, replace the parts. NOTE: 쐌 Do not disassemble water separator. ST OK or NG RS BT OK 䊳 GO TO 3. NG 䊳 Clean or replace water separator. HA SC EL IDX EC-631 DTC P1446 EVAP CANISTER VENT CONTROL VALVE Diagnostic Procedure (Cont’d) 3 CHECK EVAP CANISTER VENT CONTROL VALVE-I 1. Remove EVAP canister vent control valve from EVAP canister. 2. Check portion B of EVAP canister vent control valve for being rusted. SEF376Z OK or NG OK 䊳 GO TO 4. NG 䊳 Replace EVAP canister vent control valve. 4 CHECK EVAP CANISTER VENT CONTROL VALVE-II With CONSULT-II 1. Turn ignition switch ON. 2. Perform “VENT CONTROL/V” in “ACTIVE TEST” mode. 3. Check air passage continuity and operation delay time. SEC158D Without CONSULT-II Check air passage continuity and operation delay time under the following conditions. SEF378Z Make sure new O-ring is installed properly. OK or NG OK 䊳 GO TO 6. NG 䊳 GO TO 5. EC-632 DTC P1446 EVAP CANISTER VENT CONTROL VALVE Diagnostic Procedure (Cont’d) 5 GI CHECK EVAP CANISTER VENT CONTROL VALVE-III 1. Clean the air passage (Portion A to B) of EVAP canister vent control valve using an air blower. 2. Perform the procedure 4 again. MA OK or NG OK 䊳 GO TO 6. NG 䊳 Replace EVAP canister vent control valve. 6 EM LC CHECK IF EVAP CANISTER SATURATED WITH WATER 1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Check if water will drain from the EVAP canister. FE CL MT SEF596U AT Yes or No Yes 䊳 GO TO 7. No 䊳 GO TO 9. TF PD 7 CHECK EVAP CANISTER Weigh the EVAP canister with the EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb). OK or NG OK 䊳 GO TO 9. NG 䊳 GO TO 8. 8 Check the following. 쐌 EVAP canister for damage 쐌 EVAP hose between EVAP canister and water separator for clogging or poor connection 9 SU BR DETECT MALFUNCTIONING PART 䊳 AX ST RS Repair hose or replace EVAP canister. CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR HOSE Check disconnection or improper connection of hose connected to EVAP control system pressure sensor. OK or NG OK 䊳 GO TO 10. NG 䊳 Repair it. BT HA SC EL IDX EC-633 DTC P1446 EVAP CANISTER VENT CONTROL VALVE Diagnostic Procedure (Cont’d) 10 CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR CONNECTOR 1. Disconnect EVAP control system pressure sensor harness connector. SEC931C 2. Check connectors for water. Water should not exist. OK or NG OK 䊳 GO TO 11. NG 䊳 Replace EVAP control system pressure sensor. EC-634 DTC P1446 EVAP CANISTER VENT CONTROL VALVE Diagnostic Procedure (Cont’d) 11 GI CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR 1. Remove EVAP control system pressure sensor with its harness connector connected. 쐌 Never apply force to the air hole protector of the sensor if equipped. MA EM LC SEF799W 2. Remove EVAP control system pressure sensor from EVAP canister. Do not reuse the O-ring, replace it with a new one. 3. Install a vacuum pump to EVAP control system pressure sensor. 4. Turn ignition switch “ON” and check output voltage between ECM terminal 32 and ground under the following conditions. FE CL MT AT TF PD SEC422D CAUTION: 쐌 Always calibrate the vacuum pump gauge when using it. 쐌 Do not apply below −93.3 kPa (−700 mmHg, −27.56 inHg) or pressure over 101.3 kPa (760 mmHg, 29.92 inHg). 쐌 Discard and EVAP control system pressure 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. AX SU OK or NG BR OK 䊳 GO TO 12. NG 䊳 Replace EVAP control system pressure sensor. ST 12 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 RS INSPECTION END BT HA SC EL IDX EC-635 DTC P1448 EVAP CANISTER VENT CONTROL VALVE Component Description Component Description SEF381Z NAEC1103 NOTE: If DTC P1448 is displayed with P0442, perform trouble diagnosis for DTC P1448 first. The EVAP canister vent control valve is located on the EVAP canister and is used to seal the canister vent. This solenoid valve responds to 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 evaporative emission control system components. This solenoid valve is used only for diagnosis, and usually remains opened. When the vent is closed, under normal purge conditions, the evaporative emission control system is depressurized and allows “EVAP Control System (Small Leak)” diagnosis. SEC928C CONSULT-II Reference Value in Data Monitor Mode NAEC1104 Specification data are reference values. MONITOR ITEM CONDITION SPECIFICATION 쐌 Ignition switch: ON VENT CONT/V OFF ECM Terminals and Reference Value NAEC1105 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 117 WIRE COLOR G/R ITEM CONDITION EVAP canister vent control valve DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V) [Ignition switch “ON”] On Board Diagnosis Logic DTC No. P1448 1448 Trouble diagnosis name EVAP canister vent control valve open DTC Detecting Condition EVAP canister vent control valve remains opened under specified driving conditions. EC-636 NAEC1106 Possible Cause 쐌 EVAP canister vent control valve 쐌 EVAP control system pressure sensor and circuit 쐌 Blocked rubber tube to EVAP canister vent control valve 쐌 Water separator 쐌 EVAP canister is saturated with water. 쐌 Vacuum cut valve DTC P1448 EVAP CANISTER VENT CONTROL VALVE DTC Confirmation Procedure DTC Confirmation Procedure NAEC1107 NOTE: 쐌 If DTC P1448 is displayed with P0442 or P1442, perform trouble diagnosis for DTC P1448 first. 쐌 If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. GI MA EM LC WITH CONSULT-II SEC760C COOLAN TEMP/S 0 - 70°C (32 - 158°F) INT/A TEMP SE 0 - 30°C (32 - 86°F) 5) SEC761C SEC762C NAEC1107S01 TESTING CONDITION: 쐌 Perform “DTC WORK SUPPORT” when the fuel level is between 1/4 to 3/4 full and vehicle is placed on flat level surface. 쐌 Always perform test at a temperature of 0 to 30°C (32 to 86°F). 쐌 Open engine hood before conducting the following procedure. 1) Turn ignition switch “ON”. 2) Turn ignition switch “OFF” and wait at least 10 seconds. 3) Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 4) Make sure that the following conditions are met. Select “EVP SML LEAK P0442/P1442” of “EVAPORATIVE SYSTEM” in “DTC WORK SUPPORT” mode with CONSULTII. Follow the instruction displayed. NOTE: If the engine speed cannot be maintained within the range displayed on the CONSULT-II screen, go to “Basic Inspection”, EC-131. 6) Make sure that “OK” is displayed. If “NG” is displayed, go to the following step. NOTE: Make sure that EVAP hoses are connected to EVAP canister purge volume control solenoid valve properly. 7) Stop engine and wait at least 10 seconds, then turn “ON”. 8) Disconnect hose from water separator. 9) Select “VENT CONTROL/V” of “ACTIVE TEST” mode with CONSULT-II. 10) Touch “ON” and “OFF” alternately. FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX SEC763C EC-637 DTC P1448 EVAP CANISTER VENT CONTROL VALVE DTC Confirmation Procedure (Cont’d) 11) Make sure the following. Condition VENT CONTROL/V Air passage continuity between A and B ON No OFF Yes If the result is NG, go to “Diagnostic Procedure”, EC-640. If the result is OK, go to “Diagnostic Procedure” for DTC P0442, EC-383. PBIB0153E Overall Function Check NAEC1108 Use this procedure to check the overall function of the EVAP canister vent control valve circuit. During this check, a DTC might not be confirmed. WITH GST 1) 2) 3) NAEC1108S01 Disconnect hose from water separator. Disconnect EVAP canister vent control valve harness connector. Verify the following. SEF380Z Condition Air passage continuity 12V direct current supply between terminals 1 and 2 No No supply Yes If the result is NG, go to “Diagnostic Procedure”, EC-640. If the result is OK, go to “Diagnostic Procedure” for DTC P0442, EC-383. EC-638 DTC P1448 EVAP CANISTER VENT CONTROL VALVE Wiring Diagram Wiring Diagram NAEC1109 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC097E EC-639 IDX DTC P1448 EVAP CANISTER VENT CONTROL VALVE Diagnostic Procedure Diagnostic Procedure 1 NAEC1110 CHECK RUBBER TUBE 1. Turn ignition switch “OFF”. 2. Disconnect rubber tube connected to EVAP canister vent control valve. 3. Check the rubber tube for clogging. SEC928C OK or NG OK 䊳 GO TO 2. NG 䊳 Clean rubber tube using an air blower. 2 CHECK EVAP CANISTER VENT CONTROL VALVE-I 1. Remove EVAP canister vent control valve from EVAP canister. 2. Check portion B of EVAP canister vent control valve for being rusted. SEF376Z OK or NG OK 䊳 GO TO 3. NG 䊳 Replace EVAP canister vent control valve. EC-640 DTC P1448 EVAP CANISTER VENT CONTROL VALVE Diagnostic Procedure (Cont’d) 3 GI CHECK EVAP CANISTER VENT CONTROL VALVE-II With CONSULT-II 1. Turn ignition switch ON. 2. Perform “VENT CONTROL/V” in “ACTIVE TEST” mode. 3. Check air passage continuity and operation delay time. MA EM LC FE SEC158D CL Without CONSULT-II Check air passage continuity and operation delay time under the following conditions. MT AT TF PD SEF378Z AX Make sure new O-ring is installed properly. OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 4. SU BR 4 CHECK EVAP CANISTER VENT CONTROL VALVE-III 1. Clean the air passage (Portion A to B) of EVAP canister vent control valve using an air blower. 2. Perform Test No. 3 again. ST OK or NG RS OK 䊳 GO TO 5. NG 䊳 Replace EVAP canister vent control valve. BT HA SC EL IDX EC-641 DTC P1448 EVAP CANISTER VENT CONTROL VALVE Diagnostic Procedure (Cont’d) 5 CHECK VACUUM CUT VALVE 1. Turn ignition switch OFF. 2. Remove vacuum cut valve. 3. Check vacuum cut valve as follows: SEF379Q a. Plug port C and D with fingers. b. Apply vacuum to port A and check that there is no suction from port B. c. Apply vacuum to port B and check that there is suction from port A. d. Blow air in port B and check that there is a resistance to flow out of port A. e. Open port C and D. f. Blow air in port A check that air flows freely out of port C. g. Blow air in port B check that air flows freely out of port D. OK or NG OK 䊳 GO TO 6. NG 䊳 Replace vacuum cut valve. 6 CHECK IF EVAP CANISTER SATURATED WITH WATER 1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Check if water will drain from the EVAP canister. SEF596U Yes or No Yes 䊳 GO TO 7. No 䊳 GO TO 9. 7 CHECK EVAP CANISTER Weigh the EVAP canister with the EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb). OK or NG OK 䊳 GO TO 9. NG 䊳 GO TO 8. EC-642 DTC P1448 EVAP CANISTER VENT CONTROL VALVE Diagnostic Procedure (Cont’d) 8 GI DETECT MALFUNCTIONING PART Check the following. 쐌 EVAP canister for damage 쐌 EVAP hose between EVAP canister and water separator for clogging or poor connection 䊳 9 MA Repair hose or replace EVAP canister. EM CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR HOSE LC Check disconnection or improper connection of hose connected to EVAP control system pressure sensor. OK or NG OK 䊳 GO TO 10. NG 䊳 Repair it. FE 10 CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR CONNECTOR 1. Disconnect EVAP control system pressure sensor harness connector. CL MT AT TF SEC931C 2. Check connectors for water. Water should not exist. OK or NG OK 䊳 GO TO 11. NG 䊳 Replace EVAP control system pressure sensor. PD AX SU BR ST RS BT HA SC EL IDX EC-643 DTC P1448 EVAP CANISTER VENT CONTROL VALVE Diagnostic Procedure (Cont’d) 11 CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR 1. Remove EVAP control system pressure sensor with its harness connector connected. 쐌 Never apply force to the air hole protector of the sensor if equipped. SEF799W 2. Remove EVAP control system pressure sensor from EVAP canister. Do not reuse the O-ring, replace it with a new one. 3. Install a vacuum pump to EVAP control system pressure sensor. 4. Turn ignition switch “ON” and check output voltage between ECM terminal 32 and ground under the following conditions. SEC422D CAUTION: 쐌 Always calibrate the vacuum pump gauge when using it. 쐌 Do not apply below −93.3 kPa (−700 mmHg, −27.56 inHg) or pressure over 101.3 kPa (760 mmHg, 29.92 inHg). 쐌 Discard and EVAP control system pressure 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. OK or NG OK 䊳 GO TO 12. NG 䊳 Replace EVAP control system pressure sensor. 12 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-644 DTC P1456 EVAP CONTROL SYSTEM On Board Diagnosis Logic On Board Diagnosis Logic NAEC1380 GI MA EM LC SEF323U This diagnosis detects very small leaks in the EVAP line between fuel tank and EVAP canister purge volume control solenoid valve, using the vapor pressure in the fuel tank same as a conventional EVAP small leak diagnosis. 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 volume control solenoid 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 canister purge volume control solenoid valve. If ECM judges a leak which corresponds to a very small leak, the very small leak P1456 will be detected. If ECM judges a leak equivalent to a small leak, EVAP small leak P1442 will be detected. If ECM judges there are no leaks, the diagnosis will be OK. DTC No. P1456 1456 Trouble diagnosis name Evaporative emission control system very small leak (positive pressure check) DTC Detecting Condition 쐌 EVAP system has a very small leak. 쐌 EVAP system does not operate properly. EC-645 Possible Cause 쐌 Incorrect fuel tank vacuum relief valve 쐌 Incorrect fuel filler cap used 쐌 Fuel filler cap remains open or fails to close. 쐌 Foreign matter caught in fuel filler cap 쐌 Leak is in line between intake manifold and EVAP canister purge volume control solenoid valve. 쐌 Foreign matter caught in EVAP canister vent control valve 쐌 EVAP canister or fuel tank leaks 쐌 EVAP purge line (Pipe and rubber tube) leaks 쐌 EVAP purge line rubber tube bent 쐌 Blocked or bent rubber tube to EVAP control system pressure sensor 쐌 Loose or disconnected rubber tube 쐌 EVAP canister vent control valve and the circuit 쐌 EVAP canister purge volume control solenoid valve and the circuit 쐌 Fuel tank temperature sensor 쐌 O-ring of EVAP canister vent control valve is missing or damaged. 쐌 Water separator 쐌 EVAP canister saturated with water 쐌 EVAP control system pressure sensor 쐌 Refueling control valve 쐌 ORVR system leaks 쐌 Fuel level sensor and the circuit 쐌 Foreign matter caught in EVAP canister purge volume control solenoid valve FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX DTC P1456 EVAP CONTROL SYSTEM On Board Diagnosis Logic (Cont’d) CAUTION: 쐌 Use only a genuine NISSAN fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. 쐌 If the fuel filler cap is not tightened properly, the MIL may come on. 쐌 Use only a genuine NISSAN rubber tube as a replacement. DTC Confirmation Procedure SEC764C SEC765C SEC766C NAEC1381 CAUTION: Never remove fuel filler cap during the DTC confirmation procedure. NOTE: 쐌 If DTC P1456 is displayed with P1442, perform TROUBLE DIAGNOSIS FOR DTC P1456 first. 쐌 If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. 쐌 After repair, make sure that the hoses and clips are installed properly. TESTING CONDITION: 쐌 Open engine hood before conducting following procedure. 쐌 If any of following condition is met just before the DTC confirmation procedure, leave the vehicle for more than 1 hour. a) Fuel filler cap is removed. b) Refilled or drained the fuel. c) EVAP component parts is/are removed. 쐌 Before performing the following procedure, confirm that battery voltage is more than 11V at idle. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II. 2) Make sure the following conditions are met. FUEL LEVEL SE: 1.08 - 0.2V COOLAN TEMP/S: 0 - 32°C (32 - 90°F) FUEL T/TMP SE: 0 - 35°C (32 - 95°F) INT A/TEMP SE: More than 0°C (32°F) If NG, turn ignition switch “OFF” and leave the vehicle in a cool place (soak the vehicle) or refilling/draining fuel until the output voltage condition of the “FUEL LEVEL SE” meets within the range above and leave the vehicle for more than 1 hour. Then start from step 1). 3) Turn ignition switch “OFF” and wait at least 5 seconds. 4) Turn ignition switch “ON”. 5) Select “EVP V/S LEAK P0456/P1456” of “EVAPORATIVE SYSTEM” in “DTC WORK SUPPORT” mode with CONSULTII. Follow the instruction displayed. 6) Make sure that “OK” is displayed. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-648. EC-646 DTC P1456 EVAP CONTROL SYSTEM DTC Confirmation Procedure (Cont’d) NOTE: 쐌 If the engine speed cannot be maintained within the range displayed on CONSULT-II screen, go to “Basic inspection”, EC-131. 쐌 Make sure that EVAP hoses are connected to EVAP canister purge volume control solenoid valve properly. GI MA EM LC Overall Function Check WITH GST SEF983Y SEF462UA NAEC1382 NAEC1382S01 Use this procedure to check the overall function of the EVAP very small leak function. During this check, a DTC might not be confirmed. CAUTION: 쐌 Never use compressed air, doing so may damage the EVAP system. 쐌 Do not start engine. 쐌 Do not exceeded 4.12 kPa (0.042 kg/cm2, 0.6 psi). 1) Attach the EVAP service port adapter securely to the EVAP service port. 2) Set the pressure pump and a hose. 3) Also set a vacuum gauge via 3-way connector and a hose. 4) Turn ignition switch “ON”. 5) Connect GST and select mode 8. 6) Using mode 8 control the EVAP canister vent control valve (close) and vacuum cut valve bypass valve (open). 7) Apply pressure and make sure the following conditions are satisfied. Pressure to be applied: 2.7 kPa (20 mmHg, 0.79 inHg) Time to be waited after the pressure drawn in to the EVAP system and the pressure to be dropped: 60 seconds and the pressure should not be dropped more than 0.4 kPa (3 mmHg, 0.12 inHg) If NG, go to diagnostic procedure, EC-648. If OK, go to next step. 8) Disconnect GST. 9) Start engine and warm it up to normal operating temperature. 10) Turn ignition switch “OFF” and wait at least 10 seconds. 11) Restart engine and let it idle for 90 seconds. 12) Keep engine speed at 2,000 rpm for 30 seconds. 13) Turn ignition switch “OFF”. NOTE: For more information, refer to GST instruction manual. FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-647 DTC P1456 EVAP CONTROL SYSTEM Diagnostic Procedure Diagnostic Procedure 1 NAEC1383 CHECK FUEL FILLER CAP DESIGN 1. Turn ignition switch “OFF”. 2. Check for genuine NISSAN fuel filler cap design. SEF915U OK or NG OK 䊳 GO TO 2. NG 䊳 Replace with genuine NISSAN fuel filler cap. 2 CHECK FUEL FILLER CAP INSTALLATION Check that the cap is tightened properly by rotating the cap clockwise. OK or NG OK 䊳 GO TO 3. NG 䊳 쐌 Open fuel filler cap, then clean cap and fuel filler neck threads using air blower. 쐌 Retighten until ratcheting sound is heard. 3 CHECK FUEL FILLER CAP FUNCTION Check for air releasing sound while opening the fuel filler cap. OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 4. EC-648 DTC P1456 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 4 GI CHECK FUEL TANK VACUUM RELIEF VALVE 1. Wipe clean valve housing. 2. Check valve opening pressure and vacuum. MA EM LC SEF445Y FE CL MT AT SEF943S Pressure: 15.3 - 20.0 kPa (0.156 - 0.204 kg/cm2, 2.22 - 2.90 psi) Vacuum: −6.0 to −3.3 kPa (−0.061 to −0.034 kg/cm2, −0.87 to −0.48 psi) CAUTION: Use only a genuine fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on. TF PD AX OK or NG OK 䊳 GO TO 5. NG 䊳 Replace fuel filler cap with a genuine one. SU BR ST RS BT HA SC EL IDX EC-649 DTC P1456 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 5 INSTALL THE PRESSURE PUMP To locate the EVAP leak, install EVAP service port adapter and pressure pump to EVAP service port securely. SEF983Y SEF916U NOTE: Improper installation of the EVAP service port adapter to the EVAP service port may cause leaking. With CONSULT-II 䊳 GO TO 6. Without CONSULT-II 䊳 GO TO 7. EC-650 DTC P1456 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 6 GI CHECK FOR EVAP LEAK With CONSULT-II 1. Turn ignition switch “ON”. 2. Select “EVAP SYSTEM CLOSE” of “WORK SUPPORT” mode with CONSULT-II. 3. Touch “START” and apply pressure into the EVAP line until the pressure indicator reaches the middle of the bar graph. NOTE: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in the system. MA EM LC FE CL PEF917U 4. Using EVAP leak detector, locate the EVAP leak. For the leak detector, refer to the instruction manual for more details. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-45. MT AT TF PD AX SEF200U OK or NG OK 䊳 GO TO 8. NG 䊳 Repair or replace. SU BR ST RS BT HA SC EL IDX EC-651 DTC P1456 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 7 CHECK FOR EVAP LEAK Without CONSULT-II 1. Turn ignition switch “OFF”. 2. Apply 12 volts DC to EVAP canister vent control valve. The valve will close. (Continue to apply 12 volts until the end of test.) SEC930C 3. Apply 12 volts DC to vacuum cut valve bypass valve. The valve will open. (Continue to apply 12V until the end of test.) SEC932C 4. Pressurize the EVAP line using pressure pump with 1.3 to 2.7 kPa (10 to 20 mmHg, 0.39 to 0.79 inHg), then remove pump and EVAP service port adapter. NOTE: 쐌 Never use compressed air or a high pressure pump. 쐌 Do not exceed 4.12 kPa (0.042 kg/cm2, 0.6 psi) of pressure in the system. 5. Using EVAP leak detector, locate the EVAP leak. For the leak detector, refer to the instruction manual for more details. Refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-45. SEF200U OK or NG OK 䊳 GO TO 8. NG 䊳 Repair or replace. EC-652 DTC P1456 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 8 1. 2. 3. 4. GI CHECK WATER SEPARATOR Check Check Check Check visually for insect nests in the water separator air inlet. visually for cracks or flaws in the appearance. visually for cracks or flaws in the hose. that A and C are not clogged by blowing air into B with A, and then C plugged. MA EM LC FE PBIB1032E 5. In case of NG in items 2 - 4, replace the parts. NOTE: 쐌 Do not disassemble water separator. CL MT OK or NG OK 䊳 GO TO 9. NG 䊳 Replace water separator. 9 AT CHECK EVAP CANISTER VENT CONTROL VALVE, O-RING AND CIRCUIT TF Refer to “DTC Confirmation Procedure”, EC-404. OK or NG PD OK 䊳 GO TO 10. NG 䊳 Repair or replace EVAP canister vent control valve and O-ring or harness/connector. 10 CHECK IF EVAP CANISTER SATURATED WITH WATER AX SU 1. Remove EVAP canister with EVAP canister vent control valve attached. 2. Does water drain from the EVAP canister? BR ST RS BT SEF596U Yes or No Yes 䊳 GO TO 11. No (With CONSULT-II) 䊳 GO TO 13. No (Without CONSULTII) 䊳 GO TO 14. HA SC EL IDX EC-653 DTC P1456 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 11 CHECK EVAP CANISTER Weigh the EVAP canister with the EVAP canister vent control valve attached. The weight should be less than 1.8 kg (4.0 lb). OK or NG OK (With CONSULT-II) 䊳 GO TO 13. OK (Without CONSULTII) 䊳 GO TO 14. NG 䊳 GO TO 12. 12 DETECT MALFUNCTIONING PART Check the following. 쐌 EVAP canister for damage 쐌 EVAP hose between EVAP canister and water separator for clogging or poor connection 䊳 13 1. 2. 3. 4. 5. Repair hose or replace EVAP canister. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION With CONSULT-II Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port. Start engine. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode. Touch “Qu” on CONSULT-II screen to increase “PURG VOL CONT/V” opening to 100%. Check vacuum hose for vacuum when revving engine up to 2,000 rpm. PBIB1678E Vacuum should exist. OK or NG OK 䊳 GO TO 16. NG 䊳 GO TO 15. 14 1. 2. 3. 4. 5. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION Without CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine. Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port. Start engine and let it idle for at least 80 seconds. Check vacuum hose for vacuum when revving engine up to 2,000 rpm. Vacuum should exist. OK or NG OK 䊳 GO TO 17. NG 䊳 GO TO 15. EC-654 DTC P1456 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 15 GI CHECK VACUUM HOSE Check vacuum hoses for clogging or disconnection. Refer to “Vacuum Hose Drawing”, EC-35. MA OK or NG OK (With CONSULT-II) 䊳 GO TO 16. OK (Without CONSULTII) 䊳 GO TO 17. EM NG 䊳 Repair or reconnect the hose. LC 16 CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE With CONSULT-II 1. Start engine. 2. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Check that engine speed varies according to the valve opening. FE CL MT AT PBIB1678E TF OK or NG OK 䊳 GO TO 18. NG 䊳 GO TO 17. PD AX SU BR ST RS BT HA SC EL IDX EC-655 DTC P1456 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 17 CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE With CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions. SEC524D SEF334XA Without CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions. SEC524D SEF335X OK or NG OK 䊳 GO TO 18. NG 䊳 Replace EVAP canister purge volume control solenoid valve. EC-656 DTC P1456 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 18 GI CHECK FUEL TANK TEMPERATURE SENSOR 1. Remove fuel level sensor unit. 2. Check resistance between fuel level sensor unit terminals 1 and 2 by heating with hot water or heat gun as shown in the figure. MA EM LC SEF974Y FE OK or NG CL OK 䊳 GO TO 19. NG 䊳 Replace fuel level sensor unit. MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-657 DTC P1456 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 19 CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR 1. Remove EVAP control system pressure sensor with its harness connector connected. 쐌 Never apply force to the air hole protector of the sensor if equipped. SEF799W 2. Remove EVAP control system pressure sensor from EVAP canister. Do not reuse the O-ring, replace it with a new one. 3. Install a vacuum pump to EVAP control system pressure sensor. 4. Turn ignition switch “ON” and check output voltage between ECM terminal 32 and ground under the following conditions. SEC422D CAUTION: 쐌 Always calibrate the vacuum pump gauge when using it. 쐌 Do not apply below −93.3 kPa (−700 mmHg, −27.56 inHg) or pressure over 101.3 kPa (760 mmHg, 29.92 inHg). 쐌 Discard and EVAP control system pressure 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. OK or NG OK 䊳 GO TO 20. NG 䊳 Replace EVAP control system pressure sensor. 20 CHECK EVAP PURGE LINE Check EVAP purge line (pipe, rubber tube, fuel tank and EVAP canister) for cracks or improper connection. Refer to “Evaporative Emission System”, EC-41. OK or NG OK 䊳 GO TO 21. NG 䊳 Repair or reconnect the hose. 21 CLEAN EVAP PURGE LINE Clean EVAP purge line (pipe and rubber tube) using air blower. 䊳 GO TO 22. EC-658 DTC P1456 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 22 GI CHECK REFUELING EVAP VAPOR LINE 쐌 Check refueling EVAP vapor line between EVAP canister and fuel tank for clogging, kink, looseness and improper connection. For location, refer to “EVAPORATIVE EMISSION LINE DRAWING”, EC-45. MA OK or NG OK 䊳 GO TO 23. NG 䊳 Repair or replace hoses and tubes. 23 EM LC CHECK SIGNAL LINE AND RECIRCULATION LINE 쐌 Check signal line and recirculation line between filler neck tube and fuel tank for clogging, kink, cracks, looseness and improper connection. OK or NG FE OK 䊳 GO TO 24. NG 䊳 Repair or replace hoses, tubes or filler neck tube. 24 CHECK REFUELING CONTROL VALVE CL 1. Remove fuel filler cap. 2. Check air continuity between hose ends A and B. Blow air into hose end B. Air should flow freely into the fuel tank. 3. Blow air into hose end A and check that there is no leakage. 4. Apply pressure to both hose ends A and B [20 kPa (150 mmHg, 5.91 inHg)] using a pressure pump and a suitable 3-way connector. Check that there is no leakage. MT AT TF PD AX SU BR ST RS SEC883C OK or NG OK 䊳 GO TO 25. NG 䊳 Replace or refueling control valve with fuel tank. 25 BT HA SC CHECK FUEL LEVEL SENSOR Refer to EL-134, “Fuel Level Sensor Unit Check”. OK or NG OK 䊳 GO TO 26. NG 䊳 Replace fuel level sensor unit. EC-659 EL IDX DTC P1456 EVAP CONTROL SYSTEM Diagnostic Procedure (Cont’d) 26 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-660 DTC P1490 VACUUM CUT VALVE BYPASS VALVE Description Description =NAEC1116 COMPONENT DESCRIPTION SEF485T GI NAEC1116S01 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 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. EVAPORATIVE EMISSION SYSTEM DIAGRAM NAEC1116S02 MA EM LC FE CL MT AT SEF323U TF PD AX SU CONSULT-II Reference Value in Data Monitor Mode NAEC1117 BR Specification data are reference values. MONITOR ITEM VC/V BYPASS/V CONDITION SPECIFICATION 쐌 Ignition switch: ON ST OFF ECM Terminals and Reference Value RS NAEC1118 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 112 WIRE COLOR G/W ITEM CONDITION BT HA DATA (DC Voltage) SC Vacuum cut valve bypass valve [Ignition switch “ON”] BATTERY VOLTAGE (11 - 14V) EL IDX EC-661 DTC P1490 VACUUM CUT VALVE BYPASS VALVE On Board Diagnosis Logic On Board Diagnosis Logic DTC No. P1490 1490 Trouble diagnosis name Vacuum cut valve bypass valve circuit DTC Detecting Condition NAEC1119 Possible Cause An improper voltage signal is sent to ECM through 쐌 Harness or connectors vacuum cut valve bypass valve. (The vacuum cut valve bypass valve circuit is open or shorted.) 쐌 Vacuum cut valve bypass valve DTC Confirmation Procedure NAEC1120 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 11V at idle speed. WITH CONSULT-II 1) 2) 3) 4) NAEC1120S01 Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and wait at least 5 seconds. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-664. WITH GST Follow the procedure “WITH CONSULT-II” above. SEF058Y EC-662 NAEC1120S02 DTC P1490 VACUUM CUT VALVE BYPASS VALVE Wiring Diagram Wiring Diagram NAEC1121 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC105E EC-663 IDX DTC P1490 VACUUM CUT VALVE BYPASS VALVE Diagnostic Procedure Diagnostic Procedure 1 NAEC1122 INSPECTION START Do you have CONSULT-II? Yes or No Yes 䊳 GO TO 2. No 䊳 GO TO 3. 2 CHECK VACUUM CUT VALVE BYPASS VALVE CIRCUIT With CONSULT-II 1. Turn ignition switch “OFF” and then “ON”. 2. Select “VC/V BYPASS/V” in “ACTIVE TEST” mode with CONSULT-II. 3. Touch “ON/OFF” on CONSULT-II screen. PBIB0157E 4. Make sure that clicking sound is heard from the vacuum cut valve bypass valve. OK or NG OK 䊳 GO TO 7. NG 䊳 GO TO 3. EC-664 DTC P1490 VACUUM CUT VALVE BYPASS VALVE Diagnostic Procedure (Cont’d) 3 GI CHECK VACUUM CUT VALVE BYPASS VALUE POWER SUPPLY CIRCUIT 1. Turn ignition switch “OFF”. 2. Disconnect vacuum cut valve bypass valve harness connector. MA EM LC SEF485T FE 3. Turn ignition switch “ON”. 4. Check voltage between vacuum cut valve bypass valve terminal 2 and ground with CONSULT-II or tester. CL MT AT TF SEF015Z OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 4. 4 AX DETECT MALFUNCTIONING PART SU Check the following. 쐌 Harness connectors E1, M1 쐌 Harness connectors M33, F22 쐌 Harness connectors M94, F27 쐌 Harness connectors B1, M2 쐌 Harness connectors B43, B101 쐌 Harness connectors B151, B152 쐌 Harness for open or short between vacuum cut valve bypass valve and ECM relay 䊳 5 PD Repair open circuit or short to ground or short to power in harness or connectors. CHECK VACUUM CUT VALVE BYPASS VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 112 and vacuum cut valve bypass valve terminal 1. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. BR ST RS BT HA SC OK or NG OK 䊳 GO TO 7. NG 䊳 GO TO 6. EL IDX EC-665 DTC P1490 VACUUM CUT VALVE BYPASS VALVE Diagnostic Procedure (Cont’d) 6 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors B152, B151 쐌 Harness connectors B101, B43 쐌 Harness connectors B1, M2 쐌 Harness connectors M94, F27 쐌 Harness for open or short between vacuum cut valve bypass valve and ECM 䊳 7 1. 2. 3. 4. Repair open circuit or short to ground or short to power in harness or connectors. CHECK VACUUM CUT VALVE BYPASS VALVE With CONSULT-II Reconnect harness disconnected connectors. Turn ignition switch ON. Perform “VC/V BYPASS/V” in “ACTIVE TEST” mode. Check air passage continuity and operation delay time under the following conditions. SEC156D Without CONSULT-II Check air passage continuity and operation delay time under the following conditions. SEF358X OK or NG OK 䊳 GO TO 8. NG 䊳 Replace vacuum cut valve bypass valve. 8 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-666 DTC P1491 VACUUM CUT VALVE BYPASS VALVE Description Description NAEC1123 COMPONENT DESCRIPTION SEF485T GI NAEC1123S01 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 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. EVAPORATIVE EMISSION SYSTEM DIAGRAM NAEC1123S02 MA EM LC FE CL MT AT SEF323U TF PD AX SU CONSULT-II Reference Value in Data Monitor Mode NAEC1124 BR Specification data are reference values. MONITOR ITEM VC/V BYPASS/V CONDITION SPECIFICATION 쐌 Ignition switch: ON ST OFF ECM Terminals and Reference Value RS NAEC1125 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 112 WIRE COLOR G/W ITEM CONDITION BT HA DATA (DC Voltage) SC Vacuum cut valve bypass valve [Ignition switch “ON”] BATTERY VOLTAGE (11 - 14V) EL IDX EC-667 DTC P1491 VACUUM CUT VALVE BYPASS VALVE On Board Diagnosis Logic On Board Diagnosis Logic DTC No. P1491 1491 Trouble diagnosis name Vacuum cut valve bypass valve DTC Detecting Condition NAEC1126 Possible Cause Vacuum cut valve bypass valve does not operate properly. 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 Vacuum cut valve bypass valve Vacuum cut valve Bypass hoses for clogging EVAP control system pressure sensor and circuit EVAP canister vent control valve Hose between fuel tank and vacuum cut valve clogged Hose between vacuum cut valve and EVAP canister clogged EVAP canister EVAP purge port of fuel tank for clogging DTC Confirmation Procedure NAEC1127 CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: For best results, perform test at a temperature of 5 to 30°C (41 to 86°F). SEF210Y WITH CONSULT-II 1) 2) 3) 4) 5) 6) 7) SEF211Y NAEC1127S01 Turn ignition switch “ON”. Start engine and warm it up to normal operating temperature. Turn ignition switch “OFF” and wait at least 10 seconds. Start engine and let it idle for at least 70 seconds. Select “VC CUT/V BP/V P1491” of “EVAPORATIVE SYSTEM” in “DTC WORK SUPPORT” mode with CONSULT-II. Touch “START”. When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take at least 30 seconds.) ENG SPEED Idle speed or more Selector lever Suitable position Vehicle speed 37 km/h (23 MPH) or more B/FUEL SCHDL 1.3 - 10 msec 8) If “TESTING” is not displayed after 5 minutes, retry from step 3. Make sure that “OK” is displayed after touching “SELF-DIAG SEF239Y EC-668 DTC P1491 VACUUM CUT VALVE BYPASS VALVE DTC Confirmation Procedure (Cont’d) RESULTS”. If “NG” is displayed, refer to “Diagnostic Procedure”, EC-671. GI MA EM LC Overall Function Check NAEC1128 Use this procedure to check the overall function of vacuum cut valve bypass valve. During this check, the 1st trip DTC might not be confirmed. WITH GST 1) 2) 3) 4) 5) 6) 7) 8) NAEC1128S01 Remove vacuum cut valve and vacuum cut valve bypass valve as an assembly. Apply vacuum to port A and check that there is no suction from port B. Apply vacuum to port B and check that there is suction from port A. Blow air in port B and check that there is a resistance to flow out of port A. Supply battery voltage to the terminal. Blow air in port A and check that air flows freely out of port B. Blow air in port B and check that air flows freely out of port A. If NG, go to “Diagnostic Procedure”, EC-671. FE CL MT AT TF PD AX SU SEF530Q BR ST RS BT HA SC EL IDX EC-669 DTC P1491 VACUUM CUT VALVE BYPASS VALVE Wiring Diagram Wiring Diagram NAEC1129 MEC105E EC-670 DTC P1491 VACUUM CUT VALVE BYPASS VALVE Diagnostic Procedure Diagnostic Procedure 1 NAEC1130 GI INSPECTION START MA Do you have CONSULT-II? Yes or No Yes 䊳 GO TO 2. No 䊳 GO TO 3. EM LC 2 1. 2. 3. 4. 5. 6. 7. 8. 9. CHECK VACUUM CUT VALVE BYPASS VALVE OPERATION With CONSULT-II Turn ignition switch “OFF”. Remove vacuum cut valve and vacuum cut valve bypass valve as an assembly. Apply vacuum to port A and check that there is no suction from port B. Apply vacuum to port B and check that there is suction from port A. Blow air in port B and check that there is a resistance to flow out of port A. Turn ignition switch “ON”. Select “VC/V BYPASS/V” in “ACTIVE TEST” mode with CONSULT-II and touch “ON”. Blow air in port A and check that air flows freely out of port B. Blow air in port B and check that air flows freely out of port A. FE CL MT AT TF PD SEC157D AX OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 7. SU BR ST RS BT HA SC EL IDX EC-671 DTC P1491 VACUUM CUT VALVE BYPASS VALVE Diagnostic Procedure (Cont’d) 3 1. 2. 3. 4. 5. 6. 7. 8. 9. CHECK VACUUM CUT VALVE BYPASS VALVE OPERATION Without CONSULT-II Turn ignition switch “OFF”. Remove vacuum cut valve and vacuum cut valve bypass valve as an assembly. Apply vacuum to port A and check that there is no suction from port B. Apply vacuum to port B and check that there is suction from port A. Blow air in port B and check that there is a resistance to flow out of port A. Disconnect vacuum cut valve bypass valve harness connector. Supply battery voltage to the terminal. Blow air in port A and check that air flows freely out of port B. Blow air in port B and check that air flows freely out of port A. SEF914U OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 7. 4 CHECK EVAP PURGE LINE Check EVAP purge line between EVAP canister and fuel tank for clogging or disconnection. OK or NG OK 䊳 GO TO 5. NG 䊳 Repair it. 5 CHECK EVAP PURGE PORT Check EVAP purge port of fuel tank for clogging. OK or NG OK 䊳 GO TO 6. NG 䊳 Clean EVAP purge port. EC-672 DTC P1491 VACUUM CUT VALVE BYPASS VALVE Diagnostic Procedure (Cont’d) 6 GI CHECK EVAP CANISTER 1. Pinch the fresh air hose. 2. Blow air into port A and check that it flows freely out of port B. MA EM LC AEC630A FE OK or NG OK 䊳 GO TO 12. NG 䊳 Replace EVAP canister. 7 CL MT CHECK BYPASS HOSE Check bypass hoses for clogging. OK or NG OK 䊳 GO TO 8. NG 䊳 Repair or replace hoses. AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-673 DTC P1491 VACUUM CUT VALVE BYPASS VALVE Diagnostic Procedure (Cont’d) 8 CHECK VACUUM CUT VALVE BYPASS VALVE With CONSULT-II 1. Perform “VC/V BYPASS/V” in “ACTIVE TEST” mode. 2. Check air passage continuity and operation delay time under the following conditions. SEC156D Without CONSULT-II Check air passage continuity and operation delay time under the following conditions. SEF358X OK or NG OK 䊳 GO TO 9. NG 䊳 Replace vacuum cut valve bypass valve. EC-674 DTC P1491 VACUUM CUT VALVE BYPASS VALVE Diagnostic Procedure (Cont’d) 9 GI CHECK VACUUM CUT VALVE Check vacuum cut valve as follows: MA EM LC SEF379Q FE a. Plug port C and D with fingers. b. Apply vacuum to port A and check that there is no suction from port B. c. Apply vacuum to port B and check that there is suction from port A. d. Blow air in port B and check that there is a resistance to flow out of port A. e. Open port C and D. f. Blow air in port A check that air flows freely out of port C. g. Blow air in port B check that air flows freely out of port D. CL MT OK or NG OK 䊳 GO TO 10. NG 䊳 Replace vacuum cut valve. AT TF 10 CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR HOSE 1. Turn ignition switch “OFF”. 2. Check disconnection or improper connection of hose connected to EVAP control system pressure sensor. PD OK or NG OK 䊳 GO TO 11. NG 䊳 Repair or replace. AX SU 11 CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR CONNECTOR 1. Disconnect EVAP control system pressure sensor harness connector. BR ST RS BT SEC931C 2. Check connectors for water. Water should not exist. OK or NG OK 䊳 GO TO 12. NG 䊳 Replace EVAP control system pressure sensor. HA SC EL IDX EC-675 DTC P1491 VACUUM CUT VALVE BYPASS VALVE Diagnostic Procedure (Cont’d) 12 CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR 1. Remove EVAP control system pressure sensor with its harness connector connected. 쐌 Never apply force to the air hole protector of the sensor if equipped. SEF799W 2. Remove EVAP control system pressure sensor from EVAP canister. Do not reuse the O-ring, replace it with a new one. 3. Install a vacuum pump to EVAP control system pressure sensor. 4. Turn ignition switch “ON” and check output voltage between ECM terminal 32 and ground under the following conditions. SEC422D CAUTION: 쐌 Always calibrate the vacuum pump gauge when using it. 쐌 Do not apply below −93.3 kPa (−700 mmHg, −27.56 inHg) or pressure over 101.3 kPa (760 mmHg, 29.92 inHg). 쐌 Discard and EVAP control system pressure 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. OK or NG OK 䊳 GO TO 13. NG 䊳 Replace EVAP control system pressure sensor. 13 CHECK RUBBER TUBE FOR CLOGGING 1. Disconnect rubber tube connected to EVAP canister vent control valve. 2. Check the rubber tube for clogging. OK or NG OK 䊳 GO TO 14. NG 䊳 Clean the rubber tube using an air blower. EC-676 DTC P1491 VACUUM CUT VALVE BYPASS VALVE Diagnostic Procedure (Cont’d) CHECK EVAP CANISTER VENT CONTROL VALVE-I GI 1. Remove EVAP canister vent control valve from EVAP canister. 2. Check portion B of EVAP canister vent control valve for being rusted. MA 14 EM LC SEF376Z FE OK or NG OK 䊳 GO TO 15. NG 䊳 Replace EVAP canister vent control valve. 15 1. 2. 3. 4. CL MT CHECK EVAP CANISTER VENT CONTROL VALVE-II With CONSULT-II Reconnect harness disconnected connectors. Turn ignition switch ON. Perform “VENT CONTROL/V” in “ACTIVE TEST” mode. Check air passage continuity and operation delay time. AT TF PD AX SU SEC158D Without CONSULT-II Check air passage continuity and operation delay time under the following conditions. BR ST RS BT HA SEF378Z SC Make sure new O-ring is installed properly. OK or NG OK 䊳 GO TO 17. NG 䊳 GO TO 16. EL IDX EC-677 DTC P1491 VACUUM CUT VALVE BYPASS VALVE Diagnostic Procedure (Cont’d) 16 CHECK EVAP CANISTER VENT CONTROL VALVE-III 1. Clean the air passage (Portion A to B) of EVAP canister vent control valve using an air blower. 2. Perform the Test No. 15 again. OK or NG OK 䊳 GO TO 17. NG 䊳 Replace EVAP canister vent control valve. 17 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-678 DTC P1564 ASCD STEERING SWITCH Component Description Component Description NAEC1292 ASCD steering switch has variant values of electrical resistance for each button. ECM reads voltage variation of switch, and determines which button is operated. Refer to EC-62 for the ASCD function. GI MA EM LC SEC544D CONSULT-II Reference Value in Data Monitor Mode NAEC1293 Specification data are reference values. MONITOR ITEM CONDITION 쐌 Ignition switch: ON MAIN SW CANCEL SW RESUME/ACC SW 쐌 Ignition switch: ON 쐌 Ignition switch: ON 쐌 Ignition switch: ON SET SW SPECIFICATION 쐌 CRUISE switch pressed ON 쐌 CRUISE switch released OFF 쐌 CANCEL switch pressed ON 쐌 CANCEL switch released OFF CL MT AT 쐌 ACCEL RES switch pressed ON 쐌 ACCEL RES switch released OFF 쐌 COAST/SET switch pressed TF ON 쐌 COAST/SET switch released OFF PD ECM Terminals and Reference Value NAEC1299 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 67 99 WIRE COLOR B/P L/Y ITEM Sensors’ ground ASCD steering switch CONDITION FE DATA (DC Voltage) AX SU BR [Engine is running] 쐌 Warm-up condition 쐌 Idle speed Approximately 0V ST [Ignition switch “ON”] 쐌 ASCD steering switch is “OFF”. Approximately 4V RS [Ignition switch “ON”] 쐌 CRUISE switch is “ON”. Approximately 0V BT [Ignition switch “ON”] 쐌 CANCEL switch is “ON”. Approximately 1V [Ignition switch “ON”] 쐌 COAST/SET switch is “ON”. Approximately 2V [Ignition switch “ON”] 쐌 ACCEL/RES switch is “ON”. Approximately 3V HA SC EL IDX EC-679 DTC P1564 ASCD STEERING SWITCH On Board Diagnosis Procedure On Board Diagnosis Procedure =NAEC1294 This self-diagnosis has the one trip detection logic. The MIL will not light up for this self-diagnosis. NOTE: If DTC P1564 is displayed with DTC P0605, first perform the trouble diagnosis for DTC P0605. Refer to EC-471. DTC No. P1564 1564 Trouble diagnosis name ASCD steering switch DTC Detecting Condition Possible cause 쐌 An excessively high voltage signal from the ASCD steering switch is 쐌 Harness or connectors sent to ECM. (The ASCD steering switch circuit 쐌 ECM detects that input signal from is open or shorted.) the ASCD steering switch is out of 쐌 ASCD steering switch the specified range. 쐌 ECM 쐌 ECM detects that the ASCD steering switch is stuck ON. DTC Confirmation Procedure NAEC1295 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. With CONSULT-II 1. Turn ignition switch “ON”. 2. Select “DATA MONITOR” mode with CONSULT-II. 3. Wait at least 10 seconds. 4. Press “CRUISE” switch for at least 10 seconds, then release it and wait at least 10 seconds. 5. Press “ACCEL/RES” switch for at least 10 seconds, then release it and wait at least 10 seconds. 6. Press “COAST/SET” switch for at least 10 seconds, then release it and wait at least 10 seconds. 7. Press “CANCEL” switch for at least 10 seconds, then release it and wait at least 10 seconds. 8. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-682. With GST Follow the procedure “With CONSULT-II” above. EC-680 DTC P1564 ASCD STEERING SWITCH Wiring Diagram Wiring Diagram NAEC1296 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC117E EC-681 IDX DTC P1564 ASCD STEERING SWITCH Diagnostic Procedure Diagnostic Procedure 1 NAEC1297 CHECK ASCD STEERING SWITCH CIRCUIT With CONSULT-II 1. Turn ignition switch “ON”. 2. Select “MAIN SW”, “RESUME/ACC SW”, “SET SW” and “CANCEL SW” in “DATA MONITOR” mode with CONSULT-II. SEC006D 3. Check each item indication under the following conditions. MTBL1193 Without CONSULT-II 1. Turn ignition switch “ON”. 2. Check voltage between ECM terminal 99 and ground with pressing each button. PBIB0311E MTBL1400 OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 2. EC-682 DTC P1564 ASCD STEERING SWITCH Diagnostic Procedure (Cont’d) 2 GI CHECK ASCD STEERING SWITCH GROUND CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Disconnect ASCD steering switch harness connector. 3. Check harness continuity between ASCD steering switch terminal 2 and ground. Refer to Wiring Diagram. MA EM LC SEC545D Continuity should exist. 4. Also check harness for short to power. FE CL OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 3. 3 MT AT DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connector Z20 쐌 Spiral cable Z2 쐌 Harness connectors Z1, M47 쐌 Harness connectors M94, F27 쐌 Harness connectors F22, M33 쐌 Joint connector F204 쐌 Harness for open and short between ECM and ASCD steering switch 쐌 Harness for open and short between TCM and ASCD steering switch 䊳 4 Repair open circuit or short to power in harness or connectors. CHECK ASCD STEERING SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 99 and ASCD steering switch terminal 1. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 6. NG 䊳 GO TO 5. 5 PD AX SU BR ST RS BT DETECT MALFUNCTIONING PART HA Check the following. 쐌 Harness connector Z20 쐌 Spiral cable Z2 쐌 Harness connectors Z1, M47 쐌 Harness connectors M32, F23 쐌 Harness for open and short between ECM and ASCD steering switch 䊳 TF SC EL Repair open circuit or short to ground or short to power in harness or connectors. IDX EC-683 DTC P1564 ASCD STEERING SWITCH Diagnostic Procedure (Cont’d) 6 CHECK ASCD STEERING SWITCH Refer to “Component Inspection”, EC-684. OK or NG OK 䊳 GO TO 7. NG 䊳 Replace ASCD steering switch. 7 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END Component Inspection NAEC1298 ASCD STEERING SWITCH 1. Disconnect ASCD steering switch. 2. Check continuity between terminals 1 and 2 by pushing each switch. Switch Condition Resistance [kΩ] Pressed Approx. 0 Released Approx. 4 Pressed Approx. 0.66 Released Approx. 4 Pressed Approx. 1.48 Released Approx. 4 Pressed Approx. 0.25 Released Approx. 4 CRUISE SW SEC546D COAST/SET SW ACCEL/RES SW CANCEL SW EC-684 DTC P1572 ASCD BRAKE SWITCH Component Description Component Description NAEC1300 When the brake pedal is depressed, ASCD brake switch is turned OFF and stop lamp switch is turned ON. ECM detects the state of the brake pedal by this input of two kinds (ON/OFF signal). Refer to EC-62 for the ASCD function. GI MA EM LC SEC009D CONSULT-II Reference Value in Data Monitor Mode NAEC1301 Specification data are reference values. MONITOR ITEM BRAKE SW 1 (ASCD brake switch) BRAKE SW 2 (Stop lamp switch) CONDITION 쐌 Ignition switch: ON 쐌 Ignition switch: ON SPECIFICATION CL 쐌 Brake pedal fully released 쐌 Clutch pedal is fully released (M/T models) ON 쐌 Brake pedal depressed 쐌 Clutch pedal is depressed (M/T models) OFF 쐌 Brake pedal fully released OFF 쐌 Brake pedal depressed ON MT AT ECM Terminals and Reference Value TF NAEC1307 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 101 108 WIRE COLOR G/Y L/Y ITEM Stop lamp switch ASCD brake switch CONDITION FE DATA (DC Voltage) PD AX SU [Ignition switch “ON”] 쐌 Brake pedal is fully released Approximately 0V BR [Ignition switch “ON”] 쐌 Brake pedal is depressed BATTERY VOLTAGE (11 - 14V) ST [Ignition switch “ON”] 쐌 Brake pedal is fully released 쐌 Clutch pedal is fully released (M/T models) BATTERY VOLTAGE (11 - 14V) RS [Ignition switch “ON”] 쐌 Brake pedal is depressed 쐌 Clutch pedal is depressed (M/T models) Approximately 0V BT HA SC EL IDX EC-685 DTC P1572 ASCD BRAKE SWITCH On Board Diagnosis Procedure On Board Diagnosis Procedure =NAEC1302 This self-diagnosis has the one trip detection logic. The MIL will not light up for this self-diagnosis. NOTE: 쐌 If DTC P1572 is displayed with DTC P0605, first perform the trouble diagnosis for DTC P0605. Refer to EC-471. 쐌 If DTC P1572 is displayed with DTC P1805, first perform the trouble diagnosis for DTC P1805. Refer to EC-702. 쐌 This self-diagnosis has the one trip detection logic. When malfunction A is detected, DTC is not stored in ECM memory. And in that case, 1st trip DTC and 1st trip freeze frame data are displayed. 1st trip DTC is erased when ignition switch is OFF. And even when malfunction A is detected in two consecutive trips, DTC is not stored in ECM memory. DTC Trouble diagnosis name DTC Detecting Condition A) P1572 1572 ASCD brake switch B) Possible cause 쐌 Harness or connectors (The stop lamp switch circuit is shorted.) 쐌 When the vehicle speed is above 쐌 Harness or connectors 30 km/h (19 MPH), ON signal (The ASCD brake switch circuit is from the stop lamp switch and shorted.) ASCD brake switch are sent to the 쐌 Harness or connectors ECM at the same time. (The ASCD clutch switch circuit is shorted.) – (M/T models) 쐌 ASCD brake switch 쐌 Stop lamp switch 쐌 ASCD clutch switch (M/T models) 쐌 Incorrect stop lamp switch installation 쐌 ASCD brake switch signal is not 쐌 Incorrect ASCD brake switch sent to ECM for extremely long installation time while driving vehicle. 쐌 Incorrect ASCD clutch switch installation (M/T models) 쐌 ECM DTC Confirmation Procedure NAEC1303 CAUTION: Always drive vehicle at a safe speed. NOTE: 쐌 If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. 쐌 Procedure for malfunction B is not described here. It takes extremely long time to complete procedure for malfunction B. By performing procedure for malfunction A, the incident that caused malfunction B can be detected. TESTING CONDITION: Steps 4 and 5 may be conducted with the drive wheels lifted in the shop or by driving the vehicle. If a road test is expected to be easier, it is unnecessary to lift the vehicle. EC-686 DTC P1572 ASCD BRAKE SWITCH DTC Confirmation Procedure (Cont’d) With CONSULT-II Start engine (TCS switch “OFF”). Select “DATA MONITOR” mode with CONSULT-II. Press MAIN switch and make sure that CRUISE indicator lights up. 4) Drive the vehicle for at least 5 consecutive seconds under the following condition. 1) 2) 3) VHCL SPEED SE More than 30 km/h (19 MPH) Selector lever Suitable position GI MA EM LC PBIB2386E 5) If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-689. If 1st trip DTC is not detected, go to the following step. Drive the vehicle for at least 5 consecutive seconds under the following condition. VHCL SPEED SE More than 30 km/h (19 MPH) Selector lever Suitable position Driving location Depress the brake pedal for more than five seconds so as not to come off from the above-mentioned vehicle speed. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-689. With GST Follow the procedure “With CONSULT-II” above. FE CL MT AT 6) TF PD AX SU BR ST RS BT HA SC EL IDX EC-687 DTC P1572 ASCD BRAKE SWITCH Wiring Diagram Wiring Diagram NAEC1304 MEC118E EC-688 DTC P1572 ASCD BRAKE SWITCH Diagnostic Procedure Diagnostic Procedure 1 NAEC1305 GI CHECK OVERALL FUNCTION-I MA With CONSULT-II 1. Turn ignition switch “ON”. 2. Select “BRAKE SW1” in “DATA MONITOR” mode with CONSULT-II. 3. Check the indication of “BRAKE SW1” under the following conditions. EM LC FE SEC011D CL MT AT MTBL1334 TF PD Without CONSULT-II 1. Turn ignition switch “ON”. 2. Check voltage between ECM terminal 108 and ground under the following conditions. AX SU BR ST MBIB0061E RS BT HA MTBL1335 OK or NG OK 䊳 GO TO 2. NG 䊳 GO TO 3. SC EL IDX EC-689 DTC P1572 ASCD BRAKE SWITCH Diagnostic Procedure (Cont’d) 2 CHECK OVERALL FUNCTION-II With CONSULT-II See “BRAKE SW2” indication in “DATA MONITOR” mode. SEC013D MTBL1336 Without CONSULT-II Check voltage between ECM terminal 101 and ground under the following conditions. MBIB0060E MTBL1337 OK or NG OK 䊳 GO TO 16. NG 䊳 GO TO 11. EC-690 DTC P1572 ASCD BRAKE SWITCH Diagnostic Procedure (Cont’d) 3 1. 2. 3. 4. GI CHECK ASCD BRAKE SWITCH POWER SUPPLY CIRCUIT Turn ignition switch “OFF”. Disconnect ASCD brake switch harness connector. Turn ignition switch “ON”. Check voltage between ASCD brake switch terminal 1 and ground with CONSULT-II or tester. MA EM LC FE PBIB0857E Voltage: Battery voltage CL OK or NG OK (A/T models) 䊳 GO TO 5. OK (M/T models) 䊳 GO TO 7. NG 䊳 GO TO 4. 4 MT AT DETECT MALFUNCTIONING PART Check the following. 쐌 Fuse block (J/B) connector M10 쐌 7.5A fuse 쐌 Harness for open or short between ASCD brake switch and fuse 䊳 TF PD Repair open circuit or short to ground or short to power in harness or connectors. AX 5 CHECK ASCD BRAKE SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 108 and ASCD brake switch terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for open to ground and short to power. OK or NG OK 䊳 GO TO 10. NG 䊳 GO TO 6. 6 BR ST RS BT DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors M94, F27 쐌 Harness for open and short between ECM and ASCD brake switch 䊳 SU HA Repair open circuit or short to ground or short to power in harness or connectors. SC EL IDX EC-691 DTC P1572 ASCD BRAKE SWITCH Diagnostic Procedure (Cont’d) 7 CHECK ASCD CLUTCH SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. 3. 4. Turn ignition switch “OFF”. Disconnect ASCD clutch switch harness connector. Disconnect ECM harness connector. Check harness continuity between ASCD brake switch terminal 2 and ASCD clutch switch terminal 1, ASCD clutch switch terminal 2 and ECM terminal 108. Refer to Wiring Diagram. Continuity should exist. 5. Also check harness for open to ground and short to power. OK or NG OK 䊳 GO TO 9. NG 䊳 GO TO 8. 8 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors M94, F27 쐌 Harness for open and short between ASCD brake switch and ASCD clutch switch 쐌 Harness for open and short between ASCD clutch switch and ECM 䊳 9 Repair open circuit or short to ground or short to power in harness or connectors. CHECK ASCD CLUTCH SWITCH Refer to “Component Inspection”, EC-694. OK or NG OK 䊳 GO TO 10. NG 䊳 Replace ASCD clutch switch. 10 CHECK ASCD BRAKE SWITCH Refer to “Component Inspection”, EC-694. OK or NG OK 䊳 GO TO 16. NG 䊳 Replace ASCD brake switch. EC-692 DTC P1572 ASCD BRAKE SWITCH Diagnostic Procedure (Cont’d) 11 GI CHECK STOP LAMP SWITCH POWER SUPPLY CIRCUIT 1. Turn ignition switch “OFF”. 2. Disconnect stop lamp switch harness connector. 3. Check voltage between stop lamp switch terminal 1 and ground with CONSULT-II or tester. A/T models MA EM LC FE SEC547D M/T models CL MT AT TF PBIB0117E Voltage: Battery voltage OK or NG OK 䊳 GO TO 13. NG 䊳 GO TO 12. 12 PD AX SU DETECT MALFUNCTIONING PART Check the following. 쐌 Fuse block (J/B) connector M10 쐌 10A fuse 쐌 Harness for open or short between stop lamp switch and fuse 䊳 BR ST Repair open circuit or short to ground in harness or connectors. RS 13 CHECK STOP LAMP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Disconnect ECM harness connector. 2. Check harness continuity between stop lamp switch terminal 2 and ECM terminal 101. Refer to wiring diagram. Continuity should exist 3. Also check harness for short to ground and short to power. BT HA OK or NG OK 䊳 GO TO 15. NG 䊳 GO TO 14. SC EL IDX EC-693 DTC P1572 ASCD BRAKE SWITCH Diagnostic Procedure (Cont’d) 14 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors M94, F27 쐌 Harness for open or short between stop lamp switch and ECM 䊳 15 Repair open circuit or short to ground or short to power in harness or connectors. CHECK STOP LAMP SWITCH Refer to “Component Inspection”, EC-694. OK or NG OK 䊳 GO TO 16. NG 䊳 Replace stop lamp switch. 16 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END Component Inspection NAEC1306 ASCD BRAKE SWITCH AND STOP LAMP SWITCH Continuity Condition SEC023DA ASCD brake switch Stop lamp switch When brake pedal is depressed No Yes When brake pedal is released Yes No Check each switch after adjusting brake pedal — refer to BR section. SEC548D SEC155DA EC-694 DTC P1572 ASCD BRAKE SWITCH Component Inspection (Cont’d) ASCD CLUTCH SWITCH (FOR M/T MODELS) Condition GI Continuity When clutch pedal is depressed No When clutch pedal is released Yes MA EM LC SEC024D FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-695 DTC P1706 PNP SWITCH Component Description Component Description NAEC1134 When the gear position is “P” (A/T models only) or “N”, park/neutral position (PNP) switch is “ON”. ECM detects the position because the continuity of the line (the “ON” signal) exists. For A/T models, the park/neutral position (PNP) switch assembly also includes a transmission range switch to detect selector lever position. SEC968D CONSULT-II Reference Value in Data Monitor Mode NAEC1135 Specification data are reference values. MONITOR ITEM CONDITION 쐌 Ignition switch: ON P/N POSI SW SPECIFICATION Shift lever: “P” or “N” ON Except above OFF ECM Terminals and Reference Value NAEC1136 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 102 WIRE COLOR L ITEM PNP switch CONDITION DATA (DC Voltage) [Ignition switch “ON”] 쐌 Gear position is “P” (A/T models) or “N” (Neutral position). Approximately 0V [Ignition switch “ON”] 쐌 Except the above gear position BATTERY VOLTAGE (11 - 14V) On Board Diagnosis Logic DTC No. P1706 1706 Trouble diagnosis name Park/Neutral position switch DTC Detecting Condition The signal of the park/neutral position (PNP) switch is not changed in the process of engine starting and driving. NAEC1137 Possible Cause 쐌 Harness or connectors [The park/neutral position (PNP) switch circuit is open or shorted.] 쐌 Park/neutral position (PNP) switch DTC Confirmation Procedure NAEC1138 CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. EC-696 DTC P1706 PNP SWITCH DTC Confirmation Procedure (Cont’d) WITH CONSULT-II 1) 2) NAEC1138S01 Turn ignition switch “ON”. Select “P/N POSI SW” in “DATA MONITOR” mode with CONSULT-II. Then check the “P/N POSI SW” signal under the following conditions. Position (Selector lever) ON Except the above position OFF SEF212Y 3) 4) 5) LC If NG, go to “Diagnostic Procedure”, EC-699. If OK, go to following step. Select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to normal operating temperature. Maintain the following conditions for at least 60 consecutive seconds. ENG SPEED More than 1,500 rpm (A/T) More than 1,800 rpm (M/T) COOLAN TEMP/S More than 70°C (158°F) B/FUEL SCHDL More than 3.7 msec VHCL SPEED SE More than 64 km/h (40 MPH) Selector lever Suitable position (A/T) 5th position (M/T) FE CL MT SEF213Y 6) MA EM Known-good signal “N” and “P” position GI AT TF If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-699. PD AX SU Overall Function Check NAEC1139 Use this procedure to check the overall function of the park/neutral position (PNP) switch circuit. During this check, a 1st trip DTC might not be confirmed. ST WITH GST 1) 2) NAEC1139S01 Turn ignition switch “ON”. Check voltage between ECM terminal 102 and body ground under the following conditions. Condition (Gear position) Voltage V (Known-good data) MBIB0043E “P” and “N” position Except the above position 3) BR RS BT Approx. 0 Battery voltage HA If NG, go to “Diagnostic Procedure”, EC-699. SC EL IDX EC-697 DTC P1706 PNP SWITCH Wiring Diagram Wiring Diagram NAEC1140 MEC106E EC-698 DTC P1706 PNP SWITCH Diagnostic Procedure Diagnostic Procedure FOR M/T MODELS 1 NAEC1141 GI NAEC1141S01 MA CHECK PNP SWITCH GROUND CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Disconnect park/neutral position (PNP) switch harness connector. EM LC FE SEC968D 3. Check harness continuity between PNP switch terminal 2 and engine ground. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to power. CL MT OK or NG OK 䊳 GO TO 3. NG 䊳 GO TO 2. 2 AT TF DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors B200, B61 쐌 Harness for open or short between park/neutral position (PNP) switch and ground 䊳 3 Repair open circuit or short to power in harness or connectors. PD AX CHECK PNP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 102 and PNP switch terminal 1. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. SU BR OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 4. ST RS 4 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors F22, M33 쐌 Harness connectors M72, B52 쐌 Harness connectors B61, B200 쐌 Harness for open or short between park/neutral position (PNP) switch and ECM 䊳 Repair open circuit or short to ground or short to power in harness or connectors. BT HA SC EL IDX EC-699 DTC P1706 PNP SWITCH Diagnostic Procedure (Cont’d) 5 CHECK PARK/NEUTRAL POSITION (PNP) SWITCH Refer to MT-5 “Position Switch Check”. OK or NG OK 䊳 GO TO 6. NG 䊳 Replace park/neutral position (PNP) switch. 6 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-700 DTC P1706 PNP SWITCH Diagnostic Procedure (Cont’d) FOR A/T MODELS 1 =NAEC1141S02 GI CHECK PNP SWITCH GROUND CIRCUIT FOR OPEN AND SHORT MA 1. Turn ignition switch “OFF”. 2. Disconnect park/neutral position (PNP) switch harness connector. EM LC FE SEF011SA 3. Check harness continuity between PNP switch terminal 1 and engine ground. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to power. OK or NG OK 䊳 GO TO 2. NG 䊳 Repair open circuit or short to power in harness or connectors. 2 CHECK PNP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 102 and PNP switch terminal 2. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 3. CL MT AT TF PD AX SU 3 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors F22, M33 쐌 Harness connectors M70, B50 쐌 Harness for open or short between ECM and park/neutral position (PNP) switch 䊳 BR ST Repair open circuit or short to ground or short to power in harness or connectors. RS 4 CHECK PARK/NEUTRAL POSITION (PNP) SWITCH Refer to AT-108, “Diagnostic Procedure”. BT OK or NG OK 䊳 GO TO 5. NG 䊳 Replace park/neutral position (PNP) switch. 5 HA SC CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EL IDX EC-701 DTC P1805 BRAKE SWITCH Description Description NAEC1308 Brake switch signal is applied to the ECM through the stop lamp switch when the brake pedal is depressed. This signal is used mainly to decrease the engine speed when the vehicle is driving. CONSULT-II Reference Value in Data Monitor Mode NAEC1309 Specification data are reference values. MONITOR ITEM CONDITION 쐌 Ignition switch: ON BRAKE SW SPECIFICATION Brake pedal: Fully released OFF Brake pedal: Slightly depressed ON ECM Terminals and Reference Value NAEC1315 Specification data are reference values and are measured between each terminal and body ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR 101 G/Y ITEM Stop lamp switch CONDITION DATA (DC Voltage) [Engine is running] 쐌 Brake pedal fully released Approximately 0V [Engine is running] 쐌 Brake pedal fully depressed BATTERY VOLTAGE (11 - 14V) On Board Diagnosis Logic NAEC1310 The MIL will not light up for this self-diagnosis. DTC No. P1805 1805 Trouble diagnosis name Brake switch DTC detecting condition A brake switch signal is not sent to ECM for an extremely long time while the vehicle is driving. Possible cause 쐌 Harness or connectors (Stop lamp switch circuit is open or shorted.) 쐌 Stop lamp switch FAIL-SAFE MODE NAEC1310S01 When the malfunction is detected, the ECM enters fail-safe mode. Engine operating condition in fail-safe mode ECM controls the electric throttle control actuator by regulating the throttle opening to small range. Therefore, acceleration will be poor. Condition Driving condition When engine is idling Normal When accelerating Poor acceleration EC-702 DTC P1805 BRAKE SWITCH DTC Confirmation Procedure DTC Confirmation Procedure 1. 2. 3. 4. 5. =NAEC1311 WITH CONSULT-II Turn ignition switch “ON”. Fully depress the brake pedal for at least 5 seconds. Erase the DTC with CONSULT-II. Select “DATA MONITOR” mode with CONSULT-II. If 1st trip DTC is detected, go to “Diagnostic Procedure”, EC-705. GI MA EM LC SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-703 DTC P1805 BRAKE SWITCH Wiring Diagram Wiring Diagram NAEC1312 MEC120E EC-704 DTC P1805 BRAKE SWITCH Diagnostic Procedure Diagnostic Procedure 1 NAEC1313 GI CHECK STOP LAMP SWITCH CIRCUIT MA 1. Turn ignition switch “OFF”. 2. Check the stop lamp when depressing and releasing the brake pedal. EM MTBL1138 LC OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 2. FE 2 CHECK STOP LAMP SWITCH POWER SUPPLY CIRCUIT CL 1. Disconnect stop lamp switch harness connector. MT AT TF SEC549D PD 2. Check voltage between stop lamp switch terminal 1 and ground with CONSULT-II or tester. AX SU BR ST SEC547D RS BT HA SC SEC051DA Voltage: Battery voltage OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 3. EL IDX EC-705 DTC P1805 BRAKE SWITCH Diagnostic Procedure (Cont’d) 3 DETECT MALFUNCTIONING PART Check the following. 쐌 10A fuse 쐌 Fuse block (J/B) connector M10 쐌 Harness for open and short between stop lamp switch and battery 䊳 4 Repair open circuit or short to ground or short to power in harness or connectors. CHECK STOP LAMP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Disconnect stop lamp switch harness connector. SEC549D 4. Check harness continuity between ECM terminal 101 and stop lamp switch terminal 2. Refer to Wiring Diagram. Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 6. NG 䊳 GO TO 5. 5 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connector M94, F27 쐌 Harness for open and short between ECM and stop lamp switch 䊳 6 Repair open circuit or short to ground or short to power in harness or connectors. CHECK STOP LAMP SWITCH Refer to “Component Inspection”, EC-707. OK or NG OK 䊳 GO TO 7. NG 䊳 Replace stop lamp switch. 7 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-706 DTC P1805 BRAKE SWITCH Component Inspection Component Inspection =NAEC1314 STOP LAMP SWITCH 1. Disconnect stop lamp switch harness connector. GI MA EM LC SEC549D 2. 3. Check continuity between stop lamp switch terminals 1 and 2 under the following conditions. Conditions Continuity Brake pedal fully released Should not exist. Brake pedal depressed Should exist. If NG, replace stop lamp switch. SEC548D FE CL MT AT TF PD AX SU SEC052DA BR ST RS BT HA SC EL IDX EC-707 DTC P2122, P2123 APP SENSOR Component Description Component Description NAEC1316 The accelerator pedal position sensor is installed on the upper end of the accelerator pedal assembly. The sensor detects the accelerator position and sends a signal to the ECM. Accelerator pedal position sensor has two sensors. These sensors are a kind of potentiometers which transform the accelerator pedal position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the accelerator pedal and feed the voltage signals to the ECM. The ECM judges the current opening angle of the accelerator pedal from these signals and controls the throttle control motor based on these signals. Idle position of the accelerator pedal is determined by the ECM receiving the signal from the accelerator pedal position sensor. The ECM uses this signal for the engine operation such as fuel cut. PBIB1741E CONSULT-II Reference Value in Data Monitor Mode NAEC1317 Specification data are reference values. MONITOR ITEM ACCEL SEN1 ACCEL SEN2* CLSD THL POS CONDITION 쐌 Ignition switch: ON (engine stopped) 쐌 Shift lever: “D” (A/T models) “1st” (M/T models) 쐌 Ignition switch: ON (engine stopped) 쐌 Shift lever: “D” (A/T models) “1st” (M/T models) 쐌 Ignition switch: ON (engine stopped) 쐌 Shift lever: “D” (A/T models) “1st” (M/T models) SPECIFICATION Accelerator pedal: Fully released 0.5 - 1.0V Accelerator pedal: Fully depressed 4.0 - 4.7V Accelerator pedal: Fully released 0.3 - 1.2V Accelerator pedal: Fully depressed 3.9 - 4.8V Accelerator pedal: Fully released ON Accelerator pedal: Slightly depressed OFF *: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal. ECM Terminals and Reference Value NAEC1323 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) 82 B/R Sensor’s ground (APP sensor 1) [Engine is running] 쐌 Warm-up condition 쐌 Idle speed Approximately 0V 83 L Sensor’s ground (APP sensor 2) [Ignition switch “ON”] Approximately 0V EC-708 DTC P2122, P2123 APP SENSOR ECM Terminals and Reference Value (Cont’d) GI TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) MA 90 L Sensor’s power supply (APP sensor 1) [Ignition switch “ON”] Approximately 5V 91 W/R Sensor’s power supply (APP sensor 2) [Ignition switch “ON”] Approximately 5V 98 106 R L Accelerator pedal position sensor 2 Accelerator pedal position sensor 1 EM LC [Ignition switch “ON”] 쐌 Engine stopped 쐌 Shift lever: “D” (A/T models) 쐌 Shift lever position is “1st” (M/T models) 쐌 Accelerator pedal fully released 0.15 - 0.6V [Ignition switch “ON”] 쐌 Engine stopped 쐌 Shift lever: “D” (A/T models) 쐌 Shift lever position is “1st” (M/T models) 쐌 Accelerator pedal fully depressed 1.95 - 2.4V [Ignition switch “ON”] 쐌 Engine stopped 쐌 Shift lever: “D” (A/T models) 쐌 Shift lever position is “1st” (M/T models) 쐌 Accelerator pedal fully released 0.5 - 1.0V [Ignition switch “ON”] 쐌 Engine stopped 쐌 Shift lever: “D” (A/T models) 쐌 Shift lever position is “1st” (M/T models) 쐌 Accelerator pedal fully depressed 3.9 - 4.7V FE CL MT AT TF PD On Board Diagnosis Logic NAEC1318 These self-diagnoses have the one trip detection logic. NOTE: If DTC P2122 or P2123 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to EC-596. DTC No. Trouble diagnosis name P2122 2122 Accelerator pedal position sensor 1 circuit low input P2123 2123 Accelerator pedal position sensor 1 circuit high input DTC Detecting Condition AX SU Possible Cause An excessively low voltage from the APP sensor 1 쐌 Harness or connectors is sent to ECM. (The APP sensor 1 circuit is open or shorted.) 쐌 Accelerator pedal position sensor An excessively high voltage from the APP sensor (Accelerator pedal position sensor 1) 1 is sent to ECM. BR ST RS FAIL-SAFE MODE NAEC1318S01 When the malfunction is detected, ECM enters in fail-safe mode and the MIL lights up. BT Engine operation condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. HA SC EL IDX EC-709 DTC P2122, P2123 APP SENSOR DTC Confirmation Procedure DTC Confirmation Procedure NAEC1319 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 8V at idle. 1. 2. 3. 4. With CONSULT-II Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to “Diagnostic Procedure”, EC-712. SEF058Y With GST Follow the procedure “WITH CONSULT-II” above. EC-710 DTC P2122, P2123 APP SENSOR Wiring Diagram Wiring Diagram NAEC1320 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC184E EC-711 IDX DTC P2122, P2123 APP SENSOR Diagnostic Procedure Diagnostic Procedure 1 NAEC1321 RETIGHTEN GROUND SCREWS 1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. SEF959Y 䊳 2 GO TO 2. CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT 1. Disconnect accelerator pedal position (APP) sensor harness connector. 2. Turn ignition switch “ON”. SEC550D 3. Check voltage between APP sensor terminal 12 and ground with CONSULT-II or tester. SEC551D Voltage: Approximately 5V OK or NG OK 䊳 GO TO 3. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. EC-712 DTC P2122, P2123 APP SENSOR Diagnostic Procedure (Cont’d) 3 CHECK APP SENSOR 1 GROUND CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Check harness continuity between APP sensor terminal 9 and engine ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. GI MA EM OK or NG OK 䊳 GO TO 4. NG 䊳 Repair open circuit or short to power in harness or connectors. 4 LC CHECK APP SENSOR 1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 106 and APP sensor terminal 11. Refer to Wiring Diagram Continuity should exist. 3. Also check harness for short to ground and short to power. FE CL OK or NG OK 䊳 GO TO 5. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. MT AT 5 CHECK APP SENSOR Refer to “Component Inspection”, EC-714. TF OK or NG OK 䊳 GO TO 7. NG 䊳 GO TO 6. 6 1. 2. 3. 4. REPLACE ACCELERATOR PEDAL ASSEMBLY Replace accelerator pedal assembly. Perform “Accelerator Pedal Released Position Learning”, EC-81. Perform “Throttle Valve Closed Position Learning”, EC-81. Perform “Idle Air Volume Learning”, EC-81. 䊳 7 PD AX SU BR INSPECTION END ST CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 RS INSPECTION END BT HA SC EL IDX EC-713 DTC P2122, P2123 APP SENSOR Component Inspection Component Inspection =NAEC1322 ACCELERATOR PEDAL POSITION SENSOR 1. Reconnect all harness connectors disconnected. 2. Turn ignition switch “ON”. 3. Check voltage between ECM terminals 106 (APP sensor 1 signal), 98 (APP sensor 2 signal) and engine ground under the following conditions. Terminal MBIB0023E 106 (Accelerator pedal position sensor 1) 98 (Accelerator pedal position sensor 2) 4. 5. 6. 7. Accelerator pedal Voltage Fully released 0.5 - 1.0V Fully depressed 3.9 - 4.7V Fully released 0.15 - 0.6V Fully depressed 1.95 - 2.4V If NG, replace accelerator pedal assembly. Perform “Accelerator Pedal Released Position Learning”, EC-81. Perform “Throttle Valve Closed Position Learning”, EC-81. Perform “Idle Air Volume Learning”, EC-81. EC-714 DTC P2127, P2128 APP SENSOR Component Description Component Description NAEC1324 The accelerator pedal position sensor is installed on the upper end of the accelerator pedal assembly. The sensor detects the accelerator position and sends a signal to the ECM. Accelerator pedal position sensor has two sensors. These sensors are a kind of potentiometers which transform the accelerator pedal position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the accelerator pedal and feed the voltage signals to the ECM. The ECM judges the current opening angle of the accelerator pedal from these signals and controls the throttle control motor based on these signals. Idle position of the accelerator pedal is determined by the ECM receiving the signal from the accelerator pedal position sensor. The ECM uses this signal for the engine operation such as fuel cut. PBIB1741E GI MA EM LC FE CL MT CONSULT-II Reference Value in Data Monitor Mode NAEC1325 Specification data are reference values. MONITOR ITEM ACCEL SEN1 ACCEL SEN2* CLSD THL POS CONDITION SPECIFICATION 쐌 Ignition switch: ON (engine stopped) 쐌 Shift lever: “D” (A/T models) “1st” (M/T models) Accelerator pedal: Fully released 0.5 - 1.0V Accelerator pedal: Fully depressed 4.0 - 4.7V 쐌 Ignition switch: ON (engine stopped) 쐌 Shift lever: “D” (A/T models) “1st” (M/T models) Accelerator pedal: Fully released 0.3 - 1.2V Accelerator pedal: Fully depressed 3.9 - 4.8V 쐌 Ignition switch: ON (engine stopped) 쐌 Shift lever: “D” (A/T models) “1st” (M/T models) Accelerator pedal: Fully released ON Accelerator pedal: Slightly depressed OFF AT TF PD AX SU BR ST *: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal. ECM Terminals and Reference Value RS NAEC1331 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION BT HA DATA (DC Voltage) SC 47 L Sensor’s power supply (Throttle position sensor) [Ignition switch “ON”] Approximately 5V 82 B/R Sensor’s ground (APP sensor 1) [Engine is running] 쐌 Warm-up condition 쐌 Idle speed Approximately 0V EC-715 EL IDX DTC P2127, P2128 APP SENSOR ECM Terminals and Reference Value (Cont’d) TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) 83 L Sensor’s ground (APP sensor 2) [Ignition switch “ON”] Approximately 0V 90 L Sensor’s power supply (APP sensor 1) [Ignition switch “ON”] Approximately 5V 91 W/R Sensor’s power supply (APP sensor 2) [Ignition switch “ON”] Approximately 5V 98 R [Ignition switch “ON”] 쐌 Engine stopped 쐌 Shift lever: “D” (A/T models) 쐌 Shift lever position is “1st” (M/T models) Accelerator pedal posi- 쐌 Accelerator pedal fully released tion sensor 2 [Ignition switch “ON”] 쐌 쐌 쐌 쐌 106 L Engine stopped Shift lever: “D” (A/T models) Shift lever position is “1st” (M/T models) Accelerator pedal fully depressed [Ignition switch “ON”] 쐌 Engine stopped 쐌 Shift lever: “D” (A/T models) 쐌 Shift lever position is “1st” (M/T models) Accelerator pedal posi- 쐌 Accelerator pedal fully released tion sensor 1 [Ignition switch “ON”] 쐌 쐌 쐌 쐌 Engine stopped Shift lever: “D” (A/T models) Shift lever position is “1st” (M/T models) Accelerator pedal fully depressed 0.15 - 0.6V 1.95 - 2.4V 0.5 - 1.0V 3.9 - 4.7V On Board Diagnosis Logic NAEC1326 These self-diagnoses have the one trip detection logic. DTC No. Trouble diagnosis name P2127 2127 Accelerator pedal position sensor 2 circuit low input P2128 2128 Accelerator pedal position sensor 2 circuit high input DTC Detecting Condition Possible Cause An excessively low voltage from the APP sensor 2 쐌 Harness or connectors is sent to ECM. (The APP sensor 2 circuit is open or shorted.) 쐌 Accelerator pedal position sensor An excessively high voltage from the APP sensor (Accelerator pedal position sensor 2) 2 is sent to ECM. 쐌 Electric throttle control actuator (TP sensor 1 and 2) FAIL-SAFE MODE NAEC1326S01 When the malfunction is detected, ECM enters fail-safe mode and the MIL lights up. Engine operating condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. EC-716 DTC P2127, P2128 APP SENSOR DTC Confirmation Procedure DTC Confirmation Procedure NAEC1327 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 8V at idle. GI MA EM LC 1) 2) 3) 4) With CONSULT-II Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to “Diagnostic Procedure”, EC-719. FE CL MT SEF058Y With GST Follow the procedure “With CONSULT-II” above. AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-717 DTC P2127, P2128 APP SENSOR Wiring Diagram Wiring Diagram NAEC1328 TEC844 EC-718 DTC P2127, P2128 APP SENSOR Diagnostic Procedure Diagnostic Procedure 1 NAEC1329 GI RETIGHTEN GROUND SCREWS MA 1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. EM LC FE SEF959Y 䊳 2 CL GO TO 2. MT CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-I 1. Disconnect accelerator pedal position (APP) sensor harness connector. 2. Turn ignition switch “ON”. AT TF PD AX SEC550D 3. Check voltage between APP sensor terminal 10 and ground with CONSULT-II or tester. SU BR ST RS BT SEC552D Voltage: Approximately 5V OK or NG OK 䊳 GO TO 7. NG 䊳 GO TO 3. HA SC EL IDX EC-719 DTC P2127, P2128 APP SENSOR Diagnostic Procedure (Cont’d) 3 CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-II 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between APP sensor terminal 10 and ECM terminal 91. Refer to Wiring Diagram. Continuity should exist. OK or NG OK 䊳 GO TO 4. NG 䊳 Repair or replace open circuit. 4 CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-III Check harness for short to power and short to ground, between the following terminals. 쐌 ECM terminal 47 and electric throttle control actuator terminal 1. Refer to “Wiring Diagram”, EC-244. 쐌 ECM terminal 91 and APP sensor terminal 10. Refer to “Wiring Diagram”, EC-718. OK or NG OK 䊳 GO TO 5. NG 䊳 Repair short to ground or short to power in harness or connectors. 5 CHECK THROTTLE POSITION SENSOR Refer to “Component Inspection”, EC-247. OK or NG OK 䊳 GO TO 11. NG 䊳 GO TO 6. 6 REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. Replace the electric throttle control actuator. 2. Perform “Throttle Valve Closed Position Learning”, EC-81. 3. Perform “Idle Air Volume Learning”, EC-81. 䊳 7 INSPECTION END CHECK APP SENSOR 2 GROUND CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Check harness continuity between APP sensor terminal 7 and engine ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK 䊳 GO TO 8. NG 䊳 Repair open circuit or short to power in harness or connectors. EC-720 DTC P2127, P2128 APP SENSOR Diagnostic Procedure (Cont’d) 8 CHECK APP SENSOR 2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 98 and APP sensor terminal 8. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. GI MA EM OK or NG OK 䊳 GO TO 9. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. 9 LC CHECK APP SENSOR Refer to “Component Inspection”, EC-722. OK or NG OK 䊳 GO TO 11. NG 䊳 GO TO 10. 10 1. 2. 3. 4. 11 CL REPLACE ACCELERATOR PEDAL ASSEMBLY Replace accelerator pedal assembly. Perform “Accelerator Pedal Released Position Learning”, EC-81. Perform “Throttle Valve Closed Position Learning”, EC-81. Perform “Idle Air Volume Learning”, EC-81. 䊳 FE MT AT TF INSPECTION END CHECK INTERMITTENT INCIDENT PD Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END AX SU BR ST RS BT HA SC EL IDX EC-721 DTC P2127, P2128 APP SENSOR Component Inspection Component Inspection =NAEC1330 ACCELERATOR PEDAL POSITION SENSOR 1. Reconnect all harness connectors disconnected. 2. Turn ignition switch “ON”. 3. Check voltage between ECM terminals 106 (APP sensor 1 signal), 98 (APP sensor 2 signal) and engine ground under the following conditions. Terminal MBIB0023E 106 (Accelerator pedal position sensor 1) 98 (Accelerator pedal position sensor 2) 4. 5. 6. 7. Accelerator pedal Voltage Fully released 0.5 - 1.0V Fully depressed 3.9 - 4.7V Fully released 0.15 - 0.6V Fully depressed 1.95 - 2.4V If NG, replace accelerator pedal assembly. Perform “Accelerator Pedal Released Position Learning”, EC-81. Perform “Throttle Valve Closed Position Learning”, EC-81. Perform “Idle Air Volume Learning”, EC-81. EC-722 DTC P2135 TP SENSOR Component Description Component Description PBIB0145E NAEC1332 Electric Throttle Control Actuator Consists of throttle control motor, throttle position sensor, etc. The throttle position sensor responds to the throttle vale movement. The throttle position sensor has the two sensors. These sensors are a kind of potentiometers which transform the throttle valve position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the throttle valve and feed the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve form these signal and the ECM controls the throttle control motor to make the throttle valve opening angle properly in response to driving condition. GI MA EM LC FE CL MT CONSULT-II Reference Value in Data Monitor Mode NAEC1333 Specification data are reference values. MONITOR ITEM THRTL SEN1 THRTL SEN2* CONDITION 쐌 Ignition switch: ON (Engine stopped) 쐌 Shift lever: “D” (A/T model) “1st” (M/T model) SPECIFICATION Accelerator pedal: Fully released More than 0.36V Accelerator pedal: Fully depressed Less than 4.75V AX ECM Terminals and Reference Value SU NAEC1339 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. 47 50 WIRE COLOR L BR ITEM Sensor’s power supply (Throttle position sensor) TF PD *: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal. TERMINAL NO. AT CONDITION [Ignition switch “ON”] [Ignition switch “ON”] 쐌 Engine stopped 쐌 Shift lever position is “D” (A/T models) 쐌 Shift lever position is “1st” (M/T models) Throttle position sensor 쐌 Accelerator pedal fully released 1 [Ignition switch “ON”] 쐌 쐌 쐌 쐌 Engine stopped Shift lever position is “D” (A/T models) Shift lever position is “1st” (M/T models) Accelerator pedal fully depressed EC-723 DATA (DC Voltage) Approximately 5V BR ST RS BT HA More than 0.36V SC EL Less than 4.75V IDX DTC P2135 TP SENSOR ECM Terminals and Reference Value (Cont’d) TERMINAL NO. 66 69 WIRE COLOR BR/Y ITEM CONDITION [Engine is running] 쐌 Warm-up condition 쐌 Idle speed Sensor’s ground BR/W W/R Approximately 0V [Ignition switch “ON”] 쐌 Engine stopped 쐌 Shift lever position is “D” (A/T models) 쐌 Shift lever position is “1st” (M/T models) Throttle position sensor 쐌 Accelerator pedal fully released 2 [Ignition switch “ON”] 쐌 쐌 쐌 쐌 91 DATA (DC Voltage) Sensor’s power supply (APP sensor 2) Less than 4.75V Engine stopped Shift lever position is “D” (A/T models) Shift lever position is “1st” (M/T models) Accelerator pedal fully depressed More than 0.36V [Ignition switch “ON”] Approximately 5V On Board Diagnosis Logic NAEC1334 This self-diagnosis has the one trip detection logic. DTC No. P2135 2135 Trouble diagnosis name Throttle position sensor circuit range/ performance problem DTC Detecting Condition Rationally incorrect voltage is sent to ECM compared with the signals from TP sensor 1 and TP sensor 2. Possible Cause 쐌 Harness or connector (The TP sensor 1 and 2 circuit is open or shorted.) 쐌 Electric throttle control actuator (TP sensor 1 and 2) 쐌 Accelerator pedal position sensor (APP sensor 2) FAIL-SAFE MODE NAEC1334S01 When the malfunction is detected, the ECM enters fail-safe mode and the MIL lights up. Engine operation condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. DTC Confirmation Procedure NAEC1335 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 8V at idle. EC-724 DTC P2135 TP SENSOR DTC Confirmation Procedure (Cont’d) 1. 2. 3. 4. With CONSULT-II Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to “Diagnostic Procedure”, EC-727. GI MA EM LC SEF058Y With GST Follow the procedure “WITH CONSULT-II” above. FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-725 DTC P2135 TP SENSOR Wiring Diagram Wiring Diagram NAEC1336 TEC842 EC-726 DTC P2135 TP SENSOR Diagnostic Procedure Diagnostic Procedure 1 NAEC1337 GI RETIGHTEN GROUND SCREWS MA 1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. EM LC FE SEF959Y 䊳 2 CL GO TO 2. MT CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT-I 1. Disconnect electric throttle control actuator harness connector. 2. Turn ignition switch “ON”. AT TF PD AX SEC433D SU 3. Check voltage between electric throttle control actuator terminal 1 and ground with CONSULT-II or tester. BR ST RS BT PBIB0082E Voltage: Approximately 5V OK or NG OK 䊳 GO TO 7. NG 䊳 GO TO 3. HA SC EL IDX EC-727 DTC P2135 TP SENSOR Diagnostic Procedure (Cont’d) 3 CHECK THROTTLE POSITION SENSOR 2 POWER SUPPLY CIRCUIT-II 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between electric throttle control actuator terminal 1 and ECM terminal 47. Refer to Wiring Diagram. Continuity should exist. OK or NG OK 䊳 GO TO 4. NG 䊳 Repair or replace open circuit. 4 CHECK THROTTLE POSITION SENSOR 2 POWER SUPPLY CIRCUIT-III Check harness for short to power and short to ground, between the following terminals. 쐌 ECM terminal 47 and electric throttle control actuator terminal 1. Refer to “Wiring Diagram”, EC-726. 쐌 ECM terminal 91 and APP sensor terminal 10. Refer to “Wiring Diagram”, EC-718. OK or NG OK 䊳 GO TO 5. NG 䊳 Repair short to ground or short to power in harness or connectors. 5 CHECK APP SENSOR Refer to “Component Inspection”, EC-722. OK or NG OK 䊳 GO TO 11. NG 䊳 GO TO 6. 6 1. 2. 3. 4. REPLACE ACCELERATOR PEDAL ASSEMBLY Replace accelerator pedal assembly. Perform “Accelerator Pedal Released Position Learning”, EC-81. Perform “Throttle Valve Closed Position Learning”, EC-81. Perform “Idle Air Volume Learning”, EC-81. 䊳 7 INSPECTION END CHECK THROTTLE POSITION SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between electric throttle control actuator terminal 5 and ECM terminal 66. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 8. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. EC-728 DTC P2135 TP SENSOR Diagnostic Procedure (Cont’d) 8 GI CHECK THROTTLE POSITION SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 50 and electric throttle control actuator terminal 4, ECM terminal 69 and electric throttle control actuator terminal 2. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. MA EM OK or NG OK 䊳 GO TO 9. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. 9 LC CHECK THROTTLE POSITION SENSOR Refer to “Component Inspection”, EC-729. FE OK or NG OK 䊳 GO TO 11. NG 䊳 GO TO 10. CL REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR MT 10 1. Replace the electric throttle control actuator. 2. Perform “Throttle Valve Closed Position Learning”, EC-81. 3. Perform “Idle Air Volume Learning”, EC-81. 䊳 11 AT INSPECTION END TF CHECK INTERMITTENT INCIDENT PD Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END AX SU Component Inspection SEC434D NAEC1338 THROTTLE POSITION SENSOR 1. Reconnect all harness connectors disconnected. 2. Perform “Throttle Valve Closed Position Learning”, EC-81. 3. Turn ignition switch “ON”. 4. Set selector lever to “D” position (A/T models) or “1st” position (M/T models). 5. Check voltage between ECM terminals 50 (TP sensor 1), 69 (TP sensor 2) and engine ground under the following conditions. Terminal Accelerator pedal Voltage 50 (Throttle position sensor 1) Fully released More than 0.36V Fully depressed Less than 4.75V Fully released Less than 4.75V Fully depressed More than 0.36V 69 (Throttle position sensor 2) 6. 7. If NG, replace electric throttle control actuator and go to the next step. Perform “Throttle Valve Closed Position Learning”, EC-81. EC-729 BR ST RS BT HA SC EL IDX DTC P2135 TP SENSOR Component Inspection (Cont’d) 8. Perform “Idle Air Volume Learning”, EC-81. EC-730 DTC P2138 APP SENSOR Component Description Component Description NAEC1340 The accelerator pedal position sensor is installed on the upper end of the accelerator pedal assembly. The sensor detects the accelerator position and sends a signal to the ECM. Accelerator pedal position sensor has two sensors. These sensors are a kind of potentiometers which transform the accelerator pedal position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the accelerator pedal and feed the voltage signals to the ECM. The ECM judges the current opening angle of the accelerator pedal from these signals and controls the throttle control motor based on these signals. Idle position of the accelerator pedal is determined by the ECM receiving the signal from the accelerator pedal position sensor. The ECM uses this signal for the engine operation such as fuel cut. PBIB1741E GI MA EM LC FE CL MT CONSULT-II Reference Value in Data Monitor Mode NAEC1341 Specification data are reference values. MONITOR ITEM ACCEL SEN1 ACCEL SEN2* CLSD THL POS CONDITION 쐌 Ignition switch: ON (engine stopped) 쐌 Shift lever: “D” (A/T models) “1st” (M/T models) 쐌 Ignition switch: ON (engine stopped) 쐌 Shift lever: “D” (A/T models) “1st” (M/T models) 쐌 Ignition switch: ON (engine stopped) 쐌 Shift lever: “D” (A/T models) “1st” (M/T models) SPECIFICATION Accelerator pedal: Fully released 0.5 - 1.0V Accelerator pedal: Fully depressed 4.0 - 4.7V Accelerator pedal: Fully released 0.3 - 1.2V Accelerator pedal: Fully depressed 3.9 - 4.8V Accelerator pedal: Fully released ON Accelerator pedal: Slightly depressed OFF AT TF PD AX SU BR ST *: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal. ECM Terminals and Reference Value RS NAEC1347 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION BT HA DATA (DC Voltage) SC 47 L Sensor’s power supply (Throttle position sensor) [Ignition switch “ON”] Approximately 5V 82 B/R Sensor’s ground (APP sensor 1) [Engine is running] 쐌 Warm-up condition 쐌 Idle speed Approximately 0V EC-731 EL IDX DTC P2138 APP SENSOR ECM Terminals and Reference Value (Cont’d) TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) 83 L Sensor’s ground (APP sensor 2) [Ignition switch “ON”] Approximately 0V 90 L Sensor’s power supply (APP sensor 1) [Ignition switch “ON”] Approximately 5V 91 W/R Sensor’s power supply (APP sensor 2) [Ignition switch “ON”] Approximately 5V 98 R [Ignition switch “ON”] 쐌 Engine stopped Accelerator pedal posi- 쐌 Accelerator pedal fully released tion sensor 2 [Ignition switch “ON”] 0.15 - 0.6V 쐌 Engine stopped 쐌 Accelerator pedal fully depressed 106 L 1.95 - 2.4V [Ignition switch “ON”] 쐌 Engine stopped Accelerator pedal posi- 쐌 Accelerator pedal fully released tion sensor 1 [Ignition switch “ON”] 0.5 - 1.0V 쐌 Engine stopped 쐌 Accelerator pedal fully depressed 3.9 - 4.7V On Board Diagnosis Logic NAEC1342 This self-diagnosis has the one trip detection logic. NOTE: If DTC P2138 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to EC-596. DTC No. P2138 2138 Trouble diagnosis name DTC Detecting Condition Accelerator pedal Rationally incorrect voltage is sent to ECM composition sensor circuit pared with the signals from APP sensor 1 and range/performance APP sensor 2. problem Possible Cause 쐌 Harness or connector (The APP sensor 1 and 2 circuit is open or shorted.) (TP sensor circuit is shorted.) 쐌 Accelerator pedal position sensor 1 and 2 쐌 Electric throttle control actuator (TP sensor 1 and 2) FAIL-SAFE MODE NAEC1342S01 When the malfunction is detected, ECM enters fail-safe mode and the MIL lights up. Engine operation condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. EC-732 DTC P2138 APP SENSOR DTC Confirmation Procedure DTC Confirmation Procedure NAEC1343 NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch “OFF” and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 8V at idle. GI MA EM LC 1. 2. 3. 4. With CONSULT-II Turn ignition switch “ON”. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to “Diagnostic Procedure”, EC-735. FE CL MT SEF058Y With GST Follow the procedure “WITH CONSULT-II” above. AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-733 DTC P2138 APP SENSOR Wiring Diagram Wiring Diagram NAEC1344 TEC843 EC-734 DTC P2138 APP SENSOR Diagnostic Procedure Diagnostic Procedure 1 NAEC1345 GI RETIGHTEN GROUND SCREWS MA 1. Turn ignition switch “OFF”. 2. Loosen and retighten engine ground screws. EM LC FE SEF959Y 䊳 2 CL GO TO 2. MT CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT 1. Disconnect accelerator pedal position (APP) sensor harness connector. 2. Turn ignition switch “ON”. AT TF PD AX SEC550D 3. Check voltage between APP sensor terminal 12 and ground with CONSULT-II or tester. SU BR ST RS BT SEC551D Voltage: Approximately 5V OK or NG OK 䊳 GO TO 3. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. HA SC EL IDX EC-735 DTC P2138 APP SENSOR Diagnostic Procedure (Cont’d) 3 CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-I Check voltage between APP sensor terminal 10 and ground with CONSULT-II or tester. SEC552D Voltage: Approximately 5V OK or NG OK 䊳 GO TO 8. NG 䊳 GO TO 4. 4 CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-II 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between APP sensor terminal 10 and ECM terminal 91. Refer to Wiring Diagram. Continuity should exist. OK or NG OK 䊳 GO TO 5. NG 䊳 Repair or replace open circuit. 5 CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-III Check harness for short to power and short to ground, between the following terminals. 쐌 ECM terminal 47 and electric throttle control actuator terminal 1. Refer to “Wiring Diagram”, EC-244. 쐌 ECM terminal 91 and APP sensor terminal 10. Refer to “Wiring Diagram”, EC-734. OK or NG OK 䊳 GO TO 6. NG 䊳 Repair short to ground or short to power in harness or connectors. 6 CHECK THROTTLE POSITION SENSOR Refer to “Component Inspection”, EC-247. OK or NG OK 䊳 GO TO 12. NG 䊳 GO TO 7. 7 REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. Replace the electric throttle control actuator. 2. Perform “Throttle Valve Closed Position Learning”, EC-81. 3. Perform “Idle Air Volume Learning”, EC-81. 䊳 INSPECTION END EC-736 DTC P2138 APP SENSOR Diagnostic Procedure (Cont’d) 8 GI CHECK APP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Check harness continuity between APP sensor terminals 7, 9 and engine ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. MA EM OK or NG OK 䊳 GO TO 9. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. 9 LC CHECK APP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 106 and APP sensor terminal 11, ECM terminal 98 and APP sensor terminal 8. Refer to Wiring Diagram Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 10. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. 10 FE CL MT AT CHECK APP SENSOR TF Refer to “Component Inspection”, EC-737. OK or NG OK 䊳 GO TO 12. NG 䊳 GO TO 11. PD AX 11 1. 2. 3. 4. REPLACE ACCELERATOR PEDAL ASSEMBLY SU Replace accelerator pedal assembly. Perform “Accelerator Pedal Released Position Learning”, EC-81. Perform “Throttle Valve Closed Position Learning”, EC-81. Perform “Idle Air Volume Learning”, EC-81. 䊳 BR INSPECTION END ST 12 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 RS IINSPECTION END BT Component Inspection NAEC1346 ACCELERATOR PEDAL POSITION SENSOR 1. Reconnect all harness connectors disconnected. 2. Turn ignition switch “ON”. 3. Check voltage between ECM terminals 106 (APP sensor 1 signal), 98 (APP sensor 2 signal) and engine ground under the following conditions. HA SC EL IDX MBIB0023E EC-737 DTC P2138 APP SENSOR Component Inspection (Cont’d) Terminal 106 (Accelerator pedal position sensor 1) 98 (Accelerator pedal position sensor 2) 4. 5. 6. 7. Accelerator pedal Voltage Fully released 0.5 - 1.0V Fully depressed 3.9 - 4.7V Fully released 0.15 - 0.6V Fully depressed 1.95 - 2.4V If NG, replace accelerator pedal assembly. Perform “Accelerator Pedal Released Position Learning”, EC-81. Perform “Throttle Valve Closed Position Learning”, EC-81. Perform “Idle Air Volume Learning”, EC-81. EC-738 VARIABLE INDUCTION AIR CONTROL SYSTEM (VIAS) Description Description NAEC0596 SYSTEM DESCRIPTION Sensor Input Signal to ECM Mass air flow sensor Amount of intake air Throttle position sensor Throttle position Accelerator pedal position sensor Accelerator pedal position Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed* and piston position Engine coolant temperature sensor Engine coolant temperature Battery Battery voltage* GI NAEC0596S01 ECM function MA Actuator EM VIAS control LC VIAS control solenoid valve FE *: ECM determines the start signal status by the signals of engine speed and battery voltage. CL MT AT TF PD AX SU SEF447Z When the engine is running at low or medium speed, the power valve is fully closed. Under this condition, the effective suction port length is equivalent to the total length of the intake manifold collector’s suction port including the intake valve. This long suction port provides increased air intake which results in improved suction efficiency and higher torque generation. The surge tank and one-way valve are provided. When engine is running at high speed, the ECM sends the signal to the VIAS control solenoid valve. This signal introduces the intake manifold vacuum into the power valve actuator and therefore opens the power valve to two suction passages together in the collector. Under this condition, the effective port length is equivalent to the length of the suction port provided independently for each cylinder. This shortened port length results in enhanced engine output with reduced suction resistance under high speeds. BR ST RS BT HA SC EL IDX EC-739 VARIABLE INDUCTION AIR CONTROL SYSTEM (VIAS) Description (Cont’d) COMPONENT DESCRIPTION Power Valve NAEC0596S02 NAEC0596S0201 The power valve is installed in intake manifold collector and used to control the suction passage of the variable induction air control system. It is set in the fully closed or fully opened position by the power valve actuator operated by the vacuum stored in the surge tank. The vacuum in the surge tank is controlled by the VIAS control solenoid valve. VIAS Control Solenoid Valve SEC539D NAEC0596S0202 The VIAS control solenoid valve cuts the intake manifold vacuum signal for power valve control. It responds to ON/OFF signals from the ECM. When the solenoid is off, the vacuum signal from the intake manifold is cut. When the ECM sends an ON signal the coil pulls the plunger downward and feeds the vacuum signal to the power valve actuator. ECM Terminals and Reference Value NAEC0684 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 29 WIRE COLOR Y/G ITEM VIAS control solenoid valve CONDITION DATA (DC Voltage) [Engine is running] 쐌 Idle speed BATTERY VOLTAGE (11 - 14V) [Engine is running] 쐌 Engine speed is above 5,000 rpm. 0 - 1.0V EC-740 VARIABLE INDUCTION AIR CONTROL SYSTEM (VIAS) Wiring Diagram Wiring Diagram NAEC0597 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC107E EC-741 IDX VARIABLE INDUCTION AIR CONTROL SYSTEM (VIAS) Diagnostic Procedure Diagnostic Procedure 1 NAEC0598 CHECK OVERALL FUNCTION With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Perform “VIAS SOL VALVE” in “ACTIVE TEST” mode with CONSULT-II. 3. Turn VIAS control solenoid valve “ON” and “OFF”, and make sure that power valve actuator rod moves. PBIB0844E SEC558D Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Rev engine quickly up to above 5,000 rpm and make sure that power valve actuator rod moves. SEC558D OK or NG OK 䊳 INSPECTION END NG (With CONSULT-II) 䊳 GO TO 2. NG (Without CONSULTII) 䊳 GO TO 3. EC-742 VARIABLE INDUCTION AIR CONTROL SYSTEM (VIAS) Diagnostic Procedure (Cont’d) 2 1. 2. 3. 4. GI CHECK VACUUM EXISTENCE With CONSULT-II Stop engine and disconnect vacuum hose connected to power valve actuator. Start engine and let it idle. Perform “VIAS SOL VALVE” in “ACTIVE TEST” mode with CONSULT-II. Turn VIAS control solenoid valve “ON” and “OFF”, and check for the existence of vacuum under the following conditions. MA EM LC FE PBIB0844E CL MT AT TF SEC559D PD AX MTBL1174 SU OK or NG OK 䊳 Repair or replace power valve actuator. NG 䊳 GO TO 4. BR ST RS BT HA SC EL IDX EC-743 VARIABLE INDUCTION AIR CONTROL SYSTEM (VIAS) Diagnostic Procedure (Cont’d) 3 1. 2. 3. 4. 5. CHECK VACUUM EXISTENCE Without CONSULT-II Stop engine and disconnect vacuum hose connected to power valve actuator. Disconnect VIAS control solenoid valve harness connector. Start engine and let it idle. Apply 12V of direct current between VIAS control solenoid valve terminals 1 and 2. Check for the existence of vacuum under the following conditions. PBIB0845E SEC559D MTBL1175 OK or NG OK 䊳 Repair or replace power valve actuator. NG 䊳 GO TO 4. EC-744 VARIABLE INDUCTION AIR CONTROL SYSTEM (VIAS) Diagnostic Procedure (Cont’d) 4 GI CHECK VACUUM HOSE 1. Stop engine. 2. Check hoses and tubes between intake manifold and power valve actuator for crack, clogging, disconnection or improper connection. MA EM LC FE SEF109L OK or NG OK 䊳 GO TO 5. NG 䊳 Replace vacuum hose. 5 CL MT CHECK VACUUM TANK AT 1. Disconnect vacuum hose connected to vacuum tank. 2. Connect a vacuum pump to port A of vacuum tank. 3. Apply vacuum and make sure that vacuum exists at the port B. TF PD AX SU SEC560D BR OK or NG OK 䊳 GO TO 6. NG 䊳 Replace vacuum tank. ST RS BT HA SC EL IDX EC-745 VARIABLE INDUCTION AIR CONTROL SYSTEM (VIAS) Diagnostic Procedure (Cont’d) 6 CHECK VIAS CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT 1. Stop engine. 2. Disconnect VIAS control solenoid valve harness connector. SEC539D 3. Turn ignition switch “ON”. 4. Check voltage between terminal 1 and ground with CONSULT-II or tester. SEF603X OK or NG OK 䊳 GO TO 8. NG 䊳 GO TO 7. 7 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors E1, M1 쐌 Harness connectors M33, F22 쐌 Harness continuity between VIAS control solenoid valve and ECM relay 䊳 8 Repair harness or connectors. CHECK VIAS CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 29 and terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 9. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. EC-746 VARIABLE INDUCTION AIR CONTROL SYSTEM (VIAS) Diagnostic Procedure (Cont’d) 9 1. 2. 3. 4. GI CHECK VIAS CONTROL SOLENOID VALVE With CONSULT-II Reconnect disconnected harness connector. Turn ignition switch ON. Perform “VIAS SOL VALVE” in “ACTIVE TEST” mode. Check air passage continuity and operation delay time under the following conditions. MA EM LC FE PBIB0177E CL MT MTBL1171 Without CONSULT-II Check air passage continuity and operation delay time under the following conditions. AT TF PD AX SU MEC488B BR ST MTBL1172 OK or NG OK 䊳 GO TO 10. NG 䊳 Replace VIAS control solenoid valve. RS BT HA 10 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 SC INSPECTION END EL IDX EC-747 IGNITION SIGNAL Component Description Component Description NAEC0817 IGNITION COIL & POWER TRANSISTOR NAEC0817S01 The ignition signal from the ECM is sent to and amplified by the power transistor. The power transistor turns on and off the ignition coil primary circuit. This on-off operation induces the proper high voltage in the coil secondary circuit. SEC561D ECM Terminals and Reference Value NAEC0818 Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) 0 - 0.2V★ [Engine is running] 쐌 Warm-up condition 쐌 Idle speed 60 61 62 79 80 81 PU/W L/R Y/R GY/R GY G/R Ignition Ignition Ignition Ignition Ignition Ignition signal signal signal signal signal signal No. No. No. No. No. No. 5 3 1 6 4 2 SEC986C 0.1 - 0.3V★ [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,500 rpm. SEC987C ★: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) EC-748 IGNITION SIGNAL Wiring Diagram Wiring Diagram NAEC0819 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC108E EC-749 IDX IGNITION SIGNAL Wiring Diagram (Cont’d) MEC109E EC-750 IGNITION SIGNAL Wiring Diagram (Cont’d) GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC110E IDX EC-751 IGNITION SIGNAL Diagnostic Procedure Diagnostic Procedure 1 NAEC0820 CHECK ENGINE START Turn ignition switch “OFF”, and restart engine. Is engine running? Yes or No Yes (With CONSULT-II) 䊳 GO TO 2. Yes (Without CONSULTII) 䊳 GO TO 3. No 䊳 GO TO 4. 2 SEARCH FOR MALFUNCTIONING CIRCUIT With CONSULT-II 1. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II. 2. Search for circuit which does not produce a momentary engine speed drop. PBIB0133E OK or NG OK 䊳 INSPECTION END NG 䊳 GO TO 13. 3 CHECK OVERALL FUNCTION Without CONSULT-II 1. Let engine idle. 2. Read the voltage signal between ECM terminals 60, 61, 62, 79, 80, 81 and ground with oscilloscope. 3. Verify that the oscilloscope screen shows the signal wave as shown below. SEC579D OK or NG OK 䊳 INSPECTION END NG 䊳 GO TO 14. EC-752 IGNITION SIGNAL Diagnostic Procedure (Cont’d) 4 GI CHECK IGNITION COIL POWER SUPPLY CIRCUIT-I 1. Turn ignition switch ON. 2. Check voltage between ECM terminals 119, 120 and ground with CONSULT-II or tester. MA EM LC MBIB0034E Voltage: Battery voltage OK or NG OK 䊳 GO TO 5. NG 䊳 Go to TROUBLE DIAGNOSIS FOR POWER SUPPLY, EC-165. 5 FE CL MT CHECK IGNITION COIL POWER SUPPLY CIRCUIT-II AT 1. Turn ignition switch OFF. 2. Disconnect condenser harness connector. TF PD AX SU SEC562D 3. Turn ignition switch ON. 4. Check voltage between condenser terminal 1 and ground with CONSULT-II or tester. BR ST RS BT SEF367X HA OK or NG OK 䊳 GO TO 11. NG 䊳 GO TO 6. SC EL IDX EC-753 IGNITION SIGNAL Diagnostic Procedure (Cont’d) 6 CHECK IGNITION COIL POWER SUPPLY CIRCUIT-III 1. Turn ignition switch OFF. 2. Disconnect ECM relay. SEC425D 3. Check harness continuity between ECM relay terminal 3 and condenser terminal 1. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 8. NG 䊳 GO TO 7. 7 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors E1, M1 쐌 Harness connectors M33, F22 쐌 Harness for open or short between ECM relay and condenser 䊳 8 Repair open circuit or short to ground or short to power in harness or connectors. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-IV Check voltage between ECM relay terminal 5 and ground with CONSULT-II or tester. SEF010Z OK or NG OK 䊳 GO TO 10. NG 䊳 GO TO 9. 9 DETECT MALFUNCTIONING PART Check the following. 쐌 10A fuse 쐌 Harness for open and short between ECM relay and fuse 䊳 Repair or replace harness or connectors. EC-754 IGNITION SIGNAL Diagnostic Procedure (Cont’d) 10 GI CHECK ECM RELAY 1. Apply 12V direct current between ECM relay terminals 1 and 2. 2. Check continuity between ECM relay terminals 3 and 5, 6 and 7. MA EM LC SEF296X FE OK or NG OK 䊳 GO TO 20. NG 䊳 Replace ECM relay. 11 CL MT CHECK CONDENSER GROUND CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch OFF. 2. Check harness continuity between condenser terminal 2 and engine ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. AT TF OK or NG OK 䊳 GO TO 12. NG 䊳 Repair open circuit or short to power in harness or connectors. 12 PD AX CHECK CONDENSER Check resistance between condenser terminals 1 and 2. SU BR ST RS MBIB0031E Resistance: Above 1 MΩ at 25°C (77°F) BT OK or NG OK 䊳 GO TO 13. NG 䊳 Replace condenser. HA SC EL IDX EC-755 IGNITION SIGNAL Diagnostic Procedure (Cont’d) 13 CHECK IGNITION COIL POWER SUPPLY CIRCUIT-V 1. Turn ignition switch OFF. 2. Reconnect harness connectors disconnected. 3. Disconnect ignition coil harness connector. SEC561D 4. Turn ignition switch ON. 5. Check voltage between ignition coil terminal 3 and ground with CONSULT-II or tester. SEF370X OK or NG OK 䊳 GO TO 15. NG 䊳 GO TO 14. 14 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connector F211, F221 (Ignition coil No. 2, No. 4, No. 6) 쐌 Harness for open or short between ignition coil and harness connector F22 䊳 15 Repair or replace harness or connectors. CHECK IGNITION COIL GROUND CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch OFF. 2. Check harness continuity between ignition coil terminal 2 and engine ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK 䊳 GO TO 17. NG 䊳 GO TO 16. 16 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors F221, F211 (Ignition coil No. 2, No. 4, No. 6) 쐌 Check the harness for open between ignition coil and ground. 䊳 Repair or replace harness or connectors. EC-756 IGNITION SIGNAL Diagnostic Procedure (Cont’d) 17 GI CHECK IGNITION COIL OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminals 62, 81, 61, 80, 60, 79 and ignition coil terminal 1. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. MA EM OK or NG OK 䊳 GO TO 19. NG 䊳 GO TO 18. 18 LC DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors F211, F221 (Ignition coil No. 2, No. 4, No. 6) 쐌 Check the harness for open or short between ignition coil and ECM. 䊳 19 FE Repair open circuit or short to ground or short to power in harness or connectors. CL CHECK IGNITION COIL WITH POWER TRANSISTOR MT Check resistance between ignition coil terminals 2 and 3. AT TF PD SEC563D OK or NG OK 䊳 GO TO 20. NG 䊳 Replace ignition coil with power transistor. 20 AX SU BR CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 ST INSPECTION END RS BT HA SC EL IDX EC-757 INJECTOR Component Description Component Description NAEC0383 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 ball 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. SEF375Z CONSULT-II Reference Value in Data Monitor Mode NAEC0384 Specification data are reference values. MONITOR ITEM CONDITION INJ PULSE-B2 INJ PULSE-B1 쐌 쐌 쐌 쐌 B/FUEL SCHDL ditto Engine: After warming up Air conditioner switch: “OFF” Shift lever: “N” No-load SPECIFICATION Idle 2.4 - 3.2 msec 2,000 rpm 1.9 - 2.8 msec Idle 2.0 - 3.2 msec 2,000 rpm 1.4 - 2.6 msec ECM Terminals and Reference Value NAEC0685 Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V)★ [Engine is running] 쐌 Warm-up condition 쐌 Idle speed 21 22 23 40 41 42 L/W R/Y R/B PU/R R/L R/W Injector Injector Injector Injector Injector Injector No. No. No. No. No. No. 5 3 1 6 4 2 SEC984C BATTERY VOLTAGE (11 - 14V)★ [Engine is running] 쐌 Warm-up condition 쐌 Engine speed is 2,000 rpm SEC985C ★: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) EC-758 INJECTOR Wiring Diagram Wiring Diagram NAEC0386 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC111E EC-759 IDX INJECTOR Diagnostic Procedure Diagnostic Procedure 1 NAEC0387 INSPECTION START Turn ignition switch to “START”. Is any cylinder ignited? Yes or No Yes 䊳 GO TO 2. No 䊳 GO TO 3. 2 CHECK OVERALL FUNCTION With CONSULT-II 1. Start engine. 2. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II. PBIB0133E 3. Make sure that each circuit produces a momentary engine speed drop. Without CONSULT-II 1. Start engine. 2. Listen to each injector operating sound. MEC703B Clicking noise should be heard. OK or NG OK 䊳 INSPECTION END NG 䊳 GO TO 3. EC-760 INJECTOR Diagnostic Procedure (Cont’d) 3 GI CHECK INJECTOR POWER SUPPLY CIRCUIT 1. Turn ignition switch “OFF”. 2. Disconnect injector harness connector. MA EM LC SEF023Z 3. Turn ignition switch “ON”. 4. Check voltage between injector terminal 1 and ground with CONSULT-II or tester. FE CL MT AT TF SEF364Z OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 4. 4 AX DETECT MALFUNCTIONING PART SU Check the following. 쐌 Harness connectors M33, F22 쐌 Harness connectors F5, F100 쐌 Fuse block (J/B) connector M10 쐌 10A fuse 쐌 Harness for open or short between injector and fuse 䊳 PD BR ST Repair harness or connectors. RS 5 CHECK INJECTOR OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between injector terminal 2 and ECM terminals 23, 22, 21, 42, 41, 40. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 7. NG 䊳 GO TO 6. BT HA SC EL IDX EC-761 INJECTOR Diagnostic Procedure (Cont’d) 6 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors F100, F5 쐌 Harness for open or short between injector and ECM 䊳 7 Repair open circuit or short to ground or short to power in harness or connectors. CHECK INJECTOR 1. Disconnect injector harness connector. 2. Check resistance between terminals as shown in the figure. SEF964XB OK or NG OK 䊳 GO TO 8. NG 䊳 Replace injector. 8 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-762 FUEL PUMP System Description System Description Sensor Input Signal to ECM Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed* and piston position Battery Battery voltage* NAEC0392 ECM function Fuel pump control Actuator MA Fuel pump relay EM *: ECM determines the start signal status by the signals of engine speed and battery voltage. The ECM activates the fuel pump for several seconds after the ignition switch is turned on to improve engine startability. If the ECM receives a 120° signal from the camshaft position sensor (PHASE), it knows that the engine is rotating, and causes the pump to operate. If the 120° signal is not received when the ignition switch is on, the engine stalls. The ECM stops pump operation and prevents battery 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. Condition GI LC FE Fuel pump operation Ignition switch is turned to ON. CL Operates for 1 second. Engine running and cranking Operates. When engine is stopped Stops in 1.5 seconds. Except as shown above Stops. MT AT Component Description NAEC0393 The fuel pump with a fuel damper is an in-tank type (the pump and damper are located in the fuel tank). TF PD AX SU SEF018S CONSULT-II Reference Value in Data Monitor Mode NAEC0394 BR Specification data are reference values. MONITOR ITEM FUEL PUMP RLY CONDITION SPECIFICATION 쐌 Ignition switch is turned to ON. (Operates for 1 second.) 쐌 Engine running and cranking ON Except as shown above OFF ST RS BT HA SC EL IDX EC-763 FUEL PUMP ECM Terminals and Reference Value ECM Terminals and Reference Value =NAEC0686 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 113 WIRE COLOR R/L ITEM CONDITION DATA (DC Voltage) [Ignition switch “ON”] 쐌 For 1 second after turning ignition switch “ON” [Engine is running] 0 - 1.5V [Ignition switch “ON”] 쐌 1 second passed after turning ignition switch “ON”. BATTERY VOLTAGE (11 - 14V) Fuel pump relay EC-764 FUEL PUMP Wiring Diagram Wiring Diagram NAEC0396 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC112E EC-765 IDX FUEL PUMP Diagnostic Procedure Diagnostic Procedure 1 NAEC0397 CHECK OVERALL FUNCTION 1. Turn ignition switch “ON”. 2. Pinch fuel feed hose with two fingers. SEF025Z Fuel pressure pulsation should be felt on the fuel feed hose for 1 second after ignition switch is turned “ON”. OK or NG OK 䊳 INSPECTION END NG 䊳 GO TO 2. 2 CHECK FUEL PUMP RELAY POWER SUPPLY CIRCUIT-I 1. Turn ignition switch “OFF”. 2. Disconnect fuel pump relay. SEC564D 3. Turn ignition switch “ON”. 4. Check voltage between terminals 1, 3 and ground with CONSULT-II or tester. SEC565D Voltage: Battery voltage OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 3. EC-766 FUEL PUMP Diagnostic Procedure (Cont’d) 3 GI DETECT MALFUNCTIONING PART Check the following. 쐌 Fuse block (J/B) connector M10 쐌 15A fuse in fuse block (J/B) 쐌 Harness connectors M2, B1 쐌 Harness for open or short between fuse and fuel pump relay and fuse 䊳 4 MA EM Repair harness or connectors. LC CHECK FUEL PUMP POWER SUPPLY AND GROUND CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Disconnect fuel pump harness connector. FE CL MT SEF021S 3. Check harness continuity between fuel pump terminal 2 and body ground, fuel pump terminal 1 and fuel pump relay terminal 5. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 6. NG 䊳 GO TO 5. 5 Repair open circuit or short to ground or short to power in harness or connectors. CHECK FUEL PUMP RELAY OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 113 and fuel pump relay terminal 2. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 8. NG 䊳 GO TO 7. PD SU Check the following. 쐌 Harness connectors B24, D101 쐌 Harness connectors D106, D206 쐌 Harness for open or short between fuel pump relay and fuel pump 쐌 Harness for open between fuel pump and ground 6 TF AX DETECT MALFUNCTIONING PART 䊳 AT BR ST RS BT HA SC EL IDX EC-767 FUEL PUMP Diagnostic Procedure (Cont’d) 7 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors B1, M2 쐌 Harness connectors M32, F23 쐌 Harness for open or short between ECM and fuel pump relay 䊳 8 Repair open circuit or short to ground or short to power in harness or connectors. CHECK FUEL PUMP RELAY With CONSULT-II 1. Reconnect fuel pump relay, fuel pump harness connector and ECM harness connector. 2. Turn ignition switch “ON”. 3. Turn fuel pump relay “ON” and “OFF” in “ACTIVE TEST” mode with CONSULT-II and check operating sound. SEF073Y Without CONSULT-II Check continuity between terminals 3 and 5 under the following conditions. SEC566D MTBL1373 OK or NG OK 䊳 GO TO 9. NG 䊳 Replace fuel pump relay. EC-768 FUEL PUMP Diagnostic Procedure (Cont’d) 9 GI CHECK FUEL PUMP 1. Disconnect fuel pump harness connector. 2. Check resistance between fuel pump terminals 1 and 2. MA EM LC SEF027Z FE OK or NG OK 䊳 GO TO 10. NG 䊳 Replace fuel pump. 10 CL MT CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 AT INSPECTION END TF PD AX SU BR ST RS BT HA SC EL IDX EC-769 REFRIGERANT PRESSURE SENSOR Description Description NAEC0636 The refrigerant pressure sensor is installed at the condenser of the air conditioner system. The sensor uses an electrostatic volume pressure transducer to convert refrigerant pressure to voltage. The voltage signal is sent to ECM. SEC567D SEF099XA ECM Terminals and Reference Value NAEC0689 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) 49 P/B Sensors’ power supply [Ignition switch “ON”] Approximately 5V 67 B/P Sensors’ ground [Engine is running] 쐌 Warm-up condition 쐌 Idle speed Approximately 0V W/PU Refrigerant pressure sensor [Engine is running] 쐌 Warm-up condition 쐌 Both A/C switch and blower switch are “ON”. (Compressor operates.) 1.0 - 4.0V 70 EC-770 REFRIGERANT PRESSURE SENSOR Wiring Diagram Wiring Diagram NAEC0637 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC114E EC-771 IDX REFRIGERANT PRESSURE SENSOR Diagnostic Procedure Diagnostic Procedure 1 NAEC0638 CHECK REFRIGERANT PRESSURE SENSOR OVERALL FUNCTION 1. Start engine and warm it up to normal operating temperature. 2. Turn A/C switch and blower switch “ON”. 3. Check voltage between ECM terminal 70 and ground with CONSULT-II or tester. PBIB0832E Voltage: 1 - 4V OK or NG OK 䊳 INSPECTION END NG 䊳 GO TO 2. 2 CHECK REFRIGERANT PRESSURE SENSOR POWER SUPPLY CIRCUIT 1. Turn A/C switch and blower switch “OFF”. 2. Stop engine. 3. Disconnect refrigerant pressure sensor harness connector. SEC567D 4. Turn ignition switch “ON”. 5. Check voltage between refrigerant pressure sensor terminal 3 and ground with CONSULT-II or tester. SEF030Z OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 3. EC-772 REFRIGERANT PRESSURE SENSOR Diagnostic Procedure (Cont’d) 3 GI DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors E1, M1 쐌 Harness connectors M32, F23 쐌 Harness for open or short between ECM and refrigerant pressure sensor 䊳 4 Repair harness or connectors. CHECK REFRIGERANT PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT MA EM LC 1. Turn ignition switch “OFF”. 2. Check harness continuity between refrigerant pressure sensor terminal 1 and engine ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK 䊳 GO TO 6. NG 䊳 GO TO 5. 5 CL DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors E116, M114 쐌 Harness connectors M94, F27 쐌 Joint connector F204 쐌 Harness for open between ECM and refrigerant pressure sensor 쐌 Harness connectors F22, M33 (A/T models) 쐌 Harness for open between TCM and refrigerant pressure sensor (A/T models) 䊳 6 MT AT TF Repair open circuit or short to power in harness or connectors. PD CHECK REFRIGERANT PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Disconnect ECM harness connector. 2. Check harness continuity between ECM terminal 70 and refrigerant pressure sensor terminal 2. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 8. NG 䊳 GO TO 7. 7 FE SU BR ST DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors E1, M1 쐌 Harness connectors M94, F27 쐌 Harness for open or short between ECM and refrigerant pressure sensor 䊳 AX RS BT Repair open circuit or short to ground or short to power in harness or connectors. HA 8 CHECK REFRIGERANT PRESSURE SENSOR SC Refer to HA-16, “Refrigerant pressure sensor”. OK or NG OK 䊳 GO TO 9. NG 䊳 Replace refrigerant pressure sensor. EL IDX EC-773 REFRIGERANT PRESSURE SENSOR Diagnostic Procedure (Cont’d) 9 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-774 ASCD BRAKE SWITCH Component Description Component Description NAEC1348 When depressing the brake pedal, ASCD brake switch is turned OFF and stop lamp switch is turned ON. ECM detects the state of the brake pedal by this two kinds of input (ON/OFF signal). Refer to EC-62 for the ASCD function. GI MA EM LC SEC549D CONSULT-II Reference Value in Data Monitor Mode NAEC1349 CONSULT-II Reference Value in Data Monitor Mode Specification data are reference values. MONITOR ITEM BRAKE SW 1 (ASCD brake switch) BRAKE SW 2 (Stop lamp switch) CONDITION 쐌 Ignition switch: ON 쐌 Ignition switch: ON SPECIFICATION CL 쐌 Brake pedal fully released 쐌 Clutch pedal is fully released (M/T models) ON 쐌 Brake pedal depressed 쐌 Clutch pedal is depressed (M/T models) OFF 쐌 Brake pedal fully released OFF 쐌 Brake pedal depressed ON MT AT ECM Terminals and Reference Value TF NAEC1356 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 101 108 WIRE COLOR G/Y L/Y ITEM Stop lamp switch ASCD brake switch CONDITION FE DATA (DC Voltage) PD AX SU [Ignition switch “ON”] 쐌 Brake pedal is fully released Approximately 0V BR [Ignition switch “ON”] 쐌 Brake pedal is depressed BATTERY VOLTAGE (11 - 14V) ST [Ignition switch “ON”] 쐌 Brake pedal is fully released 쐌 Clutch pedal is fully released (M/T models) BATTERY VOLTAGE (11 - 14V) RS [Ignition switch “ON”] 쐌 Brake pedal is depressed 쐌 Clutch pedal is depressed (M/T models) Approximately 0V BT HA SC EL IDX EC-775 ASCD BRAKE SWITCH Wiring Diagram Wiring Diagram NAEC1350 MEC119E EC-776 ASCD BRAKE SWITCH Diagnostic Procedure Diagnostic Procedure 1 NAEC1351 GI CHECK OVERALL FUNCTION-I MA With CONSULT-II 1. Turn ignition switch “ON”. 2. Select “BRAKE SW1” in “DATA MONITOR” mode with CONSULT-II. 3. Check the indication of “BRAKE SW1” under the following conditions. EM LC FE SEC011D CL MT AT MTBL1334 TF PD Without CONSULT-II 1. Turn ignition switch “ON”. 2. Check voltage between ECM terminal 108 and ground under the following conditions. AX SU BR ST MBIB0061E RS BT HA MTBL1335 OK or NG OK 䊳 GO TO 2. NG 䊳 GO TO 3. SC EL IDX EC-777 ASCD BRAKE SWITCH Diagnostic Procedure (Cont’d) 2 CHECK OVERALL FUNCTION-II With CONSULT-II See “BRAKE SW2” indication in “DATA MONITOR” mode. SEC013D MTBL1336 Without CONSULT-II Check voltage between ECM terminal 101 and ground under the following conditions. MBIB0060E MTBL1337 OK or NG OK 䊳 INSPECTION END NG 䊳 GO TO 11. EC-778 ASCD BRAKE SWITCH Diagnostic Procedure (Cont’d) 3 1. 2. 3. 4. GI CHECK ASCD BRAKE SWITCH POWER SUPPLY CIRCUIT Turn ignition switch “OFF”. Disconnect ASCD brake switch harness connector. Turn ignition switch “ON”. Check voltage between ASCD brake switch terminal 1 and ground with CONSULT-II or tester. MA EM LC FE PBIB0857E Voltage: Battery voltage CL OK or NG OK (A/T models) 䊳 GO TO 5. OK (M/T models) 䊳 GO TO 7. NG 䊳 GO TO 4. 4 MT AT DETECT MALFUNCTIONING PART Check the following. 쐌 Fuse block (J/B) connector M10 쐌 7.5A fuse 쐌 Harness for open or short between ASCD brake switch and fuse 䊳 TF PD Repair open circuit or short to ground or short to power in harness or connectors. AX 5 CHECK ASCD BRAKE SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Turn ignition switch “OFF”. 2. Disconnect ECM harness connector. 3. Check harness continuity between ECM terminal 108 and ASCD brake switch terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for open to ground and short to power. OK or NG OK 䊳 GO TO 10. NG 䊳 GO TO 6. 6 BR ST RS BT DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors M94, F27 쐌 Harness for open and short between ECM and ASCD brake switch 䊳 SU HA Repair open circuit or short to ground or short to power in harness or connectors. SC EL IDX EC-779 ASCD BRAKE SWITCH Diagnostic Procedure (Cont’d) 7 CHECK ASCD CLUTCH SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. 3. 4. Turn ignition switch “OFF”. Disconnect ASCD clutch switch harness connector. Disconnect ECM harness connector. Check harness continuity between ASCD brake switch terminal 2 and ASCD clutch switch terminal 1, ASCD clutch switch terminal 2 and ECM terminal 108. Refer to Wiring Diagram. Continuity should exist. 5. Also check harness for open to ground and short to power. OK or NG OK 䊳 GO TO 9. NG 䊳 GO TO 8. 8 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors M94, F27 쐌 Harness for open and short between ASCD brake switch and ASCD clutch switch 쐌 Harness for open and short between ASCD clutch switch and ECM 䊳 9 Repair open circuit or short to ground or short to power in harness or connectors. CHECK ASCD CLUTCH SWITCH Refer to “Component Inspection”, EC-694. OK or NG OK 䊳 GO TO 10. NG 䊳 Replace ASCD clutch switch. 10 CHECK ASCD BRAKE SWITCH Refer to “Component Inspection”, EC-694. OK or NG OK 䊳 GO TO 16. NG 䊳 Replace ASCD brake switch. EC-780 ASCD BRAKE SWITCH Diagnostic Procedure (Cont’d) 11 GI CHECK STOP LAMP SWITCH POWER SUPPLY CIRCUIT 1. Turn ignition switch “OFF”. 2. Disconnect stop lamp switch harness connector. 3. Check voltage between stop lamp switch terminal 1 and ground with CONSULT-II or tester. A/T models MA EM LC FE SEC547D M/T models CL MT AT TF PBIB0117E Voltage: Battery voltage OK or NG OK 䊳 GO TO 13. NG 䊳 GO TO 12. 12 PD AX SU DETECT MALFUNCTIONING PART Check the following. 쐌 Fuse block (J/B) connector M10 쐌 10A fuse 쐌 Harness for open or short between stop lamp switch and fuse 䊳 BR ST Repair open circuit or short to ground in harness or connectors. RS 13 CHECK STOP LAMP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Disconnect ECM harness connector. 2. Check harness continuity between stop lamp switch terminal 2 and ECM terminal 101. Refer to wiring diagram. Continuity should exist 3. Also check harness for short to ground and short to power. BT HA OK or NG OK 䊳 GO TO 15. NG 䊳 GO TO 14. SC EL IDX EC-781 ASCD BRAKE SWITCH Diagnostic Procedure (Cont’d) 14 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors M94, F27 쐌 Harness for open or short between stop lamp switch and ECM 䊳 15 Repair open circuit or short to ground or short to power in harness or connectors. CHECK STOP LAMP SWITCH Refer to “Component Inspection”, EC-694. OK or NG OK 䊳 GO TO 16. NG 䊳 Replace stop lamp switch. 16 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-782 ASCD INDICATOR LAMP Component Description Component Description NAEC1352 ASCD indicator lamp illuminates to indicate ASCD operation status. Lamp has two indicators, CRUISE and SET, and is integrated in combination meter. CRUISE indicator illuminates when CRUISE switch on steering switch is turned ON to indicate that ASCD system is ready for operation. SET indicator illuminates when following conditions are met. CRUISE indicator illuminates, and SET switch on steering switch is turned ON while vehicle speed is within range of ASCD setting. SET indicator remains lit during ASCD control. Refer to EC-62 for ASCD functions. GI MA EM LC FE CL MT CONSULT-II Reference Value in Data Monitor Mode NAEC1353 Specification data are reference values. MONITOR ITEM CONDITION 쐌 CRUISE switch is depressed at first time , second time. CRUISE LAMP 쐌 Ignition switch: ON SET LAMP 쐌 When vehicle speed is between 40 km/h 쐌 COAST/SET switch pressed (25 MPH) to 144 km/h (89 MPH), and 쐌 ASCD control is canceled. CRUISE switch is ON. SPECIFICATION AT TF PD ON , OFF ON AX OFF SU BR ST RS BT HA SC EL IDX EC-783 ASCD INDICATOR LAMP Wiring Diagram Wiring Diagram NAEC1354 MEC190E EC-784 ASCD INDICATOR LAMP Diagnostic Procedure Diagnostic Procedure 1 NAEC1355 GI CHECK OVERALL FUNCTION MA Check ASCD indicator under the following conditions. EM LC MTBL1260 OK or NG OK 䊳 INSPECTION END NG 䊳 GO TO 2. 2 FE CHECK DTC CL Make sure that DTC U1000 or U1001 is not displayed. OK or NG OK 䊳 GO TO 3. NG 䊳 Perform “Diagnostic Procedure” for DTC U1000 or U1001, EC-174. 3 CHECK COMBINATION METER OPERATION Check that combination meter operates normally. MT AT TF OK or NG PD OK 䊳 GO TO 4. NG 䊳 Check combination meter circuit. Refer to EL-123. AX 4 CHECK INTERMITTENT INCIDENT Refer to “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 SU INSPECTION END BR ST RS BT HA SC EL IDX EC-785 ELECTRICAL LOAD SIGNAL ECM Terminals and Reference Value ECM Terminals and Reference Value NAEC0690 Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM’s transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 84 93 WIRE COLOR OR B/L ITEM Headlamp signal Rear window defogger signal CONDITION DATA (DC Voltage) [Engine is running] 쐌 Headlamp: ON BATTERY VOLTAGE (11 - 14V) [Engine is running] 쐌 Headlamp: OFF 0V [Engine is running] 쐌 Rear window defogger: ON BATTERY VOLTAGE (11 - 14V) [Engine is running] 쐌 Rear window defogger: OFF 0V EC-786 ELECTRICAL LOAD SIGNAL Wiring Diagram Wiring Diagram NAEC0604 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC115E EC-787 IDX ELECTRICAL LOAD SIGNAL Diagnostic Procedure Diagnostic Procedure 1 NAEC0605 CHECK LOAD SIGNAL CIRCUIT OVERALL FUNCTION-I 1. Turn ignition switch “ON”. 2. Check voltage between ECM terminal 93 and ground under the following conditions. SEC568D MTBL1374 OK or NG OK 䊳 GO TO 2. NG 䊳 GO TO 3. 2 CHECK LOAD SIGNAL CIRCUIT OVERALL FUNCTION-II Check voltage between ECM terminal 84 and ground under the following conditions. MBIB0158E MTBL1375 OK or NG OK 䊳 INSPECTION END NG 䊳 GO TO 7. EC-788 ELECTRICAL LOAD SIGNAL Diagnostic Procedure (Cont’d) 3 GI CHECK REAR WINDOW DEFOGGER FUNCTION 1. Start engine. 2. Turn “ON” the rear window defogger switch. 3. Check the rear windshield. Is the rear windshield heated up? MA Yes or No Yes 䊳 GO TO 4. No 䊳 Refer to EL-177, “Rear Window Defogger”. 4 1. 2. 3. 4. EM LC CHECK REAR WINDOW DEFOGGER INPUT SIGNAL CIRCUIT FOR OPEN OR SHORT Stop engine. Disconnect ECM harness connector. Disconnect rear window defogger relay. Check harness continuity between ECM terminal 93 and rear window defogger relay terminal 7. FE CL MT AT TF PD AX SU SEC569D BR ST MTBL1376 5. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 6. NG 䊳 GO TO 5. 5 RS BT HA DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors E1, M1 쐌 Harness connectors M33, F22 쐌 Diode M37 쐌 Harness for open and short between ECM and rear window defigger relay 䊳 Repair open circuit or short to ground or short to power in harness or connectors. EC-789 SC EL IDX ELECTRICAL LOAD SIGNAL Diagnostic Procedure (Cont’d) 6 CHECK INTERMITTENT INCIDENT Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 7 INSPECTION END CHECK HEADLAMP FUNCTION 1. Start engine. 2. Turn the lighting switch “ON” at 1st position with high beam. 3. Check that headlamps are illuminated. OK or NG OK 䊳 GO TO 8. NG 䊳 Refer to EL-35, “HEADLAMP (FOR USA)”. 8 1. 2. 3. 4. CHECK HEADLAMP INPUT SIGNAL CIRCUIT FOR OPEN OR SHORT Stop engine. Disconnect ECM harness connector. Disconnect headlamp LH relay. Check harness continuity between ECM terminal 84 and headlamp LH relay terminal 5 under the following conditions. SEC570D 5. Also check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 10. NG 䊳 GO TO 9. 9 DETECT MALFUNCTIONING PART Check the following. 쐌 Harness connectors E1, M1 쐌 Harness connectors M33, F22 쐌 Diode E121 쐌 Harness for open and short between ECM and headlamp LH relay 䊳 10 Repair open circuit or short to ground or short to power in harness or connectors. CHECK INTERMITTENT INCIDENT Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”, EC-163. 䊳 INSPECTION END EC-790 MIL & DATA LINK CONNECTORS Wiring Diagram Wiring Diagram NAEC0407 GI MA EM LC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL MEC116E EC-791 IDX SERVICE DATA AND SPECIFICATIONS (SDS) Fuel Pressure Regulator Fuel Pressure Regulator NAEC0408 Fuel pressure at idling kPa (kg/cm2, psi) Condition Vacuum hose is connected. Approximately 235 (2.4, 34) Vacuum hose is disconnected. Approximately 294 (3.0, 43) Idle Speed and Ignition Timing Target idle speed*1 NAEC0409 No-load*2 (in “P” or N” position) M/T: 750±50 rpm A/T: 750±50 rpm Air conditioner: ON In “P” or N” position 825 rpm or more Ignition timing*1 In “P” or N” position 15°±5° BTDC *1: *2: 쐌 쐌 쐌 Throttle position sensor harness connector connected Under the following conditions: Air conditioner switch: OFF Electric load: OFF (Lights, heater fan & rear window defogger) Steering wheel: Kept in straight-ahead position Mass Air Flow Sensor (Type I) Supply voltage NAEC0411 Battery voltage (11 - 14V) Output voltage at idle 1.2 - 1.8V* 2.0 - 6.0 g·m/sec at idle* 7.0 - 20.0 g·m/sec at 2,500 rpm* Mass air flow (Using CONSULT-II or GST) *: Engine is warmed up to normal operating temperature and running under no-load. Mass Air Flow Sensor (Type II) Supply voltage NAEC1412 Battery voltage (11 - 14V) Output voltage at idle 1.0 - 1.3V* 2.0 - 6.0 g·m/sec at idle* 7.0 - 20.0 g·m/sec at 2,500 rpm* Mass air flow (Using CONSULT-II or GST) *: Engine is warmed up to normal operating temperature and running under no-load. Engine Coolant Temperature Sensor Temperature °C (°F) NAEC0412 Resistance kΩ 20 (68) 2.1 - 2.9 50 (122) 0.68 - 1.00 90 (194) 0.236 - 0.260 Heated Oxygen Sensor 1 Heater Resistance [at 25°C (77°F)] NAEC0414 3.3 - 4.0Ω Heated Oxygen Sensor 2 Heater Resistance [at 25°C (77°F)] NAEC0422 5.0 - 7.0Ω Fuel Pump Resistance [at 25°C (77°F)] NAEC0415 0.2 - 5.0Ω Injector Resistance [at 20°C (68°F)] NAEC0417 13.5 - 17.5Ω EC-792 SERVICE DATA AND SPECIFICATIONS (SDS) Calculated Load Value Calculated Load Value NAEC0420 GI Calculated load value % (Using CONSULT-II or GST) At idle 14.0 - 33.0 At 2,500 rpm 12.0 - 25.0 Intake Air Temperature Sensor Temperature °C (°F) MA EM NAEC0421 LC Resistance kΩ 25 (77) 1.9 - 2.1 Fuel Tank Temperature Sensor Temperature °C (°F) NAEC0424 Resistance kΩ 20 (68) 2.3 - 2.7 50 (122) 0.79 - 0.90 Crankshaft Position Sensor (POS) FE CL NAEC1357 Refer to “Component Inspection”, EC-350. MT Camshaft Position Sensor (PHASE) Refer to “Component Inspection”, EC-357. NAEC1358 AT TF PD AX SU BR ST RS BT HA SC EL IDX EC-793 NOTES BODY & TRIM SECTION BT GI MA EM LC EC FE CONTENTS PRECAUTIONS ...............................................................3 Service Notice..............................................................3 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″...............3 PREPARATION ...............................................................4 Special Service Tools ..................................................4 Commercial Service Tool.............................................4 SQUEAK AND RATTLE TROUBLE DIAGNOSES.........5 Work Flow....................................................................5 CUSTOMER INTERVIEW ...........................................5 DUPLICATE THE NOISE AND TEST DRIVE ................6 CHECK RELATED SERVICE BULLETINS ...................6 LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE .....................................................................6 REPAIR THE CAUSE .................................................6 CONFIRM THE REPAIR .............................................7 Generic Squeak and Rattle Troubleshooting ..............7 INSTRUMENT PANEL ................................................7 CENTER CONSOLE ..................................................7 DOORS.....................................................................7 TRUNK .....................................................................8 SUNROOF/HEADLINER .............................................8 SEATS ......................................................................8 UNDERHOOD ...........................................................8 Diagnostic Worksheet..................................................9 CLIP AND FASTENER..................................................11 Description .................................................................11 BODY FRONT END.......................................................13 Removal and Installation ...........................................13 FRONT BUMPER ASSEMBLY ..................................13 BODY REAR END AND OPENER................................16 Removal and Installation ...........................................16 REAR BUMPER ASSEMBLY ....................................16 FRONT DOOR ...............................................................19 Overhaul ....................................................................19 Front Door Limit Switch Reset ..................................20 RESET CONDITIONS ..............................................20 RESET PROCEDURES ............................................20 REAR DOOR .................................................................21 Overhaul ....................................................................21 INSTRUMENT PANEL ASSEMBLY .............................22 Removal and Installation ...........................................22 SIDE AND FLOOR TRIM...............................................29 Removal and Installation ...........................................29 DOOR TRIM ...................................................................31 Removal and Installation ...........................................31 TYPE A ...................................................................31 TYPE B ...................................................................32 ROOF TRIM ...................................................................34 Removal and Installation ...........................................34 BACK DOOR TRIM .......................................................35 Removal and Installation ...........................................35 EXTERIOR .....................................................................36 Removal and Installation ...........................................36 FRONT SEAT ................................................................43 Removal and Installation ...........................................43 POWER SEAT .........................................................44 MANUAL SEAT........................................................45 HEATED SEAT ........................................................46 REAR SEAT...................................................................47 Removal and Installation ...........................................47 SUNROOF......................................................................48 Adjustment .................................................................48 Contents of Working ..................................................49 Contents of Switch Working ......................................50 JAM PROTECTION ..................................................50 Removal and Installation ...........................................50 Trouble Diagnoses.....................................................54 DIAGNOSTIC TABLE................................................54 WIND DEFLECTOR .................................................54 ADJUSTMENT .........................................................55 DRAIN HOSES ........................................................56 WEATHERSTRIP .....................................................57 LINK AND WIRE ASSEMBLY ....................................57 WINDSHIELD AND WINDOWS ....................................58 Removal and Installation ...........................................58 REMOVAL ...............................................................58 INSTALLATION........................................................58 WINDSHIELD ..........................................................59 REAR SIDE WINDOW ..............................................60 CL MT AT TF PD AX SU BR ST RS HA SC EL IDX CONTENTS DOOR MIRROR .............................................................61 Removal and Installation ...........................................61 BODY (ALIGNMENT) ....................................................62 BT-2 (Cont’d) Alignment ...................................................................62 ENGINE COMPARTMENT ........................................63 UNDERBODY ..........................................................65 PRECAUTIONS Service Notice Service Notice I I I I I NABT0030 When removing or installing various parts, place a cloth or padding onto the vehicle body to prevent scratches. Handle trim, molding, instruments, grille, etc. carefully during removing or installing. 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 (for example body outer panel, members, etc.), be sure to take rust prevention measures. Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” GI MA EM LC EC NABT0023 The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS system composition which is available to NISSAN MODEL R50 is as follows: I For a frontal collision The Supplemental Restraint System consists of driver air bag module (located in the center of the steering wheel), front passenger air bag module (located on the instrument panel on passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. I For a side collision The Supplemental Restraint System consists of side air bag module (located in the outer side of front seat), satellite sensor, side curtain air bag module (located in the headlining side of front and rear seat), diagnosis sensor unit (one of components of air bags for a frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision). Information necessary to service the system safely is included in the RS section of this Service Manual. WARNING: I 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. I Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the RS section. I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified with yellow and/or orange harness connector (and with yellow harness protector or yellow insulation tape before the harness connectors). FE CL MT AT TF PD AX SU BR ST RS HA SC EL IDX BT-3 PREPARATION Special Service Tools Special Service Tools NABT0024 The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name Description — (J-39570) Chassis ear Locating the noise SBT839 — (J-43980) Nissan Squeak and Rattle kit Repairing the cause of noize SBT840 Commercial Service Tool Tool name Description Engine ear Locating the noise SBT841 BT-4 NABT0025 SQUEAK AND RATTLE TROUBLE DIAGNOSES Work Flow Work Flow NABT0026 GI MA EM LC EC FE CL SBT842 CUSTOMER INTERVIEW NABT0026S01 Interview the customer, if possible, to determine the conditions that exist when the noise occurs. Use the Diagnostic Worksheet during the interview to document the facts and conditions when the noise occurs and any customer’s comments; refer to BT-9. This information is necessary to duplicate the conditions that exist when the noise occurs. I The customer may not be able to provide a detailed description or the location of the noise. Attempt to obtain all the facts and conditions that exist when the noise occurs (or does not occur). I If there is more than one noise in the vehicle, be sure to diagnose and repair the noise that the customer is concerned about. This can be accomplished by test driving the vehicle with the customer. I After identifying the type of noise, isolate the noise in terms of its characteristics. The noise characteristics are provided so the customer, service adviser and technician are all speaking the same language when defining the noise. I Squeak — (Like tennis shoes on a clean floor) Squeak characteristics include the light contact/fast movement/brought on by road conditions/hard surfaces = higher pitch noise/softer surfaces = lower pitch noises/edge to surface = chirping I Creak — (Like walking on an old wooden floor) Creak characteristics include firm contact/slow movement/twisting with a rotational movement/pitch dependent on materials/often brought on by activity. I Rattle — (Like shaking a baby rattle) Rattle characteristics include the fast repeated contact/vibration or similar movement/loose parts/missing clip or fastener/incorrect clearance. I Knock — (Like a knock on a door) Knock characteristics include hollow sounding/sometimes repeating/often brought on by driver action. I Tick — (Like a clock second hand) Tick characteristics include gentle contacting of light materials/loose components/can be caused by driver action or road conditions. I Thump — (Heavy, muffled knock noise) Thump characteristics include softer knock/dead sound often brought on by activity. I Buzz — (Like a bumble bee) Buzz characteristics include high frequency rattle/firm contact. I Often the degree of acceptable noise level will vary depending upon the person. A noise that you may judge as acceptable may be very irritating to the customer. I Weather conditions, especially humidity and temperature, may have a great effect on noise level. MT AT TF PD AX SU BR ST RS HA SC EL IDX BT-5 SQUEAK AND RATTLE TROUBLE DIAGNOSES Work Flow (Cont’d) DUPLICATE THE NOISE AND TEST DRIVE NABT0026S02 If possible, drive the vehicle with the customer until the noise is duplicated. Note any additional information on the Diagnostic Worksheet regarding the conditions or location of the noise. This information can be used to duplicate the same conditions when you confirm the repair. If the noise can be duplicated easily during the test drive, to help identify the source of the noise, try to duplicate the noise with the vehicle stopped by doing one or all of the following: 1) Close a door. 2) Tap or push/pull around the area where the noise appears to be coming from. 3) Rev the engine. 4) Use a floor jack to recreate vehicle “twist”. 5) At idle, apply engine load (electrical load, half-clutch on M/T model, drive position on A/T model). 6) Raise the vehicle on a hoist and hit a tire with a rubber hammer. I Drive the vehicle and attempt to duplicate the conditions the customer states exist when the noise occurs. I If it is difficult to duplicate the noise, drive the vehicle slowly on an undulating or rough road to stress the vehicle body. CHECK RELATED SERVICE BULLETINS NABT0026S03 After verifying the customer concern or symptom, check ASIST for Technical Service Bulletins (TSBs) related to that concern or symptom. If a TSB relates to the symptom, follow the procedure to repair the noise. LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE NABT0026S04 1. Narrow down the noise to a general area. To help pinpoint the source of the noise, use a listening tool (Chassis Ear: J-39570, Engine Ear: J-39565 and mechanics stethoscope). 2. Narrow down the noise to a more specific area and identify the cause of the noise by: I removing the components in the area that you suspect the noise is coming from. Do not use too much force when removing clips and fasteners, otherwise clips and fastener can be broken or lost during the repair, resulting in the creation of new noise. I tapping or pushing/pulling the component that you suspect is causing the noise. Do not tap or push/pull the component with excessive force, otherwise the noise will be eliminated only temporarily. I feeling for a vibration with your hand by touching the component(s) that you suspect is (are) causing the noise. I placing a piece of paper between components that you suspect are causing the noise. I looking for loose components and contact marks. Refer to “Generic Squeak and Rattle Troubleshooting”, BT-7. REPAIR THE CAUSE NABT0026S05 I I − − If the cause is a loose component, tighten the component securely. If the cause is insufficient clearance between components: separate components by repositioning or loosening and retightening the component, if possible. insulate components with a suitable insulator such as urethane pads, foam blocks, felt cloth tape or urethane tape. A Nissan Squeak and Rattle Kit (J-43980) is available through your authorized Nissan Parts Department. CAUTION: Do not use excessive force as many components are constructed of plastic and may be damaged. Always check with the Parts Department for the latest parts information. The following materials are contained in the Nissan Squeak and Rattle Kit (J-43980). Each item can be ordered separately as needed. URETHANE PADS [1.5 mm (0.059 in) thick] Insulates connectors, harness, etc. 76268-9E005: 100 x 135 mm (3.94 x 5.31 in)/76884-71L01: 60 x 85 mm (2.36 x 3.35 in)/76884-71L02: 15 x 25 mm (0.59 x 0.98 in) INSULATOR (Foam blocks) Insulates components from contact. Can be used to fill space behind a panel. 73982-9E000: 45 mm (1.77 in) thick, 50 x 50 mm (1.97 x 1.97 in)/73982-50Y00: 10 mm (0.39 in) thick, 50 x 50 mm (1.97 x 1.97 in) INSULATOR (Light foam block) BT-6 SQUEAK AND RATTLE TROUBLE DIAGNOSES Work Flow (Cont’d) 80845-71L00: 30 mm (1.18 in) thick, 30 x 50 mm (1.18 x 1.97 in) FELT CLOTH TAPE Used to insulate where movement does not occur. Ideal for instrument panel applications. 68370-4B000: 15 x 25 mm (0.59 x 0.98 in) pad/68239-13E00: 5 mm (0.20 in) wide tape roll The following materials, not found in the kit, can also be used to repair squeaks and rattles. UHMW (TEFLON) TAPE Insulates where slight movement is present. Ideal for instrument panel applications. SILICONE GREASE Used in place of UHMW tape that will be visible or not fit. Note: Will only last a few months. SILICONE SPRAY Use when grease cannot be applied. DUCT TAPE Use to eliminate movement. CONFIRM THE REPAIR GI MA EM LC EC NABT0026S06 Confirm that the cause of a noise is repaired by test driving the vehicle. Operate the vehicle under the same conditions as when the noise originally occurred. Refer to the notes on the Diagnostic Worksheet. Generic Squeak and Rattle Troubleshooting FE CL NABT0027 Refer to Table of Contents for specific component removal and installation information. MT INSTRUMENT PANEL NABT0027S01 Most incidents are caused by contact and movement between: 1. The cluster lid A and instrument panel 2. Acrylic lens and combination meter housing 3. Instrument panel to front pillar garnish 4. Instrument panel to windshield 5. Instrument panel mounting pins 6. Wiring harnesses behind the combination meter 7. A/C defroster duct and duct joint These incidents can usually be located by tapping or moving the components to duplicate the noise or by pressing on the components while driving to stop the noise. Most of these incidents can be repaired by applying felt cloth tape or silicon spray (in hard to reach areas). Urethane pads can be used to insulate wiring harness. CAUTION: Do not use silicone spray to isolate a squeak or rattle. If you saturate the area with silicone, you will not be able to recheck the repair. CENTER CONSOLE AT TF PD AX SU BR NABT0027S02 Components to pay attention to include: 1. Shifter assembly cover to finisher 2. A/C control unit and cluster lid C 3. Wiring harnesses behind audio and A/C control unit The instrument panel repair and isolation procedures also apply to the center console. DOORS ST RS NABT0027S03 Pay attention to the: 1. Finisher and inner panel making a slapping noise 2. Inside handle escutcheon to door finisher 3. Wiring harnesses tapping 4. Door striker out of alignment causing a popping noise on starts and stops Tapping or moving the components or pressing on them while driving to duplicate the conditions can isolate many of these incidents. You can usually insulate the areas with felt cloth tape or insulator foam blocks from the Nissan Squeak and Rattle Kit (J-43980) to repair the noise. HA SC EL IDX BT-7 SQUEAK AND RATTLE TROUBLE DIAGNOSES Generic Squeak and Rattle Troubleshooting (Cont’d) TRUNK =NABT0027S04 Trunk noises are often caused by a loose jack or loose items put into the trunk by the owner. In addition look for: 1. Trunk lid bumpers out of adjustment 2. Trunk lid striker out of adjustment 3. The trunk lid torsion bars knocking together 4. A loose license plate or bracket Most of these incidents can be repaired by adjusting, securing or insulating the item(s) or component(s) causing the noise. SUNROOF/HEADLINER NABT0027S05 Noises in the sunroof/headliner area can often be traced to one of the following: 1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise 2. Sunvisor shaft shaking in the holder 3. Front or rear windshield touching headliner and squeaking Again, pressing on the components to stop the noise while duplicating the conditions can isolate most of these incidents. Repairs usually consist of insulating with felt cloth tape. SEATS NABT0027S06 When isolating seat noises it’s important to note the position the seat is in and the load placed on the seat when the noise is present. These conditions should be duplicated when verifying and isolating the cause of the noise. Cause of seat noise include: 1. Headrest rods and holders 2. A squeak between the seat pad cushion and frame 3. The rear seat back lock and bracket These noises can be isolated by moving or pressing on the suspected components while duplicating the conditions under which the noise occurs. Most of these incidents can be repaired by repositioning the component or applying urethane tape to the contact area. UNDERHOOD NABT0027S07 Some interior noises may be caused by components under the hood or on the engine wall. The noise is then transmitted into the passenger compartment. Causes of transmitted underhood noises include: 1. Any component mounted to the engine wall 2. Components that pass through the engine wall 3. Engine wall mounts and connectors 4. Loose radiator mounting pins 5. Hood bumpers out of adjustment 6. Hood striker out of adjustment These noises can be difficult to isolate since they cannot be reached from the interior of the vehicle. The best method is to secure, move or insulate one component at a time and test drive the vehicle. Also, engine RPM or load can be changed to isolate the noise. Repairs can usually be made by moving, adjusting, securing, or insulating the component causing the noise. BT-8 SQUEAK AND RATTLE TROUBLE DIAGNOSES Diagnostic Worksheet Diagnostic Worksheet NABT0028 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS HA SC EL SBT843 BT-9 IDX SQUEAK AND RATTLE TROUBLE DIAGNOSES Diagnostic Worksheet (Cont’d) SBT844 BT-10 CLIP AND FASTENER Description Description I I NABT0003 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 No. Shapes GI MA Removal & Installation EM LC C101 EC SBF302H SBF367BA FE CL C103 MT AT SBT095 SBF423H TF PD C203 AX SU SBF258G SBF708E BR C205 ST RS MBT080A SBF638CA HA CE103 SC EL SBF104B SBF147B BT-11 IDX CLIP AND FASTENER Description (Cont’d) Symbol No. Shapes Removal & Installation CE117 SBF174D SBF175D CF109 SBF651B SBF652B CG101 SBF145B SBF085B CR103 SBF768B SBF770B CS101 SBF078B SBF992G BT-12 BODY FRONT END Removal and Installation Removal and Installation I I I I I When removing or installing hood, place a cloth or other padding on front fender panel and cowl top. This prevents vehicle body from being scratched. Bumper fascia is made of plastic. Do not use excessive force and be sure to keep oil away from it. Hood adjustment: Adjust at hinge portion. Hood lock adjustment: After adjusting, check hood lock control operation. Apply a coat of grease to hood locks engaging mechanism. Hood opener: Do not attempt to bend cable forcibly. Doing so increases effort required to unlock hood. FRONT BUMPER ASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. NABT0004 GI MA EM LC NABT0004S01 Remove bolts securing left and right side combination lamps and remove the lamps. Remove clips securing center radiator grille and remove the center radiator grille. Remove bolts securing left and right radiator grille and remove the grilles. Remove clips and screws securing left and right sides of fender protector. Remove screws securing bumper fascia. Remove clips securing radiator core support lower. Remove clips securing bumper reinforcement. Extract bumper fasica. Remove bolts and nuts securing bumper reinforcement. Extract bumper reinforcement. (When installing bumper reinforcement, remove washer tank.) EC FE CL MT AT TF PD AX SU BR ST RS HA SC EL IDX BT-13 BODY FRONT END Removal and Installation (Cont’d) SBT699 BT-14 BODY FRONT END Removal and Installation (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS HA SC EL SBT700 IDX BT-15 BODY REAR END AND OPENER Removal and Installation Removal and Installation I I NABT0005 Bumper fascia is made of plastic. Do not use excessive force and be sure to keep oil away from it. Back door lock system adjustment: Adjust lock & striker so that they are in the center. After adjustment, check back door lock operation. I Back door hatch lock system adjustment: Adjust lock & striker so that they are in the center. After adjustment, check back door hatch lock operation. I Opener cable: Do not attempt to bend cable using excessive force. I After installation, make sure that back door and fuel filler lid open smoothly. WARNING: I Be careful not to scratch back door stay and/or back door hatch stay when installing back door and/or back door hatch. A scratched stay may cause gas leakage. I The contents of the back door stay and back door hatch stay are under pressure. Do not take apart, puncture, apply heat or allow fire near them. REAR BUMPER ASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. 9. NABT0005S01 Remove screws securing left and right mudguards and remove the mudguards. Remove clips and screws securing left and right sides of wheel protector. Remove bolts and screws securing lower side and side of bumper assembly. Remove bolts securing bumper rubber assembly. Remove bolts securing spare tire hanger striker assembly. Remove bolts securing spare tire hanger guide assembly. Remove clips from upper side of bumper assembly. Extract bumper assembly. Remove nuts securing bumper reinforcement and remove the bumper reinforcement. SBT297A BT-16 BODY REAR END AND OPENER Removal and Installation (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS HA SC EL SBT298A IDX BT-17 BODY REAR END AND OPENER Removal and Installation (Cont’d) SBT299A BT-18 FRONT DOOR Overhaul Overhaul I I NABT0006 For removal of door trim, refer to “DOOR TRIM” (BT-31). After adjusting door or door lock, check door lock operation. GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS HA SC SBT512-A EL IDX BT-19 FRONT DOOR Front Door Limit Switch Reset Front Door Limit Switch Reset RESET CONDITIONS NABT0029 NABT0029S01 After each of the following operations are performed, reset the limit switch (with built-in motor). I Regulator removal and installation I Removal of motor from regulator I Operation of regulator as a single unit I Door glass removal and installation I Glass run removal and installation RESET PROCEDURES SBT041A NABT0029S02 After installing parts, proceed as follows: 1. Close the door window completely. 2. Press the reset switch and open the door window completely. 3. Release the reset switch. After making sure the reset switch has returned to the original position, close the door window completely. 4. The limit switch is now reset. CAUTION: Be sure to manually open or close the door window. (Do not use the automatic open-close procedures.) BT-20 REAR DOOR Overhaul Overhaul NABT0007 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS HA SC EL SBT736 BT-21 IDX INSTRUMENT PANEL ASSEMBLY Removal and Installation Removal and Installation NABT0008 CAUTION: I Lock the CD changer unit mechanism (models with CD changer). Refer to EL-201, “LOCKING CD CHANGER UNIT MECHANISM”. I Disconnect both battery cables in advance. I Disconnect air bag system line in advance. I Never tamper with or force air bag lid open, as this may adversely affect air bag performance. I Be careful not to scratch pad and other parts. SBT302A *1 RS-18 *2 BT-29 BT-22 INSTRUMENT PANEL ASSEMBLY Removal and Installation (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST SBT026A *1 RS-20 *2 RS BT-29 HA SC EL IDX BT-23 INSTRUMENT PANEL ASSEMBLY Removal and Installation (Cont’d) SBT300A BT-24 INSTRUMENT PANEL ASSEMBLY Removal and Installation (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS HA SC EL SBT301A IDX BT-25 INSTRUMENT PANEL ASSEMBLY Removal and Installation (Cont’d) Steering column cover After removing the screws, release the pawls by pressing on the upper cover where it meets (the bottom cover) from both sides. SBT029A Instrument lower panel on the driver side Open the pocket after removing the screws. Hold the opening and the bottom and pull out horizontally. SBT030A Cluster lid A After removing the screws, hold the bottom and pull out. CAUTION: Cover the surroundings with a cloth to prevent damage. SBT044A Center ventilator Hook a cloth-covered flat-bladed screwdriver into the right-side groove section, and pull out. CAUTION: To prevent the screwdriver from slipping and causing damage to the surface, pull out while applying pressure on the screwdriver towards the right. SBT031A Cluster lid C After removing the screws, place hands on the metal clip section, and pull forward to remove the metal clips. SBT045A BT-26 INSTRUMENT PANEL ASSEMBLY Removal and Installation (Cont’d) Console finisher 1) After removing the ashtray, place hands on the opening and pull out in an upward direction to remove the clips at the back. 2) Hold the front of the finisher, pull out in an upward direction and remove the clips at the front. GI MA EM LC SBT032A Console box 1) Pull up the parking brake lever. 2) Remove the screws, pull the console towards the back of the car until it is free of the instrument panel, lift up the front and remove. I It will be easier to remove if the parking brake lever is pulled up for more than 10 notches. EC FE CL MT SBT033A Instrument finisher Remove the screws and pull up. AT TF PD AX SU SBT034A Instrument lower panel on the passenger side After removing the screws, hold both sides and pull out horizontally. BR ST RS SBT046A Instrument mask Insert a cloth-covered flat-bladed screwdriver, and remove by lifting up. HA SC EL IDX SBT047A BT-27 INSTRUMENT PANEL ASSEMBLY Removal and Installation (Cont’d) Defroster grille REMOVAL Insert a cloth-covered flat-bladed screwdriver into the grilles of the outside, center and central grilles, respectively, lift up the front of the grilles and remove. INSTALLATION After inserting the front section, insert the rear section (pawls) to attach. CAUTION: Confirm that the pawls at the rear are securely attached. SBT035A Side ventilator-left Insert a cloth-covered flat-bladed screwdriver into the lower section, and pull out forward. SBT036A Side ventilator-right Insert a cloth-covered flat-bladed screwdriver into the corner of the lower section, and pull out forward. (Securely press the screwdriver against the ventilator.) Or, after removing the Instrument lower panel, push the ventilator out from the back. Side defroster grille After removing the side ventilator, reach in with hands from the opening, push on the pawls from behind the grille, and remove by pushing out. SBT037A BT-28 SIDE AND FLOOR TRIM Removal and Installation Removal and Installation NABT0009 CAUTION: Wrap the tip of flat-bladed screwdriver with a cloth when removing metal clips from garnishes. 1. Remove front and rear seats. Refer to “FRONT SEAT” and “REAR SEAT” for details, BT-43, BT-47. 2. Remove front and rear seat belts. Refer to RS-3, “SEAT BELT” for details. 3. Remove front and rear kicking plates. 4. Remove dash side lower finishers. 5. Remove front and rear body side welts. 6. Remove front pillar garnishes. 7. Remove center assist grips. 8. Remove center pillar lower garnishes. 9. Remove center pillar upper garnishes. 10. Remove rear gate kicking plate. 11. Remove rear net hooks. 12. Remove tonneau cover assembly and rear parcel holder. 13. Remove rear side lower garnishes. 14. Remove rear side upper garnishes. GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS HA SBT694 SC EL IDX BT-29 SIDE AND FLOOR TRIM Removal and Installation (Cont’d) SBT728 BT-30 DOOR TRIM Removal and Installation Removal and Installation TYPE A 1. 2. 3. 4. 5. 6. 7. NABT0010 GI NABT0010S01 Remove inside handle escutcheon. Remove door armrest. (Front door only) Remove power window switches, then disconnect the connectors. Remove door finisher cover. (Rear door only) Remove bolts securing door finisher. Remove clips securing door finisher. Lift out door finisher. MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS HA SC SBT207 EL IDX BT-31 DOOR TRIM Removal and Installation (Cont’d) TYPE B =NABT0010S02 Front Door Trim 1. Remove inside handle escutcheon. 2. Remove power window switch, then disconnect the connectors. 3. Remove door armrest. 4. Remove bolts securing door finisher. 5. Pull on door finisher to remove clips from door panel and remove door finisher, then disconnect glass hatch and fuel lid opener switch connector. Rear Door Trim 6. Remove inside handle escutcheon. 7. Remove power window switch, then disconnect the connector. 8. Remove door armrest cap. 9. Remove bolts securing door finisher. 10. Pull on door finisher to remove clips from door panel and remove door finisher. SBT696 BT-32 DOOR TRIM Removal and Installation (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS HA SC EL SBT697 IDX BT-33 ROOF TRIM Removal and Installation Removal and Installation 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Remove Remove Remove Remove Remove Remove Remove Remove Remove Remove Remove NABT0011 front and rear seats. Refer to “FRONT SEAT” and “REAR SEAT” for details, BT-43, BT-47. front and rear seat belts. Refer to RS-3, “SEAT BELTS” for details. body side trim. Refer to “SIDE AND FLOOR TRIM” for details, BT-29. roof console assembly. inside mirror assembly. sun visors. interior lamp assembly and luggage room lamp assembly. assist grips. clips securing headlining. rear roof garnish. headlining from vehicle through either back door. SBT487 BT-34 BACK DOOR TRIM Removal and Installation Removal and Installation 1. 2. 3. 4. Remove Remove Remove Remove NABT0012 back door grip. back door finisher assembly. high-mounted stop lamp. back door upper finisher assembly. GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS SBT223 HA SC EL IDX BT-35 EXTERIOR Removal and Installation Removal and Installation NABT0013 SBT729 BT-36 EXTERIOR Removal and Installation (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS HA SC EL SBT730 IDX BT-37 EXTERIOR Removal and Installation (Cont’d) SBT490-A BT-38 EXTERIOR Removal and Installation (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS HA SC EL SBT491-A IDX BT-39 EXTERIOR Removal and Installation (Cont’d) SBT492-B BT-40 EXTERIOR Removal and Installation (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS HA SC EL SBT493-A IDX BT-41 EXTERIOR Removal and Installation (Cont’d) SBT731 BT-42 FRONT SEAT Removal and Installation Removal and Installation NABT0014 I When removing or installing the seat trim, handle carefully to keep dirt out and avoid damage. ★ For Wiring Diagram, refer to EL-215, “POWER SEAT”. CAUTION: I Before removing the front seat, turn the ignition switch off, disconnect both battery cables and wait at least 3 minutes. I When checking the power seat circuit for continuity using a circuit tester, do not confuse its connector with the side air bag module connector. Such an error may cause the air bag to deploy. I Do not drop, tilt, or bump the side air bag module installed in the seat. Always handle it with care. I Disconnect the side air bag, power seat switch, and heated seat harness connectors from under the seat before removing the seat. I Disconnect the side air bag harness connector before removing the seat back. (Refer to RS-22, “Side Air Bag Module”.) GI MA EM LC EC FE CL MT AT SBT067A TF PD AX SU BR ST RS HA SC EL IDX BT-43 FRONT SEAT Removal and Installation (Cont’d) POWER SEAT =NABT0014S01 SBT019A BT-44 FRONT SEAT Removal and Installation (Cont’d) MANUAL SEAT NABT0014S02 GI MA EM LC EC FE CL MT AT TF PD SBT020A AX SU BR ST RS HA SC EL IDX BT-45 FRONT SEAT Removal and Installation (Cont’d) HEATED SEAT I I I ★ =NABT0014S03 When handling seat, be extremely careful not to scratch heating unit. To replace heating unit, seat trim and pad should be separated. Do not use any organic solvent, such as thinner, benzene, alcohol, gasoline, etc. to clean trims. For Wiring Diagram, refer to EL-217, “HEATED SEAT”. BT-46 REAR SEAT Removal and Installation Removal and Installation NABT0015 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS HA SC EL SBT190-B BT-47 IDX SUNROOF Adjustment Adjustment NABT0016 Install motor & limit SW assembly and sunroof rail assembly in the following sequence: 1. Arrange equal lengths of link and wire assemblies on both sides of sunroof opening. 2. Connect sunroof connector to vehicles harness. 3. Set lid assembly to fully closed position by operating OPEN switch and TILT switch. After the lid has closed all the way, keep pushing the tiling switch toward tilt DOWN for more than 1 second. 4. Fit outer side of lid assembly to the surface of roof on body outer panel. 5. Press TILT-UP switch to check lid assembly for normal tilting. 6. Check sunroof lid assembly for normal operations (tilt-up, tilt-down, open, and close). SBF920F BT-48 SUNROOF Contents of Working Contents of Working =NABT0034 GI MA EM LC EC FE CL MT AT TF SBT254A Tilt Pre-select Manual Auto Condition AX Ignition (timer) Normal working Reverse working Normal working Reverse working ON q X q*1 q OFF X X X X*2 q: Working X: Not working *1: Auto doesn’t work if the position is not at the initial starting position. *2: The motor keeps moving in reverse motion until finishing the reverse working. PD SU BR ST RS HA SC EL IDX BT-49 SUNROOF Contents of Switch Working Contents of Switch Working =NABT0035 Priority of each switch is as folllows. Tilt switch Up Down Open Close Motor stop + Follow switch input + Reverse turn continued + Reverse turn continued + Operate to tilt full open and stop + Follow switch input + After continued operation, stop at tilt full open position + Follow switch input + Reverse turn continued + Reverse turn continued + Sliding open After continued operation, stop at flap down position + Follow switch input + Sliding close Operate to flap down position and stop + Follow switch input + Reverse turn continued + Reverse turn continued + Sliding open Motor stop + Follow switch input + Sliding close Motor stop + Follow switch input + Reverse turn continued + After reverse turn, continued, follow switch input Reverse turn continued Tilting up/down & Tilt A range sliding open/close Reverse turning Sliding open Tilt B range Sliding close Reverse turning Flap range Slide switch (Pre-select) Reverse turning Slide range Reverse turning JAM PROTECTION NABT0035S01 Reverse working is as follows. Operation direction Reverse turn distance Tilt A range Open operation Tilt full open position Tilt B & flap range Open operation Tilt full open position Flap range Close operation Flap down position Slide A range Close operation 125 mm (4.92 in) min. Slide B range Close operation 125 mm (4.92 in) min. (*1) (*1): Full open position [In case of reverse start position, full open position is within 125 mm (4.92 in).] CAUTION: Don’t pinch a foreign object or your body on purpose. Removal and Installation I NABT0017 After any adjustment, check sunroof operation and lid alignment. I Handle finisher plate and glass lid with care so not to cause damage. I It is desirable for easy installation to mark each point before removal. CAUTION: I Always work with a helper. I Before removal, fully close the glass lid assembly, then after removal, do not move motor assembly. BT-50 SUNROOF Removal and Installation (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST SBT515-D *1 BT-34 *2 RS EL-208 HA SC EL IDX BT-51 SUNROOF Removal and Installation (Cont’d) SBT252A BT-52 SUNROOF Removal and Installation (Cont’d) Record the number of shims placed between glass lid assembly and link and wire assembly. Remove securing nuts and glass lid assembly. GI MA EM LC SBT249A Remove screws from left and right sides of each wind deflector holder. Extract pawls through rail holes, then remove left and right sides of wind deflector holder. Remove screws from front end of sunroof unit. Extract pawls through frame holes, then remove wind deflector from frame assembly. EC FE CL MT SBT827 AT CAUTION: I Before removing sunroof motor, make sure that sunroof is fully closed. I After removing sunroof motor, never attempt to rotate sunroof motor as a single unit. I Power supply to the motor is off when removing sunroof motor and vehicle harness or battery. Initialize at starting position. TF PD AX SU SBT250A Remove shade stoppers (2 points) from rear end of sunroof frame assembly. Remove sun shade from rear end of sunroof frame assembly. BR ST RS SBT251A HA SC EL IDX BT-53 SUNROOF Trouble Diagnoses Trouble Diagnoses =NABT0018 DIAGNOSTIC TABLE NABT0018S01 Sunroof is malfunctioning Procedure Malfunctioning item 1. Check power supply. (*1) NG Replace battery. No Initialize the sunroof switch. NG Replace the sunroof switch. OK 2. Is the position initialized at starting position? Yes 3. Check sunroof switch. I Is correct voltage value or resistance value at each position? I Does occur chattering? OK Replace sunroof motor. *1: If voltage between terminal 1 (Input voltage) and terminal 8 (ground) of sunroof motor is less than approx. 8V, do not operate. NOTE: For diagnosing electric problem, refer to EL-211, “POWER SUNROOF”. Check items (Components) Wind deflector Adjustment Drain hoses Weatherstrip Link and wire assembly Reference page BT-54 BT-55 BT-56 BT-57 BT-57 Excessive wind noise 1 2 3 Water leaks 1 2 3 Sunroof rattles 1 4 2 3 Excessive operation noise 1 2 3 Symptom The numbers in this table mean checking order. WIND DEFLECTOR 1. 2. 3. NABT0018S02 Open lid. Check visually for proper installation. Check to ensure a proper amount of petroleum jelly has been applied to wind deflector connection points; apply if necessary. SBT331 BT-54 SUNROOF Trouble Diagnoses (Cont’d) 4. Check that wind deflector is properly retracted by hand. If it is not, remove and visually check condition. (Refer to removal procedures, BT-50.) If wind deflector is damaged, replace with new one. If wind deflector is not damaged, re-install properly. GI MA EM LC SBT332 ADJUSTMENT EC NABT0018S03 FE CL MT AT TF PD AX SU BR SBT257A If any gap or height difference between glass lid and roof is found, check glass lid fit and adjust as follows: Gap Adjustment 1. 2. 3. 4. 5. 6. 7. RS NABT0018S0301 Open shade assembly. Tilt glass lid up then remove side trim. Loosen glass lid securing nuts (3 each on left and right sides), then tilt glass lid down. Adjust glass lid from outside of vehicle so it resembles “A-A” as shown in the figure above. Tilt glass lid up and down until it is adjusted to “B-B” (When sunroof is closed) as shown in the figure above. After adjusting glass lid, tilt glass lid up and tighten nuts. Tilt glass lid up and down several times to check that it moves smoothly. BT-55 ST HA SC EL IDX SUNROOF Trouble Diagnoses (Cont’d) Height Difference Adjustment 1. 2. 3. I I NABT0018S0302 Tilt glass lid up and down. Check height difference between roof panel and glass lid to see if it is as “A-A” as shown in the figure above. If necessary, adjust it by using one of following procedures. Adjust by adding or removing adjustment shim(s) between glass lid and link assembly. If glass lid protrudes above roof panel, add shim(s) or plain washer(s) at sunroof mounting bracket or stud bolt locations to adjust sunroof installation as required. DRAIN HOSES NABT0018S04 SBT376 1. 2. Remove headlining to access drain hose connections. (Refer to “Removal and Installation” in “ROOF TRIM”, BT-34, for detail.) Check visually for proper connections, damage or deterioration. (The figure shows only the front side.) SBT333 3. 4. 5. I If leakage occurs around luggage room, remove luggage room side trim and check connecting area. Check for proper connection, damage or tear. Remove drain hoses and check visually for any damage, cracks, or deterioration. Pour water into drain hoses and find damaged portion. If any damaged portion is found at each step, replace the damaged part. SBT377 BT-56 SUNROOF Trouble Diagnoses (Cont’d) WEATHERSTRIP I NABT0018S05 In the case of leakage around glass lid, close glass lid and pour water over glass lid to find damaged or gap portion, remove glass lid assembly. (Refer to removal procedures, BT-50, for details.) I Check weatherstrip visually for any damage, deterioration, or flattening. I If any damage is found, replace weatherstrip. CAUTION: Do not remove weatherstrip except when replacing, or filling up butyl seal. LINK AND WIRE ASSEMBLY GI MA EM LC EC NABT0018S06 NOTE: Before replacing a suspect part, carefully ensure it is the source of noise being experienced. 1. Visually check to determine if a sufficient amount of petroleum jelly has been applied to wire or rail groove. If not, add petroleum jelly as required. 2. Check wire for any damage or deterioration. If any damage is found, remove rear guide (refer to removal procedures, BT-50 for details), then replace wire. FE CL MT AT TF PD AX SU BR ST RS HA SC EL IDX BT-57 WINDSHIELD AND WINDOWS Removal and Installation Removal and Installation REMOVAL SBF034B I SBT473 NABT0019S01 After removing moldings, remove glass using piano wire or power cutting tool and an inflatable pump bag. WARNING: When cutting the glass from the vehicle, always wear safety glasses and heavy gloves to help prevent glass splinters from entering your eyes or cutting your hands. CAUTION: I Be careful not to scratch the glass when removing. I Do not set or stand the glass on its edge. Small chips may develop into cracks. INSTALLATION SBT472 NABT0019 NABT0019S02 Use a genuine Nissan Urethane Adhesive Kit or equivalent and follow the instructions furnished with it. I While the urethane adhesive is curing, open a door window. This will prevent the glass from being forced out by passenger compartment air pressure when a door is closed. I The molding must be installed securely so that it is in position and leaves no gap. I Inform the customer that the vehicle should remain stationary until the urethane adhesive has completely cured (preferably 24 hours). Curing time varies with temperature and humidity. WARNING: I Keep heat and open flames away as primers and adhesive are flammable. I The materials contained in the kit are harmful if swallowed, and may irritate skin and eyes. Avoid contact with the skin and eyes. I Use in an open, well ventilated location. Avoid breathing the vapors. They can be harmful if inhaled. If affected by vapor inhalation, immediately move to an area with fresh air. I Driving the vehicle before the urethane adhesive has completely cured may affect the performance of the windshield in case of an accident. CAUTION: I Do not use an adhesive which is past its usable term. Shelf life of this product is limited to six months after the date of manufacture. Carefully adhere to the expiration or manufacture date printed on the box. I Keep primers and adhesive in a cool, dry place. Ideally, they should be stored in a refrigerator. I Do not leave primers or adhesive cartridge unattended with their caps open or off. I The vehicle should not be driven for at least 24 hours or until the urethane adhesive has completely cured. Curing time varies depending on temperature and humidities. The curing time will increase under higher temperatures and lower humidities. BT-58 WINDSHIELD AND WINDOWS Removal and Installation (Cont’d) WINDSHIELD NABT0019S03 GI MA EM LC EC FE CL MT AT TF SBT191-A Repairing Water Leaks for Windshield PD NABT0019S0301 Leaks can be repaired without removing and reinstalling glass. If water is leaking between the urethane adhesive material and body or glass, determine the extent of leakage. This can be done by applying water to the windshield area while pushing glass outward. To stop the leak, apply primer (if necessary) and then urethane adhesive to the leak point. AX SU BR ST RS HA SC EL IDX BT-59 WINDSHIELD AND WINDOWS Removal and Installation (Cont’d) REAR SIDE WINDOW NABT0019S04 SBT359-A BT-60 DOOR MIRROR Removal and Installation Removal and Installation NABT0020 CAUTION: Be careful not to scratch door rearview mirror body. ★ For Wiring Diagram, refer to EL-213, “DOOR MIRROR”. 1. Remove door trim. Refer to “DOOR TRIM” for details, BT-31. 2. Remove clip securing inner cover from front corner of door. 3. Disconnect door mirror harness connector. 4. Remove bolts securing door mirror, then remove door mirror assembly. GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS HA SC SBT891 EL IDX BT-61 BODY (ALIGNMENT) Alignment Alignment I I I I I I NABT0021 All dimensions indicated in figures are actual ones. When using a tracking gauge, adjust both pointers to equal length. Then check the pointers and gauge itself to 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. 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 standard line of “X”, “Y” and “Z”. SBF874GD BT-62 BODY (ALIGNMENT) Alignment (Cont’d) ENGINE COMPARTMENT Measurement NABT0021S01 GI NABT0021S0101 MA EM LC EC FE CL MT AT TF SBT194 PD AX SU BR ST RS HA SC EL IDX BT-63 BODY (ALIGNMENT) Alignment (Cont’d) Measurement Points NABT0021S0102 SBT195 BT-64 BODY (ALIGNMENT) Alignment (Cont’d) UNDERBODY Measurement NABT0021S02 GI NABT0021S0201 MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS HA SC EL SBT196 BT-65 IDX BODY (ALIGNMENT) Alignment (Cont’d) Measurement Points NABT0021S0202 SBT197 BT-66 FRONT & REAR SUSPENSION SECTION SU GI MA EM LC EC FE CONTENTS FRONT SUSPENSION ....................................................3 Precautions ..................................................................3 PRECAUTIONS .........................................................3 Preparation ..................................................................3 SPECIAL SERVICE TOOLS ........................................3 COMMERCIAL SERVICE TOOLS ................................3 Noise, Vibration and Harshness (NVH) Troubleshooting ...........................................................4 NVH TROUBLESHOOTING CHART ............................4 Components.................................................................5 2WD .........................................................................5 4WD .........................................................................6 On-vehicle Service.......................................................7 FRONT SUSPENSION PARTS ...................................7 FRONT WHEEL ALIGNMENT .....................................8 Coil Spring and Strut Assembly.................................10 COMPONENTS .......................................................10 REMOVAL ...............................................................12 DISASSEMBLY ........................................................12 INSPECTION ...........................................................12 ASSEMBLY .............................................................13 Stabilizer Bar .............................................................13 REMOVAL AND INSTALLATION ...............................13 INSPECTION ...........................................................14 Transverse Link and Lower Ball Joint .......................14 REMOVAL AND INSTALLATION ...............................14 INSPECTION ...........................................................15 Low Tire Pressure Warning System ..........................16 SYSTEM COMPONENTS .........................................16 SYSTEM DESCRIPTION ..........................................16 Trouble Diagnoses.....................................................18 WIRING DIAGRAM ..................................................18 LOW TIRE PRESSURE WARNING CONTROL UNIT INPUT/OUTPUT SIGNAL STANDARD ..............20 ID REGISTRATION PROCEDURE ............................20 SELF-DIAGNOSIS ...................................................23 HOW TO PERFORM TROUBLE DIAGNOSIS FOR QUICK AND ACCURATE REPAIR .............................25 PRELIMINARY CHECK ............................................26 MALFUNCTION CODE/SYMPTOM CHART ...............27 Trouble Diagnoses for Self-diagnostic Items.............27 INSPECTION 1: TRANSMITTER OR TIRE PRESSURE WARNING CONTROL UNIT ...................27 INSPECTION 2: TRANSMITTER-1 ............................28 INSPECTION 3: TRANSMITTER-2 ............................29 INSPECTION 4: LOW TIRE PRESSURE WARNING CONTROL UNIT......................................29 Trouble Diagnoses for Symptoms .............................30 INSPECTION 1: WARNING LAMP DOES NOT COME ON WHEN IGNITION SWITCH IS TURNED ON. .........................................................................30 INSPECTION 2: WARNING LAMP STAYS ON WHEN IGNITION SWITCH IS TURNED ON. ..............31 INSPECTION 3: WARNING LAMP BLINKS WHEN IGNITION SWITCH IS TURNED ON. .........................33 INSPECTION 4: TAIL LAMP BLINKS WHEN IGNITION SWITCH IS TURNED ON. .........................34 INSPECTION 5: ID REGISTRATION CANNOT BE COMPLETED. .........................................................34 Service Data and Specifications (SDS).....................34 GENERAL SPECIFICATIONS (FRONT) .....................34 WHEEL ALIGNMENT (UNLADEN*1) ..........................34 LOWER BALL JOINT ...............................................35 WHEELARCH HEIGHT (UNLADEN*) .........................35 WHEEL RUNOUT AVERAGE* ..................................36 REAR SUSPENSION.....................................................37 Precautions ................................................................37 PRECAUTIONS .......................................................37 Preparation ................................................................37 COMMERCIAL SERVICE TOOLS ..............................37 Noise, Vibration and Harshness (NVH) Troubleshooting .........................................................37 Components...............................................................38 On-vehicle Service.....................................................38 REAR SUSPENSION PARTS ...................................38 Removal and Installation ...........................................39 Coil Spring and Shock Absorber ...............................40 COMPONENTS .......................................................40 REMOVAL AND INSTALLATION ...............................41 INSPECTION ...........................................................41 Upper Link, Lower Link and Panhard Rod................41 INSPECTION ...........................................................41 CL MT AT TF PD AX BR ST RS BT HA SC EL IDX CONTENTS BUSHING REPLACEMENT.......................................41 INSTALLATION........................................................42 Stabilizer Bar .............................................................42 REMOVAL AND INSTALLATION ...............................42 SU-2 (Cont’d) Low Tire Pressure Warning System ..........................42 Service Data and Specifications (SDS).....................43 GENERAL SPECIFICATIONS (REAR) .......................43 FRONT SUSPENSION Precautions Precautions GI PRECAUTIONS I I I SBR686C I NASU0001 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. Use flare nut wrench when removing and installing brake tubes. After installing removed suspension parts, check wheel alignment and adjust if necessary. Always torque brake lines when installing. Preparation SPECIAL SERVICE TOOLS NASU0002 The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name Description MA EM LC EC FE CL ST29020001 (J24319-01) Ball joint remover Removing tie-rod outer end and lower ball joint a: 34 mm (1.34 in) b: 6.5 mm (0.256 in) c: 61.5 mm (2.421 in) MT AT TF NT694 PD COMMERCIAL SERVICE TOOLS Tool name NASU0003 Description AX 1 Flare nut crowfoot 2 Torque wrench Removing and installing each brake piping a: 10 mm (0.39 in) BR NT360 Spring compressor Removing and installing coil spring ST RS NT717 BT HA SC EL IDX SU-3 FRONT SUSPENSION Noise, Vibration and Harshness (NVH) Troubleshooting Noise, Vibration and Harshness (NVH) Troubleshooting =NASU0035 NVH TROUBLESHOOTING CHART NASU0035S01 × × × Shake × × × × × × TIRES × × × × × × × × × × × × × × × × × × × × × × × Out-of-round Stabilizer bar fatigue Incorrect wheel alignment Suspension looseness × — × — × Spring fatigue × Parts interference × × × × × × × × Vibration ROAD WHEEL ST-6 × STEERING × BR-7 × BRAKES Noise × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × Shimmy × × × × × × Judder × × × × × × × × × × Poor quality ride or handling × × × × × × × × × × Noise × × × × × × × × × × × Shake × × × × × × × × × × × Shimmy, Judder × × × × × × × × × Poor quality ride or handling × × × × × × × ×: Applicable SU-4 × Refer to ROAD WHEEL in this chart. × ROAD WHEEL × Refer to TIRES in this chart. × TIRES Poor quality ride or handling × × × Refer to SUSPENSION in this chart. × × × SUSPENSION × AX-3 × AX-3 Judder AXLE × DRIVE SHAFT × PD-4 × PD-4 × DIFFERENTIAL Shimmy PROPELLER SHAFT × — × — × Incorrect tire size × Non-uniformity Vibration — × Deformation or damage × — × — × Uneven tire wear Shake Incorrect air pressure × — × SU-8 × Imbalance × SU-8 — Bushing or mounting deterioration SU-13, 42 SU-10, 40 Shock absorber deformation, damage or deflection Noise Symptom SU-10, 40 SU-5, 38 Possible Cause and SUSPECTED PARTS SUSPENSION Reference page Improper installation, looseness Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts. × FRONT SUSPENSION Components Components NASU0004 2WD GI NASU0004S01 MA EM LC EC FE CL MT AT TF PD AX BR ST RS SFA743B 1. 2. 3. Strut mounting insulator Spring upper seat Bound bumper 4. 5. 6. Coil spring Strut assembly Stabilizer connecting rod 7. 8. 9. Bracket Stabilizer bar Transverse link BT HA SC EL IDX SU-5 FRONT SUSPENSION Components (Cont’d) 4WD NASU0004S02 SFA744B 1. 2. 3. 4. Strut mounting insulator Spring upper seat Bound bumper Coil spring 5. 6. 7. Strut assembly Stabilizer connecting rod Bracket SU-6 8. Stabilizer bar 9. Transverse link 10. Drive shaft FRONT SUSPENSION On-vehicle Service On-vehicle Service FRONT SUSPENSION PARTS GI NASU0005 Check front axle and front suspension parts for excessive play, cracks, wear and other damage. 1. Shake each front wheel to check for excessive play. 2. Retighten all axle and suspensions nuts and bolts to the specified torque. Tightening torque: Refer to “Components”, SU-10. MA 3. EC EM LC SMA525A 4. 5. a. b. SFA392B c. Check strut (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. If ball joint dust cover is cracked or damaged, replace ball joint assembly. Check suspension ball joint end play. Jack up front of vehicle and set the stands. Clamp dial indicator onto transverse link and place indicator tip on lower edge of brake caliper. Make sure front wheels are straight and brake pedal is depressed. FE CL MT AT TF PD AX d. e. Place a pry bar between transverse link and knuckle. While raising and releasing pry bar, observe maximum dial indicator value. Vertical end play: 0 mm (0 in) If ball joint vertical end play exists, remove lower ball joint assembly and recheck the ball joint. Refer to “Tranverse Link and Lower Ball Joint”, SU-14. ST RS BT SFA745B 6. a. b. c. SFA746B BR Check spring height from top of wheelarch to ground using the following procedure. Park vehicle on a level surface with vehicle unladen*. *: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. Check tires for proper inflation and wear (tread wear indicator must not be showing). Bounce vehicle up and down several times and measure dimensions Hf and Hr. Refer to SDS, SU-35. Spring height is not adjustable. If out of specification, check for worn springs and suspension parts. SU-7 HA SC EL IDX FRONT SUSPENSION On-vehicle Service (Cont’d) FRONT WHEEL ALIGNMENT NASU0006 Before checking front wheel alignment, be sure to make a preliminary inspection (Unladen*). *: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. SFA975B Preliminary Inspection NASU0006S01 1. 2. Check tires for wear and improper inflation. Check wheels for deformation, cracks and other damage. If deformed, remove wheel and check wheel runout. NOTE: Measure both the inner and outer sides for the radial runout and lateral runout, and confirm the figures are within the standards. Wheel runout (Dial indicator value): Refer to SDS, SU-36. 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. 7. Check vehicle posture (Unladen). Camber, Caster and Kingpin Inclination NASU0006S02 Camber, caster and kingpin inclination are preset at factory and cannot be adjusted. 1. Measure camber, caster and kingpin inclination of both right and left wheels with a suitable alignment gauge. Camber, Caster and Kingpin inclination: Refer to SDS, SU-34. 2. If camber, caster or kingpin inclination is not within specification, inspect front suspension parts. Replace damaged or worn out parts. SFA894 SU-8 FRONT SUSPENSION On-vehicle Service (Cont’d) Toe-in SFA614B NASU0006S03 Measure toe-in using the following procedure. WARNING: I Always perform the following procedure on a flat surface. I Make sure that no person 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. 4. Measure distance “A” (rear side). 5. Push the vehicle slowly ahead to rotate the wheels 180 degrees (1/2 turn). 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 “B” (front side). Total toe-in: Refer to SDS, SU-34. SFA234AC 7. a. b. Adjust toe-in by varying the length of steering tie-rods. Loosen lock nuts. Adjust toe-in by screwing tie-rods in and out. GI MA EM LC EC FE CL MT AT TF PD AX SFA749B c. Make sure both tie-rods are the same length. Standard length “L”: Refer to ST-33, “Steering Gear and Linkage”. Tighten lock nuts to specified torque. Lock nut tightening torque: Refer to ST-18, “POWER STEERING GEAR AND LINKAGE”. ST RS BT SFA486A Front Wheel Turning Angle SFA439BA BR NASU0006S04 Turning angle is set by stroke length of steering gear rack and cannot be adjusted. 1. Set wheels in straight-ahead position. Then move vehicle forward until front wheels rest on turning radius gauge properly. 2. Rotate steering wheel all the way right and left; measure turning angle. Do not hold the steering wheel on full lock for more than 15 seconds. Wheel turning angle (Full turn): Refer to SDS, SU-34. SU-9 HA SC EL IDX FRONT SUSPENSION Coil Spring and Strut Assembly Coil Spring and Strut Assembly COMPONENTS 2WD NASU0007 NASU0007S01 SSU052 1. 2. 3. 4. 5. 6. Spacer Strut mounting insulator Bracket Strut mounting bearing Spring upper seat Bound bumper 7. 8. 9. 10. 11. 12. Coil spring (Polyurethane tube) Strut assembly Bracket Lower ball joint assembly Cotter pin SU-10 13. 14. 15. 16. 17. 18. Transverse link Stabilizer connecting rod Stabilizer bar Bushing Bracket Knuckle spindle FRONT SUSPENSION Coil Spring and Strut Assembly (Cont’d) 4WD NASU0007S02 GI MA EM LC EC FE CL MT AT TF PD AX BR ST RS SSU053 1. 2. 3. 4. 5. 6. 7. Spacer Strut mounting insulator Bracket Strut mounting bearing Spring upper seat Bound bumper Coil spring 8. 9. 10. 11. 12. 13. 14. (Polyurethane tube) Strut assembly Bracket Lower ball joint assembly Cotter pin Transverse link Stabilizer connecting rod 15. 16. 17. 18. 19. 20. 21. Stabilizer bar Bushing Bracket Knuckle spindle Snap ring Hub cap Drive shaft BT HA SC EL IDX SU-11 FRONT SUSPENSION Coil Spring and Strut Assembly (Cont’d) REMOVAL NASU0008 1. Remove stabilizer connecting rod. 2. Remove strut assembly fixing bolts and nuts (to hood-ledge). Do not remove piston rod lock nut on vehicle. SFA956A DISASSEMBLY NASU0009 1. Set strut assembly on vise, then loosen piston rod lock nut. WARNING: Do not remove piston rod lock nut at this time. 2. Compress spring with tool so that the strut mounting insulator can be turned by hand. WARNING: Make sure that the pawls of the two spring compressors are firmly hooked on the spring. The spring compressors must be tightened alternately so as not to tilt the spring. SSU002 3. Remove piston rod lock nut. SSU003 INSPECTION Strut Assembly I I I I Check for smooth operation through a full stroke, both compression and extension. Check for oil leakage on welded and gland packing portion. Check piston rod for cracks, deformation and other damage. Replace if necessary. Strut Mounting Insulator and Rubber Parts I I I NASU0010S03 Check thrust bearing parts for abnormal noise and excessive rattle in axial direction. Replace if necessary. Coil Spring I NASU0010S02 Check cemented rubber-to-metal portion for separation and cracks. Check rubber parts for deterioration. Replace if necessary. Strut Mounting Bearing I NASU0010 NASU0010S01 NASU0010S04 Check for cracks, deformation and other damage. Replace if necessary. SU-12 FRONT SUSPENSION Coil Spring and Strut Assembly (Cont’d) ASSEMBLY I NASU0011 When installing coil spring on strut, it must be positioned as shown in the figure at left. GI MA EM LC SFA725B I Install upper spring seat with its cutout facing the inner side of vehicle. EC FE CL MT SFA664AA AT Stabilizer Bar REMOVAL AND INSTALLATION I NASU0012 Remove stabilizer bar and connecting rod. TF PD AX SFA767B I When installing stabilizer, make sure that paint mark and bracket face in their correct directions. BR ST RS BT SFA768B I When removing and installing stabilizer bar fix portion A. HA SC EL IDX SFA769B SU-13 FRONT SUSPENSION Stabilizer Bar (Cont’d) I Install stabilizer bar with ball joint socket properly placed. SFA449BA INSPECTION I I I NASU0013 Check stabilizer for deformation and cracks. Replace if necessary. Check rubber bushings for deterioration and cracks. Replace if necessary. Check ball joint can rotate in all directions. If movement is not smooth and free, replace stabilizer bar connecting rod. ARA027 Transverse Link and Lower Ball Joint REMOVAL AND INSTALLATION 1. 2. 3. 4. 5. SFA757B 6. NASU0014 Separate drive shaft from knuckle. — 4WD — Refer to AX-12, “Drive Shaft”. Separate lower ball joint stud from knuckle. Remove lower ball joint assembly from transverse link. Remove transverse link. During installation, final tightening must be carried out at curb weight with tires on ground. After installation, check wheel alignment. Refer to “FRONT WHEEL ALIGNMENT”, “On-vehicle Service”, SU-8. SU-14 FRONT SUSPENSION Transverse Link and Lower Ball Joint (Cont’d) INSPECTION Transverse Link I I =NASU0015 GI NASU0015S01 Check transverse link for damage, cracks and deformation. Replace it if necessary. Check rubber bushing for damage, cracks and deformation. Replace transverse link if necessary. MA EM LC Lower Ball Joint I SFA858AA EC NASU0015S02 Check ball joint for excessive play. Replace lower ball joint assembly if any of the following exists: − Ball stud is worn. − Joint is hard to swing. − Play in axial direction is excessive. Before checking, turn ball joint at least 10 revolutions so that ball joint is properly broken in. Swinging force “A”: (measuring point: cotter pin hole of ball stud) Refer to SDS, SU-35. Turning torque “B”: Refer to SDS, SU-35. Vertical end play “C”: Refer to SDS, SU-35. Check dust cover for damage. Replace it and cover clamp if necessary. FE CL MT AT TF PD AX BR ST RS BT HA SC EL IDX SU-15 FRONT SUSPENSION Low Tire Pressure Warning System Low Tire Pressure Warning System SYSTEM COMPONENTS NASU0037 SEIA0222E SYSTEM DESCRIPTION Transmitter NASU0038 NASU0038S01 A sensor-transmitter integrated with a valve is installed on a wheel, and transmits a detected air pressure signal in the form of a radio wave. SEIA0203E Antenna NASU0038S02 Receives the radio wave signal transmitted by the transmitter. SEIA0230E SU-16 FRONT SUSPENSION Low Tire Pressure Warning System (Cont’d) Low Tire Pressure Warning Control Unit NASU0038S03 Reads the radio wave signal received by the antenna, and controls the warning lamp and the buzzer operations as shown below. It also has a judgement function to detect a system malfunction. GI MA EM LC SEIA0231E EC Condition Warning lamp Buzzer Less than 170 kPa (1.7 kg/cm2, 24 psi) [Flat tire] ON Sounds for 10 sec. System malfunction ON OFF FE CL MT AT TF PD AX BR ST RS BT HA SC EL IDX SU-17 FRONT SUSPENSION Trouble Diagnoses Trouble Diagnoses WIRING DIAGRAM NASU0039 MSU001 SU-18 FRONT SUSPENSION Trouble Diagnoses (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX BR ST RS BT HA SC EL MSU002 IDX SU-19 FRONT SUSPENSION Trouble Diagnoses (Cont’d) LOW TIRE PRESSURE WARNING CONTROL UNIT INPUT/OUTPUT SIGNAL STANDARD NASU0040 Standards using a circuit tester and oscilloscope Measurement terminal + Measuring point Standard value − 1 Battery power supply Always Battery voltage (Approx. 12V) 2 Ignition switch ON or START Ignition switch ON Battery voltage (Approx. 12V) Tire pressure warning lamp turns ON Approx. 0V Tire pressure warning lamp turns OFF Battery voltage (Approx. 12V) 3 Tire pressure warning lamp 4 Ignition switch ON or ACC Ignition switch ON Battery voltage (Approx. 12V) 8 Tire pressure warning check switch Always Approx. 5V Lighting switch in 1st position Approx. 0V 9 Tail lamp relay Lighting switch OFF Approx. 12V Ground 10 Speed meter operated [When vehicle speed is approx. 40 km/h (25 MPH)] Vehicle speed signal (8-pulse) ELF1084D 11 GND — Approx. 0V 12 Data link connector (RX) — — 13 Data link connector (TX) — — 17 Antenna — — ID REGISTRATION PROCEDURE ID Registration with Transmitter Activation Tool NASU0041 NASU0041S01 1. 2. 3. 4. Turn ignition switch “OFF”. Connect CONSULT-II to data link connector. Start engine. Touch “START”, “AIR PRESSURE MONITOR”, “WORK SUPPORT” and “ID REGIST”. 5. With the transmitter activation tool (J-45295) pushed against the front-left transmitter, press the button then keep 5 seconds. SEIA0101E SU-20 FRONT SUSPENSION Trouble Diagnoses (Cont’d) 6. Register the IDs in order from FR LH, FR RH, RR RH, to RR LH. When ID registration of each wheel has been completed, a buzzer sounds and tail lamps blinks. Activation tire position Buzzer 1 FR LH Once 2 FR RH 2 times 3 RR RH 3 times 4 RR LH 4 times Tail lamp CONSULT-II 2 times flashing “YET” " “DONE” 7. After completing all ID registrations, press “END” to complete the procedure. NOTE: Be sure to register the IDs in order from FR LH, FR RH, RR RH, to RR LH, or the self-diagnostic results display will not function properly. ID Registration without Transmitter Activation ToolNASU0041S02 1. 2. 3. 4. 5. 6. Turn ignition switch “OFF”. Connect CONSULT-II to data link connector. Start engine. Touch “START”, “AIR PRESSURE MONITOR”, “WORK” SUPPORT” and “ID REGIST”. Adjust the tire pressure to the values shown in the table below for ID registration, and drive the vehicle at 32 km/h (20 MPH) or more for a few minutes. Tire position Tire pressure kPa (kg/cm2, psi) Front-Left 250 (2.5, 36) Front-Right 230 (2.3, 33) Rear-Right 210 (2.1, 30) Rear-Left 190 (1.9, 27) Rear LH EM LC EC FE CL MT AT TF PD BR CONSULT-II ST Front LH Front RH MA AX After completing all ID registrations, press “END” to complete the procedure. Activation tire position GI “YET” " “DONE” RS Rear RH BT Transmitter Wake Up Operation NASU0041S03 With Transmitter Activation Tool NASU0041S0301 1. With the transmitter activation tool (J-45295) pushed against the front left transmitter, press the button for 5 seconds. I When ignition switch is ON, then warning lamp blinks as in the follow diagram and transmitter wakes up. 2. Register the IDs in order from FR LH, FR RH, RR RH or RR LH. When wake up of each wheel has been completed, a tail lamp blinks. HA SC EL IDX SEIA0101E SU-21 FRONT SUSPENSION Trouble Diagnoses (Cont’d) 3. Need to activate tire position Warning lamp Front LH Once (0.3 sec.) Front RH 2 times blinking Rear LH 3 times blinking Rear RH 4 times blinking All tires Once (2.0 sec.) Tail lamp 2 times flashing After completing wake up of all transmitters, make sure tire pressure warning lamp goes out. SU-22 FRONT SUSPENSION Trouble Diagnoses (Cont’d) SELF-DIAGNOSIS Description =NASU0042 GI NASU0042S01 During driving, the low tire pressure warning system receives the signal transmitted from the transmitter installed in each wheel, and gives alarms when the tire pressure becomes low. The control unit of this system has pressure judgement and trouble diagnosis functions. MA Function EM NASU0042S02 When the low tire pressure warning system detects low inflation pressure or another unusual symptom, the warning lamps in the combination meter comes on. To start the self-diagnostic results mode, ground the selfdiagnostic (check) terminal. The malfunction location is indicated by the tail lamp flashing and the buzzer sounds. LC CONSULT-II EC NASU0042S03 CONSULT-II Application to Low Tire Pressure Warning System ITEM NASU0042S0301 SELF-DIAGNOSTIC RESULTS DATA MONITOR Front - Left transmitter × × Front - Right transmitter × × Rear - Left transmitter × × Rear - Right transmitter × × Warning lamp — × Vehicle speed — × Buzzer (in control unit) — × ×: Applicable —: Not applicable FE CL MT AT TF PD AX BR ST RS BT HA SC EL IDX SU-23 FRONT SUSPENSION Trouble Diagnoses (Cont’d) Self-Diagnostic Results Mode =NASU0042S0302 Diagnostic item FLAT FLAT FLAT FLAT - TIRE TIRE TIRE TIRE [NO-DATA] [NO-DATA] [NO-DATA] [NO-DATA] - - Diagnostic item is detected when ··· Front-left tire pressure drops to 200 kPa (2.0 kg/cm2, 28 psi) or less Front-right tire pressure drops to 200 kPa (2.0 kg/cm2, 28 psi) or less Rear-right tire pressure drops to 200 kPa (2.0 kg/cm2, 28 psi) or less Rear-left tire pressure drops to 200 kPa (2.0 kg/cm2 , 28 psi) or less FL FR RR RL FL FR RR RL Data Data Data Data from from from from [CHECKSUM[CHECKSUM[CHECKSUM[CHECKSUM- ERR] ERR] ERR] ERR] - FL FR RR RL Checksum Checksum Checksum Checksum [PRESSDATA[PRESSDATA[PRESSDATA[PRESSDATA- ERR] ERR] ERR] ERR] - FL FR RR RL Air Air Air Air [CODE[CODE[CODE[CODE- ERR] ERR] ERR] ERR] - FL FR RR RL [BATT [BATT [BATT [BATT VOLT VOLT VOLT VOLT - LOW] LOW] LOW] LOW] - FL FR RR RL RECEIVER - ID - NO - REG data data data data pressure pressure pressure pressure Function Function Function Function - front-left transmitter cannot be received. front-right transmitter cannot be received. rear-right transmitter cannot be received. rear-left transmitter cannot be received. Battery Battery Battery Battery from from from from data data data data code code code code from from from from data data data data voltage voltage voltage voltage of of of of front-left transmitter is malfunctioning. front-right transmitter is malfunctioning. rear-right transmitter is malfunctioning. rear-left transmitter is malfunctioning. front-left transmitter is malfunctioning. front-right transmitter is malfunctioning. rear-right transmitter is malfunctioning. rear-left transmitter is malfunctioning. from from from from front-left transmitter is malfunctioning. front-right transmitter is malfunctioning. rear-right transmitter is malfunctioning. rear-left transmitter is malfunctioning. front-left transmitter drops. front-right transmitter drops. rear-right transmitter drops. rear-left transmitter drops. No ID registration has been made to the low tire pressure warning control unit. NOTE: Before performing the self-diagnosis, be sure to register the ID. Or, the actual malfunction location may be different from that displayed on CONSULT-II. Data Monitor Mode MONITOR NASU0042S0303 CONDITION SPECIFICATION VHCL SPEED SE Drive vehicle. AIR AIR AIR AIR I Drive vehicle for a few minutes. or Tire pressure (kPa or Psi) I Ignition switch ON and activation tool is transmitting activate signals. ID ID ID ID PRESS PRESS PRESS PRESS REGST REGST REGST REGST FL FR RR RL Vehicle speed (km/h or MPH) FL FR RR RL Registration ID: DONE No registration ID: YET Ignition switch ON WARNING LAMP Warning lamp on: ON Warning lamp off: OFF BUZZER Buzzer in low tire pressure warning control unit on: ON Buzzer in low tire pressure warning control unit off: OFF NOTE: Before performing the self-diagnosis, be sure to register the ID. Or, the actual malfunction location may be different from that displayed on CONSULT-II. SU-24 FRONT SUSPENSION Trouble Diagnoses (Cont’d) HOW TO PERFORM TROUBLE DIAGNOSIS FOR QUICK AND ACCURATE REPAIR Introduction I I I =NASU0043 NASU0043S01 Before troubleshooting, verify customer complaints. If a vehicle problem is hard to reproduce, harnesses, harness connectors or terminals may often be malfunctioning. Hold and shake these parts by hand to make sure they are securely connected. When using a circuit tester to measure voltage or resistance of each circuit, be careful not to expand connector terminals. Work Flow GI NASU0043S02 MA EM LC EC FE CL MT AT TF PD AX BR ST RS BT SEIA0100E HA SC EL IDX SU-25 FRONT SUSPENSION Trouble Diagnoses (Cont’d) PRELIMINARY CHECK BASIC INSPECTION 1 CHECK ALL TIRES PRESSURES I Check all tires pressures. Tire pressure: 210 kPa (2.1 kg/cm2, 30 psi) OK or NG OK © GO TO 2. NG © Adjust tire pressure to specified value. 2 CHECK WARNING LAMP ACTIVATION I Check warning lamp activation. I Does warning lamp activate for 1 second when ignition switch is turned “ON”? YES or NO YES © Warning lamp turns off: GO TO 3. NO © Check fuse and combination meter. Then repair or replace malfunctioning parts. 3 CHECK CONNECTOR 1. Disconnect low tire pressure warning control unit connector M156. 2. Check terminals for damage or loose connection. OK or NG OK © GO TO 4. NG © Repair or replace damaged parts. 4 CHECK TRANSMITTER ACTIVATION TOOL I Check transmitter tool battery. OK or NG OK © Carry out self-diagnosis. NG © Replace transmitter activation tool battery. SU-26 =NASU0044 FRONT SUSPENSION Trouble Diagnoses (Cont’d) MALFUNCTION CODE/SYMPTOM CHART =NASU0045 Code/Symptom Malfunction part Reference page GI MA 15 16 17 18 Front-left tire pressure drops to 200 kPa (2.0 kg/cm2, 28 psi) or less Front-right tire pressure drops to 200 kPa (2.0 kg/cm2, 28 psi) or less Rear-right tire pressure drops to 200 kPa (2.0 kg/cm2, 28 psi) or less Rear-left tire pressure drops to 200 kPa (2.0 kg/cm2, 28 psi) or less 21 22 23 24 Transmitter Transmitter Transmitter Transmitter no no no no 31 32 33 34 Transmitter Transmitter Transmitter Transmitter checksum checksum checksum checksum 35 36 37 38 Transmitter Transmitter Transmitter Transmitter pressure pressure pressure pressure 41 42 43 44 Transmitter Transmitter Transmitter Transmitter function function function function 45 46 47 48 Transmitter Transmitter Transmitter Transmitter battery battery battery battery 51 Low tire pressure warning control unit SU-29 PD Warning lamp does not come on when ignition switch is turned on. Fuse or combination meter Low tire pressure warning control unit connector or circuit Low tire pressure warning control unit SU-30 AX Warning lamp stays on when ignition switch is turned on. Fuse or combination meter Low tire pressure warning control unit connector or circuit Low tire pressure warning control unit SU-31 Warning lamp blinks when ignition switch is turned on. Low tire pressure warning control unit harness connector or circuit Low tire pressure warning control unit SU-33 BR Tail lamp blinks when ignition switch is turned on. Low tire pressure warning control unit harness connector or circuit Low tire pressure warning control unit SU-34 ST ID registration cannot be operated. Transmitter Antenna harness connector or circuit Antenna SU-34 RS Trouble Diagnoses for Self-diagnostic Items BT data data data data (front - left) (front - right) (rear - right) (rear - left) error error error error (front - left) (front - right) (rear - right) (rear - left) EM LC SU-27 EC SU-28 data data data data error error error error (front - left) (front - right) (rear - right) (rear - left) SU-29 code code code code error error error error (front - left) (front - right) (rear - right) (rear - left) SU-28 (front - left) (front - right) (rear - right) (rear - left) SU-28 voltage voltage voltage voltage low low low low INSPECTION 1: TRANSMITTER OR TIRE PRESSURE WARNING CONTROL UNIT Malfunction Code No. 21, 22, 23 or 24 1 — FE CL MT AT TF NASU0046 NASU0046S01 HA CHECK CONTROL UNIT I Drive for several minutes. Check all tires’ pressure with CONSULT-II “DATA MONITOR ITEM”. SC Are all tires’ pressure displayed 0 kPa? YES © GO TO 2. NO © GO TO 3. EL IDX SU-27 FRONT SUSPENSION Trouble Diagnoses for Self-diagnostic Items (Cont’d) 2 CHECK ANTENNA CONNECTOR I Check antenna and feeder connector M601 for damage or loose connections. OK or NG OK © Replace control unit, then GO TO 3. NG © Repair or replace antenna or feeder connector. 3 ID REGISTRATION I Carry out ID registration of all transmitters. Is there a tire that cannot register ID? YES © Replace transmitter of the tire, GO TO 5. NO © GO TO 4. 4 VEHICLE DRIVING I Drive at a speed of 40 km/h (25 MPH) or more for several minutes without stopping. Check all tires’ pressure with CONSULT-II “DATA MONITOR ITEM” within 15 minutes after vehicle speed becomes 17 km/h (11 MPH). Does “DATA MONITOR ITEM” display tire pressure as normal without any warning lamp? YES © INSPECTION END. NO © GO TO 5. 5 ID REGISTRATION AND VEHICLE DRIVING 1. Carry out ID registration of all transmitters. 2. Drive at a speed of 40 km/h (25 MPH) or more for 3 minutes, and then drive the vehicle at any speed for 10 minutes. Then check all tires’ pressure with CONSULT-II “DATA MONITOR ITEM” within 5 minutes. Does “DATA MONITOR ITEM” display tire pressure as normal without any warning lamp? YES © INSPECTION END. NG © GO TO the inspection applicable to DTC. INSPECTION 2: TRANSMITTER-1 Malfunction Code No. 31, 32, 33, 34, 41, 42, 43, 44, 45, 46, 47 or 48 1 NASU0056 NASU0056S01 ID REGISTRATION (CORRECTION OF TRANSMITTER LOCATION) 1. Carry out ID registration of all transmitters. 2. Drive at a speed of 40 km/h (25 MPH) or more for 3 minutes, and then drive the vehicle at any speed for 10 minutes. © 2 GO TO 2. REPLACE TRANSMITTER 1. Check warning lamp for blink again, replace malfunctioning transmitter. 2. Carry out ID registration of all transmitters. Can ID registration of all transmitters be completed? YES © GO TO 3. NO © GO TO Inspection 1. SU-28 FRONT SUSPENSION Trouble Diagnoses for Self-diagnostic Items (Cont’d) 3 GI VEHICLE DRIVING I Drive at a speed of 40 km/h (25 MPH) or more for 3 minutes, and then drive the vehicle at any speed for 10 minutes. Then check all tires’ pressure with CONSULT-II “DATA MONITOR ITEM” within 5 minutes. MA Does “DATA MONITOR ITEM” display tire pressure as normal without any warning lamp? YES © INSPECTION END. NO © Replace malfunctioning transmitter, and perform “Step 3” again. EM INSPECTION 3: TRANSMITTER-2 Malfunction Code No. 35, 36, 37 or 38 1 NASU0057 LC NASU0057S01 EC CHECK ALL TIRES’ PRESSURE I Check all tires’ pressure. Tire pressure: 210 kPa (2.1 kg/m2, 30 psi) FE Are there any tires’ whose pressure is “64 psi” or more? YES © Adjust tire pressure to specified value. NO © GO TO 2. CL MT 2 VEHICLE DRIVING AT 1. Carry out ID registration of all transmitters. 2. Drive at a speed of 40 km/h (25 MPH) or more for several minutes without stopping. Check all tires’ pressure with CONSULT-II “DATA MONITOR ITEM” within 15 minutes after vehicle speed becomes 17 km/h (11 MPH). TF Replace transmitter with new one if “DATA MONITOR ITEM” displays 64 psi or more. © Then GO TO 3. PD 3 ID REGISTRATION AND VEHICLE 1. Carry out ID registration of all transmitters. 2. Drive at a speed of 40 km/h (25 MPH) or more for 3 minutes, and then drive the vehicle at any speed for 10 minutes. Then check all tires’ pressure with CONSULT-II “DATA MONITOR ITEM” within 5 minutes. AX Does “DATA MONITOR ITEM” display tire pressure as normal without any warning lamp? YES © INSPECTION END. NO © GO TO the inspection applicable to DTC. INSPECTION 4: LOW TIRE PRESSURE WARNING CONTROL UNIT Malfunction Code No. 51 1 SELF-DIAGNOSIS BR NASU0048 ST NASU0048S01 RS I Carry out self-diagnosis. Does warning lamp still activate again? YES © Replace low tire pressure warning control unit. NO © INSPECTION END. BT HA SC EL IDX SU-29 FRONT SUSPENSION Trouble Diagnoses for Symptoms Trouble Diagnoses for Symptoms INSPECTION 1: WARNING LAMP DOES NOT COME ON WHEN IGNITION SWITCH IS TURNED ON. NASU0049 DIAGNOSTIC PROCEDURE 1 CHECK COMBINATION METER OPERATION I Check combination meter operation. OK or NG OK © GO TO 2. NG © Check combination meter. 2 CHECK WARNING LAMP 1. Disconnect low tire pressure warning control unit connector M156. 2. Apply ground to low tire pressure warning control unit connector M156 terminal 3 (L/Y). SEIA0232E Does the warning lamp activate? OK © Replace low tire pressure warning control unit. NG © GO TO 3. 3 CHECK COMBINATION METER CIRCUIT I Check continuity between low tire pressure warning control unit connector M156 terminal 3 (LY) and combination meter connector M24 terminal 8 (LY). 3 (LY) - 8 (LY): Continuity should exist. SEIA0233E OK or NG OK © Check combination meter. NG © Check harness for open or short between low tire pressure warning control unit and combination meter. SU-30 FRONT SUSPENSION Trouble Diagnoses for Symptoms (Cont’d) INSPECTION 2: WARNING LAMP STAYS ON WHEN IGNITION SWITCH IS TURNED ON. NASU0050 GI DIAGNOSTIC PROCEDURE 1 CHECK CONNECTOR MA 1. Disconnect low tire pressure warning control unit connector M156. 2. Check terminal for damage or loose connections. OK or NG EM LC OK © GO TO 2. NG © Repair or replace damaged parts. 2 EC CHECK CIRCUIT 1. Disconnect combination meter connector M24 and low tire pressure warning control unit connector M156. 2. Check continuity between tire pressure warning control unit connector M156 terminal 3 (L/Y) and combination meter connector M24 terminal 8 (L/Y). 3 (L/Y) - 8 (L/Y): Continuity should exist. FE CL MT AT TF SEIA0233E PD OK or NG OK © GO TO 3. NG © Check harness for open or short between low tire pressure warning control unit and combination meter. 3 AX CHECK POWER SUPPLY CIRCUIT 1 I Check voltage between low tire pressure warning control unit connector M156 terminal 1 (G/R) and ground. 1 (G/R) - Ground: Battery voltage (Approx. 12V) BR ST RS BT HA SEIA0234E OK or NG OK © GO TO 4. NG © Check low tire pressure warning control unit power supply circuit for open or short. SC EL IDX SU-31 FRONT SUSPENSION Trouble Diagnoses for Symptoms (Cont’d) 4 CHECK POWER SUPPLY CIRCUIT 2 1. Turn ignition switch ON. 2. Check voltage between low tire pressure warning control unit connector M156 terminal 2 (W/B) and ground. 2 (W/B) - Ground: Battery voltage (Approx. 12V) SEIA0235E OK or NG OK © GO TO 5. NG © Check low tire pressure warning control unit power supply circuit for open or short. 5 CHECK GROUND CIRCUIT 1. Check continuity between low tire pressure warning control unit connector M156 terminal 11 (B) and ground. 11 (B) - Ground: Continuity should exist. SEIA0236E OK or NG OK © Replace low tire pressure warning control unit. NG © Repair or replace low tire pressure warning control unit ground circuit. SU-32 FRONT SUSPENSION Trouble Diagnoses for Symptoms (Cont’d) INSPECTION 3: WARNING LAMP BLINKS WHEN IGNITION SWITCH IS TURNED ON. NASU0051 GI DIAGNOSTIC PROCEDURE 1 CHECK WARNING LAMP MA If warning lamp blinks as below, the system is normal. I This mode shows transmitter status is in OFF-mode. EM LC EC FE SEIA0347E CL OK or NG OK © Carry out transmitter wake up operation. NG © GO TO 2. 2 MT AT CHECK CIRCUIT 1. Disconnect low tire pressure warning control unit connector M156. 2. Check continuity between low tire pressure warning control unit connector M156 terminal 8 (PU/W) and ground. 8 (PU/W) - Ground: Continuity should not exist. TF PD AX BR SEIA0237E OK or NG OK © Replace low tire pressure warning control unit. NG © Repair or replace harness connector. ST RS BT HA SC EL IDX SU-33 FRONT SUSPENSION Trouble Diagnoses for Symptoms (Cont’d) INSPECTION 4: TAIL LAMP BLINKS WHEN IGNITION SWITCH IS TURNED ON. NASU0052 DIAGNOSTIC PROCEDURE 1 CHECK GROUND CIRCUIT 1. Disconnect low tire pressure warning control unit connector M156. 2. Check continuity between low tire pressure warning control unit connector M156 terminal 11 (B) and ground. 11 (B) - Ground: Continuity should exist. SEIA0236E OK or NG OK © Replace low tire pressure warning control unit. NG © Repair or replace low tire pressure warning control unit ground circuit. INSPECTION 5: ID REGISTRATION CANNOT BE COMPLETED. NASU0053 DIAGNOSTIC PROCEDURE 1 ID REGISTRATION (ALL) I Carry out ID registration of all transmitters. Can ID registration of all transmitters be completed? YES © INSPECTION END. NO © Go To Inspection 1: Transmitter or Low Tire Pressure Warning Control Unit. Service Data and Specifications (SDS) GENERAL SPECIFICATIONS (FRONT) NASU0016 Suspension type Independent macpherson strut with coil spring Strut type Double-acting hydraulic Stabilizer bar Standard equipment WHEEL ALIGNMENT (UNLADEN*1) NASU0017 Unit: Degree minute (Decimal degree) Applied model All Minimum −0°35′ (−0.58°) Nominal 0°10′ (0.17°) Maximum 0°55′ (0.92°) Camber Left and right difference 45′ (0.75°) or less Minimum 2°15′ (2.25°) Nominal 3°00′ (3.00°) Maximum 3°45′ (3.75°) Caster Left and right difference SU-34 45′ (0.75°) or less FRONT SUSPENSION Service Data and Specifications (SDS) (Cont’d) Applied model GI All Kingpin inclination Distance (A - B) Minimum 13°35′ (13.58°) Nominal 14°20′ (14.33°) Maximum 15°05′ (15.08°) Minimum 1 mm (0.04 in) Nominal 2 mm (0.08 in) Maximum 3 mm (0.12 in) Minimum 5′ (0.08°) Nominal 10′ (0.17°) Maximum 15′ (0.25°) Minimum 30°00′ (30.00°) Nominal 33°00′ (33.00°) Maximum 34°00′ (34.00°) Minimum 28°00′ (28.00°) Nominal 31°00′ (31.00°) Maximum 32°00′ (32.00°) MA EM LC Total toe-in Angle (left plus right) Inside Wheel turning angle EC FE CL Full turn*2 Outside MT *1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. *2: On power steering models, wheel turning force (at circumference of steering wheel) of 98 to 147 N (10 to 15 kg, 22 to 33 lb) with engine idle. LOWER BALL JOINT AT TF NASU0018 Swinging force “A” (Measuring point: cotter pin hole of ball stud) PD 7.8 - 76.5 N (0.8 - 7.8 kg, 1.8 - 17.2 lb) Turning torque “B” 0.5 - 4.9 N·m (5 - 50 kg-cm, 4.3 - 43.4 in-lb) Vertical end play “C” AX 0 mm (0 in) WHEELARCH HEIGHT (UNLADEN*) NASU0019 Unit: mm (in) BR ST RS BT SFA746B 2WD Applied model HA 4WD P245/70 R16 tire P245/65 R17 tire P255/65 R16 tire (With over fender) P245/70 R16 tire P245/65 R17 tire P255/65 R16 tire (With over fender) Front (Hf) 840 (33.07) 840 (33.07) 837 (32.95) 824 (32.44) Rear (Hr) 867 (34.13) 817 (32.17) 867 (34.13) 817 (32.17) SC EL *: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. IDX SU-35 FRONT SUSPENSION Service Data and Specifications (SDS) (Cont’d) WHEEL RUNOUT AVERAGE* NASU0020 Unit: mm (in) Wheel type Aluminum Steel Radial runout limit 0.3 (0.012) 0.8 (0.031) Lateral runout limit 0.3 (0.012) 0.8 (0.031) *: Wheel runout average = (Outside runout value + Inside runout value) x 0.5 SU-36 REAR SUSPENSION Precautions Precautions GI PRECAUTIONS I I I SBR686C I NASU0021 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. Use flare nut wrench when removing and installing brake tubes. After installing removed suspension parts, check wheel alignment and adjust if necessary. Always torque brake lines when installing. Preparation COMMERCIAL SERVICE TOOLS Tool name NASU0023 Description 1 Flare nut crowfoot 2 Torque wrench Removing and installing each brake piping a: 10 mm (0.39 in) MA EM LC EC FE CL MT NT360 Noise, Vibration and Harshness (NVH) Troubleshooting AT NASU0036 Refer to “Noise, Vibration and Harshness (NVH) Troubleshooting”, “FRONT SUSPENSION”, SU-4. TF PD AX BR ST RS BT HA SC EL IDX SU-37 REAR SUSPENSION Components Components NASU0024 SRA880A On-vehicle Service REAR SUSPENSION PARTS NASU0025 Check rear axle and rear suspension parts for excessive play, wear and damage. 1. Shake each rear wheel to check for excessive play. 2. Retighten all nuts and bolts to the specified torque. Tightening torque: Refer to “Coil Spring and Shock Absorber”, SU-40. SMA525A 3. 4. 5. Check shock absorber for oil leakage and other damage. Check shock absorber bushing for excessive wear and other damage. Check wheelarch height. Refer to “On-vehicle Service”, “FRONT SUSPENSION”, SU-7. SRA754A SU-38 REAR SUSPENSION Removal and Installation Removal and Installation NASU0026 1. SBR686C Support axle and suspension components with a suitable jack and block. 2. Disconnect brake hydraulic line and parking brake cables at back plates. CAUTION: I Use flare nut wrench when removing and installing brake tubes. I Before removing the rear suspension assembly, disconnect the ABS wheel sensor from the assembly. Then move it away from the rear suspension assembly. Failure to do so may result in damage to the sensor wires and the sensor becoming inoperative. 3. Remove stabilizer bar from body. 4. Remove upper links and lower links from body. 5. Remove panhard rod from body. 6. Disconnect rear end of propeller shaft. Refer to PD-8, “Removal and Installation”. 7. Remove upper end nuts of shock absorber. GI Final tightening for rubber parts requires to be carried out under unladen condition with tires on ground. MA EM LC EC FE CL MT AT TF PD AX SRA935 BR ST RS BT HA SC EL IDX SU-39 REAR SUSPENSION Coil Spring and Shock Absorber Coil Spring and Shock Absorber COMPONENTS NASU0027 SSU054 SU-40 REAR SUSPENSION Coil Spring and Shock Absorber (Cont’d) REMOVAL AND INSTALLATION NASU0028 Refer to “Removal and Installation”, “REAR SUSPENSION”, SU-39. When installing coil spring, pay attention to its direction. Be sure spring rubber seat is not twisted and has not slipped off when installing coil spring. GI MA EM LC SSU051 INSPECTION I I I EC NASU0029 Check coil spring for yield, deformation and cracks. Check shock absorber for oil leakage, cracks and deformation. Check all rubber parts for wear, cracks and deformation. Replace if necessary. FE CL MT AT Upper Link, Lower Link and Panhard Rod INSPECTION NASU0030 Check for cracks, distortion and other damage. Replace if necessary. TF PD AX BUSHING REPLACEMENT NASU0031 Check for cracks and other damage. Replace with suitable tool if necessary. I Remove bushing with suitable tool. BR ST RS BT SRA898 When installing bushing, apply a coat of 1% soapy water to outer wall of bushing. Always install new bushing. Do not tap end face of bushing directly with a hammer. HA SC EL IDX SRA900 SU-41 REAR SUSPENSION Upper Link, Lower Link and Panhard Rod (Cont’d) INSTALLATION NASU0032 When installing each link, pay attention to direction of nuts and bolts. When installing each rubber part, final tightening must be carried out under unladen condition with tires on ground. Stabilizer Bar REMOVAL AND INSTALLATION NASU0033 I When removing and installing stabilizer bar, fix portion A. I Install stabilizer bar with ball joint socket properly placed. SRA766A SFA449BA Low Tire Pressure Warning System NASU0055 Refer to “Tire Pressure Warning System”, “FRONT SUSPENSION” SU-42 REAR SUSPENSION Service Data and Specifications (SDS) Service Data and Specifications (SDS) GENERAL SPECIFICATIONS (REAR) GI NASU0034 Suspension type 5-link type rigid with coil spring Shock absorber type MA Double-acting hydraulic Stabilizer Standard equipment EM LC EC FE CL MT AT TF PD AX BR ST RS BT HA SC EL IDX SU-43 NOTES AUTOMATIC TRANSMISSION SECTION AT GI MA EM LC EC FE CONTENTS TROUBLE DIAGNOSIS - INDEX ....................................4 Alphabetical & P No. Index for DTC ...........................4 PRECAUTIONS ...............................................................6 Precautions for Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″ ......................................................6 Precautions for On Board Diagnostic (OBD) System of A/T and Engine...........................................6 Precautions ..................................................................6 Service Notice or Precautions .....................................8 Wiring Diagrams and Trouble Diagnosis.....................9 PREPARATION .............................................................10 Special Service Tools ................................................10 OVERALL SYSTEM ......................................................12 A/T Electrical Parts Location .....................................12 Circuit Diagram ..........................................................13 Cross-sectional View .................................................14 Hydraulic Control Circuit............................................15 Shift Mechanism ........................................................16 Control System ..........................................................25 Control Mechanism....................................................26 Control Valve .............................................................31 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ...............................................................33 Introduction ................................................................33 OBD-II Function for A/T System................................33 One or Two Trip Detection Logic of OBD-II ..............33 OBD-II Diagnostic Trouble Code (DTC) ....................33 Malfunction Indicator Lamp (MIL)..............................37 CONSULT-II ...............................................................37 Diagnostic Procedure Without CONSULT-II..............48 TROUBLE DIAGNOSIS - INTRODUCTION..................55 Introduction ................................................................55 Work Flow..................................................................59 TROUBLE DIAGNOSIS - BASIC INSPECTION ...........61 A/T Fluid Check .........................................................61 Stall Test ....................................................................61 Line Pressure Test.....................................................64 Road Test...................................................................65 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION ...............................................................83 Symptom Chart..........................................................83 TCM Terminals and Reference Value........................95 CAN COMMUNICATION ...............................................98 System Description....................................................98 CAN Communication Unit..........................................98 TROUBLE DIAGNOSIS FOR POWER SUPPLY........102 Wiring Diagram - AT - MAIN....................................102 Diagnostic Procedure ..............................................103 DTC P0705 PARK/NEUTRAL POSITION SWITCH ...105 Description ...............................................................105 Wiring Diagram - AT - PNP/SW...............................107 Diagnostic Procedure ..............................................108 Component Inspection.............................................109 DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT ....................................................................... 111 Description ............................................................... 111 Wiring Diagram - AT - FTS ......................................113 Diagnostic Procedure ..............................................114 Component Inspection.............................................116 DTC P0720 VEHICLE SPEED SENSOR.A/T (REVOLUTION SENSOR) ...........................................117 Description ...............................................................117 Wiring Diagram - AT - VSSA/T ................................119 Diagnostic Procedure ..............................................120 Component Inspection.............................................121 DTC P0725 ENGINE SPEED SIGNAL .......................122 Description ...............................................................122 Wiring Diagram - AT - ENGSS ................................123 Diagnostic Procedure ..............................................124 DTC P0731 IMPROPER SHIFTING TO 1ST GEAR POSITION ....................................................................126 Description ...............................................................126 Wiring Diagram - AT - 1ST ......................................129 Diagnostic Procedure ..............................................130 Component Inspection.............................................131 DTC P0732 IMPROPER SHIFTING TO 2ND GEAR POSITION ....................................................................132 CL MT TF PD AX SU BR ST RS BT HA SC EL IDX CONTENTS Description ...............................................................132 Wiring Diagram - AT - 2ND......................................135 Diagnostic Procedure ..............................................136 Component Inspection.............................................137 DTC P0733 IMPROPER SHIFTING TO 3RD GEAR POSITION ....................................................................138 Description ...............................................................138 Wiring Diagram - AT - 3RD......................................141 Diagnostic Procedure ..............................................142 Component Inspection.............................................143 DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION ....................................................................144 Description ...............................................................144 Wiring Diagram - AT - 4TH ......................................148 Diagnostic Procedure ..............................................149 Component Inspection.............................................153 DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE......................................................154 Description ...............................................................154 Wiring Diagram - AT - TCV......................................156 Diagnostic Procedure ..............................................157 Component Inspection.............................................158 DTC P0744 IMPROPER LOCK-UP OPERATION ......159 Description ...............................................................159 Wiring Diagram - AT - TCCSIG ...............................162 Diagnostic Procedure ..............................................163 Component Inspection.............................................167 DTC P0745 LINE PRESSURE SOLENOID VALVE ...168 Description ...............................................................168 Wiring Diagram - AT - LPSV....................................170 Diagnostic Procedure ..............................................171 Component Inspection.............................................173 DTC P0750 SHIFT SOLENOID VALVE A ..................174 Description ...............................................................174 Wiring Diagram - AT - SSV/A ..................................175 Diagnostic Procedure ..............................................176 Component Inspection.............................................177 DTC P0755 SHIFT SOLENOID VALVE B ..................178 Description ...............................................................178 Wiring Diagram - AT - SSV/B ..................................179 Diagnostic Procedure ..............................................180 Component Inspection.............................................181 DTC P1705 ACCELERATOR PEDAL POSITION SENSOR (THROTTLE POSITION SENSOR).............182 Description ...............................................................182 On Board Diagnosis Logic.......................................183 Possible Cause........................................................183 Diagnostic Trouble Code (DTC) Confirmation Procedure ................................................................184 Wiring Diagram - AT - TPS......................................185 Diagnostic Procedure ..............................................186 (Cont’d) DTC P1760 OVERRUN CLUTCH SOLENOID VALVE..........................................................................188 Description ...............................................................188 Wiring Diagram - AT - OVRCSV..............................190 Diagnostic Procedure ..............................................191 Component Inspection.............................................192 DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) ....193 Description ...............................................................193 Wiring Diagram - AT - BA/FTS ................................195 Diagnostic Procedure ..............................................196 Component Inspection.............................................199 DTC VEHICLE SPEED SENSOR.MTR .......................200 Description ...............................................................200 Wiring Diagram - AT - VSSMTR..............................202 Diagnostic Procedure ..............................................203 DTC U1000 CAN COMMUNICATION LINE ...............205 Description ...............................................................205 On Board Diagnosis Logic.......................................205 Possible Cause........................................................205 Diagnostic Trouble Code (DTC) Confirmation Procedure ................................................................206 Wiring Diagram - AT - CAN .....................................207 Diagnostic Procedure ..............................................208 DTC TURBINE REVOLUTION SENSOR ....................209 Description ...............................................................209 Wiring Diagram - AT - TRSA/T ................................211 Diagnostic Procedure ..............................................212 Component Inspection.............................................213 DTC CONTROL UNIT (RAM), CONTROL UNIT (ROM)...........................................................................214 Description ...............................................................214 Diagnostic Procedure ..............................................215 DTC CONTROL UNIT (EEP ROM) .............................216 Description ...............................................................216 Diagnostic Procedure ..............................................217 TROUBLE DIAGNOSES FOR SYMPTOMS ...............218 Wiring Diagram - AT - NONDTC .............................218 O/D OFF Indicator Lamp Does Not Come On........221 Engine Cannot Be Started In ″P″ and ″N″ Position ....................................................................223 In ″P″ Position, Vehicle Moves Forward Or Backward When Pushed .........................................224 In ″N″ Position, Vehicle Moves................................225 Large Shock. ″N″ -> ″R″ Position............................227 Vehicle Does Not Creep Backward In ″R″ Position ....................................................................229 Vehicle Does Not Creep Forward In ″D″, ″2″ Or ″1″ Position ..............................................................232 Vehicle Cannot Be Started From D1 .......................235 A/T Does Not Shift: D1 -> D2 Or Does Not Kickdown: D4 -> D2..................................................238 AT-2 CONTENTS A/T Does Not Shift: D2 -> D3...................................241 A/T Does Not Shift: D3 -> D4...................................244 A/T Does Not Perform Lock-up ...............................247 A/T Does Not Hold Lock-up Condition ....................249 Lock-up Is Not Released .........................................251 Engine Speed Does Not Return To Idle (Light Braking D4 -> D3).....................................................252 Vehicle Does Not Start From D1 .............................254 A/T Does Not Shift: D4 -> D3, When Overdrive Control Switch ″ON″ -> ″OFF″ ................................255 A/T Does Not Shift: D3 -> 22, When Selector Lever ″D″ -> ″2″ Position.........................................256 A/T Does Not Shift: 22 -> 11, When Selector Lever ″2″ -> ″1″ Position .........................................257 Vehicle Does Not Decelerate By Engine Brake ......258 TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control and Accelerator Pedal Position Sensor Circuit Checks)............................................258 A/T SHIFT LOCK SYSTEM.........................................265 Description ...............................................................265 Wiring Diagram - SHIFT -........................................266 Diagnostic Procedure ..............................................267 KEY INTERLOCK CABLE ..........................................270 Components.............................................................270 Removal...................................................................270 Installation................................................................271 ON-VEHICLE SERVICE ..............................................272 Control Valve Assembly and Accumulators.............272 Revolution Sensor Replacement .............................273 Turbine Revolution Sensor Replacement................273 Rear Oil Seal Replacement.....................................273 Rear Oil Seal and Companion Flange Oil Seal Replacement............................................................274 Parking Components Inspection..............................274 Park/Neutral Position Switch Adjustment ................275 Manual Control Linkage Adjustment........................275 REMOVAL AND INSTALLATION ...............................276 Removal...................................................................276 Installation................................................................277 OVERHAUL .................................................................281 (Cont’d) Components.............................................................281 Oil Channel ..............................................................284 Locations of Needle Bearings, Thrust Washers and Snap Rings .......................................................285 DISASSEMBLY............................................................286 REPAIR FOR COMPONENT PARTS .........................297 Oil Pump ..................................................................297 Control Valve Assembly...........................................301 Control Valve Upper Body .......................................307 Control Valve Lower Body .......................................312 Reverse Clutch ........................................................314 High Clutch ..............................................................317 Forward and Overrun Clutches ...............................320 Low & Reverse Brake..............................................324 Forward Clutch Drum Assembly..............................328 Rear Internal Gear and Forward Clutch Hub ..........330 Band Servo Piston Assembly ..................................333 Parking Pawl Components ......................................337 ASSEMBLY..................................................................339 Assembly (1)............................................................339 Adjustment ...............................................................347 Assembly (2)............................................................349 SERVICE DATA AND SPECIFICATIONS (SDS) .......356 General Specifications.............................................356 Shift Schedule..........................................................356 Stall Revolution........................................................356 Line Pressure...........................................................356 Return Springs.........................................................357 Accumulator O-ring..................................................358 Clutches and Brakes ...............................................358 Oil Pump and Low One-way Clutch ........................360 Total End Play..........................................................360 Reverse Clutch Drum End Play ..............................361 Removal and Installation .........................................361 Shift Solenoid Valves...............................................361 Solenoid Valves .......................................................361 A/T Fluid Temperature Sensor.................................361 Turbine Revolution Sensor ......................................361 Revolution Sensor ...................................................362 Dropping Resistor ....................................................362 GI MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL IDX AT-3 TROUBLE DIAGNOSIS — INDEX Alphabetical & P No. Index for DTC Alphabetical & P No. Index for DTC NAAT0179 ALPHABETICAL INDEX FOR DTC NAAT0179S01 DTC Items (CONSULT-II screen terms) CONSULT-II GST*1 Reference page A/T 1ST GR FNCTN P0731 AT-126 A/T 2ND GR FNCTN P0732 AT-132 A/T 3RD GR FNCTN P0733 AT-138 A/T 4TH GR FNCTN P0734 AT-144 A/T TCC S/V FNCTN P0744 AT-159 ATF TEMP SEN/CIRC P0710 AT-111 ENGINE SPEED SIG P0725 AT-122 L/PRESS SOL/CIRC P0745 AT-168 O/R CLTCH SOL/CIRC P1760 AT-188 PNP SW/CIRC P0705 AT-105 SFT SOL A/CIRC*2 P0750 AT-174 SFT SOL B/CIRC*2 P0755 AT-178 TCC SOLENOID/CIRC P0740 AT-154 TP SEN/CIRC A/T*2 P1705 AT-182 VEH SPD SEN/CIR AT*3 P0720 AT-117 *1: These numbers are prescribed by SAE J2012. *2: When the fail-safe operation occurs, the MIL illuminates. *3: The MIL illuminates when both the “Revolution sensor signal” and the “Vehicle speed sensor signal” meet the fail-safe condition at the same time. AT-4 TROUBLE DIAGNOSIS — INDEX Alphabetical & P No. Index for DTC (Cont’d) P NO. INDEX FOR DTC =NAAT0179S02 GI DTC Items (CONSULT-II screen terms) CONSULT-II GST*1 Reference page MA EM P0705 PNP SW/CIRC AT-105 P0710 ATF TEMP SEN/CIRC AT-111 P0720 VEH SPD SEN/CIR AT*3 AT-117 P0725 ENGINE SPEED SIG AT-122 P0731 A/T 1ST GR FNCTN AT-126 P0732 A/T 2ND GR FNCTN AT-132 P0733 A/T 3RD GR FNCTN AT-138 P0734 A/T 4TH GR FNCTN AT-144 P0740 TCC SOLENOID/CIRC AT-154 P0744 A/T TCC S/V FNCTN AT-159 P0745 L/PRESS SOL/CIRC AT-168 P0750 SFT SOL A/CIRC*2 AT-174 P0755 SFT SOL B/CIRC*2 AT-178 P1705 TP SEN/CIRC A/T*2 AT-182 P1760 O/R CLTCH SOL/CIRC AT-188 *1: These numbers are prescribed by SAE J2012. *2: When the fail-safe operation occurs, the MIL illuminates. *3: The MIL illuminates when both the “Revolution sensor signal” and the “Vehicle speed sensor signal” meet the fail-safe condition at the same time. LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL IDX AT-5 PRECAUTIONS Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” NAAT0001 The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS composition which is available to NISSAN MODEL R50 is as follows: 쐌 For a frontal collision The Supplemental Restraint System consists of driver air bag module (located in the center of the steering wheel), front passenger air bag module (located on the instrument panel on passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. 쐌 For a side collision The Supplemental Restraint System consists of side air bag module (located in the outer side of front seat), side curtain air bag module (locating in the headliner side of front and rear seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision). WARNING: 쐌 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. 쐌 Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. 쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connector (and by yellow harness protector or yellow insulation tape before the harness connectors). Precautions for On Board Diagnostic (OBD) System of A/T and Engine NAAT0002 The ECM has an on board diagnostic system. It will light up the malfunction indicator lamp (MIL) to warn the driver of a malfunction causing emission deterioration. CAUTION: 쐌 Be sure to turn the ignition switch “OFF” and disconnect the negative battery terminal before any repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc. will cause the MIL to light up. 쐌 Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will cause the MIL to light up due to an open circuit. (Be sure the connector is free from water, grease, dirt, bent terminals, etc.) 쐌 Be sure to route and secure the harnesses properly after work. Interference of the harness with a bracket, etc. may cause the MIL to light up due to a short circuit. 쐌 Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube may cause the MIL to light up due to a malfunction of the EGR system or fuel injection system, etc. 쐌 Be sure to erase the unnecessary malfunction information (repairs completed) from the TCM and ECM before returning the vehicle to the customer. Precautions 쐌 NAAT0003 Before connecting or disconnecting the TCM harness connector, turn ignition switch “OFF” and disconnect negative battery terminal. Failure to do so may damage the TCM. Because battery voltage is applied to TCM even if ignition switch is turned “OFF”. SEF289H AT-6 PRECAUTIONS Precautions (Cont’d) 쐌 When connecting or disconnecting pin connectors into or from TCM, take care not to damage pin terminals (bend or break). Make sure that there are not any bends or breaks on TCM pin terminal, when connecting pin connectors. GI MA EM LC SEF291H 쐌 Before replacing TCM, perform TCM input/output signal inspection and make sure whether TCM functions properly or not. (Refer to AT-95.) EC FE CL MT MEF040DA 쐌 After performing each TROUBLE DIAGNOSIS, perform “DTC (Diagnostic Trouble Code) CONFIRMATION PROCEDURE”. The DTC should not be displayed in the “DTC CONFIRMATION PROCEDURE” if the repair is completed. TF PD AX SU SAT964I 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 쐌 Before proceeding with disassembly, thoroughly clean the outside of the transmission. It is important to prevent the internal parts from becoming contaminated by dirt or other foreign matter. Disassembly should be done in a clean work area. Use lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could interfere with the operation of the transmission. Place disassembled parts in order for easier and proper assembly. All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or reassembly. Gaskets, seals and O-rings should be replaced any time the transmission is disassembled. It is very important to perform functional tests whenever they are indicated. The valve body contains precision parts and requires extreme care when parts are removed and serviced. Place disassembled valve body parts in order for easier and proper assembly. Care will also prevent springs and small parts from becoming scattered or lost. Properly installed valves, sleeves, plugs, etc. will slide along bores in valve body under their own weight. AT-7 BR ST RS BT HA SC EL IDX PRECAUTIONS Precautions (Cont’d) 쐌 쐌 쐌 쐌 쐌 Before assembly, apply a coat of recommended ATF to all parts. Apply petroleum jelly to protect O-rings and seals, or hold bearings and washers in place during assembly. Do not use grease. Extreme care should be taken to avoid damage to O-rings, seals and gaskets when assembling. Replace ATF cooler if excessive foreign material is found in oil pan or clogging strainer. Refer to “ATF COOLER SERVICE”, AT-9. After overhaul, refill the transmission with new ATF. When the A/T drain plug is removed, only some of the fluid is drained. Old A/T fluid will remain in torque converter and ATF cooling system. Always follow the procedures when changing A/T fluid. Refer to MA-22, “Changing A/T Fluid”. Service Notice or Precautions FAIL-SAFE NAAT0004 NAAT0004S01 The TCM has an electronic Fail-Safe (limp home mode). This allows the vehicle to be driven even if a major electrical input/output device circuit is damaged. Under Fail-Safe, the vehicle always runs in third gear, even with a shift lever position of “1”, “2” or “D”. The customer may complain of sluggish or poor acceleration. When the ignition key is turned “ON” following Fail-Safe operation, O/D OFF indicator lamp blinks for about 8 seconds. (For “TCM SELF-DIAGNOSTIC PROCEDURE (No Tools)”, refer to AT-48.) The blinking of the O/D OFF indicator lamp for about 8 seconds will appear only once and be cleared. The customer may resume normal driving conditions. Always follow the “WORK FLOW” (Refer to AT-59). The SELF-DIAGNOSIS results will be as follows: The first SELF-DIAGNOSIS will indicate damage to the vehicle speed sensor or the revolution sensor. During the next SELF-DIAGNOSIS, performed after checking the sensor, no damages will be indicated. TORQUE CONVERTER SERVICE NAAT0004S04 The torque converter should be replaced under any of the following conditions: 쐌 External leaks in the hub weld area. 쐌 Converter hub is scored or damaged. 쐌 Converter pilot is broken, damaged or fits poorly into crankshaft. 쐌 Steel particles are found after flushing the cooler and cooler lines. 쐌 Pump is damaged or steel particles are found in the converter. 쐌 Vehicle has TCC shudder and/or no TCC apply. Replace only after all hydraulic and electrical diagnoses have been made. (Converter clutch material may be glazed.) 쐌 Converter is contaminated with engine coolant containing antifreeze. 쐌 Internal failure of stator roller clutch. 쐌 Heavy clutch debris due to overheating (blue converter). 쐌 Steel particles or clutch lining material found in fluid filter or on magnet when no internal parts in unit are worn or damaged — indicates that lining material came from converter. The torque converter should not be replaced if: 쐌 The fluid has an odor, is discolored, and there is no evidence of metal or clutch facing particles. 쐌 The threads in one or more of the converter bolt holes are damaged. AT-8 PRECAUTIONS Service Notice or Precautions (Cont’d) 쐌 쐌 Transmission failure did not display evidence of damaged or worn internal parts, steel particles or clutch plate lining material in unit and inside the fluid filter. Vehicle has been exposed to high mileage (only). The exception may be where the torque converter clutch dampener plate lining has seen excess wear by vehicles operated in heavy and/or constant traffic, such as taxi, delivery or police use. ATF COOLER SERVICE NAAT0004S02 Replace ATF cooler if excessive foreign material is found in oil pan or clogging strainer. Replace radiator lower tank (which includes ATF cooler) with a new one and flush cooler line using cleaning solvent and compressed air. Refer to LC-21, “REMOVAL AND INSTALLATION”. OBD-II SELF-DIAGNOSIS 쐌 쐌 쐌 − − − *: 쐌 GI MA EM LC NAAT0004S03 A/T self-diagnosis is performed by the TCM in combination with the ECM. The results can be read through the blinking pattern of the O/D OFF indicator or the malfunction indicator lamp (MIL). Refer to the table on AT-38 for the indicator used to display each self-diagnostic result. The self-diagnostic results indicated by the MIL are automatically stored in both the ECM and TCM memories. Always perform the procedure “HOW TO ERASE DTC” on AT-35 to complete the repair and avoid unnecessary blinking of the MIL. The following self-diagnostic items can be detected using ECM self-diagnostic results mode* only when the O/D OFF indicator lamp does not indicate any malfunctions. PNP switch A/T 1st, 2nd, 3rd, or 4th gear function A/T TCC S/V function (lock-up) For details of OBD-II, refer to EC-85, “Introduction”. Certain systems and components, especially those related to OBD, may use the new style slidelocking type harness connector. For description and how to disconnect, refer to EL-7, “Description”. Wiring Diagrams and Trouble Diagnosis When you read wiring diagrams, refer to the following: 쐌 GI-11, “HOW TO READ WIRING DIAGRAMS”. 쐌 EL-11, “POWER SUPPLY ROUTING” for power distribution circuit. When you perform trouble diagnosis, refer to the following: 쐌 GI-35, “HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES”. 쐌 GI-24, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”. EC FE CL MT TF PD NAAT0005 AX SU BR ST RS BT HA SC EL IDX AT-9 PREPARATION Special Service Tools 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.) Tool name ST2505S001 (J34301-C) Oil pressure gauge set 1 ST25051001 ( — ) Oil pressure gauge 2 ST25052000 ( — ) Hose 3 ST25053000 ( — ) Joint pipe 4 ST25054000 ( — ) Adapter 5 ST25055000 ( — ) Adapter Description Measuring line pressure NT097 ST07870000 (J37068) Transmission case stand Disassembling and assembling A/T a: 182 mm (7.17 in) b: 282 mm (11.10 in) c: 230 mm (9.06 in) d: 100 mm (3.94 in) NT421 KV31102100 (J37065) Torque converter oneway clutch check tool Checking one-way clutch in torque converter NT098 ST25850000 (J25721-A) Sliding hammer Removing oil pump assembly a: 179 mm (7.05 in) b: 70 mm (2.76 in) c: 40 mm (1.57 in) dia. d: M12 x 1.75P NT422 KV31102400 (J34285 and J34285-87) Clutch spring compressor Removing and installing clutch return springs a: 320 mm (12.60 in) b: 174 mm (6.85 in) NT423 AT-10 NAAT0006 PREPARATION Special Service Tools (Cont’d) Tool number (Kent-Moore No.) Tool name GI Description ST33200000 (J26082) Drift Installing oil pump housing oil seal Installing rear oil seal a: 60 mm (2.36 in) dia. b: 44.5 mm (1.752 in) dia. MA EM LC NT091 (J34291) Shim setting gauge set Selecting oil pump cover bearing race and oil pump thrust washer EC FE NT101 CL MT TF PD AX SU BR ST RS BT HA SC EL IDX AT-11 OVERALL SYSTEM A/T Electrical Parts Location A/T Electrical Parts Location NAAT0007 SAT681K AT-12 OVERALL SYSTEM Circuit Diagram Circuit Diagram NAAT0008 GI MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL MAT310B AT-13 IDX OVERALL SYSTEM Cross-sectional View Cross-sectional View NAAT0010 SAT150K AT-14 OVERALL SYSTEM Hydraulic Control Circuit Hydraulic Control Circuit NAAT0011 GI MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL SAT706K AT-15 IDX OVERALL SYSTEM Shift Mechanism Shift Mechanism NAAT0012 The automatic transmission uses compact, dual planetary gear systems to improve power-transmission efficiency, simplify construction and reduce weight. It also employs an optimum shift control and superwide gear ratios. They 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 NAAT0012S01 SAT509I 1. 2. 3. 4. 5. 6. 7. 8. Torque converter clutch piston Torque converter Oil pump Input shaft Brake band Reverse clutch High clutch Front pinion gear 9. 10. 11. 12. 13. 14. 15. 16. Front sun gear Front internal gear Front planetary carrier Rear sun gear Rear pinion gear Rear internal gear Rear planetary carrier Forward clutch 17. 18. 19. 20. 21. 22. 23. Forward one-way clutch Overrun clutch Low one-way clutch Low & reverse brake Parking pawl Parking gear Output shaft FUNCTION OF CLUTCH AND BRAKE Clutch and brake components NAAT0012S02 Abbr. Function Reverse clutch 6 R/C To transmit input power to front sun gear 9. High clutch 7 H/C To transmit input power to front planetary carrier 11. Forward clutch 16 F/C To connect front planetary carrier 11 with forward one-way clutch 17. Overrun clutch 18 O/C To connect front planetary carrier 11 with rear internal gear 14. Brake band 5 B/B To lock front sun gear 9. Forward one-way clutch 17 F/O.C When forward clutch 16 is engaged, to stop rear internal gear 14 from rotating in opposite direction against engine revolution. Low one-way clutch 19 L/O.C To stop front planetary carrier 11 from rotating in opposite direction against engine revolution. Low & reverse brake 20 L & R/B To lock front planetary carrier 11. AT-16 OVERALL SYSTEM Shift Mechanism (Cont’d) CLUTCH AND BAND CHART Reverse Shift position clutch High clutch Forward clutch NAAT0012S03 Overrun clutch Band servo 2nd apply 3rd release 4th apply Forward one -way clutch Low oneway clutch Low & reverse Lock-up brake Remarks GI MA EM PARK POSITION P 쎻 R REVERSE POSITION 쎻 NEUTRAL POSITION N 1st 쎻 *1D 2nd 쎻 *1A 쎻 *1A *2C C *3C C D*4 3rd 쎻 쎻 4th 쎻 C 1st 쎻 D 2nd 쎻 *1A 1st 쎻 쎻 2nd 쎻 쎻 2 B B B B 쎻 Automatic shift 1k2 B B B 1 쎻 EC FE CL 쎻 B 쎻 *1쎻 Automatic shift 1k2k3 k4 LC B 쎻 Locks (held stationary) in 1st speed 1g2 *1: Operates when overdrive control switch is being 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: A/T will not shift to 4th when overdrive control switch is set in “OFF” position. 쎻 : Operates. A: Operates when throttle opening is less than 3/16, activating engine brake. B: Operates during “progressive” acceleration. C: Operates but does not affect power transmission. D: Operates when throttle opening is less than 3/16, but does not affect engine brake. MT TF PD AX SU BR ST RS BT HA SC EL IDX AT-17 OVERALL SYSTEM Shift Mechanism (Cont’d) POWER TRANSMISSION “N” and “P” Positions 쐌 쐌 =NAAT0012S04 NAAT0012S0401 “N” position No control members operate. Power from the input shaft is not transmitted to the output shaft since the clutch does not operate. “P” position Similar to the “N” position, no control members operate. The parking pawl interconnected with the select lever engages with the parking gear to mechanically hold the output shaft so that the power train is locked. SAT039J AT-18 OVERALL SYSTEM Shift Mechanism (Cont’d) “11” Position =NAAT0012S0406 Forward clutch Forward one-way clutch Overrun clutch Low and reverse brake As overrun clutch engages, rear internal gear is locked by the operation of low and reverse brake. This is different from that of D1 and 21. Engine brake Overrun clutch always engages, therefore engine brake can be obtained when decelerating. GI MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SAT100JC SC EL IDX AT-19 OVERALL SYSTEM Shift Mechanism (Cont’d) “D1” and “21” Positions =NAAT0012S0402 Forward one-way clutch Forward clutch Low one-way clutch Rear internal gear is locked to rotate counterclockwise because of the functioning of these three clutches. (Start-up at D1) Overrun clutch engagement conditions (Engine brake) D1: Overdrive control switch in “OFF” Throttle opening less than 3/16 21: Throttle opening less than 3/16 At D1 and 21 positions, engine brake is not activated due to free turning of low one-way clutch. SAT096JC AT-20 OVERALL SYSTEM Shift Mechanism (Cont’d) “D2”, “22” and “12” Positions =NAAT0012S0403 Forward clutch Forward one-way clutch Brake band Rear sun gear drives rear planetary carrier and combined front internal gear. Front internal gear now rotates around front sun gear accompanying front planetary carrier. As front planetary carrier transfers the power to rear internal gear through forward clutch and forward one-way clutch, this rotation of rear internal gear increases the speed of rear planetary carrier compared with that of the 1st speed. Overrun clutch engagement conditions D2: Overdrive control switch in “OFF” Throttle opening less than 3/16 22: Throttle opening less than 3/16 12: Always engaged GI MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC SAT097JC EL IDX AT-21 OVERALL SYSTEM Shift Mechanism (Cont’d) “D3” Position =NAAT0012S0404 High clutch Forward clutch Forward one-way clutch Input power is transmitted to front planetary carrier through high clutch. And front planetary carrier is connected to rear internal gear by operation of forward clutch and forward one-way clutch. This rear internal gear rotation and another input (the rear sun gear) accompany rear planetary carrier to turn at the same speed. Overrun clutch engagement conditions D3: Overdrive control switch in “OFF” Throttle opening less than 3/16 SAT098JB AT-22 OVERALL SYSTEM Shift Mechanism (Cont’d) “D4” (OD) Position =NAAT0012S0405 High clutch Brake band Forward clutch (Does not affect power transmission) Input power is transmitted to front carrier through high clutch. This front planetary carrier turns around the sun gear which is fixed by brake band and makes front internal gear (output) turn faster. Engine brake At D4 position, there is no one-way clutch in the power transmission line and engine brake can be obtained when decelerating. GI MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SAT099JB SC EL IDX AT-23 OVERALL SYSTEM Shift Mechanism (Cont’d) “R” Position =NAAT0012S0407 Reverse clutch Low and reverse brake Front planetary carrier is stationary because of the operation of low and reverse brake. Input power is transmitted to front sun gear through reverse clutch, which drives front internal gear in the opposite direction. Engine brake As there is no one-way clutch in the power transmission line, engine brake can be obtained when decelerating. SAT101JB AT-24 OVERALL SYSTEM Control System Control System =NAAT0013 OUTLINE NAAT0013S01 The automatic transmission senses vehicle operating conditions through various sensors or signals. It always controls the optimum shift position and reduces shifting and lock-up shocks. SENSORS (or SIGNALS) PNP switch Accelerator pedal position sensor (throttle position sensor) Closed throttle position signal Wide open throttle position signal Engine speed signal A/T fluid temperature sensor Revolution sensor Vehicle speed sensor Overdrive control switch signal Stop lamp switch signal Turbine revolution sensor GI TCM 왘 Shift control Line pressure control Lock-up control Overrun clutch control Timing control Fail-safe control Self-diagnosis CONSULT-II communication line Duet-EU control ACTUATORS 왘 MA EM Shift solenoid valve A Shift solenoid valve B Overrun clutch solenoid valve Torque converter clutch solenoid valve Line pressure solenoid valve O/D OFF indicator lamp T/F control unit LC EC FE CL CONTROL SYSTEM NAAT0013S02 MT TF PD AX SU BR ST RS BT HA SAT698K SC EL IDX AT-25 OVERALL SYSTEM Control System (Cont’d) TCM FUNCTION =NAAT0013S03 The function of the TCM is to: 쐌 Receive input signals sent from various switches and sensors. 쐌 Determine required line pressure, shifting point, lock-up operation, and engine brake operation. 쐌 Send required output signals to the respective solenoids. INPUT/OUTPUT SIGNAL OF TCM NAAT0013S04 Sensors and solenoid valves Input Output Function PNP switch Detects select lever position and sends a signal to TCM. Accelerator pedal position sensor (throttle position sensor) Detects accelerator pedal position sensor as throttle position signal and sends a signal from ECM to TCM. Closed throttle position signal Detects throttle valve’s fully-closed position and sends a signal from ECM to TCM. Wide open throttle position signal Detects a throttle valve position of greater than 1/2 of full throttle and sends a signal from ECM to TCM. Engine speed signal From ECM. A/T fluid temperature sensor Detects transmission fluid temperature and sends a signal to TCM. Revolution sensor Detects output shaft rpm and sends a signal to TCM. Vehicle speed signal Used as an auxiliary vehicle speed signal. Sends a signal when revolution sensor (installed on transmission) malfunctions. Overdrive control switch Sends a signal, which prohibits a shift to “D4” (overdrive) position, from unified meter control unit to the TCM. ASCD operation signal Sends the cruise signal and “D4” (overdrive) cancellation signal from ECM to TCM. Turbine revolution sensor Sends an input shaft revolution signal. Stop lamp switch Sends the lock-up release signal from unified meter control unit to the TCM at time of D4 (lock-up). Shift solenoid valve A/B Selects shifting point suited to driving conditions in relation to a signal sent from TCM. Line pressure solenoid valve Regulates (or decreases) line pressure suited to driving conditions in relation to a signal sent from TCM. Torque converter clutch solenoid valve Regulates (or decreases) lock-up pressure suited to driving conditions in relation to a signal sent from TCM. Overrun clutch solenoid valve Controls an “engine brake” effect suited to driving conditions in relation to a signal sent from TCM. O/D OFF indicator lamp Shows TCM faults, when A/T control components malfunction. Control Mechanism LINE PRESSURE CONTROL NAAT0180 NAAT0180S01 TCM has the various line pressure control characteristics to meet the driving conditions. An ON-OFF duty signal is sent to the line pressure solenoid valve based on TCM characteristics. Hydraulic pressure on the clutch and brake is electronically controlled through the line pressure solenoid valve to accommodate engine torque. This results in smooth shift operation. AT-26 OVERALL SYSTEM Control Mechanism (Cont’d) Normal Control NAAT0180S0101 The line pressure to throttle opening characteristics is set for suitable clutch operation. GI MA EM LC SAT003J Back-up Control (Engine brake) EC NAAT0180S0102 If the selector lever is shifted to “2” position while driving in D4 (OD) or D3, great driving force is applied to the clutch inside the transmission. Clutch operating pressure (line pressure) must be increased to deal with this driving force. FE CL MT SAT004J During Shift Change NAAT0180S0103 The line pressure is temporarily reduced corresponding to a change in engine torque when shifting gears (that is, when the shift solenoid valve is switched for clutch operation) to reduce shifting shock. TF PD AX SU SAT005J At Low Fluid Temperature 쐌 NAAT0180S0104 Fluid viscosity and frictional characteristics of the clutch facing change with fluid temperature. Clutch engaging or band-contacting pressure is compensated for, according to fluid temperature, to stabilize shifting quality. BR ST RS BT 쐌 The line pressure is reduced below 60°C (140°F) to prevent shifting shock due to low viscosity of automatic transmission fluid when temperature is low. HA SC EL IDX SAT006J AT-27 OVERALL SYSTEM Control Mechanism (Cont’d) 쐌 Line pressure is increased to a maximum irrespective of the throttle opening when fluid temperature drops to −10°C (14°F). This pressure rise is adopted to prevent a delay in clutch and brake operation due to extreme drop of fluid viscosity at low temperature. SAT007J SHIFT CONTROL NAAT0180S02 The shift is regulated entirely by electronic control to accommodate vehicle speed and varying engine operations. This is accomplished by electrical signals transmitted by the revolution sensor and accelerator pedal position sensor (throttle position sensor). This results in improved acceleration performance and fuel economy. Control of Shift Solenoid Valves A and B NAAT0180S0201 The TCM activates shift solenoid valves A and B according to signals from the accelerator pedal position sensor (throttle position sensor) and revolution sensor to select the optimum gear position on the basis of the shift schedule memorized in the TCM. The shift solenoid valve performs simple ON-OFF operation. When set to “ON”, the drain circuit closes and pilot pressure is applied to the shift valve. [Relation between shift solenoid valves A and B and gear positions] SAT008J Gear position Shift solenoid valve D1, 21, 11 D2, 22, 12 D3 D4 (OD) N-P A ON (Closed) OFF (Open) OFF (Open) ON (Closed) ON (Closed) B ON (Closed) ON (Closed) OFF (Open) OFF (Open) ON (Closed) Control of Shift Valves A and B NAAT0180S0202 SAT047J AT-28 OVERALL SYSTEM Control Mechanism (Cont’d) Pilot pressure generated by the operation of shift solenoid valves A and B is applied to the end face of shift valves A and B. The drawing above shows the operation of shift valve B. When the shift solenoid valve is “ON”, pilot pressure applied to the end face of the shift valve overcomes spring force, moving the valve upward. GI LOCK-UP CONTROL EM NAAT0180S03 The torque converter clutch piston in the torque converter is locked to eliminate torque converter slip to increase power transmission efficiency. The solenoid valve is controlled by an ON-OFF duty signal sent from the TCM. The signal is converted to oil pressure signal which controls the torque converter clutch piston. NAAT0180S0301 When vehicle is driven in 4th gear position, vehicle speed and throttle opening are detected. If the detected values fall within the lock-up zone memorized in the TCM, lock-up is performed. ON Selector lever Gear position Vehicle speed sensor Accelerator pedal position sensor (Throttle position sensor) Closed throttle position switch A/T fluid temperature sensor LC EC Conditions for Lock-up Operation Overdrive control switch MA OFF FE CL “D” position D4 D3 MT More than set value Less than set opening OFF More than 40°C (104°F) TF PD AX SU Torque Converter Clutch Solenoid Valve Control NAAT0180S0302 The torque converter clutch solenoid valve is controlled by the TCM. The plunger closes the drain circuit during the “OFF” period, and opens the circuit during the “ON” period. If the percentage of OFF-time increases in one cycle, the pilot pressure drain time is reduced and pilot pressure remains high. The torque converter clutch piston is designed to slip to adjust the ratio of ON-OFF, thereby reducing lock-up shock. BR ST RS BT SAT010J OFF-time INCREASING " Amount of drain DECREASING " Pilot pressure HIGH " Lock-up RELEASING HA SC EL IDX SAT011J AT-29 OVERALL SYSTEM Control Mechanism (Cont’d) Torque Converter Clutch Control Valve OperationNAAT0180S0303 SAT048J Lock-up Released The OFF-duration of the torque converter clutch solenoid valve is long, and pilot pressure is high. The pilot pressure pushes the end face of the torque converter clutch control valve in combination with spring force to move the valve to the left. As a result, converter pressure is applied to chamber A (torque converter clutch piston release side). Accordingly, the torque converter clutch piston remains unlocked. Lock-up Applied When the OFF-duration of the torque converter clutch solenoid valve is short, pilot pressure drains and becomes low. Accordingly, the control valve moves to the right by the pilot pressure of the other circuit and converter pressure. As a result, converter pressure is applied to chamber B, keeping the torque converter clutch piston applied. Also smooth lock-up is provided by transient application and release of the lock-up. OVERRUN CLUTCH CONTROL (ENGINE BRAKE CONTROL) NAAT0180S04 Forward one-way clutch is used to reduce shifting shocks in downshifting operations. This clutch transmits engine torque to the wheels. However, drive force from the wheels is not transmitted to the engine because the one-way clutch rotates idle. This means the engine brake is not effective. The overrun clutch operates when the engine brake is needed. Overrun Clutch Operating Conditions Gear position Throttle opening “D” position D1, D2, D3 gear position Less than 3/16 “2” position 21, 22 gear position “1” position 11, 12 gear position NAAT0180S0401 At any position SAT715K AT-30 OVERALL SYSTEM Control Mechanism (Cont’d) Overrun Clutch Solenoid Valve Control NAAT0180S0402 The overrun clutch solenoid valve is operated by an ON-OFF signal transmitted by the TCM to provide overrun clutch control (engine brake control). When this solenoid valve is “ON”, the pilot pressure drain port closes. When it is “OFF”, the drain port opens. During the solenoid valve “ON” pilot pressure is applied to the end face of the overrun clutch control valve. GI MA EM LC SAT015J Overrun Clutch Control Valve Operation EC NAAT0180S0403 When the solenoid valve is “ON”, pilot pressure A is applied to the overrun clutch control valve. This pushes up the overrun clutch control valve. The line pressure is then shut off so that the clutch does not engage. When the solenoid valve is “OFF”, pilot pressure A is not generated. At this point, the overrun clutch control valve moves downward by spring force. As a result, overrun clutch operation pressure is provided by the overrun clutch reducing valve. This causes the overrun clutch to engage. In the “1” position, the overrun clutch control valve remains pushed down so that the overrun clutch is engaged at all times. FE CL MT TF PD AX SU SAT049J Control Valve NAAT0181 FUNCTION OF CONTROL VALVE NAAT0181S01 Valve name BR Function ST 쐌 Pressure regulator valve 쐌 Pressure regulator plug 쐌 Pressure regulator sleeve plug Regulate oil discharged from the oil pump to provide optimum line pressure for all driving conditions. Pressure modifier valve Used as a signal supplementary valve to the pressure regulator valve. Regulates pressure-modifier pressure (signal pressure) which controls optimum line pressure for all driving conditions. Modifier accumulator piston Smooths hydraulic pressure regulated by the pressure modifier valve to prevent pulsations. Pilot valve Regulates line pressure to maintain a constant pilot pressure level which controls lock-up mechanism, overrun clutch, 3-2 timing required for shifting. Accumulator control valve Accumulator control sleeve Regulate accumulator back-pressure to pressure suited to driving conditions. SC Manual valve Directs line pressure to oil circuits corresponding to select positions. Hydraulic pressure drains when the shift lever is in Neutral. EL RS BT HA IDX AT-31 OVERALL SYSTEM Control Valve (Cont’d) Valve name Function Shift valve A Simultaneously switches three oil circuits using output pressure of shift solenoid valve A to meet driving conditions (vehicle speed, throttle opening, etc.). Provides automatic downshifting and up-shifting (1st , 2nd , 3rd , 4th gears/4th , 3rd , 2nd , 1st gears) in combination with shift valve B. Shift valve B Simultaneously switches three oil circuits using output pressure of shift solenoid valve B in relation to driving conditions (vehicle speed, throttle opening, etc.). Provides automatic downshifting and up-shifting (1st , 2nd , 3rd , 4th gears/4th , 3rd , 2nd , 1st gears) in combination with shift valve A. Shuttle shift valve S Switches hydraulic circuits to provide 3-2 timing control and overrun clutch control in relation to the throttle opening. Inactivates the overrun clutch to prevent interlocking in 4th gear when the throttle is wide open. Overrun clutch control valve Switches hydraulic circuits to prevent engagement of the overrun clutch simultaneously with application of the brake band in 4th gear. (Interlocking occurs if the overrun clutch engages during D4 gear operation.) 4-2 relay valve Memorizes that the transmission is in 4th gear. Prevents the transmission from downshifting from 4th gear to 3rd and then to 2nd in combination with 4-2 sequence valve and shift valves A and B when downshifting from 4th to 2nd gear. 4-2 sequence valve Prevents band servo pressure from draining before high clutch operating pressure and band servo releasing pressure drain (from the same circuit) during downshifting from 4th to 2nd gear. Servo charger valve An accumulator and a one-way orifice are used in the 2nd gear band servo oil circuit to dampen shifting shock when shifting from 1st to 2nd gear. To maintain adequate flow rate when downshifting from 4th or 3rd gear to 2nd gear, the servo charger valve directs 2nd gear band servo hydraulic pressure to the circuit without going through the one-way orifice when downshifting from 3rd or a higher gear. 3-2 timing valve Prevents a late operation of the brake band when shifting selector lever from “D” to “1” or “2” position while driving in D3. “1” reducing valve Reduces low & reverse brake pressure to dampen engine-brake shock when downshifting from the “1” position 2nd gear to 1st gear. Overrun clutch reducing valve Reduces oil pressure directed to the overrun clutch and prevents engine-brake shock. In “1” and “2” positions, line pressure acts on the overrun clutch reducing valve to increase the pressure-regulating point, with resultant engine brake capability. Torque converter relief valve Prevents an excessive rise in torque converter pressure. Torque converter clutch control valve, torque converter clutch control plug and torque converter clutch control sleeve Activate or inactivate the lock-up function. Also provide smooth lock-up through transient application and release of the lock-up system. Shuttle shift valve D Switches hydraulic circuits so that output pressure of the torque converter clutch solenoid valve acts on the lock-up valve in the “D” position of 2nd, 3rd and 4th gears. (In the “D” position 1st gear, lock-up is inhibited.) 쐌 Lock-up control is not affected in “D” position 2nd, 3rd or 4th gears, unless output pressure of the torque converter clutch solenoid valve is generated by a signal from the control unit. AT-32 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Introduction Introduction NAAT0014 The A/T system has two self-diagnostic systems. The first is the emission-related on board diagnostic system (OBD-II) performed by the TCM in combination with the ECM. The malfunction is indicated by the MIL (malfunction indicator lamp) and is stored as a DTC in the ECM memory but not the TCM memory. The second is the TCM original self-diagnosis indicated by the O/D OFF indicator lamp. The malfunction is stored in the TCM memory. The detected items are overlapped with OBD-II self-diagnostic items. For detail, refer to AT-38. GI MA EM LC OBD-II Function for A/T System NAAT0182 The ECM provides emission-related on board diagnostic (OBD-II) functions for the A/T system. One function is to receive a signal from the TCM used with OBD-related parts of the A/T system. The signal is sent to the ECM when a malfunction occurs in the corresponding OBD-related part. The other function is to indicate a diagnostic result by means of the MIL (malfunction indicator lamp) on the instrument panel. Sensors, switches and solenoid valves are used as sensing elements. The MIL automatically illuminates in One or Two Trip Detection Logic when a malfunction is sensed in relation to A/T system parts. One or Two Trip Detection Logic of OBD-II ONE TRIP DETECTION LOGIC EC FE CL NAAT0015 NAAT0015S01 If a malfunction is sensed during the first test drive, the MIL will illuminate and the malfunction will be stored in the ECM memory as a DTC. The TCM is not provided with such a memory function. TWO TRIP DETECTION LOGIC MT NAAT0015S02 When a malfunction is sensed during the first test drive, it is stored in the ECM memory as a 1st trip DTC (diagnostic trouble code) or 1st trip freeze frame data. At this point, the MIL will not illuminate. — First Trip If the same malfunction as that experienced during the first test drive is sensed during the second test drive, the MIL will illuminate. — Second Trip A/T-related parts for which the MIL illuminates during the first or second test drive are listed below. TF PD MIL Items One trip detection Shift solenoid valve A — DTC: P0750 X Shift solenoid valve B — DTC: P0755 X Accelerator pedal position sensor (throttle position sensor) or switch — DTC: P1705 X Except above Two trip detection AX SU BR X The “trip” in the “One or Two Trip Detection Logic” means a driving mode in which self-diagnosis is performed during vehicle operation. OBD-II Diagnostic Trouble Code (DTC) HOW TO READ DTC AND 1ST TRIP DTC NAAT0016 ST RS NAAT0016S01 DTC and 1st trip DTC can be read by the following methods. ( with CONSULT-II or GST) CONSULT-II or GST (Generic Scan Tool) Examples: P0705, P0710, P0720, P0725, etc. These DTCs are prescribed by SAE J2012. (CONSULT-II also displays the malfunctioning component or system.) 쐌 1st trip DTC No. is the same as DTC No. 쐌 Output of the diagnostic trouble code indicates that the indicated circuit has a malfunction. However, in case of the Mode II and GST they do not indicate whether the malfunction is still occurring or occurred in the past and returned to normal. CONSULT-II can identify them as shown below. Therefore, using CONSULT-II (if available) is recommended. A sample of CONSULT-II display for DTC and 1st trip DTC is shown on the next page. DTC or 1st trip DTC of a malfunction is displayed in SELF-DIAGNOSTIC RESULTS mode for “ENGINE” with CONSULT-II. Time data indicates how many times the vehicle was driven after the last detection of a DTC. AT-33 BT HA SC EL IDX ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION OBD-II Diagnostic Trouble Code (DTC) (Cont’d) SAT014K If the DTC is being detected currently, the time data will be “0”. SAT015K If a 1st trip DTC is stored in the ECM, the time data will be “1t”. SAT016K Freeze Frame Data and 1st Trip Freeze Frame Data NAAT0016S0101 The ECM has a memory function, which stores the driving condition 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 the ECM detects a malfunction. Data which are stored in the ECM memory, along with the 1st trip DTC, are called 1st trip freeze frame data, and the data, stored together with the DTC data, are called freeze frame data and displayed on CONSULT-II or GST. The 1st trip freeze frame data can only be displayed on the CONSULT-II screen, not on the GST. For detail, refer to EC-111, “CONSULT-II”. Only one set of freeze frame data (either 1st trip freeze frame data of 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 priority 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 following priorities to update the data. AT-34 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION OBD-II Diagnostic Trouble Code (DTC) (Cont’d) Priority 1 Freeze frame data 2 3 GI Items Misfire — DTC: P0300 - P0306 Fuel Injection System Function — DTC: P0171, P0172, P0174, P0175 MA Except the above items (Includes A/T related items) EM 1st trip freeze frame data Both 1st trip freeze frame data and freeze frame data (along with the DTCs) are cleared when the ECM memory is erased. HOW TO ERASE DTC LC NAAT0016S02 The diagnostic trouble code can be erased by CONSULT-II, GST or ECM DIAGNOSTIC TEST MODE as described following. 쐌 If the battery terminal is disconnected, the diagnostic trouble code will be lost within 24 hours. 쐌 When you erase the DTC, using CONSULT-II or GST is easier and quicker than switching the mode selector on the ECM. The following emission-related diagnostic information is cleared from the ECM memory when erasing DTC related to OBD-II. For details, refer to EC-86, “Emission-related Diagnostic Information”. 쐌 Diagnostic trouble codes (DTC) 쐌 1st trip diagnostic trouble codes (1st trip DTC) 쐌 Freeze frame data 쐌 1st trip freeze frame data 쐌 System readiness test (SRT) codes 쐌 Test values HOW TO ERASE DTC (WITH CONSULT-II) EC FE CL MT TF NAAT0016S03 쐌 If a DTC is displayed for both ECM and TCM, it needs to be erased for both ECM and TCM. 1. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least 5 seconds and then turn it “ON” (engine stopped) again. 2. Turn CONSULT-II “ON” and touch “A/T”. 3. Touch “SELF-DIAG RESULTS”. 4. Touch “ERASE”. (The DTC in the TCM 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.) PD AX SU BR ST RS BT HA SC EL IDX AT-35 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION OBD-II Diagnostic Trouble Code (DTC) (Cont’d) SCIA5586E HOW TO ERASE DTC (WITH GST) NAAT0016S04 1. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least 5 seconds and then turn it “ON” (engine stopped) again. 2. Perform “TCM SELF-DIAGNOSTIC PROCEDURE”. Refer to AT-48. 3. Select Mode 4 with Generic Scan Tool (GST). For details, refer to EC-125, “DESCRIPTION”. HOW TO ERASE DTC (NO TOOLS) NAAT0016S05 1. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least 5 seconds and then turn it “ON” (engine stopped) again. 2. Perform “TCM SELF-DIAGNOSTIC PROCEDURE (No Tools)”. Refer to AT-48. (The engine warm-up step can be skipped when performing the diagnosis only to erase the DTC.) AT-36 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Malfunction Indicator Lamp (MIL) Malfunction Indicator Lamp (MIL) =NAAT0183 The MIL is located on the instrument panel. 1. The MIL will light up when the ignition switch is turned ON without the engine running. This is a bulb check. 쐌 If the MIL does not light up, refer to EL-127, “Schematic”. (Or refer to EC-791, “Wiring Diagram”.) 2. When the engine is started, the MIL should go off. If the MIL remains on, the on board diagnostic system has detected an engine system malfunction. For detail, refer to EC-85, “Introduction”. GI MA EM LC SAT964I EC CONSULT-II NAAT0184 After performing “SELF-DIAGNOSTIC PROCEDURE (WITH CONSULT-II)” (AT-38), place check marks for results on the “DIAGNOSTIC WORKSHEET”, AT-57. Reference pages are provided following the items. NOTICE: 1) The CONSULT-II electrically displays shift timing and lock-up timing (that is, operation timing of each solenoid). Check for time difference between actual shift timing and the CONSULT-II display. If the difference is noticeable, mechanical parts (except solenoids, sensors, etc.) may be malfunctioning. Check mechanical parts using applicable diagnostic procedures. 2) Shift schedule (which implies gear position) displayed on CONSULT-II and that indicated in Service Manual may differ slightly. This occurs because of the following reasons: 쐌 Actual shift schedule has more or less tolerance or allowance, 쐌 Shift schedule indicated in Service Manual refers to the point where shifts start, and 쐌 Gear position displayed on CONSULT-II indicates the point where shifts are completed. 3) Shift solenoid valve “A” or “B” is displayed on CONSULT-II at the start of shifting. Gear position is displayed upon completion of shifting (which is computed by TCM). 4) Additional CONSULT-II information can be found in the Operation Manual supplied with the CONSULT-II unit. FUNCTION Diagnostic test mode NAAT0184S07 Function Reference Work support This mode enables a technician to adjust some devices faster and more accurately by following the indications on CONSULT-II. — Self-diagnostic results Self-diagnostic results can be read and erased quickly. Refer to AT-38 Data monitor Input/Output data in the ECM can be read. Refer to AT-40 CAN diagnostic support monitor The results of transmit/receive diagnosis of CAN communication can be read. — Function test Performed by CONSULT-II instead of a technician to determine whether each system is “OK” or “NG”. — DTC work support Select the operating condition to confirm Diagnostic Trouble Codes. TCM part number TCM part number can be read. FE CL MT TF PD AX SU BR ST RS BT HA SC Refer to AT-44 — EL IDX AT-37 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) SELF-DIAGNOSTIC PROCEDURE (WITH CONSULT-II) NAAT0184S01 1. Turn on CONSULT-II and touch “ENGINE” for OBD-II detected items or touch “A/T” for TCM self-diagnosis. If A/T is not displayed, check TCM power supply and ground circuit. Refer to AT-95. If result is NG, refer to EL-11, “Schematic”. 2. Touch “SELF-DIAG RESULTS”. Display shows malfunction experienced since the last erasing operation. CONSULT-II performs REAL-TIME SELF-DIAGNOSIS. Also, any malfunction detected while in this mode will be displayed at real time. SAT014K SAT987J SELF-DIAGNOSTIC RESULT TEST MODE NAAT0184S02 TCM self-diagnosis OBD-II (DTC) Available by O/D OFF indicator lamp Available by malfunction indicator lamp*2, “ENGINE” on CONSULT-II or GST — P0705 X P0720 X — — P0731*1 A/T 1ST GR FNCTN 쐌 A/T cannot be shifted to the 1st gear position even if electrical circuit is good. — P0732*1 A/T 2ND GR FNCTN 쐌 A/T cannot be shifted to the 2nd gear position even if electrical circuit is good. — P0733*1 A/T 3RD GR FNCTN 쐌 A/T cannot be shifted to the 3rd gear position even if electrical circuit is good. — P0734*1 A/T 4TH GR FNCTN 쐌 A/T cannot be shifted to the 4th gear position even if electrical circuit is good. Detected items (Screen terms for CONSULT-II, “SELF-DIAG RESULTS” test mode) Malfunction is detected when ... “A/T” “ENGINE” PNP switch circuit — PNP SW/CIRC Revolution sensor VHCL SPEED SEN·A/T VEH SPD SEN/CIR AT Vehicle speed sensor (Meter) VHCL SPEED SEN·MTR — A/T 1st gear function — A/T 2nd gear function — A/T 3rd gear function — A/T 4th gear function — 쐌 TCM does not receive the correct voltage signal (based on the gear position) from the switch. 쐌 TCM does not receive the proper voltage signal from the sensor. 쐌 TCM does not receive the proper voltage signal from the sensor. AT-38 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) TCM self-diagnosis OBD-II (DTC) Available by O/D OFF indicator lamp Available by malfunction indicator lamp*2, “ENGINE” on CONSULT-II or GST — P0744*1 Detected items (Screen terms for CONSULT-II, “SELF-DIAG RESULTS” test mode) MA Malfunction is detected when ... “A/T” “ENGINE” A/T TCC S/V function (lock-up) — A/T TCC S/V FNCTN SHIFT SOLENOID/V A SFT SOL A/CIRC SFT SOL B/CIRC 쐌 TCM detects an improper voltage drop when it tries to operate the solenoid valve. Shift solenoid valve B SHIFT SOLENOID/V B Overrun clutch solenoid valve OVERRUN CLUTCH S/V O/R CLUCH SOL/ CIRC T/C clutch solenoid valve T/C CLUTCH SOL/V TCC SOLENOID/ CIRC Line pressure solenoid valve LINE PRESSURE S/V L/PRESS SOL/CIRC Accelerator pedal position sensor (throttle position sensor) THROTTLE POSI SEN TP SEN/CIRC A/T ENGINE SPEED SIG A/T fluid temperature sensor ATF TEMP SEN/ CIRC CAN communication CAN COMM LINE — Turbine revolution sensor TURBINE REV — TCM (RAM) CONTROL UNIT (RAM) 쐌 TCM detects an improper voltage drop when it tries to operate the solenoid valve. 쐌 TCM detects an improper voltage drop when it tries to operate the solenoid valve. 쐌 TCM receives an excessively low or high voltage from the sensor. EM LC EC X P0750 FE X P0755 X P1760 X P0740 X P0745 CL MT TF PD AX X P1705 SU 쐌 TCM receives an excessively low or high voltage from the sensor. 쐌 The CAN communication line is open or shorted. 쐌 TCM does not receive the proper voltage signal from the sensor. X P0725 X P0710 BR ST RS X EC-57 BT X — HA 쐌 TCM memory (RAM) is malfunctioning. — — 쐌 TCM memory (ROM) is malfunctioning. — — — TCM (ROM) CONTROL UNIT (ROM) 쐌 TCM detects an improper voltage drop when it tries to operate the solenoid valve. 쐌 TCM does not receive the proper voltage signal from the ECM. Engine speed signal BATT/FLUID TEMP SEN 쐌 A/T cannot perform lock-up even if electrical circuit is good. 쐌 TCM detects an improper voltage drop when it tries to operate the solenoid valve. Shift solenoid valve A GI SC EL — IDX AT-39 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) TCM self-diagnosis OBD-II (DTC) Available by O/D OFF indicator lamp Available by malfunction indicator lamp*2, “ENGINE” on CONSULT-II or GST — — X — X X Detected items (Screen terms for CONSULT-II, “SELF-DIAG RESULTS” test mode) Malfunction is detected when ... “A/T” “ENGINE” 쐌 TCM memory (EEP ROM) is malfunctioning. TCM (EEP ROM) CONTROL UNIT (EEP ROM) — Initial start INITIAL START — No failure (NO DTC IS DETECTED FURTHER TESTING MAY BE REQUIRED) 쐌 This is not a malfunction message (Whenever shutting off a power supply to the TCM, this message appears on the screen.) 쐌 No failure has been detected. X: Applicable —: Not applicable *1: These malfunctions cannot be displayed by MIL *2: Refer to EC-102, “DESCRIPTION”. if another malfunction is assigned to MIL. DATA MONITOR MODE (A/T) NAAT0184S03 Selection monitor item Item Display Vehicle speed sensor 1 (A/T) (Revolution sensor) VHCL/S SE·A/T [km/h] or [mph] Vehicle speed sensor 2 (Meter) VHCL/S SE·MTR [km/h] or [mph] TCM MAIN INPUT SIGNALS SIGNALS X X Accelerator pedal position sensor (throttle position sensor) THRTL POS SEN [V] A/T fluid temperature sensor FLUID TEMP SE [V] Battery voltage BATTERY VOLT [V] X SELECTION FROM MENU — — — 왔 왔 Description 쐌 Vehicle speed computed from signal of revolution sensor is displayed. When racing engine in “N” or “P” position with vehicle stationary, CONSULT-II data may not indicate 0 km/h (0 mph). 쐌 Vehicle speed computed from signal of vehicle speed sensor is displayed. Vehicle speed display may not be accurate under approx. 10 km/h (6 mph). It may not indicate 0 km/h (0 mph) when vehicle is stationary. 왔 쐌 Accelerator pedal position sensor (throttle position sensor) signal voltage is displayed. X — 왔 쐌 A/T fluid temperature sensor signal voltage is displayed. 쐌 Signal voltage lowers as fluid temperature rises. X — 왔 쐌 Source voltage of TCM is displayed. AT-40 Remarks ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) GI Selection monitor item Item Engine speed Turbine revolution sensor Overdrive control switch PN position switch R position switch D position switch 2 position switch 1 position switch ASCD cruise signal Display ENGINE SPEED [rpm] TURBINE REV [rpm] OVERDRIVE SW [ON/OFF] PN POSI SW [ON/OFF] R POSITION SW [ON/OFF] D POSITION SW [ON/OFF] 2 POSITION SW [ON/OFF] 1 POSITION SW [ON/OFF] TCM MAIN INPUT SIGNALS SIGNALS X X X X X X X X — — — — — — — 왔 왔 — KICKDOWN SW [ON/OFF] X — — Description Engine speed display may not be accurate under approx. 800 rpm. It may not indicate 0 rpm even when engine is not running. 쐌 Turbine revolution computed from signal of turbine revolution sensor is displayed. Error may occur under approx. 800 rpm and will not indicate 0 rpm even if engine is not running. 왔 왔 쐌 ON/OFF state computed from signal of PN position SW is displayed. 왔 쐌 ON/OFF state computed from signal of R position SW is displayed. 왔 쐌 ON/OFF state computed from signal of D position SW is displayed. 왔 쐌 ON/OFF status, computed from signal of 2 position SW, is displayed. 왔 쐌 ON/OFF status, computed from signal of 1 position SW, is displayed. 왔 쐌 Status of ASCD cruise signal is displayed. ON ... Cruising state OFF ... Normal running state 왔 왔 Remarks 쐌 Engine speed, computed from engine speed signal, is displayed. 쐌 ON/OFF state computed from signal of overdrive control SW is displayed. ASCD-OD CUT [ON/OFF] X Kickdown switch X ASCD-CRUISE [ON/OFF] X ASCD OD cut signal SELECTION FROM MENU EM LC EC FE CL MT TF PD AX SU BR ST RS BT 쐌 Status of ASCD OD release signal is displayed. ON ... OD released OFF ... OD not released 쐌 ON/OFF status, computed from signal of kickdown SW, is displayed. MA HA SC 쐌 This is displayed even when no kickdown switch is equipped. EL IDX AT-41 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) Selection monitor item Item A/T mode switch Display POWER SHIFT SW [ON/OFF] Closed throttle position signal CLOSED THL/SW [ON/OFF] Wide open throttle position signal W/O THRL/ P-SW [ON/OFF] TCM MAIN INPUT SIGNALS SIGNALS X X SELECTION FROM MENU — — 왔 쐌 ON/OFF status, computed from signal of closed throttle position SW, is displayed. 쐌 Signal input with CAN communication 쐌 ON/OFF status, computed from signal of wide open throttle position SW, is displayed. 쐌 Signal input with CAN communication X — 왔 *SHIFT S/V A [ON/OFF] — — 왔 Shift solenoid valve B *SHIFT S/V B [ON/OFF] — — 왔 Overrun clutch solenoid valve *OVRRUN/C S/V [ON/OFF] — — 왔 A/T mode switch HOLD SW [ON/OFF] X — 왔 Stop lamp signal BRAKE SW [ON/OFF] Selector lever position Vehicle speed Throttle position Line pressure duty VEHICLE SPEED [km/h] or [mph] THROTTLE POSI [/8] LINE PRES DTY [%] Displays status of check signal (re-input signal) for TCM control signal output. Remains unchanged when solenoid valves are open or shorted. 쐌 Not mounted but displayed. X — 왔 쐌 ON/OFF status is dis- 쐌 Signal input with CAN played. communication ON ... Brake pedal is depressed. OFF ... Brake pedal is released. — X 왔 쐌 Gear position data used for computation by TCM, is displayed. GEAR SLCT LVR POSI Remarks 쐌 Not mounted but displayed. 왔 Shift solenoid valve A Gear position Description — X 왔 쐌 Selector lever position 쐌 A specific value used data, used for compufor control is distation by TCM, is displayed if fail-safe is played. activated due to error. — X 왔 쐌 Vehicle speed data, used for computation by TCM, is displayed. — — X X AT-42 왔 왔 쐌 Throttle position data, used for computation by TCM, is displayed. 쐌 Control value of line pressure solenoid valve, computed by TCM from each input signal, is displayed. 쐌 A specific value used for control is displayed if fail-safe is activated due to error. ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) GI Selection monitor item Item Torque converter clutch solenoid valve duty Display TCM MAIN INPUT SIGNALS SIGNALS 왔 쐌 Control value of shift solenoid valve A, computed by TCM from each input signal, is displayed. X 왔 쐌 Control value of shift solenoid valve B, computed by TCM from each input signal, is displayed. SHIFT S/V B [ON/OFF] — Overrun clutch solenoid valve 왔 SHIFT S/V A [ON/OFF] — Shift solenoid valve B X OVERRUN/C S/V [ON/OFF] Self-diagnosis display lamp (O/D OFF indicator lamp) SELF-D DP LMP [ON/OFF] Torque converter slip ratio TC SLIP RATIO [0.000] Torque converter slip speed TC SLIP SPEED [rpm] Voltage Voltage [V] Frequency Frequency [Hz] — — — X X X — Description 쐌 Control value of torque converter clutch solenoid valve, computed by TCM from each input signal, is displayed. TCC S/V DUTY [%] — Shift solenoid valve A SELECTION FROM MENU 왔 왔 Remarks MA EM LC Control value of solenoid is displayed even if solenoid circuit is disconnected. The “OFF” signal is displayed if solenoid circuit is shorted. EC FE CL MT 쐌 Control value of overrun clutch solenoid valve computed by TCM from each input signal is displayed. TF 쐌 Control status of O/D OFF indicator lamp is displayed. PD 왔 쐌 Ratio of engine revolution to input shaft revolution of torque converter AX SU — — 왔 Difference in revolution between input shaft revolution and input shaft revolution of torque converter — — 왔 Value measured by voltage probe is displayed. RS 왔 Value measured by pulse probe is displayed. If measurement is impossible, “#” sign is displayed. “#” sign is also displayed at the final data value until the measurement result is obtained. Duty cycle value for measurement probe is displayed. SC — — Duty cycle (high) DUTY-HI [%] — — 왔 Duty cycle (low) DUTY-LOW [%] — — 왔 Display doesn’t indicate 0 rpm even if engine is stopped. But this isn’t malfunction. BR ST BT HA EL IDX AT-43 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) Selection monitor item Item TCM MAIN INPUT SIGNALS SIGNALS Display SELECTION FROM MENU Plus width (high) PLS WIDTH-HI — — 왔 Plus width (low) PLS WIDTHLOW — — 왔 Description Remarks Measured pulse width of measurement probe is displayed. X: Applicable —: Not applicable 왔: Option DTC WORK SUPPORT MODE WITH CONSULT-II CONSULT-II Setting Procedure NAAT0184S04 NAAT0184S0401 1. 2. Turn ignition switch “OFF”. Connect CONSULT-II and CONSULT-II CONVERTER to data link connector, which is located in instrument lower panel on driver side. 3. 4. Turn ignition switch “ON”. Touch “START (NISSAN BASED VHCL)”. 5. Touch “A/T”. 6. Touch “DTC WORK SUPPORT”. SAIA0450E SAT014K SCIA5358E AT-44 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) 7. Touch select item menu (1ST, 2ND, etc.). GI MA EM LC SAT018K 8. Touch “START”. EC FE CL MT SAT589J 9. Perform driving test according to “DTC CONFIRMATION PROCEDURE” in “TROUBLE DIAGNOSIS FOR DTC”. TF PD AX SU SAT019K 쐌 When testing conditions are satisfied, CONSULT-II screen changes from “OUT OF CONDITION” to “TESTING”. BR ST RS BT SAT591J HA SC EL IDX AT-45 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) 10. Stop vehicle. If “NG” appears on the screen, malfunction may exist. Go to “DIAGNOSTIC PROCEDURE”. SAT592J SAT593J 11. Perform test drive to check gear shift feeling in accordance with instructions displayed. SAT594J 12. Touch “YES” or “NO”. SAT595J AT-46 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT-II (Cont’d) 13. CONSULT-II procedure ended. If “NG” appears on the screen, a malfunction may exist. Go to “DIAGNOSTIC PROCEDURE”. GI MA EM LC SAT596J EC FE CL MT SAT593J DTC WORK SUPPORT MODE DTC work support item NAAT0184S05 Description Check item 1ST GR FNCTN P0731 Following items for “A/T 1st gear function (P0731)” can be confirmed. 쐌 Self-diagnosis status (whether the diagnosis is being conducted or not) 쐌 Self-diagnosis result (OK or NG) 쐌 쐌 쐌 쐌 2ND GR FNCTN P0732 Following items for “A/T 2nd gear function (P0732)” can be confirmed. 쐌 Self-diagnosis status (whether the diagnosis is being conducted or not) 쐌 Self-diagnosis result (OK or NG) 쐌 Shift solenoid valve B 쐌 Each clutch 쐌 Hydraulic control circuit 3RD GR FNCTN P0733 Following items for “A/T 3rd gear function (P0733)” can be confirmed. 쐌 Self-diagnosis status (whether the diagnosis is being conducted or not) 쐌 Self-diagnosis result (OK or NG) 쐌 Shift solenoid valve A 쐌 Each clutch 쐌 Hydraulic control circuit Following items for “A/T 4th gear function (P0734)” can be confirmed. 쐌 Self-diagnosis status (whether the diagnosis is being conducted or not) 쐌 Self-diagnosis result (OK or NG) 쐌 쐌 쐌 쐌 쐌 쐌 4TH GR FNCTN P0734 TCC S/V FNCTN P0744 Shift solenoid valve A Shift solenoid valve B Each clutch Hydraulic control circuit TF PD AX Shift solenoid valve A Shift solenoid valve B Overrun clutch solenoid valve Line pressure solenoid valve Each clutch Hydraulic control circuit Following items for “A/T TCC S/V function (lock-up) (P0744)” can 쐌 Torque converter clutch solebe confirmed. noid valve 쐌 Self-diagnosis status (whether the diagnosis is being con쐌 Each clutch ducted or not) 쐌 Hydraulic control circuit 쐌 Self-diagnosis result (OK or NG) SU BR ST RS BT HA SC EL IDX AT-47 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Diagnostic Procedure Without CONSULT-II Diagnostic Procedure Without CONSULT-II NAAT0206 OBD-II SELF-DIAGNOSTIC PROCEDURE (WITH NAAT0206S01 GST) Refer to EC-125, “DESCRIPTION”. OBD-II SELF-DIAGNOSTIC PROCEDURE (NO TOOLS) NAAT0206S02 Refer to EC-102, “DESCRIPTION”. TCM SELF-DIAGNOSTIC PROCEDURE (NO TOOLS) NAAT0206S03 Preparation NAAT0206S0301 1. 2. 3. 4. 5. SAT491J 6. Turn ignition switch to “OFF” position. Connect the handy type vacuum pump to the throttle opener and apply vacuum −25.3 kPa (−190 mmHg, −7.48 inHg). Disconnect the throttle position switch harness connector. Turn ignition switch to “ON” position. Check continuity of the closed throttle position switch. Continuity should exist. (If continuity does not exist, check throttle opener and closed throttle position switch. Then increase vacuum until closed throttle position switch shows continuity.) Go to “DIAGNOSIS START” on next page. SAT132K AT-48 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Diagnostic Procedure Without CONSULT-II (Cont’d) 1 GI CHECK O/D OFF INDICATOR LAMP 1. Start the engine with selector lever in “P” position. Warm engine to normal operating temperature. 2. Turn ignition switch to “OFF” position. 3. Wait 5 seconds. MA EM LC EC FE SAT967I 4. Turn ignition switch to “ON” position. (Do not start engine.) 5. Does O/D OFF indicator lamp come on for about 2 seconds? CL MT TF PD SAT204K Yes or No Yes 䊳 GO TO 2. No 䊳 Stop procedure. Perform O/D OFF Indicator Lamp Does Not Come On”, AT-221 before proceeding. AX SU BR ST RS BT HA SC EL IDX AT-49 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Diagnostic Procedure Without CONSULT-II (Cont’d) 2 JUDGEMENT PROCEDURE STEP 1 1. 2. 3. 4. 5. 6. Turn ignition switch to “OFF” position. Push shift lock release button. Move selector lever from “P” to “D” position. Turn ignition switch to “ON” position. (Do not start engine.) Wait 3 seconds. Push the overdrive control switch in “O/D OFF” position (the O/D OFF indicator lamp will be “ON”) If O/D OFF indicator lamp does not come on, go to step 5 on AT-258. 7. Turn ignition switch to “OFF” position. SAT968I 8. Turn ignition switch to “ON” position (Do not start engine.). 9. Push the overdrive control switch in “O/D ON” position (the O/D OFF indicator lamp will be “OFF”). 10. Wait 2 seconds. 11. Move selector lever to “2” position. 12. Push the overdrive control switch in “O/D OFF” position (the O/D OFF indicator lamp will be “ON”). 13. Push the overdrive control switch in “O/D OFF” position (the O/D OFF indicator lamp will be “OFF”). SAT969I 䊳 GO TO 3. AT-50 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Diagnostic Procedure Without CONSULT-II (Cont’d) 3 1. 2. 3. 4. GI JUDGEMENT PROCEDURE STEP 2 Move selector lever to “1” position. Push the overdrive control switch in “O/D OFF” position (the O/D OFF indicator lamp will be “ON”). Push the overdrive control switch in “O/D ON” position (the O/D OFF indicator lamp will be “OFF”). Push the overdrive control switch in “O/D OFF” position (the O/D OFF indicator lamp will be “ON”). MA EM LC EC FE SAT970I CL 5. Depress accelerator pedal fully and release it. 6. Push the overdrive control switch (the O/D OFF indicator lamp will begin to flash “ON” and “OFF”). MT TF PD SAT981F GO TO 4. AX CHECK SELF-DIAGNOSIS CODE SU 䊳 4 Check O/D OFF indicator lamp. Refer to JUDGEMENT OF SELF-DIAGNOSIS CODE, AT-52. BR ST RS BT SAT204K 䊳 HA DIAGNOSIS END SC EL IDX AT-51 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Diagnostic Procedure Without CONSULT-II (Cont’d) JUDGEMENT OF SELF-DIAGNOSIS CODE NAAT0206S04 O/D OFF indicator lamp: All judgement flickers are same. 1st judgement flicker is longer than others. SAT666I SAT667I All circuits that can be confirmed by self-diagnosis are OK. Revolution sensor circuit is short-circuited or disconnected. ⇒ Go to DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR), AT-117. 2nd judgement flicker is longer than others. 3rd judgement flicker is longer than others. SAT668I SAT669I Vehicle speed signal circuit is short-circuited or disconnected. ⇒ Go to DTC VEHICLE SPEED SIGNAL·MTR, AT-200. Accelerator pedal position sensor circuit is short-circuited or disconnected. ⇒ Go to DTC P1705 ACCELERATOR PEDAL POSITION SENSOR, AT-182. 4th judgement flicker is longer than others. 5th judgement flicker is longer than others. SAT670I Shift solenoid valve A circuit is short-circuited or disconnected. ⇒ Go to DTC P0750 SHIFT SOLENOID VALVE A, AT-174. SAT671I Shift solenoid valve B circuit is short-circuited or disconnected. ⇒ Go to DTC P0755 SHIFT SOLENOID VALVE B, AT-178. AT-52 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Diagnostic Procedure Without CONSULT-II (Cont’d) GI O/D OFF indicator lamp: 6th judgement flicker is longer than others. 7th judgement flicker is longer than others. MA EM LC EC FE SAT672I SAT673I Overrun clutch solenoid valve circuit is short-circuited or disconnected. ⇒ Go to DTC P1760 OVERRUN CLUTCH SOLENOID VALVE, AT-188. Torque converter clutch solenoid valve circuit is short-circuited or disconnected. ⇒ Go to DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE, AT-154. CL 8th judgement flicker is longer than others. 9th judgement flicker is longer than others. MT TF PD AX SAT674I SAT675I A/T fluid temperature sensor is disconnected or TCM power source circuit is damaged. ⇒ Go to DTC BATT/FLUID TEMP SEN (A/T FLUID TEMPERATURE SENSOR AND TCM POWER SOURCE), AT-193. Engine speed signal circuit is short-circuited or disconnected. ⇒ Go to DTC P0725 ENGINE SPEED SIGNAL, AT-122. 10th judgement flicker is longer than others. 11th judgement flicker is longer than others. SU BR ST RS BT HA SAT676I Turbine revolution sensor circuit is short-circuited or disconnected. ⇒ Go to DTC Turbine Revolution Sensor, AT-209. SAT677I Line pressure solenoid valve circuit is short-circuited or disconnected. ⇒ Go to DTC P0745 LINE PRESSURE SOLENOID VALVE, AT-168. SC EL IDX AT-53 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Diagnostic Procedure Without CONSULT-II (Cont’d) O/D OFF indicator lamp: 12th judgement flicker is longer than others. Flickers as shown below. SAT678I CAN communication line is open or shorted. ⇒ Go to DTC U1000 CAN COMMUNICATION LINE, AT-206. SAT679I Battery power is low. Battery has been disconnected for a long time. Battery is connected conversely. (When reconnecting TCM connectors. — This is not a problem.) SAT705K Park/neutral position (PNP) switch, overdrive control switch, closed throttle position signal or wide-open throttle position signal circuit is disconnected or TCM is damaged. ⇒ Go to 21. TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control and Accelerator Pedal Position Sensor Circuit Checks), AT-258. t1 = 2.5 seconds t2 = 2.0 seconds t3 = 1.0 second t4 = 1.0 second AT-54 TROUBLE DIAGNOSIS — INTRODUCTION Introduction Introduction SAT631IB SAT632I NAAT0019 The TCM receives a signal from the vehicle speed sensor, throttle position sensor or PNP switch and provides shift control or lock-up control via A/T solenoid valves. The TCM also communicates with the ECM by means of a signal sent from sensing elements used with the OBD-related parts of the A/T system for malfunction-diagnostic purposes. The TCM is capable of diagnosing malfunctioning parts while the ECM can store malfunctions in its memory. Input and output signals must always be correct and stable in the operation of the A/T system. The A/T system must be in good operating condition and be free of valve seizure, solenoid valve malfunction, etc. It is much more difficult to diagnose a problem that occurs intermittently rather than continuously. Most intermittent problems are 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-II (or GST) or a circuit tester connected should be performed. Follow the “Work Flow”. Refer to AT-59. Before undertaking actual checks, take a few minutes to talk with a customer who approaches with a driveability complaint. The customer can supply good information about such problems, especially intermittent ones. Find out what symptoms are present and under what conditions they occur. A “Diagnostic Worksheet” like the example (AT-57) should be used. Start your diagnosis by looking for “conventional” problems first. This will help troubleshoot driveability problems on an electronically controlled engine vehicle. Also check related Service bulletins. GI MA EM LC EC FE CL MT TF PD AX SU SEF234G BR ST RS BT HA SC EL IDX AT-55 TROUBLE DIAGNOSIS — INTRODUCTION Introduction (Cont’d) DIAGNOSTIC WORKSHEET Information From Customer KEY POINTS WHAT ..... Vehicle & A/T model WHEN..... Date, Frequencies WHERE..... Road conditions HOW..... Operating conditions, Symptoms Customer name MR/MS Model & Year VIN Trans. model Engine Mileage Incident Date Manuf. Date In Service Date Frequency 쏔 Continuous Symptoms 쏔 Vehicle does not move. 쏔 No up-shift 쏔 Intermittent ( times a day) (쏔 Any position 쏔 Particular position) (쏔 1st , 2nd 쏔 2nd , 3rd 쏔 No down-shift (쏔 O/D , 3rd 쏔 3rd , O/D) 쏔 3rd , 2nd 쏔 2nd , 1st) 쏔 Lockup malfunction 쏔 Shift point too high or too low. 쏔 Shift shock or slip (쏔 N , D 쏔 Lockup 쏔 Any drive position) 쏔 Noise or vibration 쏔 No kickdown 쏔 No pattern select 쏔 Others ( O/D OFF indicator lamp Malfunction indicator lamp (MIL) ) Blinks for about 8 seconds. 쏔 Continuously lit 쏔 Not lit 쏔 Continuously lit 쏔 Not lit AT-56 =NAAT0019S01 NAAT0019S0101 TROUBLE DIAGNOSIS — INTRODUCTION Introduction (Cont’d) Diagnostic Worksheet =NAAT0019S0102 1. 쏔 Read the Fail-safe Remarks and listen to customer complaints. AT-8 2. 쏔 CHECK A/T FLUID AT-61 쏔 Leakage (Follow specified procedure) 쏔 Fluid condition 쏔 Fluid level 3. 쏔 Stall test — Mark possible damaged components/others. AT-61, AT-64 쏔 Low & reverse brake 쏔 Low one-way clutch 쏔 Engine 쏔 Line pressure is low 쏔 Clutches and brakes except high clutch and brake band are OK Torque converter one-way clutch Reverse clutch Forward clutch Overrun clutch Forward one-way clutch LC EC FE 쏔 Pressure test — Suspected parts: 4. MA EM Perform STALL TEST and LINE PRESSURE TEST. 쏔 쏔 쏔 쏔 쏔 GI CL 쏔 Perform all ROAD TEST and mark required procedures. AT-65 4-1. AT-66 Check before engine is started. MT 쏔 O/D OFF Indicator Lamp Does Not Come On, AT-221. 쏔 SELF-DIAGNOSTIC PROCEDURE - Mark detected items. 쏔 쏔 쏔 쏔 쏔 쏔 쏔 쏔 쏔 쏔 쏔 쏔 쏔 쏔 쏔 쏔 쏔 쏔 쏔 4-2. DTC P0705 PNP switch, AT-105. DTC P0710 A/T fluid temperature sensor, AT-111. DTC P0720 Vehicle speed sensor·A/T (Revolution sensor), AT-117. DTC P0725 Engine speed signal, AT-122. DTC P0740 Torque converter clutch solenoid valve, AT-154. DTC P0745 Line pressure solenoid valve, AT-168. DTC P0750 Shift solenoid valve A, AT-174. DTC P0755 Shift solenoid valve B, AT-178. DTC P1705 Accelerator pedal position sensor, AT-182. DTC P1760 Overrun clutch solenoid valve, AT-188. DTC BATT/FLUID TEMP SEN (A/T fluid temperature sensor and TCM power source), AT-193. DTC Vehicle speed sensor·MTR, AT-200. DTC Turbine revolution sensor, AT-209. DTC U1000 CAN communication line, AT-206. DTC Control unit (RAM), control unit (ROM), AT-214. DTC Control unit (EEP ROM), AT-216. PNP, overdrive control and accelerator pedal position sensor, AT-258. Battery Others Check at idle 쏔 쏔 쏔 쏔 쏔 쏔 TF PD AX SU BR ST AT-68 Engine Cannot Be Started In “P” And “N” Position, AT-223. In “P” Position, Vehicle Moves Forward Or Backward When Pushed, AT-224. In “N” Position, Vehicle Moves, AT-225. Large Shock. “N” , “R” Position, AT-227. Vehicle Does Not Creep Backward In “R” Position, AT-229. Vehicle Does Not Creep Forward In “D”, “2” Or “1” Position, AT-232. RS BT HA SC EL IDX AT-57 TROUBLE DIAGNOSIS — INTRODUCTION Introduction (Cont’d) 4. 4-3. Cruise test AT-69 AT-73 Part-1 쏔 Vehicle Cannot Be Started From D1, AT-235. 쏔 A/T Does Not Shift: D1 , D2 Or Does Not Kickdown: D4 , D2, AT-238. 쏔 A/T Does Not Shift: D2 , D3, AT-241. 쏔 A/T Does Not Shift: D3 , D4, AT-244. 쏔 A/T Does Not Perform Lock-up, AT-247. 쏔 A/T Does Not Hold Lock-up Condition, AT-249. 쏔 Lock-up Is Not Released, AT-251. 쏔 Engine Speed Does Not Return To Idle (Light Braking D4 , D3), AT-252. Part-2 AT-77 쏔 Vehicle Does Not Start From D1, AT-254. 쏔 A/T Does Not Shift: D1 , D2 Or Does Not Kickdown: D4 , D2, AT-238. 쏔 A/T Does Not Shift: D2 , D3, AT-241. 쏔 A/T Does Not Shift: D3 , D4, AT-244. Part-3 AT-79 쏔 A/T Does Not Shift: D4 , D3 When Overdrive Control Switch “ON” , “OFF”, AT-255 쏔 Engine Speed Does Not Return To Idle (Engine Brake In D3 ), AT-252. 쏔 A/T Does Not Shift: D3 , 22, When Selector Lever “D” , “2” Position, AT-256. 쏔 Engine Speed Does Not Return To Idle (Engine Brake In 22 ), AT-252. 쏔 A/T Does Not Shift: 22 , 11, When Selector Lever “2” , “1” Position, AT-257. 쏔 Vehicle Does Not Decelerate By Engine Brake, AT-258. 쏔 SELF-DIAGNOSTIC PROCEDURE — Mark detected items. 쏔 쏔 쏔 쏔 쏔 쏔 쏔 쏔 쏔 쏔 쏔 쏔 쏔 쏔 쏔 쏔 쏔 쏔 쏔 DTC P0705 PNP switch, AT-105. DTC P0710 A/T fluid temperature sensor, AT-111. DTC P0720 Vehicle speed sensor·A/T (Revolution sensor), AT-117. DTC P0725 Engine speed signal, AT-122. DTC P0740 Torque converter clutch solenoid valve, AT-154. DTC P0745 Line pressure solenoid valve, AT-168. DTC P0750 Shift solenoid valve A, AT-174. DTC P0755 Shift solenoid valve B, AT-178. DTC P1705 Accelerator pedal position sensor, AT-182. DTC P1760 Overrun clutch solenoid valve, AT-188. DTC BATT/FLUID TEMP SEN (A/T fluid temperature sensor and TCM power source), AT-193. DTC Vehicle speed sensor·MTR, AT-200. DTC Turbine revolution sensor, AT-209. DTC U1000 CAN communication line, AT-206. DTC Control unit (RAM), control unit (ROM), AT-214. DTC Control unit (EEP ROM), AT-216. PNP, overdrive control and accelerator pedal position sensor, AT-258. Battery Others 5. 쏔 For self-diagnosis NG items, inspect each component. Repair or replace the damaged parts. AT-38 6. 쏔 Perform all ROAD TEST and re-mark required procedures. AT-65 7. 쏔 Perform DTC CONFIRMATION PROCEDURE for following MIL indicating items and check out NG items. Refer to EC-86, “Emission-related Diagnostic Information”. EC-86 쏔 쏔 쏔 쏔 쏔 DTC DTC DTC DTC DTC (P0731, (P0732, (P0733, (P0734, (P0744, 1103) A/T 1st gear function, AT-126. 1104) A/T 2nd gear function, AT-132. 1105) A/T 3rd gear function, AT-138. 1106) A/T 4th gear function, AT-144. 1107) A/T TCC S/V function (lock-up), AT-159. 8. 쏔 Perform the Diagnostic Procedures for all remaining items marked NG. Repair or replace the damaged parts. Refer to the Symptom Chart when you perform the procedures. (The chart also shows some other possible symptoms and the component inspection orders.) AT-95 AT-103 9. 쏔 Erase DTC from TCM and ECM memories. AT-35 AT-58 TROUBLE DIAGNOSIS — INTRODUCTION Work Flow Work Flow HOW TO PERFORM TROUBLE DIAGNOSES FOR QUICK AND ACCURATE REPAIR NAAT0020 GI NAAT0020S01 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. Make good use of the two sheets provided, “INFORMATION FROM CUSTOMER” (AT-56) and “DIAGNOSTIC WORKSHEET” (AT-57), to perform the best troubleshooting possible. MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL IDX AT-59 TROUBLE DIAGNOSIS — INTRODUCTION Work Flow (Cont’d) WORK FLOW CHART NAAT0020S02 SAT086JF *1: *2: *3: *4: *5: *6: AT-56 AT-57 AT-8 AT-61 AT-61, 64 AT-65 *7: *8: *9: *10: *11: *12: *13: *14: *15: *16: *17: *18: AT-37 AT-33 AT-52 AT-105 AT-216 AT-218 AT-60 AT-258 AT-83 AT-35 AT-106 AT-216 EC-86 TROUBLE DIAGNOSIS — BASIC INSPECTION A/T Fluid Check A/T Fluid Check NAAT0021 FLUID LEAKAGE CHECK 1. 2. 3. 4. NAAT0021S01 Clean area suspected of leaking. — for example, mating surface of converter housing and transmission case. Start engine, apply foot brake, place selector lever in “D” position and wait a few minutes. Stop engine. Check for fresh leakage. MA EM LC EC FLUID CONDITION CHECK NAAT0021S02 Fluid color SAT638A GI Suspected problem FE Dark or black with burned odor Wear of frictional material Milky pink Water contamination — Road water entering through filler tube or breather CL Varnished fluid, light to dark brown and tacky Oxidation — Over or under filling, — Overheating MT FLUID LEVEL CHECK NAAT0021S03 Refer to MA-22, “Checking A/T Fluid”. TF PD AX SU Stall Test STALL TEST PROCEDURE 1. 2. NAAT0022 NAAT0022S01 Check A/T fluid and engine oil levels. If necessary, add fluid and oil. Drive vehicle for approx. 10 minutes or until fluid and oil reach operating temperature. ATF operating temperature: 50 - 80°C (122 - 176°F) BR ST RS BT SAT647B 3. 4. 쐌 Set parking brake and block wheels. 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 rpm on indicator. HA SC EL IDX SAT513G AT-61 TROUBLE DIAGNOSIS — BASIC INSPECTION Stall Test (Cont’d) 5. 6. 7. 쐌 Start engine, apply foot brake, and place selector lever in “D” position. Accelerate to wide open throttle gradually while applying foot brake. Quickly note the engine stall revolution and immediately release throttle. During test, never hold throttle wide open for more than 5 seconds. Stall revolution: Refer to SDS, AT-356. SAT514G 8. 9. 쐌 10. Move selector lever to “N” position. Cool off ATF. Run engine at idle for at least one minute. Repeat steps 5 through 9 with selector lever in “2”, “1” and “R” positions. SAT771B JUDGEMENT OF STALL TEST NAAT0022S02 The test result and possible damaged components relating to each result are shown in the illustration. In order to pinpoint the possible damaged components, refer to “Work Flow”, AT-59. NOTE: Stall revolution is too high in “D” or “2” position: 쐌 Slippage occurs in 1st gear but not in 2nd and 3rd gears. ..... Low one-way clutch slippage 쐌 Slippage occurs at the following gears: 1st through 3rd gears in “D” position and engine brake functions. 1st and 2nd gears in “2” position and engine brake functions with accelerator pedal released (fully closed throttle). ..... Forward clutch or forward one-way clutch slippage Stall revolution is too high in “R” position: 쐌 Engine brake does not function in “1” position. ..... Low & reverse brake slippage 쐌 Engine brake functions in “1” position. ..... Reverse clutch slippage Stall revolution within specifications: 쐌 Vehicle does not achieve speed of more than 80 km/h (50 MPH). ..... One-way clutch seizure in torque converter housing CAUTION: Be careful since automatic fluid temperature increases abnormally. 쐌 Slippage occurs in 3rd and 4th gears in “D” position. ..... High clutch slippage 쐌 Slippage occurs in 2nd and 4th gear in “D” position. ..... Brake band slippage 쐌 Engine brake does not function in 2nd and 3rd gears in “D” position, 2nd gear in 2nd position, and 1st position. ..... Overrun clutch slippage AT-62 TROUBLE DIAGNOSIS — BASIC INSPECTION Stall Test (Cont’d) Stall revolution less than specifications: 쐌 Poor acceleration during starts. ..... One-way clutch slippage in torque converter GI MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL IDX SAT392H AT-63 TROUBLE DIAGNOSIS — BASIC INSPECTION Line Pressure Test Line Pressure Test 쐌 쐌 NAAT0023 Location of line pressure test ports. Always replace line pressure plugs as they are self-sealing bolts. SAT209GA LINE PRESSURE TEST PROCEDURE 1. 2. NAAT0023S01 Check A/T fluid and engine oil levels. If necessary, add fluid and oil. Drive vehicle for approx. 10 minutes or until fluid and oil reach operating temperature. ATF operating temperature: 50 - 80°C (122 - 176°F) SAT647B 3. Install pressure gauge to corresponding line pressure port. 4. 쐌 Set parking brake and block wheels. Continue to depress brake pedal fully while line pressure test is being performed at stall speed. SAT518GB SAT519GB SAT513G AT-64 TROUBLE DIAGNOSIS — BASIC INSPECTION Line Pressure Test (Cont’d) 5. 쐌 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: Refer to SDS, AT-356. GI MA EM LC SAT493G JUDGEMENT OF LINE PRESSURE TEST Judgement EC NAAT0023S02 Suspected parts 쐌 쐌 쐌 쐌 쐌 쐌 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 쐌 Fluid pressure leakage between manual valve and particular clutch 쐌 For example, line pressure is: — Low in “R” and “1” positions, but — Normal in “D” and “2” positions. Then, fluid leakage exists at or around low and reverse brake circuit. Refer to “CLUTCH AND BAND CHART”, AT-17. Line pressure is low in particular position. At idle Line pressure is high. Line pressure is low. At stall speed 쐌 쐌 쐌 쐌 쐌 쐌 쐌 Mal-adjustment 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 Open in dropping resistor circuit 쐌 쐌 쐌 쐌 쐌 쐌 Mal-adjustment of throttle position sensor 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 FE CL MT TF PD AX SU BR ST RS BT Road Test DESCRIPTION 쐌 쐌 1. 2. 3. NAAT0024 HA NAAT0024S01 The purpose of the test is to determine overall performance of A/T and analyze causes of problems. The road test consists of the following three parts: Check before engine is started Check at idle Cruise test SC EL IDX SAT786A AT-65 TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d) 쐌 쐌 Before road test, familiarize yourself with all test procedures and items to check. Conduct tests on all items until specified symptom is found. Troubleshoot items which check out No Good after road test. Refer to “ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION” and “TROUBLE DIAGNOSES FOR SYMPTOMS”, AT-33 - AT-52 and AT-218 - AT-258. SAT496G 1. CHECK BEFORE ENGINE IS STARTED 1 NAAT0024S02 CHECK O/D OFF INDICATOR LAMP 1. Park vehicle on flat surface. 2. Move selector lever to “P” position. 3. Turn ignition switch to “OFF” position. Wait at least 5 seconds. SAT967I 4. Turn ignition switch to “ON” position. (Do not start engine.) 5. Does O/D OFF indicator lamp come on for about 2 seconds? SAT204K Yes or No Yes 䊳 GO TO 2. No 䊳 Stop Road Test. Go to “O/D OFF Indicator Lamp Does Not Come On”, AT-221. AT-66 TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d) 2 GI CHECK O/D OFF INDICATOR LAMP Does O/D OFF indicator lamp flicker for about 8 seconds? MA EM LC EC SAT204K Yes or No Yes 䊳 Perform self-diagnosis. Refer to TCM SELF-DIAGNOSIS PROCEDURE (No Tools), AT-48. No 䊳 GO TO 3. 3 FE CL MT CHECK NG ITEM 1. Turn ignition switch to “OFF” position. 2. Perform self-diagnosis and note NG items. Refer to TCM SELF-DIAGNOSIS PROCEDURE (No Tools), AT-48. 䊳 Go to “2. CHECK AT IDLE”, AT-68. TF PD AX SU BR ST RS BT HA SC EL IDX AT-67 TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d) 2. CHECK AT IDLE 1 1. 2. 3. 4. 5. =NAAT0024S03 CHECK ENGINE START Park vehicle on flat surface. Turn ignition switch to “OFF” position. Move selector lever to “P” or “N” position. Turn ignition switch to start position. Is engine started? Yes or No Yes 䊳 GO TO 2. No 䊳 Go to “Engine Cannot Be Started In “P” and “N” Position”, AT-223. 2 1. 2. 3. 4. CHECK ENGINE START Turn ignition switch to “OFF” position. Move selector lever to “D”, “1”, “2” or “R” position. Turn ignition switch to start position. Is engine started? Yes or No Yes 䊳 Go to “Engine Cannot Be Started In “P” and “N” Position”, AT-223. No 䊳 GO TO 3. 3 1. 2. 3. 4. 5. CHECK VEHICLE MOVE Turn ignition switch to “OFF” position. Move selector lever to “P” position. Release parking brake. Push vehicle forward or backward. Does vehicle move when it is pushed forward or backward? SAT796A Yes or No Yes 䊳 Go to “In “P” Position, Vehicle Moves Forward Or Backward When Pushed”, AT-224. No 䊳 GO TO 4. 4 1. 2. 3. 4. 5. CHECK VEHICLE MOVE Apply parking brake. Move selector lever to “N” position. Turn ignition switch to “START” position and start engine. Release parking brake. Does vehicle move forward or backward? Yes or No Yes 䊳 Go to “In “N” Position, Vehicle Moves”, AT-225. No 䊳 GO TO 5. AT-68 TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d) 5 GI CHECK SHIFT SHOCK 1. Apply foot brake. 2. Move selector lever to “R” position. 3. Is there large shock when changing from “N” to “R” position? MA EM LC EC FE SAT082J Yes or No Yes 䊳 Go to “Large Shock. “N” , “R” Position”, AT-227. No 䊳 GO TO 6. 6 CL MT CHECK VEHICLE MOVE 1. Release foot brake for several seconds. 2. Does vehicle creep backward when foot brake is released? Yes or No Yes 䊳 GO TO 7. No 䊳 Go to “Vehicle Does Not Creep Backward In “R” Position”, AT-229. 7 TF PD CHECK VEHICLE MOVE AX 1. Move selector lever to “D”, “2” and “1” position and check if vehicle creeps forward. 2. Does vehicle creep forward in all three positions? SU Yes or No Yes 䊳 Go to “CRUISE TEST”, AT-69. No 䊳 Go to “Vehicle Does Not Creep Forward In “D”, “2” Or “1” Position”, AT-232. BR ST RS BT 3. CRUISE TEST 쐌 With CONSULT-II 쐌 쐌 NAAT0024S04 Check all items listed in Parts 1 through 3. NAAT0024S0401 Using CONSULT-II, conduct a cruise test and record the result. Print the result and ensure that shifts and lock-ups take place as per “Shift Schedule”. HA SC EL IDX SAT601J AT-69 TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d) CONSULT-II Setting Procedure NAAT0024S0402 1. 2. Turn ignition switch “OFF”. Connect CONSULT-II and CONSULT-II CONVERTER to data link connector, which is located in instrument lower panel on driver side. 3. 4. Turn ignition switch “ON”. Touch “START (NISSAN BASED VHCL)”. 5. Touch “A/T”. 6. Touch “DATA MONITOR”. 7. 8. Touch “MAIN SIGNALS” or “TCM INPUT SIGNALS”. See “Numerical Display”, “Barchart Display” or “Line Graph Display”. SAIA0450E SAT014K SCIA5358E SAT175K AT-70 TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d) 9. Touch “SETTING” to set recording condition (“AUTO TRIG” or “MANU TRIG”) and touch “BACK”. 10. Touch “Start”. GI MA EM LC SAT973J 11. When performing cruise test, touch “RECORD”. EC FE CL MT SAT134K 12. After finishing cruise test part 1, touch “STOP”. TF PD AX SU SAT135K 13. Touch “STORE” and touch “BACK”. BR ST RS BT SAT987J HA SC EL IDX SAT974J AT-71 TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d) 14. 15. 16. 17. Touch “DISPLAY”. Touch “PRINT”. Check the monitor data printed out. Continue cruise test part 2 and 3. SAT975J Without CONSULT-II 쐌 NAAT0024S0403 Accelerator pedal position sensor (throttle position sensor) can be checked by voltage across terminals 41 and 42 of TCM. SAT513J AT-72 TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d) Cruise Test — Part 1 1 =NAAT0024S0404 GI CHECK STARTING GEAR (D1) POSITION MA 1. Drive vehicle for approx. 10 minutes to warm engine oil and ATF up to operating temperature. ATF operating temperature: 50 - 80°C (122 - 176°F) 2. Park vehicle on flat surface. 3. Set overdrive control switch to “ON” position. 4. Move selector lever to “P” position. EM LC EC FE CL SAT001J 5. Start engine. 6. Move selector lever to “D” position. MT TF PD SAT952I 7. Accelerate vehicle by constantly depressing accelerator pedal halfway. AX SU BR ST SAT953I 8. Does vehicle start from D1? Read gear position. RS Yes or No BT Yes 䊳 GO TO 2. No 䊳 Go to “Vehicle Cannot Be Started From D1”, AT-235. HA SC EL IDX AT-73 TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d) 2 CHECK SHIFT UP (D1 TO D2) Does A/T shift from D1 to D2 at the specified speed? Read gear position, throttle opening and vehicle speed. Specified speed when shifting from D1 to D2: Refer to Shift schedule, AT-356. SAT954I Yes or No Yes 䊳 GO TO 3. No 䊳 Go to “A/T Does Not Shift: D1 , D2 or Does Not Kickdown: D4 , D2”, AT-238. 3 CHECK SHIFT UP (D2 TO D3) Does A/T shift from D2 to D3 at the specified speed? Read gear position, throttle opening and vehicle speed. Specified speed when shifting from D2 to D3: Refer to Shift schedule, AT-356. SAT955I Yes or No Yes 䊳 GO TO 4. No 䊳 Go to “A/T Does Not Shift: D2 , D3”, AT-241. AT-74 TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d) 4 GI CHECK SHIFT UP (D3 TO D4) Does A/T shift from D3 to D4 at the specified speed? Read gear position, throttle opening and vehicle speed. Specified speed when shifting from D3 to D4: Refer to Shift schedule, AT-356. MA EM LC EC SAT956I FE Yes or No Yes 䊳 GO TO 5. No 䊳 Go to “A/T Does Not Shift: D3 , D4”, AT-244. CL MT 5 CHECK LOCK-UP (D4 TO D4 L/U) Does A/T perform lock-up at the specified speed? Read vehicle speed, throttle position when lock-up duty becomes 94%. Specified speed when lock-up occurs: Refer to Shift schedule, AT-356. TF PD AX SAT957I Yes or No Yes 䊳 GO TO 6. No 䊳 Go to “A/T Does Not Perform Lock-up”, AT-247. SU BR ST 6 CHECK HOLD LOCK-UP Does A/T hold lock-up condition for more than 30 seconds? RS Yes or No BT Yes 䊳 GO TO 7. No 䊳 Go to “A/T Does Not Hold Lock-up Condition”, AT-249. HA SC EL IDX AT-75 TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d) 7 CHECK LOCK-UP OFF (D4 L/U TO D4) 1. Release accelerator pedal. 2. Is lock-up released when accelerator pedal is released? SAT958I Yes or No Yes 䊳 GO TO 8. No 䊳 Go to “Lock-up Is Not Released”, AT-251. 8 CHECK SHIFT DOWN (D4 TO D3) 1. Decelerate vehicle by applying foot brake lightly. 2. Does engine speed return to idle smoothly when A/T is shifted from D4 to D3? Read gear position and engine speed. SAT959I Yes or No Yes 䊳 1. Stop vehicle. 2. Go to “Cruise Test — Part 2”, AT-77. No 䊳 Go to “Engine Speed Does Not Return To Idle (Light Braking D4 , D3)”, AT-252. AT-76 TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d) Cruise Test — Part 2 1 1. 2. 3. 4. =NAAT0024S0405 GI CHECK STARTING GEAR (D1) POSITION MA Confirm overdrive control switch is in “ON” position. Confirm selector lever is in “D” position. Accelerate vehicle by half throttle again. Does vehicle start from D1? Read gear position. EM LC EC FE CL SAT495G Yes or No Yes 䊳 GO TO 2. No 䊳 Go to “Vehicle Does Not Start From D1”, AT-254. 2 MT CHECK SHIFT UP AND SHIFT DOWN (D3 TO D4 TO D2) TF 1. Accelerate vehicle to 80 km/h (50 MPH) as shown in illustration. 2. Release accelerator pedal and then quickly depress it fully. 3. Does A/T shift from D4 to D2 as soon as accelerator pedal is depressed fully? Read gear position and throttle position. PD AX SU BR SAT404H ST Yes or No RS Yes 䊳 GO TO 3. No 䊳 Go to “A/T Does Not Shift: D3 , D4, AT-244 Or Does Not Kickdown: D4 , D2”, AT-238. BT HA SC EL IDX AT-77 TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d) 3 CHECK SHIFT UP (D2 TO D3) Does A/T shift from D2 to D3 at the specified speed? Read gear position, throttle position and vehicle speed. Specified speed when shifting from D2 to D3: Refer to Shift schedule, AT-356. SAT960I Yes or No Yes 䊳 GO TO 4. No 䊳 Go to “A/T Does Not Shift: D2 , D3”, AT-241. 4 CHECK SHIFT UP (D3 TO D4) AND ENGINE BRAKE Release accelerator pedal after shifting from D2 to D3. Does A/T shift from D3 to D4 and does vehicle decelerate by engine brake? Read gear position, throttle position and vehicle speed. SAT405H Yes or No Yes 䊳 1. Stop vehicle. 2. Go to “Cruise test — Part 3”, AT-79. No 䊳 Go to “A/T Does Not Shift: D3 , D4”, AT-244. AT-78 TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d) Cruise Test — Part 3 1 =NAAT0024S0406 GI VEHICLE SPEED D4 POSITION MA 1. Confirm overdrive control switch is in “ON” position. 2. Confirm selector lever is in “D” position. 3. Accelerate vehicle using half-throttle to D4. EM LC EC FE SAT812A 䊳 CL GO TO 2. MT 2 CHECK SHIFT DOWN (D4 TO D3) 1. Release accelerator pedal. 2. Set overdrive control switch to “OFF” position while driving in D4. 3. Does A/T shift from D4 to D3 (O/D OFF)? Read gear position and vehicle speed. TF PD AX SU SAT999IA BR Yes or No Yes 䊳 GO TO 3. No 䊳 Go to “A/T Does Not Shift: D4 , D3, When Overdrive Control Switch “ON” , “OFF”, AT-255. ST RS BT HA SC EL IDX AT-79 TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d) 3 CHECK ENGINE BRAKE Does vehicle decelerate by engine brake? SAT999IA Yes or No Yes 䊳 GO TO 4. No 䊳 Go to “Engine Speed Does Not Return To Idle (Light Braking D4 , D3)”, AT-252. 4 CHECK SHIFT DOWN (D3 TO 22) 1. Move selector lever from “D” to “2” position while driving in D3 (O/D OFF). 2. Does A/T shift from D3 (O/D OFF) to 22? Read gear position. SAT791GB Yes or No Yes 䊳 GO TO 5. No 䊳 Go to “A/T Does Not Shift: D3 , 22, When Selector Lever “D” , “2” Position”, AT-256. AT-80 TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d) 5 GI CHECK ENGINE BRAKE Does vehicle decelerate by engine brake? MA EM LC EC SAT791GB FE Yes or No Yes 䊳 GO TO 6. No 䊳 Go to “Engine Speed Does Not Return To Idle (Light Braking D4 , D3)”, AT-252. 6 CL MT CHECK SHIFT DOWN (22 TO 11) 1. Move selector lever from “2” to “1” position while driving in 22. 2. Does A/T shift from 22 to 11 position? TF PD AX SAT778B SU Yes or No Yes 䊳 GO TO 7. No 䊳 Go to “A/T Does Not Shift: 22 , 11, When Selector lever “2” , “1” Position”, AT-257. BR ST RS BT HA SC EL IDX AT-81 TROUBLE DIAGNOSIS — BASIC INSPECTION Road Test (Cont’d) 7 CHECK ENGINE BRAKE Does vehicle decelerate by engine brake? SAT778B Yes or No Yes 䊳 1. Stop vehicle. 2. Perform self-diagnosis. Refer to TCM SELF-DIAGNOSTIC PROCEDURE (No Tools), AT-48. No 䊳 Go to “Vehicle Does Not Decelerate By Engine Brake”, AT-258. AT-82 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Chart Symptom Chart NAAT0233 Numbers are arranged in order of inspection. Perform inspections starting with number one and work up. Items Symptom Torque converter is not locked up. Condition ON vehicle OFF vehicle No Lock-up Engagement/TCC Inoperative Torque converter clutch piston slip. ON vehicle OFF vehicle Lock-up point is extremely high or low. AT-247 Shift Shock Sharp shock in shifting from N to D position. ON vehicle ON vehicle Diagnostic Item Reference Page 1. Accelerator pedal position sensor (throttle position sensor) AT-182 2. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR AT-117, 200 3. Park/neutral position (PNP) switch adjustment AT-275 4. Engine speed signal AT-122 5. A/T fluid temperature sensor AT-111 6. Line pressure test AT-64 7. Torque converter clutch solenoid valve AT-154 8. Control valve assembly AT-272 9. Torque converter AT-286 1. Fluid level AT-61 2. Accelerator pedal position sensor (throttle position sensor) AT-182 3. Line pressure test AT-64 4. Torque converter clutch solenoid valve AT-154 5. Line pressure solenoid valve AT-168 6. Control valve assembly AT-272 7. Torque converter AT-286 1. Accelerator pedal position sensor (throttle position sensor) AT-182 2. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR AT-117, 200 3. Torque converter clutch solenoid valve AT-154 4. Control valve assembly AT-272 1. Engine idling rpm EC-792 2. Accelerator pedal position sensor (throttle position sensor) AT-182 3. Line pressure test AT-64 4. A/T fluid temperature sensor AT-111 5. Engine speed signal AT-122 6. Line pressure solenoid valve AT-168 7. Control valve assembly AT-272 8. Accumulator N-D AT-272 9. Turbine revolution sensor AT-209 10. Forward clutch AT-320 GI MA EM LC EC FE CL MT TF PD AX SU OFF vehicle BR ST RS BT HA SC EL IDX AT-83 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Chart (Cont’d) Items Symptom Too sharp a shock in change from D1 to D2. Condition ON vehicle OFF vehicle Too sharp a shock in change from D2 to D3. ON vehicle Diagnostic Item Reference Page 1. Accelerator pedal position sensor (throttle position sensor) AT-182 2. Line pressure test AT-64 3. Accumulator servo release AT-272 4. Control valve assembly AT-272 5. A/T fluid temperature sensor AT-111 6. Brake band AT-333 1. Accelerator pedal position sensor (throttle position sensor) AT-182 2. Line pressure test AT-64 3. Control valve assembly AT-272 4. High clutch AT-317 5. Brake band AT-333 1. Accelerator pedal position sensor (throttle position sensor) AT-182 2. Line pressure test AT-64 3. Control valve assembly AT-272 4. Brake band AT-333 5. Overrun clutch AT-320 1. Accelerator pedal position sensor (throttle position sensor) AT-182 2. Line pressure test AT-64 3. Overrun clutch solenoid valve AT-188 4. Control valve assembly AT-272 1. Control valve assembly AT-272 2. Low & reverse brake AT-324 OFF vehicle Shift Shock Too sharp a shock in change from D3 to D4. ON vehicle OFF vehicle Gear change shock felt during deceleration by releasing accelerator pedal. ON vehicle Large shock ON vehicle changing from 12 to 11 in 1 position. ON vehicle AT-84 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Chart (Cont’d) Items Symptom Condition Too high a gear change point from D1 to D2, from D2 ON vehicle to D3, from D3 to D4. AT-238, 241, 244 Improper Shift Timing Gear change ON vehicle directly from D1 to D3 occurs. OFF vehicle Too high a change point from D4 to D3, from D3 ON vehicle to D2, from D2 to D1. Kickdown does not operate when depressing pedal in D4 within kickdown vehicle speed. Improper Shift Timing ON vehicle Kickdown operates or engine overruns when depressing pedal ON vehicle in D4 beyond kickdown vehicle speed limit. Gear change from 22 to 23 in 2 posi- ON vehicle tion. Gear change from 11 to 12 in 1 posi- ON vehicle tion. Diagnostic Item Reference Page GI 1. Accelerator pedal position sensor (throttle position sensor) AT-182 2. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR AT-117, 200 3. Shift solenoid valve A AT-174 4. Shift solenoid valve B AT-178 1. Fluid level AT-61 2. Accumulator servo release AT-272 3. Brake band AT-333 1. Accelerator pedal position sensor (throttle position sensor) AT-182 FE 2. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR AT-117, 200 CL 1. Accelerator pedal position sensor (throttle position sensor) AT-182 MT 2. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR AT-117, 200 3. Shift solenoid valve A AT-174 4. Shift solenoid valve B AT-178 1. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR AT-117, 200 2. Accelerator pedal position sensor (throttle position sensor) AT-182 3. Shift solenoid valve A AT-174 4. Shift solenoid valve B AT-178 1. Park/neutral position (PNP) switch adjustment AT-275 MA EM LC EC TF PD AX SU BR 1. Park/neutral position (PNP) switch adjustment AT-275 2. Manual control linkage adjustment AT-275 ST RS BT HA SC EL IDX AT-85 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Chart (Cont’d) Items Symptom Failure to change gear from D4 to D3. Condition ON vehicle Diagnostic Item Reference Page 1. Fluid level AT-61 2. Accelerator pedal position sensor (throttle position sensor) AT-182 3. Overrun clutch solenoid valve AT-188 4. Shift solenoid valve A AT-174 5. Line pressure solenoid valve AT-168 6. Control valve assembly AT-272 7. Low & reverse brake AT-324 8. Overrun clutch AT-320 1. Fluid level AT-61 2. Accelerator pedal position sensor (throttle position sensor) AT-182 3. Shift solenoid valve A AT-174 4. Shift solenoid valve B AT-178 5. Control valve assembly AT-272 6. High clutch AT-317 7. Brake band AT-333 1. Fluid level AT-61 2. Accelerator pedal position sensor (throttle position sensor) AT-182 3. Shift solenoid valve A AT-182 4. Shift solenoid valve B AT-178 5. Control valve assembly AT-272 6. Low one-way clutch AT-328 7. High clutch AT-317 8. Brake band AT-333 OFF vehicle No Down Shift Failure to change gear from D3 to D2 or from D4 to D2. ON vehicle OFF vehicle ON vehicle Failure to change gear from D2 to D1 or from D3 to D1. OFF vehicle AT-86 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Chart (Cont’d) Items Symptom Failure to change from D3 to 22 when changing lever into 2 position. AT-252 No Down Shift Condition ON vehicle Diagnostic Item Reference Page 1. Park/neutral position (PNP) switch adjustment AT-275 2. Accelerator pedal position sensor (throttle position sensor) AT-182 3. Overrun clutch solenoid valve AT-188 4. Shift solenoid valve B AT-178 5. Shift solenoid valve A AT-174 6. Control valve assembly AT-272 7. Manual control linkage adjustment AT-275 8. Brake band AT-333 9. Overrun clutch AT-320 1. Park/neutral position (PNP) switch adjustment AT-275 CL 2. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR AT-117, 200 MT Does not change from 12 to 11 in 1 position. 3. Shift solenoid valve A AT-174 4. Control valve assembly AT-272 5. Overrun clutch solenoid valve AT-188 6. Overrun clutch AT-320 7. Low & reverse brake AT-324 1. Park/neutral position (PNP) switch adjustment AT-275 2. Manual control linkage adjustment AT-275 3. Shift solenoid valve A AT-174 4. Control valve assembly AT-272 5. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR AT-117, 200 6. Brake band AT-333 1. Park/neutral position (PNP) switch adjustment AT-275 2. Manual control linkage adjustment AT-275 3. Shift solenoid valve B AT-178 4. Control valve assembly AT-272 5. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR AT-117, 200 6. High clutch AT-317 7. Brake band AT-333 MA EM OFF vehicle ON vehicle GI LC EC FE TF OFF vehicle Failure to change gear from D1 to D2. ON vehicle OFF vehicle No Up Shift Failure to change gear from D2 to D3. ON vehicle PD AX SU BR ST RS BT HA OFF vehicle SC EL IDX AT-87 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Chart (Cont’d) Items Symptom Failure to change gear from D3 to D4. Condition Diagnostic Item Reference Page 1. Park/neutral position (PNP) switch adjustment AT-275 2. Manual control linkage adjustment AT-275 3. Shift solenoid valve A AT-174 4. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR AT-117, 200 5. A/T fluid temperature sensor AT-111 6. Brake band AT-333 1. Accelerator pedal position sensor (throttle position sensor) AT-182 2. Park/neutral position (PNP) switch adjustment AT-275 3. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR AT-117, 200 4. Shift solenoid valve A AT-174 5. Overrun clutch solenoid valve AT-188 6. Control valve assembly AT-272 7. A/T fluid temperature sensor AT-111 8. Line pressure solenoid valve AT-168 9. Brake band AT-333 10. Overrun clutch AT-320 1. Manual control linkage adjustment AT-275 2. Line pressure test AT-64 3. Line pressure solenoid valve AT-168 4. Control valve assembly AT-272 5. Reverse clutch AT-314 6. High clutch AT-317 7. Forward clutch AT-320 8. Overrun clutch AT-320 9. Low & reverse brake AT-324 ON vehicle 1. Manual control linkage adjustment AT-275 OFF vehicle 2. Low one-way clutch AT-328 ON vehicle OFF vehicle No Up Shift A/T does not shift ON vehicle to D4 when driving with overdrive control switch ON. OFF vehicle Slips/Will Not Engage Vehicle will not run in R position (but runs in D, 2 and 1 positions). Clutch slips. Very poor acceleration. AT-229 Vehicle will not run in D and 2 positions (but runs in 1 and R positions). ON vehicle OFF vehicle AT-88 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Chart (Cont’d) Items Symptom Vehicle will not run in D, 1, 2 positions (but runs in R position). Clutch slips. Very poor acceleration. AT-232 Condition ON vehicle OFF vehicle ON vehicle Slips/Will Not Engage Clutches or brakes slip somewhat in starting. OFF vehicle ON vehicle No creep at all. AT-229, 232 OFF vehicle Almost no shock or clutches slipping in change from D1 to D2. ON vehicle OFF vehicle Diagnostic Item Reference Page 1. Fluid level AT-61 2. Line pressure test AT-64 3. Line pressure solenoid valve AT-168 4. Control valve assembly AT-272 5. Accumulator N-D AT-272 6. Reverse clutch AT-314 7. High clutch AT-317 8. Forward clutch AT-320 9. Forward one-way clutch AT-330 10. Low one-way clutch AT-328 1. Fluid level AT-61 2. Manual control linkage adjustment AT-275 3. Accelerator pedal position sensor (throttle position sensor) AT-182 4. Line pressure test AT-64 5. Line pressure solenoid valve AT-168 6. Control valve assembly AT-272 7. Accumulator N-D AT-272 8. Forward clutch AT-320 9. Reverse clutch AT-314 10. Low & reverse brake AT-324 11. Oil pump AT-297 12. Torque converter AT-286 1. Fluid level AT-61 2. Line pressure test AT-64 3. Control valve assembly AT-272 4. Forward clutch AT-320 5. Oil pump AT-297 6. Torque converter AT-286 1. Fluid level AT-61 2. Accelerator pedal position sensor (throttle position sensor) AT-182 3. Line pressure test AT-64 4. Accumulator servo release AT-272 5. Control valve assembly AT-272 6. Brake band AT-333 GI MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL IDX AT-89 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Chart (Cont’d) Items Symptom Condition ON vehicle Almost no shock or slipping in change from D2 to D3 . Diagnostic Item Reference Page 1. Fluid level AT-61 2. Accelerator pedal position sensor (throttle position sensor) AT-182 3. Line pressure test AT-64 4. Control valve assembly AT-272 5. High clutch AT-317 6. Forward clutch AT-320 1. Fluid level AT-61 2. Accelerator pedal position sensor (throttle position sensor) AT-182 3. Line pressure test AT-64 4. Control valve assembly AT-272 5. High clutch AT-317 6. Brake band AT-333 1. Fluid level AT-61 2. Accelerator pedal position sensor (throttle position sensor) AT-182 3. Line pressure test AT-64 4. Line pressure solenoid valve AT-168 5. Control valve assembly AT-272 6. High clutch AT-317 7. Forward clutch AT-320 1. Fluid level AT-61 2. Accelerator pedal position sensor (throttle position sensor) AT-182 3. Line pressure test AT-64 4. Line pressure solenoid valve AT-168 5. Shift solenoid valve A AT-174 6. Control valve assembly AT-272 7. Brake band AT-333 8. Forward clutch AT-320 1. Fluid level AT-61 2. Accelerator pedal position sensor (throttle position sensor) AT-182 3. Line pressure test AT-64 4. Line pressure solenoid valve AT-168 5. Control valve assembly AT-272 6. A/T fluid temperature sensor AT-111 OFF vehicle ON vehicle Almost no shock or slipping in change from D3 to D4 . OFF vehicle Slips/Will Not Engage Races extremely fast or slips in changing from D4 to D3 when depressing pedal. ON vehicle OFF vehicle Races extremely fast or slips in changing from D4 to D2 when depressing pedal. ON vehicle OFF vehicle Races extremely fast or slips in changing from D3 to D2 when depressing pedal. ON vehicle AT-90 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Chart (Cont’d) Items Symptom Races extremely fast or slips in changing from D3 to D2 when depressing pedal. Races extremely fast or slips in changing from D4 or D3 to D1 when depressing pedal. Condition OFF vehicle ON vehicle OFF vehicle Slips/Will Not Engage Diagnostic Item Reference Page 7. Brake band AT-333 8. Forward clutch AT-320 9. High clutch AT-317 1. Fluid level AT-61 2. Accelerator pedal position sensor (throttle position sensor) AT-182 3. Line pressure test AT-64 4. Line pressure solenoid valve AT-168 5. Control valve assembly AT-272 6. Forward clutch AT-320 7. Forward one-way clutch AT-330 8. Low one-way clutch AT-328 1. Fluid level AT-61 2. Manual control linkage adjustment AT-275 3. Line pressure test AT-64 4. Line pressure solenoid valve AT-168 5. Oil pump AT-297 6. High clutch AT-317 7. Brake band AT-333 8. Low & reverse brake AT-324 9. Torque converter AT-286 10. Parking pawl components AT-337 1. Ignition switch and starter EL-16, and SC-10 2. Manual control linkage adjustment AT-275 3. Park/neutral position (PNP) switch adjustment AT-275 1. Manual control linkage adjustment AT-275 2. Park/neutral position (PNP) switch adjustment AT-275 1. Fluid level AT-61 2. Line pressure test AT-64 3. Accelerator pedal position sensor (throttle position sensor) AT-182 4. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR AT-117, 200 5. Engine speed signal AT-122 6. Oil pump AT-297 7. Torque converter AT-286 GI MA EM LC EC FE CL MT ON vehicle Vehicle will not run in any position. TF PD OFF vehicle Engine cannot be started in P and N ON vehicle positions. AT-223 Engine starts in positions other than P and N. AT-223 ON vehicle NOT USED Transmission noise in P and N positions. ON vehicle OFF vehicle AX SU BR ST RS BT HA SC EL IDX AT-91 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Chart (Cont’d) Items Symptom Condition Vehicle moves when changing ON vehicle into P position or parking gear does not disengage when shifted out OFF vehicle of P position. AT-224 Vehicle runs in N position. AT-225 Diagnostic Item Reference Page 1. Manual control linkage adjustment AT-275 2. Parking pawl components AT-337 1. Manual control linkage adjustment AT-275 2. Forward clutch AT-320 3. Reverse clutch AT-314 4. Overrun clutch AT-320 1. Fluid level AT-61 2. Manual control linkage adjustment AT-275 3. Line pressure test AT-64 4. Line pressure solenoid valve AT-168 5. Control valve assembly AT-272 6. High clutch AT-317 7. Brake band AT-333 8. Forward clutch AT-320 9. Overrun clutch AT-320 1. Engine idling rpm EC-792 1. Engine idling rpm EC-792 2. Torque converter clutch solenoid valve AT-154 3. Control valve assembly AT-272 OFF vehicle 4. Torque converter AT-286 ON vehicle 1. Fluid level AT-61 2. Reverse clutch AT-314 3. Low & reverse brake AT-324 4. High clutch AT-317 5. Low one-way clutch AT-328 1. Fluid level AT-61 2. Brake band AT-333 1. Fluid level AT-61 2. Overrun clutch AT-320 3. Forward one-way clutch AT-330 4. Reverse clutch AT-314 ON vehicle OFF vehicle ON vehicle Vehicle braked when shifting into R position. OFF vehicle NOT USED Excessive creep. Engine stops when shifting lever into R, D, 2 and 1. ON vehicle ON vehicle Vehicle braked by gear change from OFF vehicle D1 to D2. Vehicle braked by ON vehicle gear change from OFF vehicle D2 to D3. ON vehicle Vehicle braked by gear change from OFF vehicle D3 to D4. AT-92 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Chart (Cont’d) Items Symptom Condition Diagnostic Item Reference Page 1. Fluid level AT-61 2. Park/neutral position (PNP) switch adjustment AT-275 3. Shift solenoid valve A AT-174 4. Shift solenoid valve B AT-178 5. Control valve assembly AT-272 6. Reverse clutch AT-314 7. High clutch AT-317 8. Brake band AT-333 9. Low & reverse brake AT-324 10. Oil pump AT-297 11. Torque converter AT-286 ON vehicle 1. Fluid level AT-61 ON vehicle 2. Torque converter AT-286 1. Park/neutral position (PNP) switch adjustment AT-275 2. Manual control linkage adjustment AT-275 3. Accelerator pedal position sensor (throttle position sensor) AT-182 4. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR AT-117, 200 5. Shift solenoid valve A AT-174 6. Control valve assembly AT-272 7. Overrun clutch solenoid valve AT-188 8. Overrun clutch AT-320 9. Low & reverse brake AT-324 ON vehicle Maximum speed not attained. Acceleration poor. MA OFF vehicle NOT USED Transmission noise in D, 2, 1 and R positions. Engine brake does not operate in “1” position. AT-254 ON vehicle GI OFF vehicle EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL IDX AT-93 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION Symptom Chart (Cont’d) Items Symptom Condition ON vehicle Transmission overheats. Diagnostic Item Reference Page 1. Fluid level AT-61 2. Engine idling rpm EC-792 3. Accelerator pedal position sensor (throttle position sensor) AT-182 4. Line pressure test AT-64 5. Line pressure solenoid valve AT-168 6. Control valve assembly AT-272 7. Oil pump AT-297 8. Reverse clutch AT-314 9. High clutch AT-317 10. Brake band AT-333 11. Forward clutch AT-320 12. Overrun clutch AT-320 13. Low & reverse brake AT-324 14. Torque converter AT-286 1. Fluid level AT-61 2. Reverse clutch AT-314 3. High clutch AT-317 4. Brake band AT-333 5. Forward clutch AT-320 6. Overrun clutch AT-320 7. Low & reverse brake AT-324 1. Fluid level AT-61 2. Torque converter AT-286 3. Oil pump AT-297 4. Reverse clutch AT-314 5. High clutch AT-317 6. Brake band AT-333 7. Forward clutch AT-320 8. Overrun clutch AT-320 9. Low & reverse brake AT-324 1. Fluid level AT-61 2. Torque converter clutch solenoid valve AT-154 3. Shift solenoid valve B AT-178 4. Shift solenoid valve A AT-174 5. Control valve assembly AT-272 OFF vehicle ON vehicle NOT USED ATF shoots out during operation. White smoke emitted from exhaust pipe during operation. OFF vehicle ON vehicle Offensive smell at fluid charging OFF vehicle pipe. Engine is stopped at R, D, 2 and 1 ON vehicle positions. AT-94 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION TCM Terminals and Reference Value TCM Terminals and Reference Value =NAAT0027 PREPARATION 쐌 GI NAAT0027S01 Measure voltage between each terminal and terminal 25 or 48 by following “TCM INSPECTION TABLE”. MA EM LC AAT475A EC FE CL MT SAT217JB TCM HARNESS CONNECTOR TERMINAL LAYOUTNAAT0027S02 TCM INSPECTION TABLE NAAT0027S03 (Data are reference values.) Terminal No. 1 2 Wire color GY BR/Y Item Judgement standard (Approx.) Condition Line pressure solenoid valve PD When releasing accelerator pedal after warm1.5 - 3.0V ing up engine. AX When depressing accelerator pedal fully after warming up engine. SU 0V When releasing accelerator pedal after warm5 - 14V ing up engine. Line pressure solenoid valve (with dropping resistor) TF When depressing accelerator pedal fully after warming up engine. 0V When A/T performs lock-up. 8 - 15V When A/T does not perform lock- up. 0V BR ST 3 G/OR Torque converter clutch solenoid valve 5 L CAN (high) 6 R CAN (low) — — — — or 10 W/R RS BT When turning ignition switch to “ON”. Battery voltage HA When turning ignition switch to “OFF”. 0V SC Power source EL IDX AT-95 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION TCM Terminals and Reference Value (Cont’d) Terminal No. 11 12 19 20 25 26 Wire color L/W L/R W/R L/B B L/Y Item Judgement standard (Approx.) Condition When shift solenoid valve A operates. (When driving in “D1” or “D4”.) Shift solenoid valve A Battery voltage When shift solenoid valve A does not operate. 0V (When driving in “D2” or “D3”.) When shift solenoid valve B operates. (When driving in “D1” or “D2”.) Shift solenoid valve B Battery voltage When shift solenoid valve B does not operate. 0V (When driving in “D3” or “D4”.) Power source Same as No. 10 Overrun clutch solenoid valve When overrun clutch solenoid valve operates. Battery voltage When overrun clutch solenoid valve does not operate. 0V — 0V Ground When setting selector lever to “1” position. PNP switch “1” position Battery voltage When setting selector lever to other positions. 0V 27 G/W When setting selector lever to “2” position. PNP switch “2” position Battery voltage When setting selector lever to other positions. 0V 28 29 R/Y W Power source (Memory back-up) W Data link connector (RX) 31* L Data link connector (TX) 32 P/B Battery voltage When turning ignition switch to “ON”. Battery voltage When vehicle cruises at 30 km/h (19 MPH). 1V or more Voltage rises gradually in response to vehicle speed. When vehicle parks. 0V or Revolution sensor (Measure in AC range) 30* When turning ignition switch to “OFF”. or — — — — Ignition switch “ON”. 4.5 - 5.5V Ignition switch “OFF”. 0V Sensor power AT-96 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION TCM Terminals and Reference Value (Cont’d) Terminal No. 34 Wire color L Item PNP switch “D” position Judgement standard (Approx.) Condition When setting selector lever to “D” position. Battery voltage 35 Y When setting selector lever to “R” position. MA EM When setting selector lever to other positions. 0V PNP switch “R” position GI Battery voltage LC When setting selector lever to other positions. 0V 36 38 P W PNP switch “N” or “P” position Turbine revolution sensor (Measure in AC range) When setting selector lever to “N” or “P” posi- Battery volttion. age EC When setting selector lever to other positions. 0V FE When engine is running at 1,000 rpm 1.2V Voltage rises gradually in response to engine speed. CL MT 39 W/B Engine speed signal Refer to EC-149, “ECM INSPECTION TABLE”. — TF W/L Vehicle speed sensor When moving vehicle at 2 to 3 km/h (1 to 2 MPH) for 1 m (3 ft) or more. Voltage varies between less than 1.0V and more than 4.5V. 41 P/L When depressing accelerator pedal slowly after warming up engine. (Voltage rises gradually in response to throttle position.) Fully-closed throttle: 0.5V - 0.7V Fully-open throttle: 4V AX Accelerator pedal position sensor (throttle position sensor) 42 B Sensor ground — 0V BR 46 W/G Transfer control unit Refer to TF section, “Transfer Control Unit Terminals and Reference Value”. 47 R 40 48 B A/T fluid temperature sensor — When ATF temperature is 20°C (68°F). 1.5V When ATF temperature is 80°C (176°F). 0.5V Ground — 0V PD SU ST RS BT *: These terminals are connected to the Data link connector for CONSULT-II. HA SC EL IDX AT-97 CAN COMMUNICATION System Description System Description NAAT0234 CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. CAN Communication Unit NAAT0235 Go to CAN system, when selecting your car model from the following table. Body type Axle Wide/Wagon 4WD (All-mode) 4WD (Part time) Engine 2WD 4WD (Part time) VQ35DE Brake control VDC ABS CAN communication unit ECM X X X X TCM X X X X Transfer control unit X Steering angle sensor X X X ABS actuator and electric unit (control unit) X X X Combination meter X X X X CAN communication type (Reference page) Type 1 (EL-447) Type 2 (EL-447) Type 3 (EL-447) CAN system trouble diagnosis (Reference page) Type 1 (EL-447) Type 2 (EL-447) Type 3 (EL-447) X: Applicable TYPE 1 System Diagram NAAT0235S01 NAAT0235S0101 SEL683Y AT-98 CAN COMMUNICATION CAN Communication Unit (Cont’d) Input/Output Signal Chart NAAT0235S0102 GI T: Transmit R: Receive Signals ECM TCM Transfer control unit ABS actuaSteering tor and elec- Combination angle sensor tric unit meter (control unit) Engine speed signal T R R Accelerator pedal position signal T R R Closed throttle position signal T R Wide open throttle position signal T R VDC operation signal R R T TCS operation signal R R T ABS operation signal R R T Output shaft revolution signal R ETC fail signal T During shifting signal R T EM R LC EC FE CL R R T R Steering angle sensor signal Wheel speed sensor signal R MT R T Stop lamp switch signal MA R T R T MIL signal T R Engine coolant temperature signal T R Fuel consumption signal T R T R Vehicle speed signal R T Lock-up prohibition signal T R Lock-up signal R T TF PD AX SU Neutral range switch signal R T Parking range switch signal R T Overdrive control switch signal R T A/C compressor feedback signal T R Fuel level sensor signal R T A/T position indicator signal T R O/D OFF indicator signal T R BR ST RS BT HA SC EL IDX AT-99 CAN COMMUNICATION CAN Communication Unit (Cont’d) TYPE 2 System Diagram NAAT0235S02 NAAT0235S0201 SEL682Y Input/Output Signal Chart NAAT0235S0202 T: Transmit R: Receive Signals ECM TCM Steering angle sensor ABS actuator and electric unit (control unit) Combination meter R Engine speed signal T R Accelerator pedal position signal T R Closed throttle position signal T R Wide open throttle position signal T R VDC operation signal R T TCS operation signal R T ABS operation signal R T Steering angle sensor signal T R MIL signal T R Engine coolant temperature signal T R Fuel consumption signal T R T R Vehicle speed signal R T Stop lamp switch signal R Lock-up prohibition signal T R Lock-up signal R T T Neutral range switch signal R T Parking range switch signal R T Overdrive control switch signal R T A/C compressor feedback signal T R Fuel level sensor signal R T A/T position indicator signal T R O/D OFF indicator signal T R AT-100 CAN COMMUNICATION CAN Communication Unit (Cont’d) TYPE 3 System Diagram NAAT0235S03 GI NAAT0235S0301 MA EM LC EC SEL684Y FE Input/Output Signal Chart NAAT0235S0302 T: Transmit R: Receive Signals ECM TCM Engine speed signal T Closed throttle position signal T R Wide open throttle position signal T R Stop lamp switch signal Combination meter CL R R Lock-up prohibition signal T R Lock-up signal R T MT T TF Neutral range switch signal R T Parking range switch signal R T Overdrive control switch signal R T MIL signal T R Engine coolant temperature signal T R Fuel consumption signal T R Vehicle speed signal R T A/C compressor feedback signal T R Fuel level sensor signal R T A/T position indicator signal T R O/D OFF indicator signal T R PD AX SU BR ST RS BT HA SC EL IDX AT-101 TROUBLE DIAGNOSIS FOR POWER SUPPLY Wiring Diagram — AT — MAIN Wiring Diagram — AT — MAIN NAAT0185 MAT311B AT-102 TROUBLE DIAGNOSIS FOR POWER SUPPLY Wiring Diagram — AT — MAIN (Cont’d) TCM TERMINALS AND REFERENCE VALUE NAAT0185S01 GI Remarks: Specification data are reference values. Terminal No. 10 Wire color W/R Item W/R When turning ignition switch to “ON”. Battery voltage When turning ignition switch to “OFF”. 0V Power source or 19 Judgement standard (Approx.) Condition Power source MA EM LC Same as No. 10 EC 25 B Ground — 0V FE When turning ignition switch to “OFF”. 28 R/Y Power source (Memory back-up) or When turning ignition switch to “ON”. 48 B Battery voltage Ground — Battery voltage CL MT 0V TF PD AX SU Diagnostic Procedure 1 NAAT0223 BR CHECK TCM POWER SOURCE STEP 1 1. Turn ignition switch to ON position. (Do not start engine.) 2. Check voltage between TCM harness connector M119, M120 terminals 10, 19, 28 and ground. ST RS BT HA SAT611J SC OK or NG OK 䊳 GO TO 2. NG 䊳 GO TO 3. EL IDX AT-103 TROUBLE DIAGNOSIS FOR POWER SUPPLY Diagnostic Procedure (Cont’d) 2 CHECK TCM POWER SOURCE STEP 2 1. Turn ignition switch to OFF position. 2. Check voltage between TCM harness connector M120 terminal 28 and ground. SAT612JC OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 3. 3 DETECT MALFUNCTIONING ITEM Check the following items: 쐌 Harness for short or open between ignition switch and TCM harness connector M119, M120 terminals 10, 19 and 28 (Main harness) 쐌 Ignition switch and 10A or 7.5A fuse [No. 18 or 24, located in the fuse block (J/B)] Refer to EL-11, “Schematic”. OK or NG OK 䊳 GO TO 4. NG 䊳 Repair or replace damaged parts. 4 CHECK TCM GROUND CIRCUIT 1. Turn ignition switch to OFF position. 2. Disconnect TCM harness connector. 3. Check continuity between TCM harness connector M120 terminals 25, 48 and ground. Refer to wiring diagram — AT — MAIN. Continuity should exist. If OK, check harness for short to ground and short to power. OK or NG OK 䊳 INSPECTION END NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. AT-104 DTC P0705 PARK/NEUTRAL POSITION SWITCH Description Description 쐌 쐌 NAAT0028 The PNP switch assemble includes a transmission range switch. The transmission range switch detects the selector position and sends a signal to the TCM. GI MA EM LC EC FE CL MT SAT136K TCM TERMINALS AND REFERENCE VALUE NAAT0028S02 Remarks: Specification data are reference values. Terminal No. 26 Wire color L/Y Item PNP switch “1” position Judgement standard (Approx.) Condition When setting selector lever to “1” position. G/W PNP switch “2” position When setting selector lever to “2” position. PD Battery voltage AX When setting selector lever to other positions. 0V 27 TF Battery voltage SU When setting selector lever to other positions. 0V 34 L PNP switch “D” position When setting selector lever to “D” position. Battery voltage When setting selector lever to other positions. 0V 35 Y PNP switch “R” position When setting selector lever to “R” position. ST Battery voltage When setting selector lever to other positions. 0V 36 P PNP switch “N” or “P” position BR When setting selector lever to “N” or “P” posi- Battery volttion. age RS BT When setting selector lever to other positions. 0V ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : PNP SW/CIRC : P0705 Malfunction is detected when ... TCM does not receive the correct voltage signal from the switch based on the gear position. HA NAAT0028S03 Check item (Possible cause) SC 쐌 Harness or connectors (The PNP switch circuit is open or shorted.) 쐌 PNP switch EL IDX AT-105 DTC P0705 PARK/NEUTRAL POSITION SWITCH Description (Cont’d) DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NAAT0028S01 SAT014K PBIB2308E CAUTION: Always drive vehicle at a safe speed. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode for “ENGINE” with CONSULTII. 3) Start engine and maintain the following conditions for at least 5 consecutive seconds. VHCL SPEED SE: 10 km/h (6 MPH) or more THRTL POS SEN: More than 1.3V Selector lever: D position (OD “ON” or “OFF”) With GST Follow the procedure “With CONSULT-II”. AT-106 DTC P0705 PARK/NEUTRAL POSITION SWITCH Wiring Diagram — AT — PNP/SW Wiring Diagram — AT — PNP/SW NAAT0186 GI MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL MAT312B AT-107 IDX DTC P0705 PARK/NEUTRAL POSITION SWITCH Diagnostic Procedure Diagnostic Procedure 1 NAAT0029 CHECK PNP SWITCH CIRCUIT (WITH CONSULT-II) With CONSULT-II 1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out “P”, “R”, “N”, “D”, “2” and “1” position switches moving selector lever to each position. Check the signal of the selector lever position is indicated properly. SAT643J OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 3. 2 CHECK PNP SWITCH CIRCUIT (WITHOUT CONSULT-II) Without CONSULT-II 1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Check voltage between TCM harness connector M120 terminals 26, 27, 34, 35, 36 and ground while moving selector lever through each position. MTBL0205 SAT517J Does battery voltage exist (B) or non-existent (0)? Yes 䊳 GO TO 4. No 䊳 GO TO 3. AT-108 DTC P0705 PARK/NEUTRAL POSITION SWITCH Diagnostic Procedure (Cont’d) 3 GI DETECT MALFUNCTIONING ITEM Check the following items: 쐌 PNP switch Refer to “Component Inspection”, AT-109. 쐌 Harness for short or open between ignition switch and PNP switch (Main harness) 쐌 Harness for short or open between PNP switch and TCM (Main harness) 쐌 Diode (P, N position) 쐌 Ignition switch and 10A fuse [No. 18, located in the fuse block (J/B)] Refer to EL-11, “Schematic”. MA EM LC OK or NG OK 䊳 GO TO 4. NG 䊳 Repair or replace damaged parts. 4 EC FE CHECK DTC Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-106. CL OK or NG OK 䊳 INSPECTION END NG 䊳 GO TO 5. 5 MT CHECK TCM INSPECTION 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. TF OK or NG OK 䊳 INSPECTION END NG 䊳 Repair or replace damaged parts. PD AX SU Component Inspection NAAT0030 PARK/NEUTRAL POSITION SWITCH 1. Lever position SAT517GB NAAT0030S02 Check continuity between terminals 1 and 2 and between terminals 3 and 4, 5, 6, 7, 8, 9 while moving manual shaft through each position. BR ST Terminal No. P 1-2 R 3-5 N 1-2 D 3-7 2 3-8 1 3-9 3-4 RS 3-6 BT HA SC EL IDX SAT843BG AT-109 DTC P0705 PARK/NEUTRAL POSITION SWITCH Component Inspection (Cont’d) 2. 3. If NG, check again with manual control linkage disconnected from manual shaft of A/T assembly. Refer to step 1. If OK on step 2, adjust manual control linkage. Refer to AT-275. SAT807B 4. 5. 6. If NG on step 2, remove PNP switch from A/T and check continuity of PNP switch terminals. Refer to step 1. If OK on step 4, adjust PNP switch. Refer to AT-275. If NG on step 4, replace PNP switch. SAT386HC AT-110 DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT Description Description NAAT0031 The A/T fluid temperature sensor detects the A/T fluid temperature and sends a signal to the TCM. GI MA EM LC SAT342HA EC FE CL MT SAT021J CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE NAAT0031S04 Remarks: Specification data are reference values. Monitor item Condition Specification Cold [20°C (68°F)] " Hot [80°C (176°F)] A/T fluid temperature sensor Approximately 1.5V " Approximately 0.5V Approximately 2.5 kΩ " Approximately 0.3 kΩ TCM TERMINALS AND REFERENCE VALUE Wire color 42 B 47 R A/T fluid temperature sensor Judgement standard (Approx.) Condition — 0V When ATF temperature is 20°C (68°F). 1.5V When ATF temperature is 80°C (176°F). 0.5V ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : ATF TEMP SEN/CIRC : P0710 AX SU Item Throttle position sensor (Ground) PD NAAT0031S02 Remarks: Specification data are reference values. Terminal No. TF Malfunction is detected when ... TCM receives an excessively low or high voltage from the sensor. BR ST RS NAAT0031S03 BT Check item (Possible cause) 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 A/T fluid temperature sensor HA SC EL IDX AT-111 DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT Description (Cont’d) DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NAAT0031S01 SAT014K PBIB2308E CAUTION: Always drive vehicle at a safe speed. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode for “ENGINE” with CONSULT-II. 2) Start engine and maintain the following conditions for at least 10 minutes (Total). (It is not necessary to maintain continuously.) CMPS·RPM (REF): 450 rpm or more VHCL SPEED SE: 10 km/h (6 MPH) or more THRTL POS SEN: More than 1.2V Selector lever: D position (OD “ON”) With GST Follow the procedure “With CONSULT-II”. AT-112 DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT Wiring Diagram — AT — FTS Wiring Diagram — AT — FTS NAAT0187 GI MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL MAT313B AT-113 IDX DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT Diagnostic Procedure Diagnostic Procedure 1 NAAT0032 INSPECTION START Do you have CONSULT-II? Yes or No Yes 䊳 GO TO 2. No 䊳 GO TO 6. 2 CHECK INPUT SIGNAL OF A/T FLUID TEMPERATURE SENSOR (WITH CONSULT-II) With CONSULT-II 1. Start engine. 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “FLUID TEMP SE”. Voltage: Cold [20°C (68°F)] → Hot [80°C (176°F)]: Approximately 1.5V → 0.5V SAT614J OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 3. 3 DETECT MALFUNCTIONING ITEM Check the following item: 쐌 Harness for short to ground or short to power or open between TCM, ECM and terminal cord assembly (Main harness) 쐌 Ground circuit for ECM. Refer to EC-165, “Wiring Diagram”. OK or NG OK 䊳 GO TO 4. NG 䊳 Repair or replace damaged parts. AT-114 DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT Diagnostic Procedure (Cont’d) 4 GI CHECK A/T FLUID TEMPERATURE SENSOR WITH TERMINAL CORD ASSEMBLY 1. Turn ignition switch to “OFF” position. 2. Disconnect terminal cord assembly connector on the right side of transfer assmebly. 3. Check resistance between terminals 8 and 9 when A/T is cold [20°C (68°F)]. MA EM LC EC FE SAT697I Is resistance approx. 2.5 kΩ? Yes 䊳 GO TO 7. No 䊳 GO TO 5. 5 CL MT DETECT MALFUNCTIONING ITEM 1. Remove oil pan. 2. Check the following items: 쐌 A/T fluid temperature sensor Refer to “Component Inspection”, AT-116. 쐌 Harness of terminal cord assembly for short or open TF OK or NG PD AX OK 䊳 GO TO 7. NG 䊳 Repair or replace damaged parts. 6 CHECK INPUT SIGNAL OF A/T FLUID TEMPERATURE SENSOR (WITHOUT CONSULT-II) SU Without CONSULT-II 1. Start engine. 2. Check voltage between TCM harness connector M120 terminal 47 and ground while warming up A/T. Voltage: Cold [20°C (68°F)] → Hot [80°C (176°F)]: Approximately 1.5V → 0.5V BR ST RS BT HA SAT518J OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 3. SC EL IDX AT-115 DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT Diagnostic Procedure (Cont’d) 7 CHECK DTC Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-112. OK or NG OK 䊳 INSPECTION END NG 䊳 GO TO 8. 8 CHECK TCM INSPECTION 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK 䊳 INSPECTION END NG 䊳 Repair or replace damaged parts. Component Inspection NAAT0033 A/T FLUID TEMPERATURE SENSOR 쐌 쐌 NAAT0033S01 For removal, refer to AT-272. Check resistance between terminals 8 and 9 while changing temperature as shown at left. Temperature °C (°F) Resistance 20 (68) Approximately 2.5 kΩ 80 (176) Approximately 0.3 kΩ SAT687I AT-116 DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR) Description Description NAAT0034 The revolution sensor detects the revolution of the out put shaft parking pawl lock gear and emits a pulse signal. The pulse signal is sent to the TCM which converts it into vehicle speed. GI MA EM LC EC FE CL MT SAT136K TCM TERMINALS AND REFERENCE VALUE NAAT0034S02 Remarks: Specification data are reference values. Terminal No. 29 Wire color W Item Revolution sensor (Measure in AC range) Judgement standard (Approx.) Condition TF PD When vehicle cruises at 30 km/h (19 MPH). 1V or more Voltage rises gradually in response to vehicle speed. AX When vehicle parks. 0V SU BR 42 B Sensor ground — 0V ST ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : VEH SPD SEN/CIR AT : P0720 Malfunction is detected when ... TCM does not receive the proper voltage signal from the sensor. NAAT0034S03 Check item (Possible cause) 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Revolution sensor RS BT HA SC EL IDX AT-117 DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR) Description (Cont’d) DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NAAT0034S01 SAT014K SCIA5358E SAT014K CAUTION: 쐌 Always drive vehicle at a safe speed. 쐌 Be careful not to rev engine into the red zone on the tachometer. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode for “A/T” with CONSULT-II. 2) Drive vehicle and check for an increase of “VHCL/S SE·MTR” value. If the check result is NG, go to “DIAGNOSTIC PROCEDURE”, AT-203. If the check result is OK, go to following step. 3) Select “DATA MONITOR” mode for “ENGINE” with CONSULTII. 4) Start engine and maintain the following conditions for at least 5 consecutive seconds. VHCL SPEED SE: 30 km/h (19 MPH) or more THRTL POS SEN: More than 1.2V Selector lever: D position (OD “ON”) Driving pattern: Driving the vehicle uphill (increased engine load) will help maintain the driving conditions required for this test. If the check result is NG, go to “DIAGNOSTIC PROCEDURE”, AT-120. If the check result is OK, go to following step. 5) Maintain the following conditions for at least 5 consecutive seconds. CMPS·RPM (REF): 3,500 rpm or more THRTL POS SEN: More than 1.2V Selector lever: D position (OD “ON”) Driving pattern: Driving the vehicle uphill (increased engine load) will help maintain the driving conditions required for this test. With GST Follow the procedure “With CONSULT-II”. PBIB2308E AT-118 DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR) Wiring Diagram — AT — VSSA/T Wiring Diagram — AT — VSSA/T NAAT0188 GI MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL MAT314B AT-119 IDX DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR) Diagnostic Procedure Diagnostic Procedure 1 NAAT0035 INSPECTION START Do you have CONSULT-II? Yes or No Yes (With CONSULT-II) 䊳 GO TO 2. No (Without CONSULTII) 䊳 GO TO 5. 2 CHECK INPUT SIGNAL (WITH CONSULT-II) With CONSULT-II 1. Start engine. 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “VHCL/S SE·A/T” while driving. Check the value changes according to driving speed. SAT614J OK or NG OK 䊳 GO TO 6. NG 䊳 GO TO 3. 3 CHECK REVOLUTION SENSOR Refer to “Component Inspection”, AT-121. OK or NG OK 䊳 GO TO 4. NG 䊳 Repair or replace revolution sensor. 4 DETECT MALFUNCTIONING ITEM Check the following items: 쐌 Harness for short or open between TCM and revolution sensor. 쐌 Harness for short or open between revolution sensor and ECM. 쐌 Ground circuit for ECM Refer to EC-165, “WIRING DIAGRAM”. OK or NG OK 䊳 GO TO 6. NG 䊳 Repair or replace damaged parts. AT-120 DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR) Diagnostic Procedure (Cont’d) 5 GI CHECK INPUT SIGNAL (WITHOUT CONSULT-II) Without CONSULT-II 1. Start engine. 2. Check voltage between TCM harness connector M120 terminal 29 and ground while driving. (Measure with AC range.) Voltage: At 0 km/h (0 MPH): 0V At 30 km/h (19 MPH): 1V or more (Voltage rises gradually in response to vehicle speed.) MA EM LC EC FE CL SAT519J MT OK or NG OK 䊳 GO TO 6. NG 䊳 GO TO 3. 6 TF CHECK DTC Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-118. PD OK or NG OK 䊳 INSPECTION END NG 䊳 GO TO 7. 7 AX SU CHECK TCM INSPECTION 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. BR OK or NG OK 䊳 INSPECTION END NG 䊳 Repair or replace damaged parts. ST RS BT Component Inspection NAAT0036 REVOLUTION SENSOR 쐌 쐌 For removal, refer to AT-272. Check resistance between terminals 1, 2 and 3. Terminal No. 2 500 - 650Ω 2 3 No continuity 1 3 No continuity AT-121 SC Resistance 1 SAT210IA HA NAAT0036S01 EL IDX DTC P0725 ENGINE SPEED SIGNAL Description Description NAAT0037 The engine speed signal is sent from the ECM to the TCM. TCM TERMINALS AND REFERENCE VALUE NAAT0037S02 Remarks: Specification data are reference values. Terminal No. Wire color Item 39 W/G Engine speed signal Judgement standard (Approx.) Condition Refer to EC-149, “ECM INSPECTION TABLE”. — ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : ENGINE SPEED SIG : P0725 Malfunction is detected when ... NAAT0037S03 Check item (Possible cause) TCM does not receive the proper voltage 쐌 Harness or connectors signal from ECM. (The sensor circuit is open or shorted.) DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NAAT0037S01 SAT014K CAUTION: Always drive vehicle at a safe speed. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode for “ENGINE” with CONSULT-II. 2) Start engine and maintain the following conditions for at least 10 consecutive seconds. VHCL SPEED SE: 10 km/h (6 MPH) or more THRTL POS SEN: More than 1.2V Selector lever: D position (OD “ON”) With GST Follow the procedure “With CONSULT-II”. PBIB2308E AT-122 DTC P0725 ENGINE SPEED SIGNAL Wiring Diagram — AT — ENGSS Wiring Diagram — AT — ENGSS NAAT0189 GI MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL MAT315B AT-123 IDX DTC P0725 ENGINE SPEED SIGNAL Diagnostic Procedure Diagnostic Procedure 1 NAAT0038 CHECK DTC WITH ECM 쐌 Check P code with CONSULT-II. Turn ignition switch “ON” and select “SELF-DIAG RESULTS” mode for “ENGINE” with CONSULT-II. Refer to EC-102, “DESCRIPTION”. OK or NG OK (With CONSULT-II) 䊳 GO TO 2. OK (Without CONSULTII) 䊳 GO TO 4. NG 䊳 Check ignition signal circuit for engine control. Refer to EC-748, “Component Description”. 2 CHECK INPUT SIGNAL (WITH CONSULT-II) With CONSULT-II 1. Start engine. 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “ENGINE SPEED”. Check engine speed changes according to throttle position. SAT645J Refer to EC-149, “ECM INSPECTION TABLE”. Yes 䊳 GO TO 5. No 䊳 GO TO 3. 3 DETECT MALFUNCTIONING ITEM Check the following items: 쐌 Harness for short or open between TCM and ECM 쐌 Resistor 쐌 Ignition coil Refer to EC-748, “Component Description”. OK or NG OK 䊳 GO TO 5. NG 䊳 Repair or replace damaged parts. AT-124 DTC P0725 ENGINE SPEED SIGNAL Diagnostic Procedure (Cont’d) 4 GI CHECK INPUT SIGNAL (WITHOUT CONSULT-II) Without CONSULT-II 1. Start engine. 2. Check voltage between TCM harness connector M120 terminal 39 and ground. MA EM LC EC SAT520J Refer to EC-149, “ECM INSPECTION TABLE”. Yes 䊳 GO TO 5. No 䊳 GO TO 3. 5 FE CL MT CHECK DTC Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-122. OK or NG OK 䊳 INSPECTION END NG 䊳 GO TO 6. 6 TF CHECK TCM INSPECTION PD 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG AX SU OK 䊳 INSPECTION END NG 䊳 Repair or replace damaged parts. BR ST RS BT HA SC EL IDX AT-125 DTC P0731 IMPROPER SHIFTING TO 1ST GEAR POSITION Description Description 쐌 쐌 쐌 NAAT0039 This is an OBD-II self-diagnostic item and not available in TCM self-diagnosis. This malfunction will not be detected while the O/D OFF indicator lamp is indicating another self-diagnosis malfunction. This malfunction is detected when the A/T does not shift into first gear position as instructed by the TCM. This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction such as control valve sticking, improper solenoid valve operation, etc. Gear position 1 2 3 4 Shift solenoid valve A ON (Closed) OFF (Open) OFF (Open) ON (Closed) Shift solenoid valve B ON (Closed) ON (Closed) OFF (Open) OFF (Open) TCM TERMINALS AND REFERENCE VALUE NAAT0039S02 Remarks: Specification data are reference values. Terminal No. 11 Wire color L/W 12 L/R Item Judgement standard (Approx.) Condition When shift solenoid valve A operates. (When driving in “D1” or “D4”.) Shift solenoid valve A Battery voltage When shift solenoid valve A does not operate. 0V (When driving in “D2” or “D3”.) Battery voltage When shift solenoid valve B operates. (When driving in “D1” or “D2”.) Shift solenoid valve B When shift solenoid valve B does not operate. 0V (When driving in “D3” or “D4”.) ON BOARD DIAGNOSIS LOGIC NAAT0039S03 This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM as follows: Torque converter slip ratio = A x C/B A: Output shaft revolution signal from revolution sensor B: Engine speed signal from ECM C: Gear ratio determined as gear position which TCM supposes If the actual gear position is higher than the position (1st) supposed by TCM, the slip ratio will be more than normal. In case the ratio exceeds the specified value, TCM judges this diagnosis malfunction. This malfunction will be caused when either shift solenoid valve A is stuck open or shift solenoid valve B is stuck open. Gear position supposed by TCM 1 2 3 4 In case of gear position with no malfunctions 1 2 3 4 In case of gear position with shift solenoid valve A stuck open 2* 2 3 3 In case of gear position with shift solenoid valve B stuck open 4* 3 3 4 *: P0731 is detected. Diagnostic trouble code : A/T 1ST GR FNCTN : P0731 Malfunction is detected when ... A/T cannot be shifted to the 1st gear position even if electrical circuit is good. AT-126 Check item (Possible cause) 쐌 쐌 쐌 쐌 Shift solenoid valve A Shift solenoid valve B Each clutch Hydraulic control circuit DTC P0731 IMPROPER SHIFTING TO 1ST GEAR POSITION Description (Cont’d) DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION GI PROCEDURE NAAT0039S01 SAT014K SCIA5358E SAT021J CAUTION: 쐌 Always drive vehicle at a safe speed. 쐌 Be careful not to rev engine into the red zone on the tachometer. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. TESTING CONDITIONS: Always drive vehicle on a level road to improve the accuracy of test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) Start engine and select “DATA MONITOR” mode for “A/T” with CONSULT-II. 2) Make sure that output voltage of A/T fluid temperature sensor is within the range below. FLUID TEMP SEN: 0.4 - 1.5V If out of range, drive the vehicle to decrease the voltage (warm up the fluid) or stop engine to increase the voltage (cool down the fluid). 3) Select “1ST GR FNCTN P0731” of “DTC WORK SUPPORT” mode for “A/T” with CONSULT-II and touch “START”. 4) Accelerate vehicle to 10 to 20 km/h (6 to 12 MPH) under the following condition and release the accelerator pedal completely. THROTTLE POSI: Less than 1.0/8 (at all times during step 4) Selector lever: D position (OD “ON”) 쐌 Check that “GEAR” shows “2” after releasing pedal. 5) Depress accelerator pedal to WOT (more than 7.0/8 of “THROTTLE POSI”) quickly from a speed of 10 to 20 km/h (6 to 12 MPH) until “TESTING” changes to “STOP VEHICLE” or “COMPLETED”. (It will take approximately 3 seconds.) If the check result NG appears on CONSULT-II screen, go to “DIAGNOSTIC PROCEDURE”, AT-130. If “STOP VEHICLE” appears on CONSULT-II screen, go to the following step. 쐌 Check that “GEAR” shows “1” when depressing accelerator pedal to WOT. 쐌 If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS” for “ENGINE”. In case a 1st trip DTC other than P0731 is shown, refer to applicable “TROUBLE DIAGNOSIS FOR DTC”. 6) Stop vehicle. 7) Follow the instruction displayed. (Check for normal shifting referring to the table below.) Vehicle condition No malfunction exists Gear on actual transmission shift pattern when screen is changed to 1 , 2 , 3 , 4 MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL 1,2,3,4 IDX AT-127 DTC P0731 IMPROPER SHIFTING TO 1ST GEAR POSITION Description (Cont’d) 2,2,3,3 Malfunction for P0731 exists. 4,3,3,4 8) Make sure that “OK” is displayed. (If “NG” is displayed, refer to “DIAGNOSTIC PROCEDURE”.) Refer to “DIAGNOSTIC PROCEDURE”, AT-130. Refer to shift schedule, AT-356. With GST Follow the procedure “With CONSULT-II”. AT-128 DTC P0731 IMPROPER SHIFTING TO 1ST GEAR POSITION Wiring Diagram — AT — 1ST Wiring Diagram — AT — 1ST NAAT0190 GI MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL MAT731A AT-129 IDX DTC P0731 IMPROPER SHIFTING TO 1ST GEAR POSITION Diagnostic Procedure Diagnostic Procedure 1 NAAT0040 CHECK SHIFT SOLENOID VALVE 1. Remove control valve assembly. Refer to AT-272. 2. Check shift solenoid valve operation. 쐌 Shift solenoid valve A 쐌 Shift solenoid valve B Refer to “Component Inspection”, AT-131. SAT648I OK or NG OK 䊳 GO TO 2. NG 䊳 Repair or replace shift solenoid valve assembly. 2 CHECK CONTROL VALVE 1. Disassemble control valve assembly. Refer to “Control Valve Assembly”, AT-301. 2. Check to ensure that: 쐌 Valve, sleeve and plug slide along valve bore under their own weight. 쐌 Valve, sleeve and plug are free from burrs, dents and scratches. 쐌 Control valve springs are free from damage, deformation and fatigue. 쐌 Hydraulic line is free from obstacles. SAT367H OK or NG OK 䊳 GO TO 3. NG 䊳 Repair control valve assembly. 3 CHECK DTC Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-127. OK or NG OK 䊳 INSPECTION END NG 䊳 Check control valve again. Repair or replace control valve assembly. AT-130 DTC P0731 IMPROPER SHIFTING TO 1ST GEAR POSITION Component Inspection Component Inspection =NAAT0041 SHIFT SOLENOID VALVE A AND B 쐌 NAAT0041S01 For removal, refer to AT-272. MA Resistance Check 쐌 NAAT0041S0101 Check resistance between terminals (3 or 2) and ground. Solenoid valve GI Terminal No. Shift solenoid valve A 3 Shift solenoid valve B 2 Ground EM Resistance (Approx.) 20 - 40Ω LC SAT649I Operation Check 쐌 EC NAAT0041S0102 Check solenoid valve by listening for its operating sound while applying battery voltage to the terminals (3 or 2) and ground. FE CL MT SAT648I TF PD AX SU BR ST RS BT HA SC EL IDX AT-131 DTC P0732 IMPROPER SHIFTING TO 2ND GEAR POSITION Description Description 쐌 쐌 쐌 NAAT0042 This is an OBD-II self-diagnostic item and not available in TCM self-diagnosis. This malfunction will not be detected while the O/D OFF indicator lamp is indicating another self-diagnosis malfunction. This malfunction is detected when the A/T does not shift into second gear position as instructed by the TCM. This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction such as control valve sticking, improper solenoid valve operation, etc. Gear position 1 2 3 4 Shift solenoid valve A ON (Closed) OFF (Open) OFF (Open) ON (Closed) Shift solenoid valve B ON (Closed) ON (Closed) OFF (Open) OFF (Open) TCM TERMINALS AND REFERENCE VALUE NAAT0042S02 Remarks: Specification data are reference values. Terminal No. 12 Wire color L/R Item Judgement standard (Approx.) Condition When shift solenoid valve B operates. (When driving in “D1” or “D2”.) Shift solenoid valve B Battery voltage When shift solenoid valve B does not operate. 0V (When driving in “D3” or “D4”.) ON BOARD DIAGNOSIS LOGIC NAAT0042S03 This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM as follows: Torque converter slip ratio = A x C/B A: Output shaft revolution signal from revolution sensor B: Engine speed signal from ECM C: Gear ratio determined as gear position which TCM supposes If the actual gear position is higher than the position (2nd) supposed by TCM, the slip ratio will be more than normal. In case the ratio exceeds the specified value, TCM judges this diagnosis malfunction. This malfunction will be caused when shift solenoid valve B is stuck open. Gear position supposed by TCM 1 2 3 4 In case of gear position with no malfunctions 1 2 3 4 In case of gear position with shift solenoid valve B stuck open 4 3* 3 4 *: P0732 is detected. Diagnostic trouble code : A/T 2ND GR FNCTN : P0732 Malfunction is detected when ... A/T cannot be shifted to the 2nd gear position even if electrical circuit is good. AT-132 Check item (Possible cause) 쐌 Shift solenoid valve B 쐌 Each clutch 쐌 Hydraulic control circuit DTC P0732 IMPROPER SHIFTING TO 2ND GEAR POSITION Description (Cont’d) DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION GI PROCEDURE NAAT0042S01 SAT014K SCIA5358E SAT021J CAUTION: 쐌 Always drive vehicle at a safe speed. 쐌 Be careful not to rev engine into the red zone on the tachometer. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. TESTING CONDITIONS: Always drive vehicle on a level road to improve the accuracy of test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) Start engine and select “DATA MONITOR” mode for “A/T” with CONSULT-II. 2) Make sure that output voltage of A/T fluid temperature sensor is within the range below. FLUID TEMP SEN: 0.4 - 1.5V If out of range, drive the vehicle to decrease the voltage (warm up the fluid) or stop engine to increase the voltage (cool down the fluid). 3) Select “2ND GR FNCTN P0732” of “DTC WORK SUPPORT” mode for “A/T” with CONSULT-II and touch “START”. 4) Accelerate vehicle to 25 to 30 km/h (16 to 19 MPH) under the following condition and release the accelerator pedal completely. THROTTLE POSI: Less than 1.0/8 (at all times during step 4) Selector lever: D position (OD “ON”) 쐌 Check that “GEAR” shows “3” or “4” after releasing pedal. 5) Depress accelerator pedal to WOT (more than 7.0/8 of “THROTTLE POSI”) quickly from a speed of 25 to 30 km/h (16 to 19 MPH) until “TESTING” changes to “STOP VEHICLE” or “COMPLETED”. (It will take approximately 3 seconds.) If the check result NG appears on CONSULT-II screen, go to “DIAGNOSTIC PROCEDURE”, AT-136. If “STOP VEHICLE” appears on CONSULT-II screen, go to following step. 쐌 Check that “GEAR” shows “2” when depressing accelerator pedal to WOT. 쐌 If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS” for “ENGINE”. In case a 1st trip DTC other than P0732 is shown, refer to applicable “TROUBLE DIAGNOSIS FOR DTC”. 6) Stop vehicle. 7) Follow the instruction displayed. (Check for normal shifting referring to the table below.) Vehicle condition Gear on actual transmission shift pattern when screen is changed to 1 , 2 , 3 , 4 No malfunction exists 1,2,3,4 Malfunction for P0732 exists. 4,3,3,4 AT-133 MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL IDX DTC P0732 IMPROPER SHIFTING TO 2ND GEAR POSITION Description (Cont’d) 8) Make sure that “OK” is displayed. (If “NG” is displayed, refer to “DIAGNOSTIC PROCEDURE”.) Refer to “DIAGNOSTIC PROCEDURE”, AT-136. Refer to shift schedule, AT-356. With GST Follow the procedure “With CONSULT-II”. AT-134 DTC P0732 IMPROPER SHIFTING TO 2ND GEAR POSITION Wiring Diagram — AT — 2ND Wiring Diagram — AT — 2ND NAAT0191 GI MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL MAT732A AT-135 IDX DTC P0732 IMPROPER SHIFTING TO 2ND GEAR POSITION Diagnostic Procedure Diagnostic Procedure 1 NAAT0043 CHECK SHIFT SOLENOID VALVE 1. Remove control valve assembly. Refer to AT-272. 2. Check shift solenoid valve operation. 쐌 Shift solenoid valve B Refer to “Component Inspection”, AT-137. SAT650I OK or NG OK 䊳 GO TO 2. NG 䊳 Repair or replace shift solenoid valve assembly. 2 CHECK CONTROL VALVE 1. Disassemble control valve assembly. Refer to “Control Valve Assembly”, AT-301. 2. Check to ensure that: 쐌 Valve, sleeve and plug slide along valve bore under their own weight. 쐌 Valve, sleeve and plug are free from burrs, dents and scratches. 쐌 Control valve springs are free from damage, deformation and fatigue. 쐌 Hydraulic line is free from obstacles. SAT367H OK or NG OK 䊳 GO TO 3. NG 䊳 Repair control valve assembly. 3 CHECK DTC Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-133. OK or NG OK 䊳 INSPECTION END NG 䊳 Check control valve again. Repair or replace control valve assembly. AT-136 DTC P0732 IMPROPER SHIFTING TO 2ND GEAR POSITION Component Inspection Component Inspection NAAT0044 SHIFT SOLENOID VALVE B 쐌 NAAT0044S01 For removal, refer to AT-272. MA Resistance Check 쐌 NAAT0044S0101 Check resistance between terminal 2 and ground. Solenoid valve Shift solenoid valve B GI Terminal No. 2 Ground EM Resistance (Approx.) 20 - 40Ω LC SAT651I Operation Check 쐌 EC NAAT0044S0102 Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal 2 and ground. FE CL MT SAT650I TF PD AX SU BR ST RS BT HA SC EL IDX AT-137 DTC P0733 IMPROPER SHIFTING TO 3RD GEAR POSITION Description Description 쐌 쐌 쐌 NAAT0045 This is an OBD-II self-diagnostic item and not available in TCM self-diagnosis. This malfunction will not be detected while the O/D OFF indicator lamp is indicating another self-diagnosis malfunction. This malfunction is detected when the A/T does not shift into third gear position as instructed by the TCM. This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction such as control valve sticking, improper solenoid valve operation, malfunctioning servo piston or brake band, etc. Gear position 1 2 3 4 Shift solenoid valve A ON (Closed) OFF (Open) OFF (Open) ON (Closed) Shift solenoid valve B ON (Closed) ON (Closed) OFF (Open) OFF (Open) TCM TERMINALS AND REFERENCE VALUE NAAT0045S02 Remarks: Specification data are reference values. Terminal No. 11 Wire color L/W Item Judgement standard (Approx.) Condition When shift solenoid valve A operates. (When driving in “D1” or “D4”.) Shift solenoid valve A Battery voltage When shift solenoid valve A does not operate. 0V (When driving in “D2” or “D3”.) ON BOARD DIAGNOSIS LOGIC NAAT0045S03 This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM as follows: Torque converter slip ratio = A x C/B A: Output shaft revolution signal from revolution sensor B: Engine speed signal from ECM C: Gear ratio determined as gear position which TCM supposes If the actual gear position is higher than the position (3rd) supposed by TCM, the slip ratio will be more than normal. In case the ratio exceeds the specified value, TCM judges this diagnosis malfunction. This malfunction will be caused when shift solenoid valve A is stuck closed. Gear position supposed by TCM 1 2 3 4 In case of gear position with no malfunctions 1 2 3 4 In case of gear position with shift solenoid valve A stuck closed 1 1 4* 4 *: P0733 is detected. Diagnostic trouble code : A/T 3RD GR FNCTN : P0733 Malfunction is detected when ... A/T cannot be shifted to the 3rd gear position even if electrical circuit is good. AT-138 Check item (Possible cause) 쐌 Shift solenoid valve A 쐌 Each clutch 쐌 Hydraulic control circuit DTC P0733 IMPROPER SHIFTING TO 3RD GEAR POSITION Description (Cont’d) DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION GI PROCEDURE NAAT0045S01 SAT014K SCIA5358E SAT021J CAUTION: 쐌 Always drive vehicle at a safe speed. 쐌 Be careful not to rev engine into the red zone on the tachometer. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. TESTING CONDITIONS: Always drive vehicle on a level road to improve the accuracy of test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) Start engine and select “DATA MONITOR” mode for “A/T” with CONSULT-II. 2) Make sure that output voltage of A/T fluid temperature sensor is within the range below. FLUID TEMP SEN: 0.4 - 1.5V If out of range, drive the vehicle to decrease the voltage (warm up the fluid) or stop engine to increase the voltage (cool down the fluid). 3) Select “3RD GR FNCTN P0733” of “DTC WORK SUPPORT” mode for “A/T” with CONSULT-II and touch “START”. 4) Accelerate vehicle to 35 to 45 km/h (22 to 28 MPH) under the following condition and release the accelerator pedal completely. THROTTLE POSI: Less than 1.0/8 (at all times during step 4) Selector lever: D position (OD “ON”) 쐌 Check that “GEAR” shows “4” after releasing pedal. 5) Depress accelerator pedal steadily with 3.5/8 - 4.5/8 of “THROTTLE POSI” from a speed of 35 to 45 km/h (22 to 28 MPH) until “TESTING” changes to “STOP VEHICLE” or “COMPLETED”. (It will take approximately 3 seconds.) If the check result NG appears on CONSULT-II screen, go to “DIAGNOSTIC PROCEDURE”, AT-142. If “STOP VEHICLE” appears on CONSULT-II screen, go to following step. 쐌 Check that “GEAR” shows “3” when depressing accelerator pedal with 3.5/8 - 4.5/8 of “THROTTLE POSI”. 쐌 If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS” for “ENGINE”. In case a 1st trip DTC other than P0733 is shown, refer to applicable “TROUBLE DIAGNOSIS FOR DTC”. 6) Stop vehicle. 7) Follow the instruction displayed. (Check for normal shifting referring to the table below.) Vehicle condition Gear on actual transmission shift pattern when screen is changed to 1 , 2 , 3 , 4 No malfunction exists. 1,2,3,4 Malfunction for P0733 exists. 1,1,4,4 AT-139 MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL IDX DTC P0733 IMPROPER SHIFTING TO 3RD GEAR POSITION Description (Cont’d) 8) Make sure that “OK” is displayed. (If “NG” is displayed, refer to “DIAGNOSTIC PROCEDURE”.) Refer to “DIAGNOSTIC PROCEDURE”, AT-142. Refer to shift schedule, AT-356. With GST Follow the procedure “With CONSULT-II”. AT-140 DTC P0733 IMPROPER SHIFTING TO 3RD GEAR POSITION Wiring Diagram — AT — 3RD Wiring Diagram — AT — 3RD NAAT0192 GI MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL MAT733A AT-141 IDX DTC P0733 IMPROPER SHIFTING TO 3RD GEAR POSITION Diagnostic Procedure Diagnostic Procedure 1 NAAT0046 CHECK SHIFT SOLENOID VALVE 1. Remove control valve assembly. Refer to AT-272. 2. Check shift solenoid valve operation. 쐌 Shift solenoid valve A Refer to “Component Inspection”, AT-143. SAT653I OK or NG OK 䊳 GO TO 2. NG 䊳 Repair or replace shift solenoid valve assembly. 2 CHECK CONTROL VALVE 1. Disassemble control valve assembly. Refer to “Control Valve Assembly”, AT-301. 2. Check to ensure that: 쐌 Valve, sleeve and plug slide along valve bore under their own weight. 쐌 Valve, sleeve and plug are free from burrs, dents and scratches. 쐌 Control valve springs are free from damage, deformation and fatigue. 쐌 Hydraulic line is free from obstacles. SAT367H OK or NG OK 䊳 GO TO 3. NG 䊳 Repair control valve assembly. 3 CHECK DTC Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-139. OK or NG OK 䊳 INSPECTION END NG 䊳 Check control valve again. Repair or replace control valve assembly. AT-142 DTC P0733 IMPROPER SHIFTING TO 3RD GEAR POSITION Component Inspection Component Inspection NAAT0047 SHIFT SOLENOID VALVE A 쐌 NAAT0047S01 For removal, refer to AT-272. MA Resistance Check 쐌 NAAT0047S0101 Check resistance between terminal 3 and ground. Solenoid valve Shift solenoid valve A GI Terminal No. 3 Ground EM Resistance (Approx.) 20 - 40Ω LC SAT654I Operation Check 쐌 EC NAAT0047S0102 Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal 3 and ground. FE CL MT SAT653I TF PD AX SU BR ST RS BT HA SC EL IDX AT-143 DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION Description Description 쐌 쐌 쐌 NAAT0048 This is an OBD-II self-diagnostic item and not available in TCM self-diagnosis. This malfunction will not be detected while the O/D OFF indicator lamp is indicating another self-diagnosis malfunction. This malfunction is detected when the A/T does not shift into fourth gear position or the torque converter clutch does not lock up as instructed by the TCM. This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction such as control valve sticking, improper solenoid valve operation, malfunctioning oil pump or torque converter clutch, etc. CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE NAAT0048S04 Remarks: Specification data are reference values. Monitor item Condition Specification Line pressure solenoid valve duty Small throttle opening (Low line pressure) " Large throttle opening (High line pressure) Approximately 24% " Approximately 95% Gear position 1 2 3 4 Shift solenoid valve A ON (Closed) OFF (Open) OFF (Open) ON (Closed) Shift solenoid valve B ON (Closed) ON (Closed) OFF (Open) OFF (Open) TCM TERMINALS AND REFERENCE VALUE NAAT0048S02 Remarks: Specification data are reference values. Terminal No. 1 2 11 12 Wire color GY BR/Y L/W L/R Item Line pressure solenoid valve Line pressure solenoid valve (with dropping resistor) Shift solenoid valve A Shift solenoid valve B Condition Judgement standard (Approx.) When releasing accelerator pedal after warm1.5 - 3.0V ing up engine. When depressing accelerator pedal fully after warming up engine. 0V When releasing accelerator pedal after warm5 - 14V ing up engine. When depressing accelerator pedal fully after warming up engine. 0V When shift solenoid valve A operates. (When driving in “D1” or “D4”.) Battery voltage When shift solenoid valve A does not operate. 0V (When driving in “D2” or “D3”.) When shift solenoid valve B operates. (When driving in “D1” or “D2”.) Battery voltage When shift solenoid valve B does not operate. 0V (When driving in “D3” or “D4”.) AT-144 DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION Description (Cont’d) ON BOARD DIAGNOSIS LOGIC =NAAT0048S03 This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM as follows: Torque converter slip ratio = A x C/B A: Output shaft revolution signal from revolution sensor B: Engine speed signal from ECM C: Gear ratio determined as gear position which TCM supposes If the actual gear position is much lower than the position (4th) supposed by TCM, the slip ratio will be much less than normal. In case the ratio does not reach the specified value, TCM judges this diagnosis malfunction. This malfunction will be caused when shift solenoid valve B, line pressure solenoid valve are stuck closed and shift solenoid valve A is stuck open. Gear position supposed by TCM 1 2 3 4 In case of gear position with no malfunctions 1 2 3 4 In case of gear position with shift solenoid valve B stuck closed 1 2 2 1* *: P0734 is detected. Diagnostic trouble code GI MA EM LC EC FE CL MT Malfunction is detected when ... : A/T 4TH GR FNCTN A/T cannot be shifted to the 4th gear position even if electrical circuit is good. : P0734 Check item (Possible cause) 쐌 쐌 쐌 쐌 쐌 Shift solenoid valve A Shift solenoid valve B Line pressure solenoid valve Each clutch Hydraulic control circuit TF PD AX SU BR ST RS BT HA SC EL IDX AT-145 DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION Description (Cont’d) DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NAAT0048S01 SAT014K SCIA5358E SAT021J CAUTION: 쐌 Always drive vehicle at a safe speed. 쐌 Be careful not to rev engine into the red zone on the tachometer. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. TESTING CONDITIONS: Always drive vehicle on a level road to improve the accuracy of test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) Start engine and select “DATA MONITOR” mode for “A/T” with CONSULT-II. 2) Make sure that output voltage of A/T fluid temperature sensor is within the range below. FLUID TEMP SEN: 0.4 - 1.5V If out of range, drive the vehicle to decrease the voltage (warm up the fluid) or stop engine to increase the voltage (cool down the fluid). 3) Select “4TH GR FNCTN P0734” of “DTC WORK SUPPORT” mode for “A/T” with CONSULT-II and touch “START”. 4) Accelerate vehicle to 55 to 65 km/h (34 to 40 MPH) under the following condition and release the accelerator pedal completely. THROTTLE POSI: Less than 5.5/8 (at all times during step 4) Selector lever: D position (OD “ON”) 쐌 Check that “GEAR” shows “3” after releasing pedal. 5) Depress accelerator pedal steadily with 1.0/8 - 2.0/8 of “THROTTLE POSI” from a speed of 55 to 65 km/h (34 to 40 MPH) until “TESTING” has turned to “STOP VEHICLE” or “COMPLETED”. (It will take approximately 3 seconds.) If the check result NG appears on CONSULT-II screen, go to “DIAGNOSTIC PROCEDURE”, AT-149. If “STOP VEHICLE” appears on CONSULT-II screen, go to following step. 쐌 Check that “GEAR” shows “4” when depressing accelerator pedal with 1.0/8 - 2.0/8 of “THROTTLE POSI”. 쐌 If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS” for “ENGINE”. In case a 1st trip DTC other than P0734 is shown, refer to applicable “TROUBLE DIAGNOSIS FOR DTC”. 6) Stop vehicle. 7) Follow the instruction displayed. (Check for normal shifting referring to the table below.) Vehicle condition Gear on actual transmission shift pattern when screen is changed to 1 , 2 , 3 , 4 No malfunction exists 1,2,3,4 Malfunction for P0734 exists. 1,2,2,1 AT-146 DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION Description (Cont’d) 8) Make sure that “OK” is displayed. (If “NG” is displayed, refer to “DIAGNOSTIC PROCEDURE”.) Refer to “DIAGNOSTIC PROCEDURE”, AT-149. Refer to shift schedule, AT-356. With GST Follow the procedure “With CONSULT-II”. GI MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL IDX AT-147 DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION Wiring Diagram — AT — 4TH Wiring Diagram — AT — 4TH NAAT0193 MAT912A AT-148 DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION Diagnostic Procedure Diagnostic Procedure 1 NAAT0049 GI CHECK SHIFT UP (D3 TO D4) MA During “Cruise test — Part 1”, AT-73. Does A/T shift from D3 to D4 at the specified speed? EM LC EC FE SAT988H Yes or No Yes 䊳 GO TO 9. No 䊳 GO TO 2. 2 CL MT CHECK LINE PRESSURE Perform line pressure test. Refer to AT-64. OK or NG OK 䊳 GO TO 3. NG 䊳 GO TO 6. TF PD AX SU BR ST RS BT HA SC EL IDX AT-149 DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION Diagnostic Procedure (Cont’d) 3 CHECK SOLENOID VALVES 1. Remove control valve assembly. Refer to AT-272. 2. Refer to “Component Inspection”, AT-153. SAT158J OK or NG OK 䊳 GO TO 4. NG 䊳 Replace solenoid valve assembly. 4 CHECK CONTROL VALVE 1. Disassemble control valve assembly. Refer to AT-301. 2. Check to ensure that: 쐌 Valve, sleeve and plug slide along valve bore under their own weight. 쐌 Valve, sleeve and plug are free from burrs, dents and scratches. 쐌 Control valve springs are free from damage, deformation and fatigue. 쐌 Hydraulic line is free from obstacles. SAT367H OK or NG OK 䊳 GO TO 5. NG 䊳 Repair control valve. AT-150 DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION Diagnostic Procedure (Cont’d) 5 GI CHECK SHIFT UP (D3 TO D4) Does A/T shift from D3 to D4 at the specified speed? MA Yes or No Yes 䊳 GO TO 9. No 䊳 Check control valve again. Repair or replace control valve assembly. 6 EM CHECK LINE PRESSURE SOLENOID VALVE LC 1. Remove control valve assembly. Refer to AT-272. 2. Refer to “Component Inspection”, AT-153. EC FE CL MT TF PD AX SAT158J OK or NG OK 䊳 GO TO 7. NG 䊳 Replace solenoid valve assembly. SU BR ST RS BT HA SC EL IDX AT-151 DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION Diagnostic Procedure (Cont’d) 7 CHECK CONTROL VALVE 1. Disassemble control valve assembly. Refer to AT-301. 2. Check line pressure circuit valves for sticking. 쐌 Pressure regulator valve 쐌 Pilot valve 쐌 Pressure modifier valve SAT367H OK or NG OK 䊳 GO TO 8. NG 䊳 Repair control valve. 8 CHECK SHIFT UP (D3 TO D4) Does A/T shift from D3 to D4 at the specified speed? OK or NG OK 䊳 GO TO 9. NG 䊳 Check control valve again. Repair or replace control valve assembly. 9 CHECK DTC Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-146. OK or NG OK 䊳 INSPECTION END NG 䊳 Perform “Cruise test — Part 1” again and return to the start point of this flow chart. AT-152 DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION Component Inspection Component Inspection NAAT0050 SOLENOID VALVES 쐌 NAAT0050S01 For removal, refer to AT-272. MA Resistance Check 쐌 NAAT0050S0101 Check resistance between terminals (3, 2 or 6) and ground. Solenoid valve GI Terminal No. Shift solenoid valve A 3 Shift solenoid valve B 2 Line pressure solenoid valve 6 EM Resistance (Approx.) 20 - 40Ω LC 2.5 - 5Ω EC Ground FE CL MT SAT159J Operation Check 쐌 NAAT0050S0102 Check solenoid valve by listening for its operating sound while applying battery voltage to the terminals (3, 2 or 6) and ground. TF PD AX SU BR ST RS BT SAT158J HA SC EL IDX AT-153 DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE Description Description NAAT0051 The torque converter clutch solenoid valve is activated, with the gear in “D4”, by the TCM in response to signals sent from the vehicle speed and throttle position sensors. Lock-up piston operation will then be controlled. Lock-up operation, however, is prohibited when A/T fluid temperature is too low. When the accelerator pedal is depressed (less than 2/8) in lock-up condition, the engine speed should not change abruptly. If there is a big jump in engine speed, there is no lock-up. SAT342HA CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE NAAT0051S02 Remarks: Specification data are reference values. Monitor item Torque converter clutch solenoid valve duty Condition Specification Lock-up “OFF” " Lock-up “ON” Approximately 4% " Approximately 94% TCM TERMINALS AND REFERENCE VALUE NAAT0051S03 Remarks: Specification data are reference values. Terminal No. 3 Wire color Item G/OR Torque converter clutch solenoid valve Judgement standard (Approx.) Condition When A/T performs lock-up. 8 - 15V When A/T does not perform lock-up. 0V ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : TCC SOLENOID/CIRC : P0740 Malfunction is detected when ... TCM detects an improper voltage drop when it tires to operate the solenoid valve. AT-154 NAAT0051S04 Check item (Possible cause) 쐌 Harness or connectors (The solenoid circuit is open or shorted.) 쐌 Torque converter clutch solenoid valve DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE Description (Cont’d) DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION GI PROCEDURE NAAT0051S01 SAT014K PBIB2308E NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) Turn ignition switch “ON”. 2) Select “DATA MONITOR” mode for “ENGINE” with CONSULT-II and wait at least 1 second. 3) Start engine and maintain the following conditions for at least 5 consecutive seconds. VHCL SPEED SE: 80 km/h (50 MPH) or more THROTTLE POSI: 0.5/8 - 1.0/8 Selector lever: D position Driving location: Driving the vehicle uphill (increased engine load) will help maintain the driving conditions required for this test. With GST Follow the procedure “With CONSULT-II”. MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL IDX AT-155 DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE Wiring Diagram — AT — TCV Wiring Diagram — AT — TCV NAAT0194 MAT735A AT-156 DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE Diagnostic Procedure Diagnostic Procedure 1 NAAT0052 GI CHECK VALVE RESISTANCE MA 1. Turn ignition switch to “OFF” position. 2. Disconnect terminal cord assembly connector on the right side of transfer assembly. 3. Check resistance between terminal 7 and ground. EM LC EC FE SAT156J Is resistance approx. 10 - 20Ω? Yes 䊳 GO TO 3. No 䊳 GO TO 2. 2 MT CHECK VALVE OPERATION 1. Remove oil pan. Refer to AT-272. 2. Check the following items: 쐌 Torque converter clutch solenoid valve Refer to “Component Inspection”, AT-158. 쐌 Harness of terminal cord assembly for short or open TF OK or NG OK 䊳 GO TO 3. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. 3 PD AX SU CHECK RESISTANCE 1. Turn ignition switch to “OFF” position. 2. Disconnect TCM harness connector. 3. Check resistance between terminal 7 and TCM harness connector terminal 3. Refer to wiring diagram — AT — TCV. Continuity should exist. If OK, check harness for short to ground and short to power. 4. Reinstall any part removed. OK or NG OK 䊳 GO TO 4. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. 4 CL BR ST RS BT CHECK DTC Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-155. HA OK or NG OK 䊳 INSPECTION END NG 䊳 GO TO 5. SC EL IDX AT-157 DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE Diagnostic Procedure (Cont’d) 5 CHECK TCM INSPECTION 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK 䊳 INSPECTION END NG 䊳 Repair or replace damaged parts. Component Inspection NAAT0053 TORQUE CONVERTER CLUTCH SOLENOID VALVENAAT0053S01 쐌 For removal, refer to AT-272. Resistance Check 쐌 NAAT0053S0101 Check resistance between terminal 7 and ground. Solenoid valve Torque converter clutch solenoid valve Terminal No. 7 Ground Resistance (Approx.) 10 - 20Ω SAT160J Operation Check 쐌 NAAT0053S0102 Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal 7 and ground. SAT161J AT-158 DTC P0744 IMPROPER LOCK-UP OPERATION Description Description 쐌 쐌 쐌 Remarks: Specification data are reference values. Monitor item NAAT0054 This is an OBD-II self-diagnostic item and not available in TCM self-diagnosis. This malfunction will not be detected while the O/D OFF indicator lamp is indicating another self-diagnosis malfunction. This malfunction is detected when the A/T does not shift into fourth gear position or the torque converter clutch does not lock up as instructed by the TCM. This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction such as control valve sticking, improper solenoid valve operation, malfunctioning oil pump or torque converter clutch, etc. Specification Torque converter clutch solenoid valve duty Lock-up “OFF” " Lock-up “ON” Approximately 4% " Approximately 94% Line pressure solenoid valve duty Small throttle opening (Low line pressure) " Large throttle opening (High line pressure) Approximately 24% " Approximately 95% 2 GY BR/Y Item Line pressure solenoid valve Line pressure solenoid valve (with dropping resistor) LC EC MT TCM TERMINALS AND REFERENCE VALUE 1 EM CL NAAT0054S03 Remarks: Specification data are reference values. Wire color MA CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE NAAT0054S02 FE Condition Terminal No. GI Condition Judgement standard (Approx.) TF PD When releasing accelerator pedal after warm1.5 - 3.0V ing up engine. AX When depressing accelerator pedal fully after warming up engine. SU 0V When releasing accelerator pedal after warm5 - 14V ing up engine. When depressing accelerator pedal fully after warming up engine. 0V When A/T performs lock-up. 8 - 15V When A/T does not perform lock- up. 0V BR ST 3 G/OR Torque converter clutch solenoid valve ON BOARD DIAGNOSIS LOGIC RS NAAT0054S04 This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM as follows: Torque converter slip ratio = A x C/B A: Output shaft revolution signal from revolution sensor B: Engine speed signal from ECM C: Gear ratio determined as gear position which TCM supposes If the actual gear position is much lower than the position (4th) supposed by TCM, the slip ratio will be much less than normal. In case the ratio does not reach the specified value, TCM judges this BT HA SC EL IDX AT-159 DTC P0744 IMPROPER LOCK-UP OPERATION Description (Cont’d) diagnosis malfunction. This malfunction will be caused when shift solenoid valve B, line pressure solenoid valve and torque converter clutch solenoid valve are stuck closed. Gear position supposed by TCM 1 2 3 4 In case of gear position with no malfunctions 1 2 3 4 In case of gear position with shift solenoid valve B stuck closed 1 2 2 1* *: P0744 is detected. Diagnostic trouble code Malfunction is detected when ... : A/T TCC S/V FNCTN A/T cannot perform lock-up even if electrical circuit is good. : P0744 Check item (Possible cause) 쐌 쐌 쐌 쐌 쐌 Line pressure solenoid valve Torque converter clutch solenoid valve Each clutch Hydraulic control circuit Shift solenoid valve B DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NAAT0054S01 SAT014K SCIA5358E CAUTION: Always drive vehicle at a safe speed. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) Start engine and select “DATA MONITOR” mode for “A/T” with CONSULT-II. 2) Make sure that output voltage of A/T fluid temperature sensor is within the range below. FLUID TEMP SEN: 0.4 - 1.5V If out of range, drive the vehicle to decrease the voltage (warm up the fluid) or stop engine to increase the voltage (cool down the fluid). 3) Select “TCC S/V FNCTN P0744” of “DTC WORK SUPPORT” mode for “A/T” with CONSULT-II and touch “START”. 4) SAT021J 쐌 쐌 Accelerate vehicle to more than 67 to 100 km/h (42 to 62 MPH) and maintain the following condition continuously until “TESTING” has turned to “COMPLETED”. (It will take approximately 30 seconds after “TESTING” shows.) THROTTLE POSI: 1.0/8 - 2.0/8 (at all times during step 4) Selector lever: D position (OD “ON”) TCC S/V DUTY: More than 94% VHCL/S SE·A/T: Constant speed of more than 67 to 100 km/h (42 to 62 MPH) Check that “GEAR” shows “4”. For shift schedule, refer to SDS, AT-356. AT-160 DTC P0744 IMPROPER LOCK-UP OPERATION Description (Cont’d) 쐌 If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS”. In case a 1st trip DTC other than P0744 is shown, refer to applicable “TROUBLE DIAGNOSIS FOR DTC”. 5) Make sure that “OK” is displayed. (If “NG” is displayed, refer to “DIAGNOSTIC PROCEDURE”.) Refer to “DIAGNOSTIC PROCEDURE”, AT-163. Refer to shift schedule, AT-356. With GST Follow the procedure “With CONSULT-II”. GI MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL IDX AT-161 DTC P0744 IMPROPER LOCK-UP OPERATION Wiring Diagram — AT — TCCSIG Wiring Diagram — AT — TCCSIG NAAT0195 MAT913A AT-162 DTC P0744 IMPROPER LOCK-UP OPERATION Diagnostic Procedure Diagnostic Procedure 1 =NAAT0055 GI CHECK SHIFT UP (D3 TO D4) MA During “Cruise test — Part 1”, AT-73. Does A/T shift from D3 to D4 at the specified speed? EM LC EC FE SAT988H CL Yes or No Yes 䊳 쐌 GO TO 10. 쐌 And check for proper lock-up. No 䊳 GO TO 2. 2 MT CHECK LINE PRESSURE Perform line pressure test. Refer to AT-64. TF OK or NG OK 䊳 GO TO 3. NG 䊳 GO TO 6. 3 PD AX CHECK CONTROL VALVE 1. Disassemble control valve assembly. Refer to AT-301. 2. Check to ensure that: 쐌 Valve, sleeve and plug slide along valve bore under their own weight. 쐌 Valve, sleeve and plug are free from burrs, dents and scratches. 쐌 Control valve springs are free from damage, deformation and fatigue. 쐌 Hydraulic line is free from obstacles. SU BR ST RS BT SAT367H HA OK or NG OK 䊳 GO TO 4. NG 䊳 Repair control valve. SC EL IDX AT-163 DTC P0744 IMPROPER LOCK-UP OPERATION Diagnostic Procedure (Cont’d) 4 CHECK SHIFT UP (D3 TO D4) Does A/T shift from D3 to D4 at the specified speed? Yes or No Yes 䊳 GO TO 5. No 䊳 Check control valve again. Repair or replace control valve assembly. 5 CHECK DTC Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-160. OK or NG OK 䊳 INSPECTION END NG 䊳 쐌 GO TO 10. 쐌 And check for proper lock-up. 6 CHECK LINE PRESSURE SOLENOID VALVE 1. Remove control valve assembly. Refer to AT-272. 2. Check line pressure solenoid valve operation. Refer to AT-167. SAT158J OK or NG OK 䊳 GO TO 7. NG 䊳 Replace solenoid valve assembly. AT-164 DTC P0744 IMPROPER LOCK-UP OPERATION Diagnostic Procedure (Cont’d) 7 GI CHECK CONTROL VALVE 1. Disassemble control valve assembly. Refer to AT-301. 2. Check line pressure circuit valves for sticking. 쐌 Pressure regulator valve 쐌 Pilot valve 쐌 Pressure modifier valve MA EM LC EC FE SAT367H CL OK or NG OK 䊳 GO TO 8. NG 䊳 Repair control valve. 8 MT CHECK SHIFT UP (D3 TO D4) Does A/T shift from D3 to D4 at the specified speed? TF Yes or No Yes 䊳 GO TO 9. No 䊳 Check control valve again. Repair or replace control valve assembly. 9 PD AX CHECK DTC Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-160. OK or NG OK 䊳 INSPECTION END NG 䊳 쐌 GO TO 10. 쐌 And check for proper lock-up. SU BR ST 10 CHECK LOCK-UP CONDITION During “Cruise test — Part 1”, AT-73. Does A/T perform lock-up at the specified speed? RS Yes or No Yes 䊳 Perform “Cruise test − Part 1” again and return to the start point of this flow chart. No 䊳 GO TO 11. BT HA 11 CHECK TORQUE CONVERTER CLUTCH SOLENOID VALVE 1. Remove control valve assembly. Refer to AT-272. 2. Check torque converter clutch solenoid valve operation. Refer to AT-167. OK or NG OK 䊳 GO TO 12. NG 䊳 Replace solenoid valve assembly. AT-165 SC EL IDX DTC P0744 IMPROPER LOCK-UP OPERATION Diagnostic Procedure (Cont’d) 12 CHECK CONTROL VALVE 1. Disassemble control valve assembly. Refer to AT-301. 2. Check control valves for sticking. 쐌 Torque converter clutch control valve 쐌 Torque converter clutch relief valve SAT367H OK or NG OK 䊳 GO TO 13. NG 䊳 Repair control valve 13 CHECK LOCK-UP CONDITION Does A/T perform lock-up at the specified speed? Yes or No Yes 䊳 GO TO 14. No 䊳 Check control valve again. Repair or replace control valve assembly. 14 CHECK DTC Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-160. OK or NG OK 䊳 INSPECTION END NG 䊳 Perform “Cruise test — Part 1” again and return to the start point of this flow chart. AT-166 DTC P0744 IMPROPER LOCK-UP OPERATION Component Inspection Component Inspection NAAT0056 SOLENOID VALVES 쐌 NAAT0056S01 For removal, refer to AT-272. MA Resistance Check 쐌 NAAT0056S0101 Check resistance between terminals (6 or 7) and ground. Solenoid valve Line pressure solenoid valve Torque converter clutch solenoid valve GI Terminal No. 6 EM Resistance (Approx.) 2.5 - 5Ω LC Ground 7 10 - 20Ω EC FE CL MT SAT159J Operation Check 쐌 NAAT0056S0102 Check solenoid valve by listening for its operating sound while applying battery voltage to the terminals (6 or 7) and ground. TF PD AX SU BR ST RS BT SAT158J HA SC EL IDX AT-167 DTC P0745 LINE PRESSURE SOLENOID VALVE Description Description NAAT0057 The line pressure solenoid valve regulates the oil pump discharge pressure to suit the driving condition in response to a signal sent from the TCM. The line pressure duty cycle value is not consistent when the closed throttle position switch is “ON”. To confirm the line pressure duty cycle at low pressure, the accelerator (throttle) should be open until the closed throttle position switch is “OFF”. SAT341H CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE NAAT0057S02 Remarks: Specification data are reference values. Monitor item Line pressure solenoid valve duty Condition Specification Small throttle opening (Low line pressure) " Large throttle opening (High line pressure) Approximately 24% " Approximately 95% NOTE: The line pressure duty cycle value is not consistent when the closed throttle position switch is “ON”. To confirm the line pressure duty cycle at low pressure, the accelerator (throttle) should be open until the closed throttle position switch is “OFF”. TCM TERMINALS AND REFERENCE VALUE NAAT0057S03 Remarks: Specification data are reference values. Terminal No. 1 2 Wire color Item GY Line pressure solenoid valve BR/Y Line pressure solenoid valve (with dropping resistor) Judgement standard (Approx.) Condition When releasing accelerator pedal after warm1.5 - 3.0V ing up engine. When depressing accelerator pedal fully after warming up engine. 0V When releasing accelerator pedal after warm5 - 14V ing up engine. When depressing accelerator pedal fully after warming up engine. 0V ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : L/PRESS SOL/CIRC : P0745 Malfunction is detected when ... TCM detects an improper voltage drop when it tries to operate the solenoid valve. AT-168 NAAT0057S04 Check item (Possible cause) 쐌 Harness or connectors (The solenoid circuit is open or shorted.) 쐌 Line pressure solenoid valve DTC P0745 LINE PRESSURE SOLENOID VALVE Description (Cont’d) DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION GI PROCEDURE NAAT0057S01 SAT014K NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode for “ENGINE” with CONSULT-II. 2) Depress accelerator pedal completely and wait at least 1 second. With GST Follow the procedure “With CONSULT-II”. MA EM LC EC FE CL MT PBIB2308E TF PD AX SU BR ST RS BT HA SC EL IDX AT-169 DTC P0745 LINE PRESSURE SOLENOID VALVE Wiring Diagram — AT — LPSV Wiring Diagram — AT — LPSV NAAT0196 MAT914A AT-170 DTC P0745 LINE PRESSURE SOLENOID VALVE Diagnostic Procedure Diagnostic Procedure 1 NAAT0058 GI CHECK VALVE RESISTANCE MA 1. Turn ignition switch to “OFF” position. 2. Disconnect terminal cord assembly connector on the right side of transfer assembly. 3. Check resistance between terminal 6 and ground. EM LC EC FE SAT162J Is resistance approx. 2.5 - 5Ω? Yes 䊳 GO TO 3. No 䊳 GO TO 2. 2 CL MT CHECK VALVE OPERATION 1. Remove control valve assembly. Refer to AT-272. 2. Check the following items: 쐌 Line pressure solenoid valve Refer to “Component Inspection”, AT-173. 쐌 Harness of terminal cord assembly for short or open TF PD OK or NG AX OK 䊳 GO TO 3. NG 䊳 Repair or replace damaged parts. SU BR ST RS BT HA SC EL IDX AT-171 DTC P0745 LINE PRESSURE SOLENOID VALVE Diagnostic Procedure (Cont’d) 3 CHECK POWER SOURCE AND DROPPING RESISTOR CIRCUIT 1. Turn ignition switch to “OFF” position. 2. Disconnect TCM harness connector. 3. Check resistance between sub-harness connector B64 terminal 6 and TCM harness connector M119 terminal 2. SAT522J Is resistance approx. 11.2 - 12.8Ω? Yes 䊳 GO TO 5. No 䊳 GO TO 4. 4 DETECT MALFUNCTIONING ITEM Check the following items: 쐌 Dropping resistor Refer to “Component Inspection”, AT-173. 쐌 Harness for short or open between TCM harness connector M119 terminal 2 and terminal cord assembly (Main harness) OK or NG OK 䊳 GO TO 5. NG 䊳 Repair or replace damaged parts. 5 CHECK POWER SOURCE CIRCUIT 1. Turn ignition switch to “OFF” position. 2. Check continuity between terminal 6 and TCM harness connector M119 terminal 1. Refer to wiring diagram — AT — LPSV. Continuity should exist. If OK, check harness for short to ground or to power. 3. Reinstall any part removed. Yes 䊳 GO TO 6. No 䊳 Repair or replace harness between TCM terminal 1 and terminal cord assembly. AT-172 DTC P0745 LINE PRESSURE SOLENOID VALVE Diagnostic Procedure (Cont’d) 6 GI CHECK DTC Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-169. MA OK or NG OK 䊳 INSPECTION END NG 䊳 GO TO 7. 7 EM CHECK TCM INSPECTION LC 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. EC OK or NG OK 䊳 INSPECTION END NG 䊳 Repair or replace damaged parts. FE CL MT Component Inspection NAAT0059 LINE PRESSURE SOLENOID VALVE 쐌 NAAT0059S01 For removal, refer to AT-272. Resistance Check 쐌 NAAT0059S0101 Check resistance between terminal 6 and ground. Solenoid valve Line pressure solenoid valve Terminal No. 6 Ground TF PD Resistance (Approx.) AX 2.5 - 5Ω SU SAT657I Operation Check 쐌 NAAT0059S0102 Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal 6 and ground. BR ST RS BT SAT658I DROPPING RESISTOR 쐌 Check resistance between two terminals. Resistance: 11.2 - 12.8Ω NAAT0059S02 HA SC EL IDX SAT848BD AT-173 DTC P0750 SHIFT SOLENOID VALVE A Description Description NAAT0060 Shift solenoid valves A and B are turned “ON” or “OFF” by the TCM in response to signals sent from the PNP switch, vehicle speed and throttle position sensors. Gears will then be shifted to the optimum position. SAT341H Gear position 1 2 3 4 Shift solenoid valve A ON (Closed) OFF (Open) OFF (Open) ON (Closed) Shift solenoid valve B ON (Closed) ON (Closed) OFF (Open) OFF (Open) TCM TERMINALS AND REFERENCE VALUE NAAT0060S02 Remarks: Specification data are reference values. Terminal No. 11 Wire color L/W Item Judgement standard (Approx.) Condition When shift solenoid valve A operates. (When driving in “D1” or “D4”.) Shift solenoid valve A Battery voltage When shift solenoid valve A does not operate. 0V (When driving in “D2” or “D3”.) ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : SFT SOL A/CIRC : P0750 Malfunction is detected when ... TCM detects an improper voltage drop when it tires to operate the solenoid valve. NAAT0060S03 Check item (Possible cause) 쐌 Harness or connectors (The solenoid circuit is open or shorted.) 쐌 Shift solenoid valve A DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NAAT0060S01 SAT014K CAUTION: Always drive vehicle at a safe speed. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode for “ENGINE” with CONSULT-II. 2) Start engine. 3) Drive vehicle in “D” position and allow the transmission to shift “1” , “2” (“GEAR”). With GST Follow the procedure “With CONSULT-II”. PBIB2308E AT-174 DTC P0750 SHIFT SOLENOID VALVE A Wiring Diagram — AT — SSV/A Wiring Diagram — AT — SSV/A NAAT0197 GI MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL MAT738A AT-175 IDX DTC P0750 SHIFT SOLENOID VALVE A Diagnostic Procedure Diagnostic Procedure 1 NAAT0061 CHECK VALVE RESISTANCE 1. Turn ignition switch to “OFF” position. 2. Disconnect terminal cord assembly connector on the right side of transfer assembly. 3. Check resistance between terminal 3 and ground. SAT164J Is resistance approx. 20 - 40Ω? Yes 䊳 GO TO 3. No 䊳 GO TO 2. 2 CHECK VALVE OPERATION 1. Remove control valve assembly. Refer to AT-272. 2. Check the following items: 쐌 Shift solenoid valve A Refer to “Component Inspection”, AT-177. 쐌 Harness of terminal cord assembly for short or open OK or NG OK 䊳 GO TO 3. NG 䊳 Repair or replace damaged parts. 3 CHECK POWER SOURCE CIRCUIT 1. Turn ignition switch to “OFF” position. 2. Disconnect TCM harness connector. 3. Check resistance between terminal 3 and TCM harness connector terminal 11. Refer to wiring diagram — AT — SSV/A. Continuity should exist. If OK, check harness for short to ground and short to power. 4. Reinstall any part removed. OK or NG OK 䊳 GO TO 4. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. 4 CHECK DTC Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-174. OK or NG OK 䊳 INSPECTION END NG 䊳 GO TO 5. AT-176 DTC P0750 SHIFT SOLENOID VALVE A Diagnostic Procedure (Cont’d) 5 GI CHECK TCM INSPECTION 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. MA OK or NG OK 䊳 INSPECTION END NG 䊳 Repair or replace damaged parts. EM LC EC Component Inspection NAAT0062 SHIFT SOLENOID VALVE A 쐌 NAAT0062S01 For removal, refer to AT-272. Resistance Check 쐌 NAAT0062S0101 Check resistance between terminal 3 and ground. Solenoid valve Shift solenoid valve A FE Terminal No. 3 Ground CL Resistance (Approx.) 20 - 40Ω MT SAT654I Operation Check 쐌 NAAT0062S0102 Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal 3 and ground. TF PD AX SU SAT653I BR ST RS BT HA SC EL IDX AT-177 DTC P0755 SHIFT SOLENOID VALVE B Description Description NAAT0063 Shift solenoid valves A and B are turned “ON” or “OFF” by the TCM in response to signals sent from the PNP switch, vehicle speed and throttle position sensors. Gears will then be shifted to the optimum position. SAT341H Gear position 1 2 3 4 Shift solenoid valve A ON (Closed) OFF (Open) OFF (Open) ON (Closed) Shift solenoid valve B ON (Closed) ON (Closed) OFF (Open) OFF (Open) TCM TERMINALS AND REFERENCE VALUE NAAT0063S02 Remarks: Specification data are reference values. Terminal No. 12 Wire color L/R Item Judgement standard (Approx.) Condition When shift solenoid valve B operates. (When driving in “D1” or “D2”.) Shift solenoid valve B Battery voltage When shift solenoid valve B does not operate. 0V (When driving in “D3” or “D4”.) ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : SFT SOL B/CIRC : P0755 Malfunction is detected when ... TCM detects an improper voltage drop when it tires to operate the solenoid valve. NAAT0063S03 Check item (Possible cause) 쐌 Harness or connectors (The solenoid circuit is open or shorted.) 쐌 Shift solenoid valve B DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NAAT0063S01 SAT014K CAUTION: Always drive vehicle at a safe speed. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode for “ENGINE” with CONSULT-II. 2) Drive vehicle in “D” position and allow the transmission to shift 1 , 2 , 3 (“GEAR”). With GST Follow the procedure “With CONSULT-II”. PBIB2308E AT-178 DTC P0755 SHIFT SOLENOID VALVE B Wiring Diagram — AT — SSV/B Wiring Diagram — AT — SSV/B NAAT0198 GI MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL MAT739A AT-179 IDX DTC P0755 SHIFT SOLENOID VALVE B Diagnostic Procedure Diagnostic Procedure 1 NAAT0064 CHECK VALVE RESISTANCE 1. Turn ignition switch to “OFF” position. 2. Disconnect terminal cord assembly connector on the right side of transfer assembly. 3. Check resistance between terminal 2 and ground. SAT166J Is resistance approx. 20 - 40Ω? Yes 䊳 GO TO 3. No 䊳 GO TO 2. 2 CHECK VALVE OPERATION 1. Remove control valve assembly. Refer to AT-272. 2. Check the following items: 쐌 Shift solenoid valve B Refer to “Component Inspection”, AT-181. 쐌 Harness of terminal cord assembly for short or open OK or NG OK 䊳 GO TO 3. NG 䊳 Repair or replace damaged parts. 3 CHECK POWER SOURCE CIRCUIT 1. Turn ignition switch to “OFF” position. 2. Disconnect TCM harness connector. 3. Check resistance between terminal 2 and TCM harness connector terminal 12. Refer to wiring diagram — AT — SSV/B. Continuity should exist. If OK, check harness for short to ground and short to power. 4. Reinstall any part removed. Is resistance approx. 0Ω? Yes 䊳 GO TO 4. No 䊳 Repair open circuit or short to ground or short to power in harness or connectors. 4 CHECK DTC Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-178. OK or NG OK 䊳 INSPECTION END NG 䊳 GO TO 5. AT-180 DTC P0755 SHIFT SOLENOID VALVE B Diagnostic Procedure (Cont’d) 5 GI CHECK TCM INSPECTION 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. MA OK or NG OK 䊳 INSPECTION END NG 䊳 Repair or replace damaged parts. EM LC EC Component Inspection NAAT0065 SHIFT SOLENOID VALVE B 쐌 NAAT0065S01 For removal, refer to AT-272. Resistance Check 쐌 NAAT0065S0101 Check resistance between terminal 2 and ground. Solenoid valve Shift solenoid valve B FE Terminal No. 2 Ground CL Resistance (Approx.) 20 - 40Ω MT SAT651I Operation Check 쐌 NAAT0065S0102 Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal 2 and ground. TF PD AX SU SAT650I BR ST RS BT HA SC EL IDX AT-181 DTC P1705 ACCELERATOR PEDAL POSITION SENSOR (THROTTLE POSITION SENSOR) Description Description NAAT0236 The accelerator pedal position sensor is part of the system that controls throttle position. Accelerator pedal position signal is sent to the ECM. And the signal is also sent to TCM as throttle valve position signal. SAT516KA CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE NAAT0236S01 Remarks: Specification data are reference values. Monitor item Accelerator pedal position sensor (throttle position sensor) Condition Specification Fully-closed throttle Approximately 0.5V Fully-open throttle Approximately 4V TCM TERMINALS AND REFERENCE VALUE NAAT0236S02 Remarks: Specification data are reference values. Terminal No. Wire color 32 R 41 P/L 42 B Item Condition Judgement standard (Approx.) Ignition switch ON. 4.5 - 5.5V Ignition switch OFF. 0V When depressing accelerator pedal slowly after warming up engine. (Voltage rises gradually in response to throttle position.) Fully-closed throttle: 0.5V Fully-open throttle: 4V Sensor power Accelerator pedal position sensor (throttle position sensor) Sensor ground — AT-182 0V DTC P1705 ACCELERATOR PEDAL POSITION SENSOR (THROTTLE POSITION SENSOR) On Board Diagnosis Logic On Board Diagnosis Logic =NAAT0237 Diagnostic trouble code TP SEN/CIRC A/T with CONSULT-II or P1705 without CONSULT-II is detected when TCM receives an excessively low or high voltage from the ECM. GI MA EM LC Possible Cause EC NAAT0239 Check the following items. 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Accelerator pedal position sensor (throttle position sensor) FE CL MT TF PD AX SU BR ST RS BT HA SC EL IDX AT-183 DTC P1705 ACCELERATOR PEDAL POSITION SENSOR (THROTTLE POSITION SENSOR) Diagnostic Trouble Code (DTC) Confirmation Procedure Diagnostic Trouble Code (DTC) Confirmation Procedure NAAT0240 CAUTION: Always drive vehicle at a safe speed. NOTE: If “DTC Confirmation Procedure” has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. After the repair, perform the following procedure to confirm the malfunction is eliminated. SAT014K WITH CONSULT-II 1) SCIA5358E 2) 3) SAT014K 4) NAAT0240S01 Turn ignition switch ON and select “DATA MONITOR” mode for “A/T” with CONSULT-II. Accelerator pedal condition Accelerator pedal position sensor (THRTL POS SEN) Fully released Less than 4.7V Partially depressed 0.1 - 4.6V Fully depressed 1.9 - 4.6V If the check result is NG, go to “DIAGNOSTIC PROCEDURE”, AT-224. If the check result is OK, go to following step. Turn ignition switch ON and select “DATA MONITOR” mode for “ENGINE” with CONSULT-II. Start engine and maintain the following conditions for at least 3 consecutive seconds. Then release accelerator pedal completely. VHCL SPEED SE: 10 km/h (6 MPH) or more THRTL POS SEN (electric throttle control actuator): Approximately 3V or less Selector lever: D position If the check result is NG, go to “DIAGNOSTIC PROCEDURE”, AT-224. If the check result is OK, go to following step. Maintain the following conditions for at least 3 consecutive seconds. Then release accelerator pedal completely. VHCL SPEED SE: 10 km/h (6 MPH) or more Accelerator pedal: Wide open throttle Selector lever: D position WITH GST Follow the procedure “With CONSULT-II”. PBIB2308E AT-184 NAAT0240S02 DTC P1705 ACCELERATOR PEDAL POSITION SENSOR (THROTTLE POSITION SENSOR) Wiring Diagram — AT — TPS Wiring Diagram — AT — TPS NAAT0199 GI MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL MAT316B AT-185 IDX DTC P1705 ACCELERATOR PEDAL POSITION SENSOR (THROTTLE POSITION SENSOR) Diagnostic Procedure Diagnostic Procedure 1 NAAT0241 CHECK DTC WITH ECM 쐌 Check P code with CONSULT-II “ENGINE”. Turn ignition switch ON and select “SELF DIAGNOSTIC RESULTS” mode for “ENGINE” with CONSULT-II. Refer to EC-174, “Malfunction Indicator Lamp (MIL)”. OK or NG OK (with CONSULT-II) 䊳 GO TO 2. OK (without CONSULTII) 䊳 GO TO 3. NG 䊳 Check accelerator pedal position sensor (throttle position sensor) circuit for engine control. Refer to EC-603, “DTC P0226 APP SENSOR”. 2 CHECK INPUT SIGNAL (With CONSULT-II) With CONSULT-II 1. Turn ignition switch to ON position. (Do not start engine.) 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “THRTL POS SEN”. Voltage: Fully-closed throttle: Approximately 0.5V Fully-open throttle: Approximately 4V SAT614J OK or NG OK 䊳 GO TO 4. NG 䊳 Check harness for short or open between ECM and TCM regarding accelerator pedal position sensor (throttle position sensor) circuit. (Main harness) AT-186 DTC P1705 ACCELERATOR PEDAL POSITION SENSOR (THROTTLE POSITION SENSOR) Diagnostic Procedure (Cont’d) 3 GI CHECK INPUT SIGNAL (Without CONSULT-II) Without CONSULT-II 1. Turn ignition switch to ON position. (Do not start engine.) 2. Check voltage between TCM harness connector M120 terminals 41 (P/L) and 42 (B) while accelerator pedal is depressed slowly. MA EM LC EC FE SAT349JB Voltage: Fully-closed throttle valve: Approximately 0.5V Fully-open throttle valve: Approximately 4V (Voltage rises gradually in response to throttle position.) CL MT OK or NG OK 䊳 GO TO 4. NG 䊳 Check harness for short or open between ECM and TCM regarding accelerator pedal position sensor (throttle position sensor) circuit. (Main harness) 4 TF PD CHECK DTC Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-205. OK or NG OK 䊳 INSPECTION END NG 䊳 GO TO 5. 5 AX SU CHECK TCM INSPECTION BR 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK 䊳 INSPECTION END NG 䊳 Repair or replace damaged parts. ST RS BT HA SC EL IDX AT-187 DTC P1760 OVERRUN CLUTCH SOLENOID VALVE Description Description NAAT0068 The overrun clutch solenoid valve is activated by the TCM in response to signals sent from the park/neutral position (PNP) switch, overdrive control switch, vehicle speed and throttle position sensors. The overrun clutch operation will then be controlled. SAT341H TCM TERMINALS AND REFERENCE VALUE NAAT0068S02 Remarks: Specification data are reference values. Terminal No. 20 Wire color L/B Item Judgement standard (Approx.) Condition Overrun clutch solenoid valve When overrun clutch solenoid valve operates. Battery voltage When overrun clutch solenoid valve does not operate. 0V ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : O/R CLTCH SOL/CIRC : P1760 Malfunction is detected when ... TCM detects an improper voltage drop when it tries to operate the solenoid valve. NAAT0068S03 Check item (Possible cause) 쐌 Harness or connectors (The solenoid circuit is open or shorted.) 쐌 Overrun clutch solenoid valve DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NAAT0068S01 SAT014K SCIA5358E CAUTION: Always drive vehicle at a safe speed. NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. TESTING CONDITION: Always drive vehicle on a level road to improve accuracy of test. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode for “ENGINE” with CONSULT-II. 2) Start engine. 3) Accelerate vehicle to a speed of more than 10 km/h (6MPH) in “D” position (OD “ON”). 4) Release accelerator pedal completely in “D” position (OD “OFF”). AT-188 DTC P1760 OVERRUN CLUTCH SOLENOID VALVE Description (Cont’d) With GST Follow the procedure “With CONSULT-II”. GI MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL IDX AT-189 DTC P1760 OVERRUN CLUTCH SOLENOID VALVE Wiring Diagram — AT — OVRCSV Wiring Diagram — AT — OVRCSV NAAT0200 MAT741A AT-190 DTC P1760 OVERRUN CLUTCH SOLENOID VALVE Diagnostic Procedure Diagnostic Procedure 1 NAAT0069 GI CHECK VALVE RESISTANCE MA 1. Turn ignition switch to “OFF” position. 2. Disconnect terminal cord assembly connector on the right side of transfer assembly. 3. Check resistance between terminal 4 and ground. EM LC EC FE SAT170J Is resistance approx. 20 - 40Ω? Yes 䊳 GO TO 3. No 䊳 GO TO 2. 2 CL MT CHECK VALVE OPERATION 1. Remove control valve assembly. Refer to AT-272. 2. Check the following items: 쐌 Overrun clutch solenoid valve Refer to “Component Inspection”, AT-192. 쐌 Harness of terminal cord assembly for short or open TF PD OK or NG AX OK 䊳 GO TO 3. NG 䊳 Repair or replace damaged parts. SU 3 CHECK POWER SOURCE CIRCUIT 1. Turn ignition switch to “OFF” position. 2. Disconnect TCM harness connector. 3. Check resistance between terminal 4 and TCM harness connector terminal 20. Refer to wiring diagram — AT — OVRCSV. Continuity should exist. If OK, check harness for short to ground and short to power. 4. Reinstall any part removed. BR ST RS OK or NG OK 䊳 GO TO 4. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. 4 BT HA CHECK DTC Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-188. OK or NG OK 䊳 INSPECTION END NG 䊳 GO TO 5. SC EL IDX AT-191 DTC P1760 OVERRUN CLUTCH SOLENOID VALVE Diagnostic Procedure (Cont’d) 5 CHECK TCM INSPECTION 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK 䊳 INSPECTION END NG 䊳 Repair or replace damaged parts. Component Inspection NAAT0070 OVERRUN CLUTCH SOLENOID VALVE 쐌 NAAT0070S01 For removal, refer to AT-272. Resistance Check 쐌 NAAT0070S0101 Check resistance between terminal 4 and ground. Solenoid valve Overrun clutch solenoid valve Terminal No. 4 Ground Resistance (Approx.) 20 - 40Ω SAT139K Operation Check 쐌 NAAT0070S0102 Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal 4 and ground. SAT688I AT-192 DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) Description Description NAAT0172 The A/T fluid temperature sensor detects the A/T fluid temperature and sends a signal to the TCM. GI MA EM LC SAT342HA EC FE CL MT SAT021J CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE NAAT0172S02 Remarks: Specification data are reference values. Monitor item Condition A/T fluid temperature sensor Specification Cold [20°C (68°F)] " Hot [80°C (176°F)] Approximately 1.5V " Approximately 0.5V Approximately 2.5 kΩ " Approximately 0.3 kΩ TCM TERMINALS AND REFERENCE VALUE 10 19 28 Wire color W/R W/R R/Y Judgement standard (Approx.) Condition When turning ignition switch to “ON”. Battery voltage When turning ignition switch to “OFF”. 0V Power source Same as No. 10 or B Throttle position sensor (Ground) 47 R A/T fluid temperature sensor BR ST RS When turning ignition switch to “OFF”. Battery voltage When turning ignition switch to “ON”. Battery voltage Power source (Memory back-up) 42 AX SU Item Power source PD NAAT0172S03 Remarks: Specification data are reference values. Terminal No. TF BT HA — 0V When ATF temperature is 20°C (68°F). 1.5V When ATF temperature is 80°C (176°F). 0.5V SC EL IDX AT-193 DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) Description (Cont’d) ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : BATT/FLUID TEMP SEN : 8th judgement flicker Malfunction is detected when ... TCM receives an excessively low or high voltage from the sensor. NAAT0172S04 Check item (Possible cause) 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 A/T fluid temperature sensor DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NAAT0172S01 After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) Start engine. 2) Select “DATA MONITOR” mode for “A/T” with CONSULT-II. 3) Drive vehicle under the following conditions: Selector lever in “D” position, vehicle speed higher than 20 km/h (12 MPH). SAT014K SCIA5358E No Tools Start engine. Drive vehicle under the following conditions: Selector lever in “D” position, vehicle speed higher than 20 km/h (12 MPH). 3) Perform self-diagnosis. Refer to TCM SELF-DIAGNOSTIC PROCEDURE (No Tools), AT-48. 1) 2) SAT674I AT-194 DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) Wiring Diagram — AT — BA/FTS Wiring Diagram — AT — BA/FTS NAAT0201 GI MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL MAT317B AT-195 IDX DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) Diagnostic Procedure Diagnostic Procedure 1 NAAT0173 INSPECTION START Do you have CONSULT-II? Yes or No Yes 䊳 GO TO 2. No 䊳 GO TO 6. 2 CHECK INPUT SIGNAL OF A/T FLUID TEMPERATURE SENSOR (WITH CONSULT-II) With CONSULT-II 1. Start engine. 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “FLUID TEMP SE”. Voltage: Cold [20°C (68°F)] → Hot [80°C (176°F)]: Approximately 1.5V → 0.5V SAT614J OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 3. 3 DETECT MALFUNCTIONING ITEM Check the following items: 쐌 Harness for short to ground or short to power or open between TCM, ECM and terminal cord assembly (Main harness) 쐌 Ground circuit for ECM. Refer to EC-165, “Wiring Diagram”. OK or NG OK 䊳 GO TO 4. NG 䊳 Repair or replace damaged parts. AT-196 DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) Diagnostic Procedure (Cont’d) 4 GI CHECK A/T FLUID TEMPERATURE SENSOR WITH TERMINAL CORD ASSEMBLY 1. Turn ignition switch to “OFF” position. 2. Disconnect terminal cord assembly connector on the right side of transfer assmebly. 3. Check resistance between terminals 8 and 9 when A/T is cold [20°C (68°F)]. MA EM LC EC FE SAT697I Is resistance approx. 2.5 kΩ? Yes 䊳 GO TO 7. No 䊳 GO TO 5. 5 CL MT DETECT MALFUNCTIONING ITEM 1. Remove oil pan. 2. Check the following items: 쐌 A/T fluid temperature sensor Refer to “Component Inspection”, AT-116. 쐌 Harness of terminal cord assembly for short or open TF OK or NG PD AX OK 䊳 GO TO 7. NG 䊳 Repair or replace damaged parts. 6 CHECK INPUT SIGNAL OF A/T FLUID TEMPERATURE SENSOR (WITHOUT CONSULT-II) SU Without CONSULT-II 1. Start engine. 2. Check voltage between TCM harness connector M120 terminal 47 and ground while warming up A/T. Voltage: Cold [20°C (68°F)] → Hot [80°C (176°F)]: Approximately 1.5V → 0.5V BR ST RS BT HA SAT518J OK or NG OK 䊳 GO TO 11. NG 䊳 GO TO 3. SC EL IDX AT-197 DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) Diagnostic Procedure (Cont’d) 7 CHECK TCM POWER SOURCE STEP 1 1. Turn ignition switch to ON position. (Do not start engine.) 2. Check voltage between TCM harness connector M119, M120 terminals 10, 19, 28 and ground. SAT611J OK or NG OK 䊳 GO TO 8. NG 䊳 GO TO 9. 8 CHECK TCM POWER SOURCE STEP 2 1. Turn ignition switch to OFF position. 2. Check voltage between TCM harness connector M120 terminal 28 and ground. SAT612JC OK or NG OK 䊳 GO TO 10. NG 䊳 GO TO 9. 9 DETECT MALFUNCTIONING ITEM Check the following items: 쐌 Harness for short or open between ignition switch and TCM terminals 10, 19 and 28 (Main harness) 쐌 Ignition switch and 10A or 7.5A fuse [No. 18 or 24, located in the fuse block (J/B)] Refer to EL-11, “Schematic”. OK or NG OK 䊳 GO TO 10. NG 䊳 Repair or replace damaged parts. AT-198 DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) Diagnostic Procedure (Cont’d) 10 GI CHECK TCM GROUND CIRCUIT 1. Turn ignition switch to OFF position. 2. Disconnect TCM harness connector. 3. Check continuity between TCM terminals 25, 48 and ground. Refer to wiring diagram — AT — MAIN. Continuity should exist. If OK, check harness for short to ground and short to power. MA EM OK or NG OK 䊳 GO TO 11. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. 11 LC EC CHECK DTC Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-112. FE OK or NG OK 䊳 INSPECTION END NG 䊳 GO TO 12. 12 CL MT CHECK TCM INSPECTION 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK 䊳 INSPECTION END NG 䊳 Repair or replace damaged parts. TF PD AX SU Component Inspection NAAT0174 A/T FLUID TEMPERATURE SENSOR 쐌 쐌 NAAT0174S01 For removal, refer to AT-272. Check resistance between terminals 8 and 9 while changing temperature as shown at left. Temperature °C (°F) Resistance 20 (68) Approximately 2.5 kΩ 80 (176) Approximately 0.3 kΩ BR ST RS BT SAT687I HA SC EL IDX AT-199 DTC VEHICLE SPEED SENSOR·MTR Description Description NAAT0071 The vehicle speed sensor·MTR is built into the speedometer assembly. The sensor functions as an auxiliary device to the revolution sensor when it is malfunctioning. The TCM will then use a signal sent from the vehicle speed sensor·MTR. TCM TERMINALS AND REFERENCE VALUE NAAT0071S02 Remarks: Specification data are reference values. Terminal No. 40 Wire color W/L Item Judgement standard (Approx.) Condition Vehicle speed sensor When moving vehicle at 2 to 3 km/h (1 to 2 MPH) for 1 m (3 ft) or more. Voltage varies between less than 1V and more than 4.5V ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : VHCL SPEED SEN·MTR : 2nd judgement flicker Malfunction is detected when ... TCM does not receive the proper voltage signal from the sensor. NAAT0071S03 Check item (Possible cause) 쐌 Harness or connectors (The sensor circuit is open or shorted.) 쐌 Vehicle speed sensor DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NAAT0071S01 SAT014K CAUTION: 쐌 Always drive vehicle at a safe speed. 쐌 If conducting this “DTC CONFIRMATION PROCEDURE” again, always turn ignition switch “OFF” and wait at least 5 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode for “A/T” with CONSULT-II. 2) Start engine and accelerate vehicle from 0 to 25 km/h (0 to 6 MPH). SCIA5358E AT-200 DTC VEHICLE SPEED SENSOR·MTR Description (Cont’d) No Tools Start engine. Drive vehicle under the following conditions: Selector lever in “D” position and vehicle speed higher than 25 km/h (16 MPH). 3) Perform self-diagnosis. Refer to TCM SELF-DIAGNOSTIC PROCEDURE (No Tools), AT-48. 1) 2) GI MA EM LC SAT668I EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL IDX AT-201 DTC VEHICLE SPEED SENSOR·MTR Wiring Diagram — AT — VSSMTR Wiring Diagram — AT — VSSMTR NAAT0202 MAT318B AT-202 DTC VEHICLE SPEED SENSOR·MTR Diagnostic Procedure Diagnostic Procedure 1 NAAT0072 GI CHECK INPUT SIGNAL. MA With CONSULT-II 1. Start engine. 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “VHCL/S SE·MTR” while driving. Check the value changes according to driving speed. EM LC EC FE CL SAT614J Without CONSULT-II 1. Start engine. 2. Check voltage between TCM harness connector M120 terminal 40 and ground while driving at 2 to 3 km/h (1 to 2 MPH) for 1 m (3 ft) or more. MT TF PD AX SAT528J Does battery voltage vary between less than 1V and more than 4.5V? Yes 䊳 GO TO 3. No 䊳 GO TO 2. 2 BR DETECT MALFUNCTIONING ITEM Check the following items: 쐌 Vehicle speed sensor and ground circuit for vehicle speed sensor Refer to EL-35, “Component Parts and Harness Connector Location”. 쐌 Harness for short or open between TCM and vehicle speed sensor (Main harness) 쐌 Harness for short or open between ABS actuator and electrical unit and combination meter HA GO TO 3. NG 䊳 Repair or replace damaged parts. CHECK DTC Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-200. OK or NG 䊳 INSPECTION END NG 䊳 GO TO 4. RS BT 䊳 OK ST OK or NG OK 3 SU SC EL IDX AT-203 DTC VEHICLE SPEED SENSOR·MTR Diagnostic Procedure (Cont’d) 4 CHECK TCM INSPECTION 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK 䊳 INSPECTION END NG 䊳 Repair or replace damaged parts. AT-204 DTC U1000 CAN COMMUNICATION LINE Description Description NAAT0242 CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control units transmits/receives data but selectively reads required data only. TCM TERMINALS AND REFERENCE VALUE NAAT0242S01 GI MA EM LC EC Remarks: Specification data are reference values. Judgement standard (Approx.) Terminal No. Wire color 5 L CAN (high) — — — 6 R CAN (low) — — — Item Condition FE CL MT *: This terminal is connected to the ECM. On Board Diagnosis Logic NAAT0243 Diagnostic trouble code CAN COMM CIRCUIT or U1000 with CONSULT-II or 12th judgement flicker without CONSULT-II is detected when TCM cannot communicate to other control unit. TF PD AX SU Possible Cause Check harness or connector. (CAN communication line is open or shorted.) NAAT0244 BR ST RS BT HA SC EL IDX AT-205 DTC U1000 CAN COMMUNICATION LINE Diagnostic Trouble Code (DTC) Confirmation Procedure Diagnostic Trouble Code (DTC) Confirmation Procedure NAAT0245 After the repair, perform the following procedure to confirm the malfunction is eliminated. WITH CONSULT-II 1) 2) 3) SAT014K WITHOUT CONSULT-II 1) 2) 3) NAAT0245S01 Turn ignition switch “ON”. Select “DATA MONITOR” mode for “A/T” with CONSULT-II. Wait at least 6 seconds or start engine and wait for at least 6 seconds. NAAT0245S02 Turn ignition switch “ON”. Wait at least 6 seconds or start engine and wait at least 6 seconds. Perform self-diagnosis. Refer to TCM SELF-DIAGNOSTIC PROCEDURE (NO TOOLS), AT-48. SCIA5358E SAT683K AT-206 DTC U1000 CAN COMMUNICATION LINE Wiring Diagram — AT — CAN Wiring Diagram — AT — CAN NAAT0246 GI MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL MAT320B AT-207 IDX DTC U1000 CAN COMMUNICATION LINE Diagnostic Procedure Diagnostic Procedure 1 NAAT0247 CHECK CAN COMMUNICATION CIRCUIT With CONSULT-II 1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Select “SELF-DIAG RESULTS” mode for “A/T” with CONSULT-II. 3. The “CAN COMM CIRCUIT” is detected. PCIA0061E Yes or No? Yes 䊳 Print out CONSULT-II screen, go to EL-447, “CAN Communication Unit”. No 䊳 INSPECTION END AT-208 DTC TURBINE REVOLUTION SENSOR Description Description NAAT0224 The turbine revolution sensor detects input shaft rpm (revolutions per minute). It is located on the input side of the automatic transmission. The vehicle speed sensor A/T (Revolution sensor) is located on the output side of the automatic transmission. With the two sensors, input and output shaft rpms are accurately detected. The result is optimal shift timing during deceleration and improved shifting. GI MA EM LC EC FE CL MT SAT136K TCM TERMINALS AND REFERENCE VALUE NAAT0224S01 Remarks: Specification data are reference values. Terminal No. 38 Wire color W Item Turbine revolution sensor (Measure in AC range) Judgement standard (Approx.) Condition When engine is running at 1,000 rpm 1.2V Voltage rises gradually in response to engine speed. TF PD AX SU 42 B Sensor ground — 0V ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : TURBINE REV : 10th judgement flicker Malfunction is detected when ... BR ST NAAT0224S02 Check item (Possible cause) 쐌 Harness or connectors TCM does not receive the proper voltage (The sensor circuit is open or shorted.) signal from the sensor. 쐌 Turbine revolution sensor RS BT HA SC EL IDX AT-209 DTC TURBINE REVOLUTION SENSOR Description (Cont’d) DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NAAT0224S03 SAT014K SCIA5358E CAUTION: 쐌 Always drive vehicle at a safe speed. 쐌 If conducting this “DTC CONFIRMATION PROCEDURE” again, always turn ignition switch “OFF” and wait at least 5 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. With CONSULT-II 1) Start engine. 2) Select “DATA MONITOR” mode for “A/T” with CONSULT-II. 3) Drive vehicle under the following conditions: Selector lever in “D”, vehicle speed higher than 40 km/h (25 MPH), engine speed higher than 1,500 rpm, throttle opening greater than 1.0/8 of the full throttle position and driving for more than 5 seconds. No Tools 1) Start engine. 2) Drive vehicle under the following conditions: Selector lever in “D”, vehicle speed higher than 40 km/h (25 MPH), engine speed higher than 1,500 rpm, throttle opening greater than 1/8 of the full throttle position and driving for more than 5 seconds. 3) Perform self-diagnosis. Refer to TCM SELF-DIAGNOSTIC PROCEDURE (No Tools), AT-48. SAT635I AT-210 DTC TURBINE REVOLUTION SENSOR Wiring Diagram — AT — TRSA/T Wiring Diagram — AT — TRSA/T NAAT0225 GI MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL MAT319B AT-211 IDX DTC TURBINE REVOLUTION SENSOR Diagnostic Procedure Diagnostic Procedure 1 NAAT0226 CHECK INPUT SIGNAL With CONSULT-II 1. Start engine. 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “TURBINE REV”. Check the value changes according to engine speed. SAT740J Without CONSULT-II 1. Start engine. 2. Check voltage between TCM harness connector M120 terminal 38 and ground. (Measure in AC range.) SAT140K OK or NG OK 䊳 GO TO 3. NG 䊳 GO TO 2. 2 DETECT MALFUNCTIONING ITEM Check harness for short or open between TCM and turbine revolution sensor. OK or NG OK 䊳 GO TO 3. NG 䊳 Repair or replace damaged parts. 3 CHECK DTC Perform Diagnostic Trouble Code (DTC) confirmation procedure, AT-210. OK or NG OK 䊳 INSPECTION END NG 䊳 GO TO 4. AT-212 DTC TURBINE REVOLUTION SENSOR Diagnostic Procedure (Cont’d) 4 GI CHECK TCM INSPECTION 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminal for damage or loose connection with harness connector. MA OK or NG OK 䊳 INSPECTION END NG 䊳 Repair or replace damaged parts. EM LC EC Component Inspection NAAT0227 TURBINE REVOLUTION SENSOR 쐌 NAAT0227S01 Check resistance between terminals 1, 2 and 3. Terminal No. FE Resistance (Approx.) 1 2 2.4 - 2.8 kΩ 1 3 No continuity 2 3 No continuity CL MT TF PD AX SU SAT141K BR ST RS BT HA SC EL IDX AT-213 DTC CONTROL UNIT (RAM), CONTROL UNIT (ROM) Description Description NAAT0207 The TCM consists of a microcomputer and connectors for signal input and output and for power supply. The unit controls the A/T. SAT574J ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : CONTROL UNIT (RAM) : CONTROL UNIT (ROM) Malfunction is detected when ... TCM memory (RAM) or (ROM) is malfunctioning. NAAT0207S01 Check item (Possible cause) TCM DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NAAT0207S02 SAT014K NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode for A/T with CONSULT-II. 2) Start engine. 3) Run engine for at least 2 seconds at idle speed. SCIA5358E AT-214 DTC CONTROL UNIT (RAM), CONTROL UNIT (ROM) Diagnostic Procedure Diagnostic Procedure 1 =NAAT0208 GI CHECK DTC With CONSULT-II 1. Turn ignition switch “ON” and select “SELF DIAG RESULTS” mode for A/T with CONSULT-II. 2. Touch “ERASE”. PERFORM DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE. See previous page. Is the “CONTROL UNIT (RAM) or CONTROL UNIT (ROM)” displayed again? Yes 䊳 Replace TCM. No 䊳 INSPECTION END MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL IDX AT-215 DTC CONTROL UNIT (EEP ROM) Description Description NAAT0215 The TCM consists of a microcomputer and connectors for signal input and output and for power supply. The unit controls the A/T. SAT574J ON BOARD DIAGNOSIS LOGIC Diagnostic trouble code : CONT UNIT (EEP ROM) Malfunction is detected when ... TCM memory (EEP ROM) is malfunctioning. NAAT0215S01 Check item (Possible cause) TCM DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE NAAT0215S02 SAT014K NOTE: If “DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch “OFF” and wait at least 5 seconds before conducting the next test. With CONSULT-II 1) Turn ignition switch “ON” and select “DATA MONITOR” mode for A/T with CONSULT-II. 2) Start engine. 3) Run engine for at least 2 seconds at idle speed. SCIA5358E AT-216 DTC CONTROL UNIT (EEP ROM) Diagnostic Procedure Diagnostic Procedure 1 =NAAT0216 GI CHECK DTC With CONSULT-II 1. Turn ignition switch “ON” and select “SELF DIAG RESULTS” mode for A/T with CONSULT-II. 2. Move selector lever to “R” position. 3. Depress accelerator pedal (Full throttle position). 4. Touch “ERASE”. 5. Turn ignition switch “OFF” position for 10 seconds. PERFORM DIAGNOSTIC TROUBLE CODE (DTC) CONFIRMATION PROCEDURE. See previous page. Is the “CONTROL UNIT (EEP ROM)” displayed again? Yes 䊳 Replace TCM. No 䊳 INSPECTION END MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL IDX AT-217 TROUBLE DIAGNOSES FOR SYMPTOMS Wiring Diagram — AT — NONDTC Wiring Diagram — AT — NONDTC NAAT0203 MAT321B AT-218 TROUBLE DIAGNOSES FOR SYMPTOMS Wiring Diagram — AT — NONDTC (Cont’d) GI MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL MAT241B IDX AT-219 TROUBLE DIAGNOSES FOR SYMPTOMS Wiring Diagram — AT — NONDTC (Cont’d) MAT229B AT-220 TROUBLE DIAGNOSES FOR SYMPTOMS O/D OFF Indicator Lamp Does Not Come On O/D OFF Indicator Lamp Does Not Come On NAAT0073 SYMPTOM: O/D OFF indicator lamp does not come on for about 2 seconds when turning ignition switch to “ON”. 1 CHECK TCM POWER SOURCE STEP 1 GI MA EM 1. Turn ignition switch to ON position. (Do not start engine.) 2. Check voltage between TCM harness connector M119, M120 terminals 10, 19, 28 and ground. LC EC FE CL SAT611J OK or NG OK 䊳 GO TO 2. NG 䊳 GO TO 3. 2 MT TF CHECK TCM POWER SOURCE STEP 2 1. Turn ignition switch to OFF position. 2. Check voltage between TCM harness connector M120 terminal 28 and ground. PD AX SU BR SAT612JC ST OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 3. 3 RS BT DETECT MALFUNCTIONING ITEM Check the following items: 쐌 Harness for short or open between ignition switch and TCM harness connector M119, M120 terminals 10, 19 and 28 (Main harness) 쐌 Ignition switch and 10A or 7.5A fuse [No. 18 or 24, located in the fuse block (J/B)] Refer to EL-11, “Schematic”. HA SC OK or NG OK 䊳 GO TO 4. NG 䊳 Repair or replace damaged parts. EL IDX AT-221 TROUBLE DIAGNOSES FOR SYMPTOMS O/D OFF Indicator Lamp Does Not Come On (Cont’d) 4 CHECK TCM GROUND CIRCUIT 1. Turn ignition switch to OFF position. 2. Disconnect TCM harness connector. 3. Check continuity between TCM harness connector M120 terminals 25, 48 and ground. Refer to wiring diagram — AT — MAIN. Continuity should exist. If OK, check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 5. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. 5 CHECK MALFUNCTIONING ITEM Check the following items: 쐌 Fuse 쐌 O/D OFF indicator lamp 쐌 Harness for short or open between ignition switch and O/D OFF indicator lamp 쐌 Harness for short or open between O/D OFF indicator lamp and TCM OK or NG Yes 䊳 GO TO 6. No 䊳 Repair or replace damaged parts. 6 CHECK SYMPTOM Check again. OK or NG OK 䊳 INSPECTION END NG 䊳 GO TO 7. 7 CHECK TCM INSPECTION 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK 䊳 INSPECTION END NG 䊳 Repair or replace damaged parts. AT-222 TROUBLE DIAGNOSES FOR SYMPTOMS Engine Cannot Be Started In “P” and “N” Position Engine Cannot Be Started In “P” and “N” Position GI =NAAT0074 SYMPTOM: Engine cannot be started with selector lever in “P” or “N” position. Engine cannot be started with selector lever in “P”Engine can be started with selector lever in “D”, “2”, “1” or “R” position. 1 CHECK PNP SWITCH CIRCUIT MA EM LC With CONSULT-II Does “TCM INPUT SIGNALS” in Data Monitor show damage to PNP switch circuit? EC Without CONSULT-II Does self-diagnosis show damage to PNP switch circuit? FE CL MT SAT367J TF Yes or No Yes 䊳 Check PNP switch circuit. Refer to “DTC P0705”, AT-105. No 䊳 GO TO 2. 2 PD CHECK PNP SWITCH INSPECTION AX Check for short or open of PNP switch 2-pin connector. Refer to “Components Inspection”, AT-109. SU BR ST RS SAT838BB OK or NG OK 䊳 GO TO 3. NG 䊳 Repair or replace PNP switch. 3 BT HA CHECK STARTING SYSTEM Check starting system. Refer to SC-10, “System Description”. SC OK or NG EL OK 䊳 INSPECTION END NG 䊳 Repair or replace damaged parts. IDX AT-223 TROUBLE DIAGNOSES FOR SYMPTOMS In “P” Position, Vehicle Moves Forward Or Backward When Pushed In “P” Position, Vehicle Moves Forward Or Backward When Pushed =NAAT0075 SYMPTOM: Vehicle moves when it is pushed forward or backward with selector lever in “P” position. 1 CHECK PARKING COMPONENTS Check parking components. Refer to “Parking Pawl Components”, AT-337. SAT133B OK or NG OK 䊳 INSPECTION END NG 䊳 Repair or replace damaged parts. AT-224 TROUBLE DIAGNOSES FOR SYMPTOMS In “N” Position, Vehicle Moves In “N” Position, Vehicle Moves =NAAT0076 SYMPTOM: Vehicle moves forward or backward when selecting “N” position. 1 CHECK PNP SWITCH CIRCUIT GI MA EM With CONSULT-II Does “TCM INPUT SIGNALS” in Data Monitor show damage to PNP switch circuit? LC Without CONSULT-II Does self-diagnosis show damage to PNP switch circuit? EC FE CL MT SAT367J Yes or No Yes 䊳 Check PNP switch circuit. Refer to “DTC P0705”, AT-105. No 䊳 GO TO 2. 2 TF CHECK CONTROL LINKAGE PD Check control linkage. Refer to AT-275. AX SU BR SAT032G ST OK or NG OK 䊳 GO TO 3. NG 䊳 Adjust control linkage. Refer to AT-275. RS BT HA SC EL IDX AT-225 TROUBLE DIAGNOSES FOR SYMPTOMS In “N” Position, Vehicle Moves (Cont’d) 3 CHECK A/T FLUID LEVEL Check A/T fluid level again. SAT638A OK or NG OK 䊳 GO TO 4. NG 䊳 Refill ATF. 4 CHECK A/T FLUID CONDITION 1. Remove oil pan. 2. Check A/T fluid condition. SAT171B OK or NG OK 䊳 GO TO 5. NG 䊳 1. Disassemble A/T. 2. Check the following items: 쐌 Forward clutch assembly 쐌 Overrun clutch assembly 쐌 Reverse clutch assembly 5 CHECK SYMPTOM Check again. OK or NG OK 䊳 INSPECTION END NG 䊳 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. AT-226 TROUBLE DIAGNOSES FOR SYMPTOMS Large Shock. “N” → “R” Position Large Shock. “N” → “R” Position =NAAT0077 SYMPTOM: There is large shock when changing from “N” to “R” position. 1 GI MA CHECK SELF-DIAGNOSTIC RESULTS Does self-diagnosis show damage to A/T fluid temperature sensor, line pressure solenoid valve or accelerator pedal position sensor circuit? EM LC EC FE SAT579IC CL Yes or No Yes 䊳 Check damaged circuit. Refer to “DTC P0710, DTC P0745 or DTC P1705”, AT-111, 168 or 182. No 䊳 GO TO 2. 2 CHECK ACCELERATOR PEDAL POSITION SENSOR (THROTTLE POSITION SENSOR) MT TF Check accelerator pedal position sensor (throttle position sensor). Refer to EC section. PD AX SU BR SAT516KA OK or NG OK 䊳 GO TO 3. NG 䊳 Repair or replace accelerator pedal position sensor (throttle position sensor). ST RS BT HA SC EL IDX AT-227 TROUBLE DIAGNOSES FOR SYMPTOMS Large Shock. “N” → “R” Position (Cont’d) 3 CHECK LINE PRESSURE Check line pressure at idle with selector lever in “D” position. Refer to “LINE PRESSURE TEST”, AT-64. SAT494G OK or NG OK 䊳 GO TO 4. NG 䊳 1. Remove control valve assembly. Refer to AT-272. 2. Check the following items: 쐌 Valves to control line pressure (Pressure regulator valve, pressure modifier valve, pilot valve and pilot filter) 쐌 Line pressure solenoid valve 4 CHECK SYMPTOM Check again. OK or NG OK 䊳 INSPECTION END NG 䊳 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. AT-228 TROUBLE DIAGNOSES FOR SYMPTOMS Vehicle Does Not Creep Backward In “R” Position Vehicle Does Not Creep Backward In “R” Position GI =NAAT0078 SYMPTOM: Vehicle does not creep backward when selecting “R” position. 1 CHECK A/T FLUID LEVEL MA EM Check A/T fluid level again. LC EC FE SAT638A OK or NG OK 䊳 GO TO 2. NG 䊳 Refill ATF. 2 CL MT CHECK STALL TEST TF Check stall revolution with selector lever in “1” and “R” positions. Refer to AT-356. PD AX SU BR SAT493G OK or NG OK 䊳 GO TO 3. OK in “1” position, NG in “R” position 䊳 1. Remove control valve assembly. Refer to “ON-VEHICLE SERVICE”, AT-272. 2. Check the following items: 쐌 Valves to control line pressure (Pressure regulator valve, pressure modifier valve, pilot valve and pilot filter) 쐌 Line pressure solenoid valve 3. Disassemble A/T. 4. Check the following items: 쐌 Oil pump assembly 쐌 Torque converter 쐌 Reverse clutch assembly 쐌 High clutch assembly NG in both “1” and “R” positions 䊳 ST RS BT HA SC GO TO 6. EL IDX AT-229 TROUBLE DIAGNOSES FOR SYMPTOMS Vehicle Does Not Creep Backward In “R” Position (Cont’d) 3 CHECK LINE PRESSURE Check line pressure at idle with selector lever in “R” position. Refer to “LINE PRESSURE TEST”, AT-64. SAT494G OK or NG OK 䊳 GO TO 4. NG 䊳 1. Remove control valve assembly. Refer to “ON-VEHICLE SERVICE”, AT-272. 2. Check the following items: 쐌 Valves to control line pressure (Pressure regulator valve, pressure modifier valve, pilot valve and pilot filter) 쐌 Line pressure solenoid valve 3. Disassemble A/T. 4. Check the following items: 쐌 Oil pump assembly 4 CHECK A/T FLUID CONDITION 1. Remove oil pan. 2. Check A/T fluid condition. SAT171B OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 6. 5 CHECK SYMPTOM Check again. OK or NG OK 䊳 INSPECTION END NG 䊳 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. AT-230 TROUBLE DIAGNOSES FOR SYMPTOMS Vehicle Does Not Creep Backward In “R” Position (Cont’d) 6 GI DETECT MALFUNCTIONING ITEM 1. Remove control valve assembly. Refer to “ON-VEHICLE SERVICE”, AT-272. 2. Check the following items: 쐌 Valves to control line pressure (Pressure regulator valve, pressure modifier valve, pilot valve and pilot filter) 쐌 Line pressure solenoid valve 3. Disassemble A/T. 4. Check the following items: 쐌 Oil pump assembly 쐌 Torque converter 쐌 Reverse clutch assembly 쐌 High clutch assembly 쐌 Low & reverse brake assembly 쐌 Low one-way clutch 䊳 MA EM LC EC Repair or replace damaged parts. FE CL MT TF PD AX SU BR ST RS BT HA SC EL IDX AT-231 TROUBLE DIAGNOSES FOR SYMPTOMS Vehicle Does Not Creep Forward In “D”, “2” Or “1” Position Vehicle Does Not Creep Forward In “D”, “2” Or “1” Position =NAAT0079 SYMPTOM: Vehicle does not creep forward when selecting “D”, “2” or “1” position. 1 CHECK A/T FLUID LEVEL Check A/T fluid level again. SAT638A OK or NG OK 䊳 GO TO 2. NG 䊳 Refill ATF. 2 CHECK STALL TEST Check stall revolution with selector lever in “D” position. Refer to “STALL TEST”, AT-61. SAT493G OK or NG OK 䊳 GO TO 3. NG 䊳 GO TO 6. AT-232 TROUBLE DIAGNOSES FOR SYMPTOMS Vehicle Does Not Creep Forward In “D”, “2” Or “1” Position (Cont’d) 3 GI CHECK LINE PRESSURE Check line pressure at idle with selector lever in “R” position. Refer to “LINE PRESSURE TEST”, AT-64. MA EM LC EC SAT494G OK or NG OK 䊳 GO TO 4. NG 䊳 1. Remove control valve assembly. Refer to AT-272. 2. Check the following items: 쐌 Valves to control line pressure (Pressure regulator valve, pressure modifier valve, pilot valve and pilot filter) 쐌 Line pressure solenoid valve 3. Disassemble A/T. 4. Check the following items: 쐌 Oil pump assembly 4 CHECK A/T FLUID CONDITION FE CL MT TF PD 1. Remove oil pan. 2. Check A/T fluid condition. AX SU BR ST SAT171B OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 6. 5 RS BT CHECK SYMPTOM HA Check again. OK or NG OK 䊳 INSPECTION END NG 䊳 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. SC EL IDX AT-233 TROUBLE DIAGNOSES FOR SYMPTOMS Vehicle Does Not Creep Forward In “D”, “2” Or “1” Position (Cont’d) 6 DETECT MALFUNCTIONING ITEM 1. Remove control valve assembly. Refer to “ON-VEHICLE SERVICE”, AT-272. 2. Check the following items: 쐌 Valves to control line pressure (Pressure regulator valve, pressure modifier valve, pilot valve and pilot filter) 쐌 Line pressure solenoid valve 3. Disassemble A/T. 4. Check the following items: 쐌 Oil pump assembly 쐌 Forward clutch assembly 쐌 Forward one-way clutch 쐌 Low one-way clutch 쐌 Low & reverse brake assembly 쐌 Torque converter 䊳 Repair or replace damaged parts. AT-234 TROUBLE DIAGNOSES FOR SYMPTOMS Vehicle Cannot Be Started From D1 Vehicle Cannot Be Started From D1 =NAAT0080 SYMPTOM: Vehicle cannot be started from D1 on Cruise test — Part 1. 1 GI MA CHECK SYMPTOM Is “Vehicle Does Not Creep Backward In “R” Position” OK? EM Yes or No Yes 䊳 GO TO 2. No 䊳 Go to “Vehicle Does Not Creep Backward In “R” Position”, AT-229. 2 LC EC CHECK SELF-DIAGNOSTIC RESULTS Does self-diagnosis show damage to vehicle speed sensor·A/T (revolution sensor), shift solenoid valve A, B or vehicle speed sensor·MTR after cruise test? FE CL MT SAT686I TF Yes or No Yes 䊳 Check damaged circuit. Refer to “DTC P0720, DTC P0750, DTC P0755 or VEHICLE SPEED SENSOR. MTR”, AT-117, 174, 178 or 200. PD No 䊳 GO TO 3. AX 3 CHECK ACCELERATOR PEDAL POSITION SENSOR (THROTTLE POSITION SENSOR) SU Check accelerator pedal position sensor (throttle position sensor). Refer to EC section. BR ST RS SAT516KA OK or NG OK 䊳 GO TO 4. NG 䊳 Repair or replace accelerator pedal position sensor (throttle position sensor). BT HA SC EL IDX AT-235 TROUBLE DIAGNOSES FOR SYMPTOMS Vehicle Cannot Be Started From D1 (Cont’d) 4 CHECK LINE PRESSURE Check line pressure at stall point with selector lever in “D” position. Refer to “LINE PRESSURE TEST”, AT-64. SAT494G OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 8. 5 CHECK A/T FLUID CONDITION 1. Remove oil pan. 2. Check A/T fluid condition. SAT171B OK or NG OK 䊳 GO TO 6. NG 䊳 GO TO 8. 6 DETECT MALFUNCTIONING ITEM 1. Remove control valve assembly. Refer to AT-272. 2. Check the following items: 쐌 Shift valve A 쐌 Shift valve B 쐌 Shift solenoid valve A 쐌 Shift solenoid valve B 쐌 Pilot valve 쐌 Pilot filter OK or NG OK 䊳 GO TO 7. NG 䊳 Repair or replace damaged parts. AT-236 TROUBLE DIAGNOSES FOR SYMPTOMS Vehicle Cannot Be Started From D1 (Cont’d) 7 GI CHECK SYMPTOM Check again. OK or NG OK 䊳 INSPECTION END NG 䊳 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. MA EM LC 8 DETECT MALFUNCTIONING ITEM EC 1. Remove control valve assembly. Refer to AT-272. 2. Check the following items: 쐌 Shift valve A 쐌 Shift valve B 쐌 Shift solenoid valve A 쐌 Shift solenoid valve B 쐌 Pilot valve 쐌 Pilot filter 3. Disassemble A/T. 4. Check the following items: 쐌 Forward clutch assembly 쐌 Forward one-way clutch 쐌 Low one-way clutch 쐌 High clutch assembly 쐌 Torque converter 쐌 Oil pump assembly FE CL MT TF OK or NG OK 䊳 GO TO 7. NG 䊳 Repair or replace damaged parts. PD AX SU BR ST RS BT HA SC EL IDX AT-237 TROUBLE DIAGNOSES FOR SYMPTOMS A/T Does Not Shift: D1 → D2 Or Does Not Kickdown: D4 → D2 A/T Does Not Shift: D1 → D2 Or Does Not Kickdown: D4 → D2 =NAAT0081 SYMPTOM: A/T does not shift from D1 to D2 at the specified speed. A/T does not shift from D4 to D2 when depressing accelerator pedal fully at the specified speed. 1 CHECK SYMPTOM Are “Vehicle Does Not Creep Forward In “D”, “2” Or “1” Position” and “Vehicle Cannot Be Started From D1” OK? Yes or No Yes 䊳 GO TO 2. No 䊳 Go to “Vehicle Does Not Creep Forward In “D”, “2” Or “1” Position” and “Vehicle Cannot Be Started From D1”, AT-232, 235. 2 CHECK PNP SWITCH CIRCUIT With CONSULT-II Does “TCM INPUT SIGNALS” in Data Monitor show damage to PNP switch circuit? Without CONSULT-II Does self-diagnosis show damage to PNP switch circuit? SAT705K Yes or No Yes 䊳 Check PNP switch circuit. Refer to “DTC P0705”, AT-105. No 䊳 GO TO 3. 3 CHECK VEHICLE SPEED SENSOR·A/T AND VEHICLE SPEED SENSOR·MTR CIRCUIT Check vehicle speed sensor·A/T (revolution sensor) and vehicle speed sensor·MTR circuit. Refer to “DTC P0720 and VEHICLE SPEED SENSOR·MTR”, AT-117, 200. OK or NG OK 䊳 GO TO 4. NG 䊳 Repair or replace vehicle speed sensor·A/T (revolution sensor) and vehicle speed sensor·MTR circuits. AT-238 TROUBLE DIAGNOSES FOR SYMPTOMS A/T Does Not Shift: D1 → D2 Or Does Not Kickdown: D4 → D2 (Cont’d) 4 GI CHECK ACCELERATOR PEDAL POSITION SENSOR (THROTTLE POSITION SENSOR) Check accelerator pedal position sensor (throttle position sensor). Refer to EC section. MA EM LC EC SAT516KA FE OK or NG OK 䊳 GO TO 5. NG 䊳 Repair or replace accelerator pedal position sensor (throttle position sensor). 5 CL CHECK A/T FLUID CONDITION MT 1. Remove oil pan. 2. Check A/T fluid condition. TF PD AX SAT171B OK or NG OK 䊳 GO TO 6. NG 䊳 GO TO 8. 6 SU BR ST DETECT MALFUNCTIONING ITEM 1. Remove control valve. Refer to AT-272. 2. Check the following items: 쐌 Shift valve A 쐌 Shift solenoid valve A 쐌 Pilot valve 쐌 Pilot filter RS BT OK or NG HA OK 䊳 GO TO 7. NG 䊳 Repair or replace damaged parts. SC EL IDX AT-239 TROUBLE DIAGNOSES FOR SYMPTOMS A/T Does Not Shift: D1 → D2 Or Does Not Kickdown: D4 → D2 (Cont’d) 7 CHECK SYMPTOM Check again. OK or NG OK 䊳 INSPECTION END NG 䊳 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. 8 DETECT MALFUNCTIONING ITEM 1. Remove control valve. Refer to AT-272. 2. Check the following items: 쐌 Shift valve A 쐌 Shift solenoid valve A 쐌 Pilot valve 쐌 Pilot filter 3. Disassemble A/T. 4. Check the following items: 쐌 Servo piston assembly 쐌 Brake band 쐌 Oil pump assembly OK or NG OK 䊳 GO TO 7. NG 䊳 Repair or replace damaged parts. AT-240 TROUBLE DIAGNOSES FOR SYMPTOMS A/T Does Not Shift: D2 → D3 A/T Does Not Shift: D2 → D3 =NAAT0082 SYMPTOM: A/T does not shift from D2 to D3 at the specified speed. 1 GI MA CHECK SYMPTOM Are “Vehicle Does Not Creep Forward In “D”, “2” Or “1” Position” and “Vehicle Cannot Be Started From D1” OK? EM Yes or No Yes 䊳 GO TO 2. No 䊳 Go to “Vehicle Does Not Creep Forward In “D”, “2” Or “1” Position” and “Vehicle Cannot Be Started From D1”, AT-232, 235. LC EC 2 CHECK PNP SWITCH CIRCUIT FE With CONSULT-II Does “TCM INPUT SIGNALS” in Data Monitor show damage to PNP switch circuit? Without CONSULT-II Does self-diagnosis show damage to PNP switch circuit? CL MT TF SAT705K PD Yes or No Yes 䊳 Check PNP switch circuit. Refer to “DTC P0705”, AT-105. No 䊳 GO TO 3. AX SU 3 CHECK ACCELERATOR PEDAL POSITION SENSOR (THROTTLE POSITION SENSOR) BR Check accelerator pedal position sensor (throttle position sensor). Refer to EC section. ST RS BT SAT516KA HA OK or NG OK 䊳 GO TO 4. NG 䊳 Repair or replace accelerator pedal position sensor (throttle position sensor). SC EL IDX AT-241 TROUBLE DIAGNOSES FOR SYMPTOMS A/T Does Not Shift: D2 → D3 (Cont’d) 4 CHECK A/T FLUID CONDITION 1. Remove oil pan. 2. Check A/T fluid condition. SAT171B OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 7. 5 DETECT MALFUNCTIONING ITEM 1. Remove control valve Assembly. Refer to AT-272. 2. Check the following items: 쐌 Shift valve B 쐌 Shift solenoid valve B 쐌 Pilot valve 쐌 Pilot filter OK or NG OK 䊳 GO TO 6. NG 䊳 Repair or replace damaged parts. 6 CHECK SYMPTOM Check again. OK or NG OK 䊳 INSPECTION END NG 䊳 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. AT-242 TROUBLE DIAGNOSES FOR SYMPTOMS A/T Does Not Shift: D2 → D3 (Cont’d) 7 GI DETECT MALFUNCTIONING ITEM 1. Remove control valve Assembly. Refer to AT-272. 2. Check the following items: 쐌 Shift valve B 쐌 Shift solenoid valve B 쐌 Pilot valve 쐌 Pilot filter 3. Disassemble A/T. 4. Check the following items: 쐌 Servo piston assembly 쐌 High clutch assembly 쐌 Oil pump assembly MA EM LC EC OK or NG OK 䊳 GO TO 6. NG 䊳 Repair or replace damaged parts. FE CL MT TF PD AX SU BR ST RS BT HA SC EL IDX AT-243 TROUBLE DIAGNOSES FOR SYMPTOMS A/T Does Not Shift: D3 → D4 A/T Does Not Shift: D3 → D4 =NAAT0083 SYMPTOM: 쐌 A/T does not shift from D3 to D4 at the specified speed. 쐌 A/T must be warm before D3 to D4 shift will occur. 1 CHECK SYMPTOM Are “Vehicle Does Not Creep Forward In “D”, “2” Or “1” Position” and “Vehicle Cannot Be Started From D1” OK? Yes or No Yes 䊳 GO TO 2. No 䊳 Go to “Vehicle Does Not Creep Forward In “D”, “2” Or “1” Position” and “Vehicle Cannot Be Started From D1”, AT-232, 235. 2 CHECK SELF-DIAGNOSTIC RESULTS With CONSULT-II Does self-diagnosis, after cruise test, show damage to any of the following circuits? 쐌 Inhibitor switch 쐌 Overdrive control switch 쐌 A/T fluid temperature sensor 쐌 Revolution sensor 쐌 Shift solenoid valve A or B 쐌 Vehicle speed sensor SAT580I Yes or No Yes 䊳 Check damaged circuit. Refer to “DTC P0705, P0710, P0720, P0750, P0755 or VHCL SPEED SEN·MTR”, AT-105, 111, 117, 174, 178 or 200. No 䊳 GO TO 3. AT-244 TROUBLE DIAGNOSES FOR SYMPTOMS A/T Does Not Shift: D3 → D4 (Cont’d) 3 GI CHECK ACCELERATOR PEDAL POSITION SENSOR (THROTTLE POSITION SENSOR) Check accelerator pedal position sensor (throttle position sensor). Refer to EC section. MA EM LC EC SAT516KA FE OK or NG OK 䊳 GO TO 4. NG 䊳 Repair or replace accelerator pedal position sensor (throttle position sensor). 4 CL CHECK A/T FLUID CONDITION MT 1. Remove oil pan. 2. Check A/T fluid condition. TF PD AX SAT171B OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 7. 5 SU BR ST DETECT MALFUNCTIONING ITEM 1. Remove control valve Assembly. Refer to AT-272. 2. Check the following items: 쐌 Shift valve B 쐌 Overrun clutch control valve 쐌 Shift solenoid valve B 쐌 Pilot valve 쐌 Pilot filter RS BT OK or NG HA SC OK 䊳 GO TO 6. NG 䊳 Repair or replace damaged parts. EL IDX AT-245 TROUBLE DIAGNOSES FOR SYMPTOMS A/T Does Not Shift: D3 → D4 (Cont’d) 6 CHECK SYMPTOM Check again. OK or NG OK 䊳 INSPECTION END NG 䊳 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. 7 DETECT MALFUNCTIONING ITEM 1. Remove control valve Assembly. Refer to AT-272. 2. Check the following items: 쐌 Shift valve B 쐌 Overrun clutch control valve 쐌 Shift solenoid valve B 쐌 Pilot valve 쐌 Pilot filter 3. Disassemble A/T. 4. Check the following items: 쐌 Servo piston assembly 쐌 Brake band 쐌 Torque converter 쐌 Oil pump assembly OK or NG OK 䊳 GO TO 6. NG 䊳 Repair or replace damaged parts. AT-246 TROUBLE DIAGNOSES FOR SYMPTOMS A/T Does Not Perform Lock-up A/T Does Not Perform Lock-up =NAAT0084 SYMPTOM: A/T does not perform lock-up at the specified speed. 1 GI MA CHECK SELF-DIAGNOSTIC RESULTS Does self-diagnosis show damage to torque converter clutch solenoid valve circuit after cruise test? EM LC EC FE SAT581I CL Yes or No Yes 䊳 Check torque converter clutch solenoid valve circuit. Refer to “DTC P0740”, AT-154. No 䊳 GO TO 2. 2 MT CHECK ACCELERATOR PEDAL POSITION SENSOR (THROTTLE POSITION SENSOR) Check accelerator pedal position sensor (throttle position sensor). Refer to EC section. TF PD AX SU SAT516KA OK or NG OK 䊳 GO TO 3. NG 䊳 Repair or replace accelerator pedal position sensor (throttle position sensor). 3 BR ST RS DETECT MALFUNCTIONING ITEM 1. Remove control valve. Refer to AT-272. 2. Check following items: 쐌 Torque converter clutch control valve 쐌 Torque converter relief valve 쐌 Torque converter clutch solenoid valve 쐌 Pilot valve 쐌 Pilot filter BT HA OK or NG SC EL OK 䊳 GO TO 4. NG 䊳 Repair or replace damaged parts. IDX AT-247 TROUBLE DIAGNOSES FOR SYMPTOMS A/T Does Not Perform Lock-up (Cont’d) 4 CHECK SYMPTOM Check again. OK or NG OK 䊳 INSPECTION END NG 䊳 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. AT-248 TROUBLE DIAGNOSES FOR SYMPTOMS A/T Does Not Hold Lock-up Condition A/T Does Not Hold Lock-up Condition =NAAT0085 SYMPTOM: A/T does not hold lock-up condition for more than 30 seconds. 1 GI MA CHECK DIAGNOSTIC RESULTS Does self-diagnosis show damage to engine speed signal circuit after cruise test? EM LC EC FE SAT582I CL Yes or No Yes 䊳 Check engine speed signal circuit. Refer to “DTC P0725”, AT-122. No 䊳 GO TO 2. 2 MT CHECK A/T FLUID CONDITION 1. Remove oil pan. 2. Check A/T fluid condition. TF PD AX SU SAT171B BR OK or NG OK 䊳 GO TO 3. NG 䊳 GO TO 5. ST RS 3 DETECT MALFUNCTIONING ITEM 1. Remove control valve assembly. Refer to AT-272. 2. Check the following items: 쐌 Torque converter clutch control valve 쐌 Pilot valve 쐌 Pilot filter BT HA OK or NG SC OK 䊳 GO TO 4. NG 䊳 Repair or replace damaged parts. EL IDX AT-249 TROUBLE DIAGNOSES FOR SYMPTOMS A/T Does Not Hold Lock-up Condition (Cont’d) 4 CHECK SYMPTOM Check again. OK or NG OK 䊳 INSPECTION END NG 䊳 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. 5 DETECT MALFUNCTIONING ITEM 1. Remove control valve assembly. Refer to AT-272. 2. Check the following items: 쐌 Torque converter clutch control valve 쐌 Pilot valve 쐌 Pilot filter 3. Disassemble A/T. 4. Check torque converter and oil pump assembly. OK or NG OK 䊳 GO TO 4. NG 䊳 Repair or replace damaged parts. AT-250 TROUBLE DIAGNOSES FOR SYMPTOMS Lock-up Is Not Released Lock-up Is Not Released =NAAT0086 SYMPTOM: Lock-up is not released when accelerator pedal is released. 1 GI MA CHECK ACCELERATOR PEDAL POSITION SENSOR CIRCUIT With CONSULT-II Does “TCM INPUT SIGNALS” in Data Monitor show damage to closed throttle position switch circuit? EM Without CONSULT-II Does self-diagnosis show damage to closed throttle position switch circuit? LC EC FE CL SAT705K MT Yes or No Yes 䊳 Check accelerator pedal position sensor circuit. Refer to “DTC P1705”, AT-182. No 䊳 GO TO 2. TF 2 CHECK SYMPTOM Check again. PD OK or NG OK 䊳 INSPECTION END NG 䊳 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. AX SU BR ST RS BT HA SC EL IDX AT-251 TROUBLE DIAGNOSES FOR SYMPTOMS Engine Speed Does Not Return To Idle (Light Braking D4 → D3) Engine Speed Does Not Return To Idle (Light Braking D4 → D3) =NAAT0087 SYMPTOM: 쐌 Engine speed does not smoothly return to idle when A/T shifts from D4 to D3. 쐌 Vehicle does not decelerate by engine brake when turning overdrive control switch OFF. 쐌 Vehicle does not decelerate by engine brake when shifting A/T from “D” to “2” position. 1 CHECK SELF-DIAGNOSTIC RESULTS Does self-diagnosis show damage to overrun clutch solenoid valve circuit after cruise test? SAT583I Yes or No Yes 䊳 Check overrun clutch solenoid valve circuit. Refer to “DTC P1760”, AT-188. No 䊳 GO TO 2. 2 CHECK ACCELERATOR PEDAL POSITION SENSOR (THROTTLE POSITION SENSOR) Check accelerator pedal position sensor (throttle position sensor). Refer to EC section. SAT516KA OK or NG OK 䊳 GO TO 3. NG 䊳 Repair or replace accelerator pedal position sensor (throttle position sensor). AT-252 TROUBLE DIAGNOSES FOR SYMPTOMS Engine Speed Does Not Return To Idle (Light Braking D4 → D3) (Cont’d) 3 GI CHECK A/T FLUID CONDITION 1. Remove oil pan. 2. Check A/T fluid condition. MA EM LC EC SAT171B FE OK or NG OK 䊳 GO TO 4. NG 䊳 GO TO 6. 4 CL MT DETECT MALFUNCTIONING ITEM 1. Remove control valve assembly. Refer to AT-272. 2. Check the following items: 쐌 Overrun clutch control valve 쐌 Overrun clutch reducing valve 쐌 Overrun clutch solenoid valve TF OK or NG OK 䊳 GO TO 5. NG 䊳 Repair or replace damaged parts. PD AX 5 CHECK SYMPTOM Check again. SU OK or NG OK 䊳 INSPECTION END NG 䊳 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. 6 DETECT MALFUNCTIONING ITEM BR ST RS 1. Remove control valve assembly. Refer to AT-272. 2. Check the following items: 쐌 Overrun clutch control valve 쐌 Overrun clutch reducing valve 쐌 Overrun clutch solenoid valve 3. Disassemble A/T. 4. Check the following items: 쐌 Overrun clutch assembly 쐌 Oil pump assembly BT HA SC OK or NG OK 䊳 GO TO 5. NG 䊳 Repair or replace damaged parts. EL IDX AT-253 TROUBLE DIAGNOSES FOR SYMPTOMS Vehicle Does Not Start From D1 Vehicle Does Not Start From D1 NAAT0088 SYMPTOM: Vehicle does not start from D1 on Cruise test — Part 2. 1 CHECK SELF-DIAGNOSTIC RESULTS Does self-diagnosis show damage to vehicle speed sensor·A/T (revolution sensor), shift solenoid valve A, B or vehicle speed sensor·MTR after cruise test? SAT686I Yes or No Yes 䊳 Check damaged circuit. Refer to “DTC P0720, P0750, P0755 or VHCL SPEED SEN·MTR”, AT-117, 174, 178 or 200. No 䊳 GO TO 2. 2 CHECK SYMPTOM Check again. OK or NG OK 䊳 Go to “Vehicle Cannot Be Started From D1”, AT-235. NG 䊳 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. AT-254 TROUBLE DIAGNOSES FOR SYMPTOMS A/T Does Not Shift: D4 → D3, When Overdrive Control Switch “ON” → “OFF” A/T Does Not Shift: D4 → D3, When Overdrive Control Switch “ON” → “OFF” GI SYMPTOM: A/T does not shift from D4 to D3 when changing overdrive control switch to “OFF” position. MA =NAAT0089 1 EM CHECK OVERDRIVE CONTROL SWITCH CIRCUIT With CONSULT-II Does “TCM INPUT SIGNALS” in Data Monitor show damage to overdrive control switch circuit? LC Without CONSULT-II Does self-diagnosis show damage to overdrive control switch circuit? EC FE CL MT SAT705K Yes or No Yes 䊳 Check overdrive control switch circuit. Refer to AT-258. No 䊳 Go to “A/T Does Not Shift: D2 , D3”, AT-241. TF PD AX SU BR ST RS BT HA SC EL IDX AT-255 TROUBLE DIAGNOSES FOR SYMPTOMS A/T Does Not Shift: D3 → 22, When Selector Lever “D” → “2” Position A/T Does Not Shift: D3 → 22, When Selector Lever “D” → “2” Position =NAAT0090 SYMPTOM: A/T does not shift from D3 to 22 when changing selector lever from “D” to “2” position. 1 CHECK PNP SWITCH CIRCUIT With CONSULT-II Does “TCM INPUT SIGNALS” in Data Monitor show damage to PNP switch circuit? Without CONSULT-II Does self-diagnosis show damage to PNP switch circuit? SAT705K Yes or No Yes 䊳 Check PNP switch circuit. Refer to “DTC P0705”, AT-105. No 䊳 Go to “A/T Does Not Shift: D1 , D2 Or Does Not Kickdown: D4 , D2”, AT-238. AT-256 TROUBLE DIAGNOSES FOR SYMPTOMS A/T Does Not Shift: 22 → 11, When Selector Lever “2” → “1” Position A/T Does Not Shift: 22 → 11, When Selector Lever “2” → “1” Position GI =NAAT0091 SYMPTOM: A/T does not shift from 22 to 11 when changing selector lever from “2” to “1” position. 1 MA EM CHECK PNP SWITCH CIRCUIT With CONSULT-II Does “TCM INPUT SIGNALS” in Data Monitor show damage to PNP switch circuit? LC Without CONSULT-II Does self-diagnosis show damage to PNP switch circuit? EC FE CL MT SAT705K Yes or No Yes 䊳 Check PNP switch circuit. Refer to “DTC P0705”, AT-105. No 䊳 GO TO 2. 2 TF PD CHECK SYMPTOM Check again. AX SU BR ST SAT778B OK or NG OK 䊳 INSPECTION END NG 䊳 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. RS BT HA SC EL IDX AT-257 TROUBLE DIAGNOSES FOR SYMPTOMS Vehicle Does Not Decelerate By Engine Brake Vehicle Does Not Decelerate By Engine Brake NAAT0092 SYMPTOM: Vehicle does not decelerate by engine brake when shifting from 22 (12) to 11. 1 CHECK SYMPTOM Is “Vehicle Does Not Creep Backward In “R” Position” OK? Yes or No Yes 䊳 Go to “Engine Speed Does Not Return To Idle (Light Braking D4 , D3)”, AT-252. No 䊳 Go to “Vehicle Does Not Creep Backward In “R” Position”, AT-229. TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control and Accelerator Pedal Position Sensor Circuit Checks) NAAT0204 SYMPTOM: O/D OFF indicator lamp does not come on in TCM self-diagnostic procedure even the lamp circuit is good. DESCRIPTION 쐌 쐌 쐌 NAAT0204S01 PNP switch The PNP switch assemble includes a transmission range switch. The transmission range switch detects the selector position and sends a signal to the TCM. Overdrive control switch Detects the overdrive control switch position (ON or OFF) and sends a signal to the TCM. Closed throttle position signal and wide-open throttle position signal ECM judges throttle opening based on a signal from accelerator pedal position sensor, and sends the signal via CAN communication to TCM. SAT136K SAT341I SAT516KA AT-258 TROUBLE DIAGNOSES FOR SYMPTOMS TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control and Accelerator Pedal Position Sensor Circuit Checks) (Cont’d) DIAGNOSTIC PROCEDURE =NAAT0204S03 NOTE: The diagnostic procedure includes inspections for the overdrive control and throttle position switch circuits. 1 GI MA INSPECTION START EM Do you have CONSULT-II? Yes or No Yes (With CONSULT-II) 䊳 GO TO 2. No (Without CONSULTII) 䊳 GO TO 3. 2 LC EC CHECK PNP SWITCH CIRCUIT (With CONSULT-II) With CONSULT-II 1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out “P”, “R”, “N”, “D”, “2” and “1” position switches moving selector lever to each position. Check the signal of the selector lever position is indicated properly. FE CL MT TF PD SAT643J AX OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 4. SU BR ST RS BT HA SC EL IDX AT-259 TROUBLE DIAGNOSES FOR SYMPTOMS TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control and Accelerator Pedal Position Sensor Circuit Checks) (Cont’d) 3 CHECK PNP SWITCH CIRCUIT (Without CONSULT-II) Without CONSULT-II 1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Check voltage between TCM harness connector M120 terminals 26, 27, 34, 35, 36 and ground while moving selector lever through each position. MTBL0205 SAT517J Does battery voltage exist (B) or non-existent (0)? Yes 䊳 GO TO 6. No 䊳 GO TO 4. 4 DETECT MALFUNCTIONING ITEM Check the following items: 쐌 PNP switch Refer to “Component Inspection”, AT-263. 쐌 Harness for short or open between ignition switch and PNP switch (Main harness) 쐌 Harness for short or open between PNP switch and TCM (Main harness) OK or NG OK (With CONSULT-II) 䊳 GO TO 5. OK (Without CONSULTII) 䊳 GO TO 6. NG 䊳 Repair or replace damaged parts. AT-260 TROUBLE DIAGNOSES FOR SYMPTOMS TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control and Accelerator Pedal Position Sensor Circuit Checks) (Cont’d) 5 GI CHECK OVERDRIVE CONTROL SWITCH CIRCUIT With CONSULT-II 1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out “OVERDRIVE SWITCH”. Check the signal of the overdrive control switch is indicated properly. (Overdrive control switch “ON” displayed on CONSULT-II means overdrive “OFF”.) MA EM LC EC FE SAT645J OK or NG OK (With CONSULT-II) 䊳 GO TO 7. NG 䊳 GO TO 6. 6 CL MT DETECT MALFUNCTIONING ITEM Check the following items: 쐌 Overdrive control switch Refer to “Component Inspection”, AT-263. 쐌 Harness for short or open between TCM and overdrive control switch (Main harness) 쐌 Harness for short or open of ground circuit for overdrive control switch (Main harness) OK or NG OK (With CONSULT-II) 䊳 GO TO 7. OK (Without CONSULTII) 䊳 GO TO 8. NG 䊳 Repair or replace damaged parts. TF PD AX SU BR ST RS BT HA SC EL IDX AT-261 TROUBLE DIAGNOSES FOR SYMPTOMS TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control and Accelerator Pedal Position Sensor Circuit Checks) (Cont’d) 7 CHECK ACCELERATOR PEDAL POSITION SENSOR CIRCUIT (With CONSULT-II) With CONSULT-II 1. Turn ignition switch to “ON” position. (Do not start engine.) 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Apply vacuum to the throttle opener, then check the following. Refer to steps 1 and 2 of “Preparation”, “TCM SELFDIAGNOSTIC PROCEDURE (No Tools)”, AT-48. 4. Read out “CLOSED THL/SW” and “W/O THRL/P-SW” depressing and releasing accelerator pedal. Check the signal of throttle position switch is indicated properly. MTBL0011 SAT646J OK or NG OK 䊳 GO TO 9. NG 䊳 GO TO 8. 8 DETECT MALFUNCTIONING ITEM Check the following items: 쐌 Accelerator pedal position sensor 쐌 Harness for short or open between ignition switch and accelerator pedal position sensor (Main harness) 쐌 Harness for short or open between accelerator pedal position sensor and ECM (Main harness) OK or NG OK 䊳 GO TO 9. NG 䊳 Repair or replace damaged parts. 9 CHECK TCM INSPECTION 1. Perform TCM input/output signal inspection. 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK 䊳 INSPECTION END NG 䊳 Repair or replace damaged parts. AT-262 TROUBLE DIAGNOSES FOR SYMPTOMS TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control and Accelerator Pedal Position Sensor Circuit Checks) (Cont’d) COMPONENT INSPECTION Overdrive Control Switch 쐌 NAAT0204S04 GI NAAT0204S0401 Check continuity between two terminals. Continuity: Switch position “ON”: No Switch position “OFF”: Yes MA EM LC SAT144K EC Park/Neutral Position Switch 1. Check continuity between terminals 1 and 2 and between terminals 3 and 4, 5, 6, 7, 8, 9 while moving manual shaft through each position. Lever position SAT517GB NAAT0204S0402 Terminal No. P 1-2 R 3-5 N 1-2 D 3-7 2 3-8 1 3-9 FE CL 3-4 MT 3-6 TF PD AX SU SAT843BG 2. 3. If NG, check again with manual control linkage disconnected from manual shaft of A/T assembly. Refer to step 1. If OK on step 2, adjust manual control linkage. Refer to AT-275. BR ST RS BT SAT807B 4. 5. 6. If NG on step 2, remove PNP switch from A/T and check continuity of PNP switch terminals. Refer to step 1. If OK on step 4, adjust PNP switch. Refer to AT-275. If NG on step 4, replace PNP switch. HA SC EL IDX SAT386HC AT-263 TROUBLE DIAGNOSES FOR SYMPTOMS TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control and Accelerator Pedal Position Sensor Circuit Checks) (Cont’d) A/T Fluid Temperature Switch 1. 2. 3. SAT251JA NAAT0204S0404 Make sure the A/T fluid warning lamp lights when the key is inserted and turned to “ON”. Make sure the A/T fluid warning lamp goes off when turning the ignition switch to “ON”. Check resistance between terminal 10 and ground while changing temperature as shown at left. Temperature °C (°F) Resistance 140 (284) or more Yes 140 (284) or less No AT-264 A/T SHIFT LOCK SYSTEM Description Description 쐌 쐌 NAAT0093 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” (parking) to any other position 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. GI MA EM LC EC FE CL MT TF PD AX SU BR ST SAT710K RS BT HA SC EL IDX AT-265 A/T SHIFT LOCK SYSTEM Wiring Diagram — SHIFT — Wiring Diagram — SHIFT — NAAT0094 MAT323B AT-266 A/T SHIFT LOCK SYSTEM Diagnostic Procedure Diagnostic Procedure NAAT0095 SYMPTOM 1: 쐌 Selector lever cannot be moved from “P” position with key in “ON” position and brake pedal applied. 쐌 Selector lever can be moved from “P” position with key in “ON” position and brake pedal released. 쐌 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. Ignition key can be removed when selector lever is set to any position except “P”. 1 GI MA EM LC EC FE CHECK KEY INTERLOCK CABLE Check key interlock cable for damage. CL OK or NG OK 䊳 GO TO 2. NG 䊳 Repair key interlock cable. Refer to “Key Interlock Cable”, AT-270. 2 MT CHECK SELECTOR LEVER POSITION Check selector lever position for damage. OK or NG TF OK 䊳 GO TO 3. NG 䊳 Check selector lever. Refer to “ON-VEHICLE SERVICE — PNP Switch and Manual Control Linkage Adjustment”, AT-275 and AT-275. 3 PD AX CHECK POWER SOURCE 1. Turn ignition switch to ON position. (Do not start engine.) 2. Check voltage between A/T device harness terminal 7 (G/W) and ground. SU BR ST RS SAT684KB BT OK or NG OK 䊳 GO TO 5. NG 䊳 GO TO 4. HA SC EL IDX AT-267 A/T SHIFT LOCK SYSTEM Diagnostic Procedure (Cont’d) 4 DETECT MALFUNCTIONING ITEM Check the following items: 1. 7.5A fuse [No. 11, located in the fuse block (J/B)] 2. Ignition switch (Refer to EL-11, “Schematic”.) 3. Harness for short or open between battery and stop lamp switch harness connector 3 (G/W) 4. Harness for short or open between stop lamp switch harness connector 4 (G/W) and A/T device harness connector 7 (G/W) 5. Diode 6. Stop lamp switch a. Check continuity between connector terminals 3 and 4. SCIA1569E Check stop lamp switch after adjusting brake pedal — refer to BR-13, “Adjustment”. OK or NG OK 䊳 GO TO 5. NG 䊳 Repair or replace damaged parts. 5 CHECK GROUND CIRCUIT 1. Turn ignition switch to OFF position. 2. Disconnect A/T device harness connector. 3. Check continuity between A/T device harness connector terminal 6 (B) and ground. Refer to wiring diagram — SHIFT —. Continuity should exist. If OK, check harness for short to ground and short to power. OK or NG OK 䊳 GO TO 6. NG 䊳 Repair open circuit or short to ground or short to power in harness or connectors. AT-268 A/T SHIFT LOCK SYSTEM Diagnostic Procedure (Cont’d) 6 GI CHECK PARK POSITION SWITCH 쐌 Check continuity between A/T device harness connector B59 terminal 6 and park position switch harness connctor M508 terminal 1. MA EM LC EC SAT713K FE OK or NG OK 䊳 GO TO 7. NG 䊳 Replace park position switch. 7 CL MT CHECK SHIFT LOCK SOLENOID 쐌 Check operation by applying battery voltage shift lock solenoid harness connctor terminals 1 and 3. TF PD AX SAT762J OK or NG OK 䊳 GO TO 8. NG 䊳 Replace shift lock solenoid. 8 SU BR ST CHECK SHIFT LOCK OPERATION 1. Reconnect shift lock harness connector. 2. Turn ignition switch from OFF to ON position. (Do not start engine.) 3. Recheck shift lock operation. RS OK or NG OK 䊳 INSPECTION END NG 䊳 GO TO 9. BT HA 9 CHECK A/T DEVICE INSPECTION 1. Perform A/T device input/output signal inspection test. 2. If NG, recheck harness connector connection. OK or NG OK 䊳 INSPECTION END NG 䊳 Repair or replace damaged parts. AT-269 SC EL IDX KEY INTERLOCK CABLE Components Components NAAT0097 SAT352I CAUTION: 쐌 Install key interlock cable in such a way that it will not be damaged by sharp bends, twists or interference with adjacent parts. 쐌 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 NAAT0098 Unlock slider from adjuster holder and remove rod from cable. SAT353I AT-270 KEY INTERLOCK CABLE Installation Installation 1. 2. 3. NAAT0099 Set key interlock cable to steering lock assembly and install lock plate. Clamp cable to steering column and fix to control cable with band. Set selector lever to P position. GI MA EM LC SAT354I 4. Insert interlock rod into adjuster holder. EC FE CL MT SAT355I 5. 6. Install casing cap to bracket. Move slider in order to fix adjuster holder to interlock rod. TF PD AX SU SAT356I BR ST RS BT HA SC EL IDX AT-271 ON-VEHICLE SERVICE Control Valve Assembly and Accumulators Control Valve Assembly and Accumulators REMOVAL NAAT0100 NAAT0100S01 1. 2. Remove exhaust front tube. Remove oil pan and gasket and drain ATF. 3. 4. Remove A/T fluid temperature sensor if necessary. Remove oil strainer. SAT359I SAT073BA 5. Remove control valve assembly by removing fixing bolts and disconnecting harness connector. Bolt length and location Bolt symbol  mm (in) A 33 (1.30) B 45 (1.77) 6. 7. Remove solenoids and valves from valve body if necessary. Remove terminal cord assembly if necessary. 8. Remove accumulator A, B, C and D by applying compressed air if necessary. Hold each piston with rag. Reinstall any part removed. Always use new sealing parts. SAT353B 쐌 9. 쐌 SAT074BA AT-272 ON-VEHICLE SERVICE Revolution Sensor Replacement Revolution Sensor Replacement — 4WD MODEL — 1. SAT360IA 2. 3. 4. 쐌 GI NAAT0210S01 Remove rear engine mounting member from side member while supporting A/T with transfer case with jack. Tighten rear engine mounting member to the specified torque. Refer to EM-61, “Rear Engine Mounting”. Lower A/T with transfer case as much as possible. Remove revolution sensor from A/T. Reinstall any part removed. Always use new sealing parts. — 2WD MODEL — 쐌 쐌 NAAT0210 MA EM LC EC NAAT0210S02 Remove revolution sensor from A/T. Always use new sealing parts. FE CL MT SAT661I Turbine Revolution Sensor Replacement 1. 2. 3. 쐌 NAAT0231 Remove A/T assembly, Refer to “Removal”, AT-276. Remove turbine revolution sensor from A/T assembly upper side. Reinstall any part removed. Always use new sealing parts. TF PD AX SU BR ST RS BT SAT136K Rear Oil Seal Replacement — 4WD MODEL — 1. 2. 쐌 3. 쐌 4. NAAT0211 HA NAAT0211S01 Remove transfer case from vehicle. Refer to TF-156, “Removal”. Remove rear oil seal. Do not remove oil seal unless it is to be replaced. Install rear oil seal. Apply ATF before installing. Reinstall any part removed. SC EL IDX SAT035E AT-273 ON-VEHICLE SERVICE Rear Oil Seal and Companion Flange Oil Seal Replacement Rear Oil Seal and Companion Flange Oil Seal Replacement NAAT0212 — 2WD MODEL — SAT544J SAT546J NAAT0212S01 NOTE: Replace rear extension assembly as a single unit because it cannot be disassembled. 1. Remove propeller shaft. Refer to PD-5, “Components”. 2. Remove exhaust mounting and mounting bracket. 3. Disconnect revolution and speedometer sensor harness connector. 4. Support A/T assembly with a jack. 5. Remove rear engine mounting member. Tighten rear engine mounting member to the specified torque. Refer to EM-61, “Rear Engine Mounting”. 6. Remove rear extension assembly. a. Remove parking gear and needle bearing. CAUTION: Insert your hand between rear extension and transmission case. Detach rear extension assembly while holding parking gear and needle bearing by hand. 7. Reinstall any part removed. 쐌 Always use new sealing parts. Parking Components Inspection — 4WD MODEL — NAAT0213 NAAT0213S01 1. 2. 3. Remove propeller shaft. Refer to PD-5, “Components”. Remove transfer case from vehicle. Refer to TF-156, “Removal”. Remove A/T control cable bracket from transmission case. 4. 5. 6. 7. 쐌 Support A/T assembly with a jack. Remove adapter case from transmission case. Replace parking components if necessary. Reinstall any part removed. Always use new sealing parts. SAT083J SAT078B AT-274 ON-VEHICLE SERVICE Parking Components Inspection (Cont’d) — 2WD MODEL — 1. 2. 3. NAAT0213S02 Remove propeller shaft from vehicle. Refer to PD-5, “Components”. Support A/T assembly with a jack. Remove rear engine mounting member. Tighten rear engine mounting member to the specified torque. Refer to EM-61, “Rear Engine Mounting”. GI MA EM LC SAT551J 4. Remove rear extension assembly. a. Remove parking gear and needle bearing. CAUTION: Insert your hand between rear extension and transmission case. Detach rear extension assembly while holding parking gear and needle bearing by hand. 5. Replace parking components if necessary. 6. Reinstall any part removed. 쐌 Always use new sealing parts. EC FE CL MT SAT546J Park/Neutral Position Switch Adjustment 1. 2. 3. 4. 5. 6. SAT081B NAAT0104 Remove manual control linkage from manual shaft of A/T assembly. Set manual shaft of A/T assembly in “N” position. Loosen PNP switch fixing bolts. Insert pin into adjustment holes in both PNP switch and manual shaft of A/T assembly as near vertical as possible. Reinstall any part removed. Check continuity of PNP switch. Refer to “Components Inspection”, AT-109. Manual Control Linkage Adjustment TF PD AX SU NAAT0105 Move selector lever from “P” position to “1” position. You should be able to feel the detents in each position. 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. 2. Loosen lock nuts. BR ST RS BT SAT361I 3. 4. 5. Tighten turn buckle until aligns with inner cable, pulling selector lever toward “R” position side without pushing button. Back off turn buckle 1 turn and tighten lock nuts to the specified torque. Lock nut: : 4.4 - 5.9 N·m (0.45 - 0.60 kg-m, 39.1 - 52.1 in-lb) Move selector lever from “P” position to “1” position. Make sure that selector lever can move smoothly. HA SC EL IDX SAT032G AT-275 REMOVAL AND INSTALLATION Removal Removal NAAT0214 SAT362IA CAUTION: When removing the A/T assembly from engine, first remove the crankshaft position sensor (OBD) from the A/T assembly lower side. Be careful not to damage sensor edge. — 4WD MODEL — 1. 2. 3. 4. 5. 6. 7. 쐌 쐌 8. 9. NAAT0214S01 Remove battery negative terminal. Remove exhaust front and rear tubes. Remove fluid charging pipe from A/T assembly. Remove oil cooler pipe from A/T assembly. Plug up openings such as the fluid charging pipe hole, etc. Remove propeller shaft. Refer to PD-5, “Components”. Remove transfer control linkage from transfer. Refer to TF-156, “Removal”. Insert plug into rear oil seal after removing rear propeller shaft. Be careful not to damage spline, sleeve yoke and rear oil seal. Remove A/T control cable from A/T assembly. Disconnect A/T solenoid, PNP switch, turbine revolution, revolution and speedometer sensor harness connectors. SAT163K 10. Remove starter motor. Refer to SC-19, “Removal and Installation”. 11. Remove bolts securing torque converter to drive plate. 쐌 Remove the bolts by turning crankshaft. SAT148K AT-276 REMOVAL AND INSTALLATION Removal (Cont’d) 12. Support A/T and transfer assembly with a jack. 13. Remove rear engine mounting member from body and A/T assembly. Tighten rear engine mounting member to the specified torque. Refer to EM-61, “Rear Engine Mounting”. 14. Remove bolts securing A/T assembly to engine. 쐌 Secure torque converter to prevent it from dropping. 쐌 Secure A/T assembly to a jack. 15. Lower A/T assembly with transfer. GI MA EM LC SAT801C — 2WD MODEL — SAT553J EC NAAT0214S02 CAUTION: 쐌 Do not attach lifting cable to or place supporting fixture under companion flange at rear of A/T (shown in the figure at left) when lifting/lowering A/T. 쐌 Be sure to attach lifting cable to rear engine mounting or dynamic damper location when lifting/lowering A/T. 1. Remove battery negative terminal. 2. Remove exhaust front and rear tubes. 3. Remove fluid charging pipe from A/T assembly. 4. Remove oil cooler pipe from A/T assembly. 5. Plug up openings such as the fluid charging pipe hole, etc. 6. Remove propeller shaft. Refer to PD-5, “Components”. 7. Remove A/T control cable from A/T assembly. 8. Disconnect A/T and speedometer sensor harness connectors. 9. Remove starter motor. Refer to SC-19, “Removal and Installation”. 10. Remove gusset and rear plate cover securing engine to A/T assembly. 11. Remove bolts securing torque converter to drive plate. 쐌 Remove the bolts by turning crankshaft. 12. Support A/T assembly with a jack. 13. Remove rear engine mounting member from body and A/T assembly. Tighten rear engine mounting member to the specified torque. Refer to EM-61, “Rear Engine Mounting”. 14. Remove bolts securing A/T assembly to engine. 15. Pull A/T assembly backwards. 쐌 Secure torque converter to prevent it from dropping. 쐌 Secure A/T assembly to a jack. 16. Lower A/T assembly. FE CL MT TF PD AX SU BR ST RS BT SAT544J Installation 쐌 NAAT0107 Drive plate runout Maximum allowable runout: Refer to EM-73, “FLYWHEEL/DRIVE PLATE RUNOUT”. If this runout is out of specification, replace drive plate with ring gear. HA SC EL IDX SAT977H AT-277 REMOVAL AND INSTALLATION Installation (Cont’d) 쐌 When connecting torque converter to transmission, measure distance “A” to be certain that they are correctly assembled. Distance “A”: 25.0 mm (0.984 in) or more 쐌 쐌 Install converter to drive plate. After converter is installed to drive plate, rotate crankshaft several turns and check to be sure that transmission rotates freely without binding. 쐌 Tighten bolts securing transmission. SAT017B SAT148K Bolt No. Tightening torque N·m (kg-m, ft-lb) Bolt length “” mm (in) 1 70 - 80 (7.1 - 8.2, 52 - 59) 65 (2.56) 2 29 - 39 (3.0 - 4.0, 22 - 29) 40 (1.57) 3 70 - 80 (7.1 - 8.2, 52 - 59) 55 (2.17) 쐌 Reinstall any part removed. 쐌 쐌 Check fluid level in transmission. Move selector lever through all positions to be sure that transmission operates correctly. With parking brake applied, rotate engine at idling. Move selector lever through “N” to “D”, to “2”, to “1” and to “R” positions. A slight shock should be felt by hand gripping selector each time transmission is shifted. Perform road test. Refer to “ROAD TEST”, AT-65. SAT149K 쐌 SAT638A AT-278 REMOVAL AND INSTALLATION Installation (Cont’d) AIR BREATHER HOSE NAAT0107S01 GI MA EM LC EC FE CL MT TF SAT662K PD AX SU BR ST RS BT HA SC EL SAT206KA AT-279 IDX REMOVAL AND INSTALLATION Installation (Cont’d) SAT153K AT-280 OVERHAUL Components Components NAAT0108 GI MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL SAT712K AT-281 IDX OVERHAUL Components (Cont’d) SAT671KA AT-282 OVERHAUL Components (Cont’d) GI MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL SAT672KA IDX AT-283 OVERHAUL Oil Channel Oil Channel NAAT0109 SAT185B AT-284 OVERHAUL Locations of Needle Bearings, Thrust Washers and Snap Rings Locations of Needle Bearings, Thrust Washers and Snap Rings GI NAAT0110 MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL SAT140JB AT-285 IDX NAAT0111 DISASSEMBLY 1. 2. 3. Drain ATF through drain plug. Remove turbine revolution sensor. Remove torque converter by holding it firmly and turning while pulling straight out. 4. a. b. Check torque converter one-way clutch. Insert Tool into spline of one-way clutch inner race. Hook bearing support unitized with one-way clutch outer race with suitable wire. Check that one-way clutch inner race rotates only clockwise with Tool while holding bearing support with wire. SAT018B c. SAT521G 5. Remove PNP switch from transmission case. 6. 쐌 Remove oil pan. Always place oil pan straight down so that foreign particles inside will not move. 7. Place transmission into Tool with the control valve facing up. SAT021BB SAT754I SAT522G AT-286 DISASSEMBLY 8. 쐌 Check foreign materials in oil pan to help determine cause of 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 build up. Varnish can cause valves, servo, and clutches to stick and may inhibit pump pressure. If frictional material is detected, replace radiator after repair of A/T. Refer to LC-21, “REMOVAL AND INSTALLATION”. GI Remove torque converter clutch solenoid valve and A/T fluid temperature sensor connectors. Be careful not to damage connector. EC MA EM LC SAT171B 9. 쐌 FE CL MT SAT024BC 10. Remove oil strainer. a. Remove oil strainer from control valve assembly. Then remove O-ring from oil strainer. TF PD AX SU SAT008B b. Check oil strainer screen for damage. BR ST RS BT SAT025B 11. Remove control valve assembly. a. Straighten terminal clips to free terminal cords then remove terminal clips. HA SC EL IDX SAT009B AT-287 DISASSEMBLY b. Remove bolts A and B, and remove control valve assembly from transmission. Bolt symbol Length mm (in) A 33 (1.30) B 45 (1.77) SAT353B c. 쐌 Remove solenoid connector. Be careful not to damage connector. d. Remove manual valve from control valve assembly. SAT026B SAT127B 12. Remove terminal cord assembly from transmission case while pushing on stopper. 쐌 Be careful not to damage cord. 쐌 Do not remove terminal cord assembly unless it is damaged. SAT128B AT-288 DISASSEMBLY 13. Remove converter housing from transmission case. 쐌 Be careful not to scratch converter housing. GI MA EM LC SAT999A 14. Remove O-ring from input shaft. EC FE CL MT SAT995A 15. Remove oil pump assembly. a. Attach Tool to oil pump assembly and extract it evenly from transmission case. TF PD AX SU SAT027B b. c. 쐌 Remove O-ring from oil pump assembly. Remove traces of sealant from oil pump housing. Be careful not to scratch pump housing. BR ST RS BT SAT028B d. Remove needle bearing and thrust washer from oil pump assembly. HA SC EL IDX SAT108B AT-289 DISASSEMBLY 16. Remove input shaft and oil pump gasket. SAT988A 17. Remove brake band and band strut. a. Loosen lock nut and remove band servo anchor end pin from transmission case. SAT029B b. Remove brake band and band strut from transmission case. c. Hold brake band in a circular shape with clip. SAT986A SAT655 18. Remove front side clutch and gear components. a. Remove clutch pack (reverse clutch, high clutch and front sun gear) from transmission case. SAT030B AT-290 DISASSEMBLY b. c. Remove front bearing race from clutch pack. Remove rear bearing race from clutch pack. GI MA EM LC SAT113B d. Remove front planetary carrier from transmission case. EC FE CL MT SAT031B e. f. Remove front needle bearing from front planetary carrier. Remove rear bearing from front planetary carrier. TF PD AX SU SAT968A g. Remove rear sun gear from transmission case. BR ST RS BT SAT974A 19. Remove rear extension assembly (2WD model only). a. Remove rear extension assembly. b. Remove parking gear and needle bearing. CAUTION: Insert your hand between rear extension and transmission case. Detach rear extension assembly while holding parking gear and needle bearing by hand. c. Remove rear extension gasket. HA SC EL IDX SAT546J AT-291 DISASSEMBLY 20. Remove adapter case (4WD model only). a. Remove adapter case from transmission case. b. Remove adapter case gasket from transmission case. SAT755I c. 쐌 쐌 Remove oil seal from adapter case. Be careful not to scratch adapter case. Do not remove oil seal unless it is to be replaced. SAT756I 21. Remove revolution sensor from rear extension or adapter case. a. Remove O-ring from revolution sensor. SAT556J 22. Remove output shaft and parking gear (4WD model only). a. Remove rear snap ring from output shaft. SAT960A b. 쐌 c. Slowly push output shaft all the way forward. Do not use excessive force. Remove snap ring from output shaft. SAT957A AT-292 DISASSEMBLY d. e. Remove output shaft and parking gear as a unit from transmission case. Remove parking gear from output shaft. GI MA EM LC SAT109B f. Remove needle bearing from transmission case. EC FE CL MT SAT033B 23. Remove rear side clutch and gear components. a. Remove front internal gear. TF PD AX SU SAT954A b. Remove bearing race from front internal gear. BR ST RS BT SAT110B c. Remove needle bearing from rear internal gear. HA SC EL IDX SAT111B AT-293 DISASSEMBLY d. Remove rear internal gear, forward clutch hub and overrun clutch hub as a set from transmission case. e. f. Remove needle bearing from overrun clutch hub. Remove overrun clutch hub from rear internal gear and forward clutch hub. g. Remove thrust washer from overrun clutch hub. h. Remove forward clutch assembly from transmission case. SAT951A SAT148G SAT036B SAT037B 24. Remove band servo and accumulator components. a. Remove band servo retainer from transmission case. SAT038B AT-294 DISASSEMBLY b. 쐌 c. 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. Remove return springs. GI MA EM LC SAT039B d. e. 쐌 Remove springs from accumulator pistons B, C and D. 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 A B C D Identification of oil holes a b c d EC FE CL MT SAT040BA f. Remove O-ring from each piston. TF PD AX SU SAT523GA 25. Remove manual shaft components, if necessary. a. Hold width across flats of manual shaft (outside the transmission case) and remove lock nut from shaft. BR ST RS BT SAT041B b. Remove retaining pin from transmission case. HA SC EL IDX SAT042B AT-295 DISASSEMBLY 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. SAT935A SAT043B SAT934A SAT044B AT-296 REPAIR FOR COMPONENT PARTS Oil Pump Oil Pump COMPONENTS GI NAAT0112 MA EM LC EC FE CL MT SAT648AF DISASSEMBLY 1. NAAT0113 Loosen bolts in numerical order and remove oil pump cover. TF PD AX SU SAT649A 2. 쐌 Remove rotor, vane rings and vanes. Inscribe a mark on back of rotor for identification of foreaft direction when reassembling rotor. Then remove rotor. BR ST RS BT SAT650A 3. 쐌 While pushing on cam ring remove pivot pin. Be careful not to scratch oil pump housing. HA SC EL IDX SAT651A AT-297 REPAIR FOR COMPONENT PARTS Oil Pump (Cont’d) 4. 쐌 쐌 While holding cam ring and spring lift out cam ring spring. Be careful not to damage oil pump housing. Hold cam ring spring to prevent it from jumping. 5. Remove cam ring and cam ring spring from oil pump housing. 6. Remove pivot pin from control piston and remove control piston assembly. 7. 쐌 Remove oil seal from oil pump housing. Be careful not to scratch oil pump housing. SAT652A SAT653A SAT654A SAT655A INSPECTION NAAT0114 Oil Pump Cover, Rotor, Vanes, Control Piston, Side Seals, Cam Ring and Friction Ring NAAT0114S01 쐌 Check for wear or damage. SAT656A AT-298 REPAIR FOR COMPONENT PARTS Oil Pump (Cont’d) Side Clearances 쐌 쐌 SAT657A 쐌 Seal Ring Clearance 쐌 쐌 NAAT0114S02 Measure side clearances between end of oil pump housing and cam ring, rotor, vanes and control piston. Measure in at least four places along their circumferences. Maximum measured values should be within specified positions. Before measurement, check that friction rings, O-ring, control piston side seals and cam ring spring are removed. Standard clearance (Cam ring, rotor, vanes and control piston): Refer to SDS, AT-360. If not within standard clearance, replace oil pump assembly except oil pump cover assembly. NAAT0114S03 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. GI MA EM LC EC FE CL MT SAT658A ASSEMBLY 1. 쐌 NAAT0115 Drive oil seal into oil pump housing. Apply ATF to outer periphery and lip surface. TF PD AX SU SAT081E 2. a. 쐌 쐌 b. Install cam ring in oil pump housing by the following Install side seal on control piston. Pay attention to its direction — Black surface goes toward control piston. Apply petroleum jelly to side seal. Install control piston on oil pump. BR ST RS BT SAT654A c. 쐌 Install O-ring and friction ring on cam ring. Apply petroleum jelly to O-ring. HA SC EL IDX SAT660A AT-299 REPAIR FOR COMPONENT PARTS Oil Pump (Cont’d) d. Assemble cam ring, cam ring spring and spring seat. Install spring by pushing it against pump housing. e. While pushing on cam ring install pivot pin. 3. 쐌 Install rotor, vanes and vane rings. Pay attention to direction of rotor. 4. a. Install oil pump housing and oil pump cover. 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. Tighten bolts in a criss-cross pattern. SAT661A SAT651A SAT662A b. SAT649A 5. 쐌 쐌 Install new seal rings carefully after packing ring grooves with petroleum jelly. Press rings down into jelly to a close fit. 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 AT-300 REPAIR FOR COMPONENT PARTS Control Valve Assembly Control Valve Assembly COMPONENTS GI NAAT0116 MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL SAT156KA AT-301 IDX REPAIR FOR COMPONENT PARTS Control Valve Assembly (Cont’d) DISASSEMBLY 1. a. NAAT0117 b. Remove solenoids. Remove torque converter clutch solenoid valve and side plate from lower body. Remove O-ring from solenoid. c. d. Remove line pressure solenoid valve from upper body. Remove O-ring from solenoid. e. f. Remove 3-unit solenoid assembly from upper body. Remove O-rings from solenoids. 2. a. Disassemble upper and lower bodies. Place upper body facedown, and remove bolts, reamer bolts and support plates. Remove lower body, separator plate as a unit from upper body. Be careful not to drop pilot filter, orifice check valve, spring and steel balls. SAT194B SAT667A SAT043G b. 쐌 SAT195B c. d. Place lower body facedown, and remove separator plate. Remove pilot filter, orifice check valve and orifice check spring. SAT670A AT-302 REPAIR FOR COMPONENT PARTS Control Valve Assembly (Cont’d) e. Check to see that steel balls are properly positioned in upper body. Then remove them from upper body. GI MA EM LC SAT671A INSPECTION Lower and Upper Bodies 쐌 EC NAAT0118 NAAT0118S01 Check to see that there are pins and retainer plates in lower body. FE CL MT SAT672A 쐌 쐌 Check to see that there are pins and retainer plates in upper body. Be careful not to lose these parts. TF PD AX SU SAT673A 쐌 쐌 Check to make sure that oil circuits are clean and free from damage. Check tube brackets and tube connectors for damage. BR ST RS BT SAT674A Separator Plate 쐌 NAAT0118S02 Make sure that separator plate is free of damage and not deformed and oil holes are clean. HA SC EL IDX SAT675A AT-303 REPAIR FOR COMPONENT PARTS Control Valve Assembly (Cont’d) Pilot Filter 쐌 NAAT0118S03 Check to make sure that filter is not clogged or damaged. SAT676A Torque Converter Clutch Solenoid Valve 쐌 쐌 Line Pressure Solenoid Valve 쐌 쐌 NAAT0118S04 Check that filter is not clogged or damaged. Measure resistance. Refer to “Component Inspection”, AT-158. NAAT0118S05 Check that filter is not clogged or damaged. Measure resistance. Refer to “Component Inspection”, AT-173. SAT149G 3-Unit Solenoid Assembly (Overrun Clutch Solenoid Valve and Shift Solenoid Valves A and B) NAAT0118S06 쐌 Measure resistance of each solenoid. Refer to “Component Inspection”, AT-177, AT-181 and AT-192. SAT095B A/T Fluid Temperature Sensor and Switch 쐌 NAAT0118S07 Measure resistance. Refer to “Component Inspection”, AT-116 and AT-264. SAT096BA ASSEMBLY 1. a. NAAT0119 Install upper and lower bodies. Place oil circuit of upper body face up. Install steel balls in their proper positions. SAT671A AT-304 REPAIR FOR COMPONENT PARTS Control Valve Assembly (Cont’d) b. Install reamer bolts from bottom of upper body. GI MA EM LC SAT681A c. Place oil circuit of lower body face up. Install orifice check spring, orifice check valve and pilot filter. EC FE CL MT TF PD AX SU SAT682A d. e. Install lower separator plate on lower body. Install and temporarily tighten support plates, A/T fluid temperature sensor and tube brackets. BR ST RS BT SAT197B f. 쐌 Temporarily assemble lower and upper bodies, using reamer bolt as a guide. Be careful not to dislocate or drop steel balls, orifice check spring, orifice check valve and pilot filter. HA SC EL IDX SAT198B AT-305 REPAIR FOR COMPONENT PARTS Control Valve Assembly (Cont’d) g. Install and temporarily tighten bolts and tube brackets in their proper locations. Bolt length and location: Bolt symbol Bolt length mm (in) a b c d 70 (2.76) 50 (1.97) 33 (1.30) 27 (1.06) SAT199BA 2. a. Install solenoids. Attach O-ring and install torque converter clutch solenoid valve and side plates onto lower body. b. Attach O-rings and install 3-unit solenoids assembly onto upper body. Attach O-ring and install line pressure solenoid valve onto upper body. Tighten all bolts. SAT200B c. 3. SAT150G AT-306 REPAIR FOR COMPONENT PARTS Control Valve Upper Body Control Valve Upper Body COMPONENTS GI NAAT0120 MA EM LC EC FE CL MT TF PD AX SU BR ST RS BT HA SC SAT142JA Apply ATF to all components before their installation. Numbers preceding valve springs correspond with those shown in SDS on page AT-357. EL IDX AT-307 REPAIR FOR COMPONENT PARTS Control Valve Upper Body (Cont’d) DISASSEMBLY NAAT0121 1. 쐌 Remove valves at parallel pins. Do not use a magnetic hand. a. Use a wire paper clip to push out parallel pins. b. Remove parallel pins while pressing their corresponding plugs and sleeves. Remove plug slowly to prevent internal parts from jumping out. SAT834A SAT822A 쐌 SAT823A c. 쐌 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. Be careful not to drop or damage valves and sleeves. 2. a. Remove valves at retainer plates. Pry out retainer plate with wire paper clip. 쐌 SAT824A SAT825A AT-308 REPAIR FOR COMPONENT PARTS Control Valve Upper Body (Cont’d) b. Remove retainer plates while holding spring. GI MA EM LC SAT826A c. 쐌 쐌 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. EC FE CL MT SAT827A 쐌 쐌 4-2 sequence valve and relay valve are located far back in upper body. If they are hard to remove, carefully push them out using stiff wire. Be careful not to scratch sliding surface of valve with wire. TF PD AX SU SAT828A INSPECTION Valve Springs 쐌 쐌 Measure free length and outer diameter of each valve spring. Also check for damage or deformation. Inspection standard: Refer to SDS, AT-357. Replace valve springs if deformed or fatigued. Control Valves 쐌 NAAT0122 NAAT0122S01 쐌 RS BT SAT829A 1. ST NAAT0122S02 Check sliding surfaces of valves, sleeves and plugs. ASSEMBLY BR NAAT0123 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. HA SC EL IDX SAT830A AT-309 REPAIR FOR COMPONENT PARTS Control Valve Upper Body (Cont’d) 쐌 Wrap a small screwdriver with vinyl tape and use it to insert the valves into proper position. SAT831A Pressure regulator valve 쐌 If pressure regulator plug is not centered properly, sleeve cannot be inserted into bore in upper body. If this happens, use vinyl tape wrapped screwdriver to center sleeve until it can be inserted. 쐌 Turn sleeve slightly while installing. SAT832A Accumulator control plug 쐌 Align protrusion of accumulator control sleeve with notch in plug. 쐌 Align parallel pin groove in plug with parallel pin, and install accumulator control valve. SAT833A 2. Install parallel pins and retainer plates. 쐌 While pushing plug, install parallel pin. SAT834A SAT823A AT-310 REPAIR FOR COMPONENT PARTS Control Valve Upper Body (Cont’d) 4-2 sequence valve and relay valve 쐌 Push 4-2 sequence valve and relay valve with wire wrapped in vinyl tape to prevent scratching valve body. Install parallel pins. GI MA EM LC SAT835A 쐌 Insert retainer plate while pushing spring. EC FE CL MT SAT836A TF PD AX SU BR ST RS BT HA SC EL IDX AT-311 REPAIR FOR COMPONENT PARTS Control Valve Lower Body Control Valve Lower Body COMPONENTS NAAT0124 SAT966I Apply ATF to all components before their installation. Numbers preceding valve springs correspond with those shown in SDS on page AT-357. AT-312 REPAIR FOR COMPONENT PARTS Control Valve Lower Body (Cont’d) DISASSEMBLY 1. 2. NAAT0125 Remove valves at parallel pins. Remove valves at retainer plates. For removal procedures, refer to “DISASSEMBLY” of Control Valve Upper Body. GI MA EM LC SAT838A INSPECTION Valve Springs 쐌 쐌 쐌 NAAT0126S02 FE CL MT Check sliding surfaces of control valves, sleeves and plugs for damage. ASSEMBLY 쐌 NAAT0126S01 Check each valve spring for damage or deformation. Also measure free length and outer diameter. Inspection standard: Refer to SDS, AT-357. Replace valve springs if deformed or fatigued. Control Valves SAT829A EC NAAT0126 NAAT0127 Install control valves. For installation procedures, refer to “ASSEMBLY” of Control Valve Upper Body, AT-309. TF PD AX SU SAT838A BR ST RS BT HA SC EL IDX AT-313 REPAIR FOR COMPONENT PARTS Reverse Clutch Reverse Clutch COMPONENTS NAAT0128 SAT699K DISASSEMBLY 1. a. b. c. 쐌 쐌 쐌 NAAT0129 Check operation of reverse clutch. Install seal ring onto oil pump cover and install reverse clutch. Apply compressed air to oil hole. Check to see that retaining plate moves to snap ring. If retaining plate does not contact snap ring, D-ring might be damaged. Lip seal might be damaged. Fluid might be leaking past piston check ball. SAT841A 2. Remove drive plates, driven plates, retaining plate, dish plate and snap ring. SAT842A AT-314 REPAIR FOR COMPONENT PARTS Reverse Clutch (Cont’d) 3. 쐌 4. Remove snap ring from clutch drum while compressing clutch springs. Do not expand snap ring excessively. Remove spring retainer. GI MA EM LC SAT524G 5. 쐌 6. 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. Remove D-ring and oil seal from piston. EC FE CL MT SAT844A INSPECTION Reverse Clutch Snap Ring and Spring Retainer 쐌 NAAT0130 NAAT0130S01 Check for deformation, fatigue or damage. TF PD AX SU Reverse Clutch Drive Plates 쐌 쐌 쐌 Reverse Clutch Dish Plate 쐌 NAAT0130S03 Check facing for burns, cracks or damage. Measure thickness of 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. 쐌 RS BT SAT845A 쐌 쐌 ST NAAT0130S04 Check for deformation or damage. Reverse Clutch Piston BR NAAT0130S05 Shake piston to assure that balls are not seized. Apply compressed air to check ball oil hole opposite the return spring. Make sure there is no air leakage. Also apply compressed air to oil hole on return spring side to assure that air leaks past ball. HA SC EL IDX SAT846A AT-315 REPAIR FOR COMPONENT PARTS Reverse Clutch (Cont’d) ASSEMBLY NAAT0131 1. 쐌 Install D-ring and oil seal on piston. Apply ATF to both parts. 2. 쐌 3. Install piston assembly by turning it slowly and evenly. Apply ATF to inner surface of drum. Install spring retainer. 4. Install snap ring while compressing clutch springs. 쐌 Do not align snap ring gap with spring retainer stopper. 5. 6. Install drive plates, driven plates, retaining plate and dish plate. Install snap ring. SAT847A SAT848A SAT524G SAT850A SAT842A AT-316 REPAIR FOR COMPONENT PARTS Reverse Clutch (Cont’d) 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-358. GI Check operation of reverse clutch. Refer to “DISASSEMBLY” of Reverse Clutch, AT-314. EC MA EM LC SAT852A 8. FE CL MT SAT841A High Clutch COMPONENTS NAAT0132 TF PD AX SU BR ST RS BT HA SC SAT158KA EL IDX AT-317 REPAIR FOR COMPONENT PARTS High Clutch (Cont’d) DISASSEMBLY AND ASSEMBLY NAAT0133 Service procedures for high clutch are essentially the same as those for reverse clutch, with the following exception: SAT853A 쐌 Check of high clutch operation 쐌 Removal and installation of return spring 쐌 Inspection of high clutch return springs Inspection standard: Refer to SDS, AT-357. 쐌 Inspection of high clutch drive plate Thickness of drive plate: Standard 1.52 - 1.67 mm (0.0598 - 0.0657 in) Wear limit 1.40 mm (0.0551 in) SAT854A SAT525G SAT829A SAT845A AT-318 REPAIR FOR COMPONENT PARTS High Clutch (Cont’d) 쐌 Measurement of clearance between retaining plate and snap ring Specified clearance: Standard 1.8 - 2.2 mm (0.071 - 0.087 in) Allowable limit 3.2 mm (0.126 in) Retaining plate: Refer to SDS, AT-358. GI MA EM LC SAT858A EC FE CL MT TF PD AX SU BR ST RS BT HA SC EL IDX AT-319 REPAIR FOR COMPONENT PARTS Forward and Overrun Clutches Forward and Overrun Clutches COMPONENTS NAAT0134 SAT711K AT-320 REPAIR FOR COMPONENT PARTS Forward and Overrun Clutches (Cont’d) DISASSEMBLY AND ASSEMBLY NAAT0135 Forward and overrun clutches are serviced essentially the same way as reverse clutch is serviced. However, note the following exceptions. 쐌 Check of forward clutch operation GI MA EM LC SAT860A 쐌 Check of overrun clutch operation EC FE CL MT SAT861A 쐌 Removal of forward clutch drum Remove forward clutch drum from transmission case by holding snap ring. TF PD AX SU SAT865A 쐌 a) Removal of forward clutch and overrun clutch pistons While holding overrun clutch piston, gradually apply compressed air to oil hole. BR ST RS BT SAT862A b) Remove overrun clutch from forward clutch. HA SC EL IDX SAT863A AT-321 REPAIR FOR COMPONENT PARTS Forward and Overrun Clutches (Cont’d) 쐌 Removal and installation of return springs 쐌 Inspection of forward clutch and overrun clutch return springs Inspection standard: Refer to SDS, AT-357. 쐌 Inspection of forward clutch drive plates Thickness of drive plate: Standard 1.52 - 1.67 mm (0.0598 - 0.0657 in) Wear limit 1.40 mm (0.0551 in) 쐌 Inspection of overrun clutch drive plates Thickness of drive plate: Standard 1.90 - 2.05 mm (0.0748 - 0.0807 in) Wear limit 1.80 mm (0.0709 in) 쐌 a) 쐌 Installation of forward clutch piston and overrun clutch piston Install forward clutch piston by turning it slowly and evenly. Apply ATF to inner surface of clutch drum. SAT526G SAT829A SAT845A SAT845A SAT866A AT-322 REPAIR FOR COMPONENT PARTS Forward and Overrun Clutches (Cont’d) 쐌 Align notch in forward clutch piston with groove in forward clutch drum. GI MA EM LC SAT867A b) 쐌 Install overrun clutch by turning it slowly and evenly. Apply ATF to inner surface of forward clutch piston. EC FE CL MT SAT868A 쐌 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-359. PD AX SU SAT869A 쐌 SAT870A TF 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 Model 4EX16, 4EX79 (2WD) 2.15 mm (0.0846 in) Model 4EX17, 4EX23, 4EX80, 4EX81 (4WD) 2.35 mm (0.0925 in) Retaining plate: Refer to SDS, AT-359. BR ST RS BT HA SC EL IDX AT-323 REPAIR FOR COMPONENT PARTS Low & Reverse Brake Low & Reverse Brake COMPONENTS NAAT0136 SAT673KA DISASSEMBLY 1. a. b. c. 쐌 쐌 쐌 NAAT0137 Check operation of low and reverse brake. Install seal ring onto oil pump cover and install reverse clutch. Apply compressed air to oil hole. Check to see that retaining plate moves to snap ring. 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. SAT872A 2. Remove snap ring, and then remove retaining plate, low and reverse brake drive plates, driven plates, dish plate and U-spring. NOTE: 쐌 U-spring can be set only at the installation position shown in component figure. 쐌 U-spring is removed when the front driven plate is removed. SAT873A AT-324 REPAIR FOR COMPONENT PARTS Low & Reverse Brake (Cont’d) 3. 4. 5. Remove low one-way clutch inner race, spring retainer and return spring from transmission case. Remove seal rings from low one-way clutch inner race. Remove needle bearing from low one-way clutch inner race. GI MA EM LC SAT382I 6. 7. Remove low and reverse brake piston using compressed air. Remove oil seal and D-ring from piston. EC FE CL MT SAT876A INSPECTION NAAT0138 Low and Reverse Brake Snap Ring and Spring Retainer NAAT0138S01 쐌 Check for deformation, or damage. TF PD AX SU Low and Reverse Brake Return Springs 쐌 NAAT0138S02 Check for deformation or damage. Also measure free length and outside diameter. Inspection standard: Refer to SDS, AT-357. BR ST RS BT SAT829A Low and Reverse Brake Drive Plates 쐌 쐌 SAT845A Check facing for burns, cracks or damage. Measure thickness of facing. Thickness of drive plate: Standard value Model 4EX16, 4EX79 (2WD) 1.90 - 2.05 mm (0.075 - 0.081 in) Model 4EX17, 4EX23, 4EX80, 4EX81 (4WD) 1.52 - 1.67 mm (0.0598 - 0.0657 in) Wear limit AT-325 NAAT0138S03 HA SC EL IDX REPAIR FOR COMPONENT PARTS Low & Reverse Brake (Cont’d) 쐌 1.40 mm (0.0551 in) If not within wear limit, replace. Low One-way Clutch Inner Race NAAT0138S04 쐌 Check frictional surface of inner race for wear or damage. 쐌 쐌 쐌 Install a new seal rings onto low one-way clutch inner race. Be careful not to expand seal ring gap excessively. Measure seal ring-to-groove clearance. Inspection standard: 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. SAT877A 쐌 SAT878A ASSEMBLY 1. 쐌 NAAT0139 쐌 Install needle bearing onto one-way clutch inner race. Pay attention to its direction — Black surface goes to rear side. Apply petroleum jelly to needle bearing. 2. 쐌 Install lip seal and D-ring onto piston. Apply ATF to oil seal and D-ring. SAT112B SAT879AB AT-326 REPAIR FOR COMPONENT PARTS Low & Reverse Brake (Cont’d) 3. 쐌 Install piston by rotating it slowly and evenly. Apply ATF to inner surface of transmission case. GI MA EM LC SAT880A 4. 5. 6. Install return springs, spring retainer and low one-way clutch inner race onto transmission case. Install dish plate, low and reverse brake drive plates, driven plates and U-spring, and then retaining plate. Install snap ring on transmission case. EC FE CL MT SAT881A 7. Check operation of low and reverse brake clutch piston. Refer to “DISASSEMBLY”, AT-324. TF PD AX SU SAT872A 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 2.7 mm (0.106 in) Retaining plate: Refer to SDS, AT-360. BR ST RS BT SAT885A 9. 쐌 쐌 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. HA SC EL IDX SAT884A AT-327 REPAIR FOR COMPONENT PARTS Forward Clutch Drum Assembly Forward Clutch Drum Assembly COMPONENTS NAAT0140 SAT211GA DISASSEMBLY 1. 2. Remove snap ring from forward clutch drum. Remove side plate from forward clutch drum. 3. 4. Remove low one-way clutch from forward clutch drum. Remove snap ring from forward clutch drum. 5. Remove needle bearing from forward clutch drum. SAT212G SAT213G SAT891A AT-328 NAAT0141 REPAIR FOR COMPONENT PARTS Forward Clutch Drum Assembly (Cont’d) INSPECTION Forward Clutch Drum 쐌 쐌 NAAT0142 GI NAAT0142S01 Check spline portion for wear or damage. Check frictional surfaces of low one-way clutch and needle bearing for wear or damage. MA EM LC SAT892A Needle Bearing and Low One-way Clutch 쐌 EC NAAT0142S02 Check frictional surface for wear or damage. FE CL MT SAT893A ASSEMBLY 1. 2. NAAT0143 Install needle bearing in forward clutch drum. Install snap ring onto forward clutch drum. TF PD AX SU SAT214G 3. Install low one-way clutch onto forward clutch drum by pushing the roller in evenly. BR ST RS BT SAT894A 쐌 Install low one-way clutch with flange facing rearward. HA SC EL IDX SAT895A AT-329 REPAIR FOR COMPONENT PARTS Forward Clutch Drum Assembly (Cont’d) 4. 5. Install side plate onto forward clutch drum. Install snap ring onto forward clutch drum. SAT887A Rear Internal Gear and Forward Clutch Hub COMPONENTS NAAT0144 SAT896AA DISASSEMBLY NAAT0145 1. Remove rear internal gear by pushing forward clutch hub forward. 2. Remove thrust washer from rear internal gear. SAT897A SAT898A AT-330 REPAIR FOR COMPONENT PARTS Rear Internal Gear and Forward Clutch Hub (Cont’d) 3. Remove snap ring from forward clutch hub. GI MA EM LC SAT899A 4. EC Remove end bearing. FE CL MT SAT900A 5. Remove forward one-way clutch and end bearing as a unit from forward clutch hub. TF PD AX SU SAT955A 6. Remove snap ring from forward clutch hub. BR ST RS BT SAT901A INSPECTION Rear Internal Gear and Forward Clutch Hub 쐌 쐌 쐌 NAAT0146 HA NAAT0146S01 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. SC EL IDX SAT902A AT-331 REPAIR FOR COMPONENT PARTS Rear Internal Gear and Forward Clutch Hub (Cont’d) Snap Ring and End Bearing 쐌 NAAT0146S02 Check for deformation or damage. SAT903A ASSEMBLY NAAT0147 1. 2. Install snap ring onto forward clutch hub. Install end bearing. 3. 쐌 4. 5. Install forward one-way clutch onto clutch hub. Install forward one-way clutch with flange facing rearward. Install end bearing. Install snap ring onto forward clutch hub. 6. 쐌 쐌 Install thrust washer onto rear internal gear. Apply petroleum jelly to thrust washer. Securely insert pawls of thrust washer into holes in rear internal gear. 7. Position forward clutch hub in rear internal gear. SAT901A SAT904A SAT906A SAT907A AT-332 REPAIR FOR COMPONENT PARTS Rear Internal Gear and Forward Clutch Hub (Cont’d) 8. After installing, check to assure that forward clutch hub rotates clockwise. GI MA EM LC SAT905A EC Band Servo Piston Assembly COMPONENTS NAAT0148 FE CL MT TF PD AX SAT161KA SU DISASSEMBLY 1. 2. 3. NAAT0149 Block one oil hole in OD servo piston retainer and the center hole in OD band servo piston. Apply compressed air to the other oil hole in piston retainer to remove OD band servo piston from retainer. Remove D-ring from OD band servo piston. BR ST RS BT SAT909A 4. Remove band servo piston assembly from servo piston retainer by pushing it forward. HA SC EL IDX SAT910A AT-333 REPAIR FOR COMPONENT PARTS Band Servo Piston Assembly (Cont’d) 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 C and piston stem from band servo piston. 7. Remove E-ring from band servo piston. SAT911A SAT912A SAT913A 8. Remove servo cushion spring retainer from band servo piston. 9. Remove D-rings from band servo piston. 10. Remove O-rings from servo piston retainer. SAT914A INSPECTION Pistons, Retainers and Piston Stem 쐌 NAAT0150 NAAT0150S01 Check frictional surfaces for abnormal wear or damage. SAT915A AT-334 REPAIR FOR COMPONENT PARTS Band Servo Piston Assembly (Cont’d) Return Springs 쐌 NAAT0150S02 Check for deformation or damage. Measure free length and outer diameter. Inspection standard: Refer to SDS, AT-357. GI MA EM LC SAT162K ASSEMBLY 1. 쐌 쐌 EC NAAT0151 Install O-rings onto servo piston retainer. Apply ATF to O-rings. Pay attention to position of each O-ring. FE CL MT SAT917A 2. Install servo cushion spring retainer onto band servo piston. TF PD AX SU SAT918A 3. Install E-ring onto servo cushion spring retainer. BR ST RS BT SAT919A 4. 쐌 Install D-rings onto band servo piston. Apply ATF to D-rings. HA SC EL IDX SAT920A AT-335 REPAIR FOR COMPONENT PARTS Band Servo Piston Assembly (Cont’d) 5. Install servo piston spring retainer, return spring C and piston stem onto band servo piston. 6. Place piston stem end on a wooden block. While pushing servo piston spring retainer down, install E-ring. 7. Install band servo piston assembly onto servo piston retainer by pushing it inward. 8. 쐌 Install D-ring on OD band servo piston. Apply ATF to D-ring. 9. Install OD band servo piston onto servo piston retainer by pushing it inward. SAT912A SAT921A SAT922A SAT923A SAT924A AT-336 REPAIR FOR COMPONENT PARTS Parking Pawl Components Parking Pawl Components COMPONENTS GI NAAT0152 MA EM LC EC FE CL MT TF PD AX SAT558JA DISASSEMBLY 1. 2. 3. SU NAAT0153 Slide return spring to the front of adapter case flange. Remove return spring, parking pawl spacer and parking pawl from adapter case. Remove parking pawl shaft from adapter case. BR ST RS BT SAT226H 4. Remove parking actuator support from adapter case. HA SC EL IDX SAT228H AT-337 REPAIR FOR COMPONENT PARTS Parking Pawl Components (Cont’d) INSPECTION Parking Pawl and Parking Actuator Support 쐌 쐌 쐌 NAAT0209S01 Check contact surface of parking rod for wear. Rear Extension Assembly (2WD model only) 쐌 NAAT0209 NAAT0209S02 Check for free play between companion flange and output shaft. Make sure bearings roll freely and are free from noise, cracks, pitting or wear. Check contact surface of output shaft for wear. SAT998G ASSEMBLY NAAT0154 1. 2. 3. Install parking actuator support onto adapter case. Insert parking pawl shaft into adapter case. Install return spring, pawl spacer and parking pawl onto parking pawl shaft. 4. Bend return spring upward and install it onto adapter case. SAT229H SAT226H AT-338 ASSEMBLY Assembly (1) Assembly (1) 1. a. 쐌 쐌 b. NAAT0155 c. Install manual shaft components. Install oil seal onto manual shaft. Apply ATF to oil seal. Wrap threads of manual shaft with masking tape. Insert manual shaft and oil seal as a unit into transmission case. Remove masking tape. d. Push oil seal evenly and install it onto transmission case. GI MA EM LC SAT931A EC FE CL MT SAT932A e. Align groove in shaft with retaining pin hole, then retaining pin into position as shown in figure at left. TF PD AX SU SAT933A f. g. Install detent spring and spacer. While pushing detent spring down, install manual plate onto manual shaft. BR ST RS BT SAT901E h. Install lock nuts onto manual shaft. HA SC EL IDX SAT936A AT-339 ASSEMBLY Assembly (1) (Cont’d) 2. Install accumulator piston. a. Install O-rings onto accumulator piston. 쐌 Apply ATF to O-rings. Accumulator piston O-rings Unit: mm (in) Accumulator A B C D Small diameter end 29 (1.14) 32 (1.26) 45 (1.77) 29 (1.14) Large diameter end 45 (1.77) 50 (1.97) 50 (1.97) 45 (1.77) SAT523GA b. Install return spring for accumulator A onto transmission case. Free length of return spring: Refer to SDS, AT-357. c. 쐌 Install accumulator pistons A, B, C and D. Apply ATF to transmission case. 3. a. Install band servo piston. Install return springs onto servo piston. b. 쐌 Install band servo piston onto transmission case. Apply ATF to O-ring of band servo piston and transmission case. Install gasket for band servo onto transmission case. SAT938A SAT939AA SAT941A c. SAT942A AT-340 ASSEMBLY Assembly (1) (Cont’d) d. Install band servo retainer onto transmission case. GI MA EM LC SAT940A 4. a. Install rear side clutch and gear components. Place transmission case in vertical position. EC FE CL MT SAT943A b. Slightly lift forward clutch drum assembly. Then slowly rotate it clockwise until its hub passes fully over clutch inner race inside transmission case. TF PD AX SU SAT944A c. Check to be sure that rotation direction of forward clutch assembly is correct. BR ST RS BT SAT945A d. 쐌 쐌 Install thrust washer onto front of overrun clutch hub. Apply petroleum jelly to the thrust washer. Insert pawls of thrust washer securely into holes in overrun clutch hub. HA SC EL IDX SAT946A AT-341 ASSEMBLY Assembly (1) (Cont’d) e. Install overrun clutch hub onto rear internal gear assembly. f. 쐌 Install needle bearing onto rear of overrun clutch hub. Apply petroleum jelly to needle bearing. g. Check that overrun clutch hub rotates as shown while holding forward clutch hub. 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. SAT947A SAT948A SAT949A SAT527G SAT951A AT-342 ASSEMBLY Assembly (1) (Cont’d) j. 쐌 Install needle bearing onto rear internal gear. Apply petroleum jelly to needle bearing. GI MA EM LC SAT952A k. 쐌 쐌 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. EC FE CL MT SAT953A l. Install front internal gear on transmission case. TF PD AX SU SAT954A 5. a. b. c. d. 쐌 Install rear extension assembly on transmission case (2WD model only). Install revolution sensor on rear extension. Install rear extension gasket on transmission case. Install parking rod on transmission case. Install parking gear and needle bearing. Insert rear extension assembly into place while holding parking gear and needle bearing by hand. BR ST RS BT SAT546J 6. a. 쐌 Install output shaft and parking gear (4WD model only). Insert output shaft from rear of transmission case while slightly lifting front internal gear. Do not force output shaft against front of transmission case. HA SC EL IDX SAT216B AT-343 ASSEMBLY Assembly (1) (Cont’d) b. 쐌 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 direction. SAT957A c. 쐌 쐌 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. e. 쐌 Install snap ring on rear of output shaft. Check to be sure output shaft cannot be removed in forward direction. 7. a. 쐌 Install adapter case (4WD model only). Install oil seal on adapter case. Apply ATF to oil seal. SAT217B SAT218B SAT960A SAT759I AT-344 ASSEMBLY Assembly (1) (Cont’d) b. 쐌 c. Install O-ring on revolution sensor. Apply ATF to O-ring. Install revolution sensor on adapter case. GI MA EM LC SAT757I d. Install adapter case gasket on transmission case. EC FE CL MT SAT963A e. Install parking rod on transmission case. TF PD AX SU SAT964A f. Install adapter case on transmission case. BR ST RS BT SAT755I 8. a. 쐌 Install front side clutch and gear components. Install rear sun gear on transmission case. Pay attention to its direction. HA SC EL IDX SAT974A AT-345 ASSEMBLY Assembly (1) (Cont’d) b. 쐌 c. 쐌 쐌 Make sure needle bearing is on front of front planetary carrier. Apply petroleum jelly to needle bearing. Make sure needle bearing is on rear of front planetary carrier. Apply petroleum jelly to bearing. Pay attention to its direction — Black side goes to front. d. While rotating forward clutch drum clockwise, install front planetary carrier on forward clutch drum. 쐌 Check that portion A of front planetary carrier protrudes approximately 2 mm (0.08 in) beyond portion B of forward clutch assembly. e. 쐌 쐌 Make sure bearing races are on front and rear of clutch pack. Apply petroleum jelly to bearing races. Securely engage pawls of bearing races with holes in clutch pack. f. Install clutch pack into transmission case. SAT967A SAT969A SAT970A SAT971A SAT973A AT-346 ASSEMBLY Adjustment Adjustment =NAAT0156 When any parts listed in the following table are replaced, total end play or reverse clutch end play must be adjusted. Part name Total end play Reverse clutch end play Transmission case 쐌 쐌 Low one-way clutch inner race 쐌 쐌 Overrun clutch hub 쐌 쐌 Rear internal gear 쐌 쐌 Rear planetary carrier 쐌 쐌 Rear sun gear 쐌 쐌 Front planetary carrier 쐌 쐌 Front sun gear 쐌 쐌 High clutch hub 쐌 쐌 High clutch drum 쐌 쐌 Oil pump cover 쐌 쐌 Reverse clutch drum — 쐌 1. Adjust total end play. Total end play “T1”: 0.25 - 0.55 mm (0.0098 - 0.0217 in) GI MA EM LC EC FE CL MT TF PD AX SU SAT975A a. With needle bearing installed, place J34291-1 (bridge), J34291-2 (legs) and the J34291-5 (gauging cylinder) onto oil pump. The long ends of legs should be placed firmly on machined surface of oil pump assembly. The gauging cylinder should rest on top of the needle bearing. Lock gauging cylinder in place with set screw. BR ST RS BT SAT976A b. Install J34291-23 (gauging plunger) into gauging cylinder. HA SC EL IDX SAT977A AT-347 ASSEMBLY Adjustment (Cont’d) c. Install original bearing race inside reverse clutch drum. Place shim selecting gauge with its legs on machined surface of transmission case (no gasket). Allow gauging plunger to rest on bearing race. Lock gauging plunger in place with set screw. d. Remove Tool and use feeler gauge to measure gap between 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-360. SAT978A 쐌 SAT979A 2. Adjust reverse clutch drum end play. Reverse clutch drum end play “T2”: 0.55 - 0.90 mm (0.0217 - 0.0354 in) a. Place J34291-1 (bridge), J34291-2 (legs) and J34291-5 (gauging cylinder) on machined surface of transmission case (no gasket). Allow gauging cylinder to rest on front thrust surface of reverse clutch drum. Lock cylinder in place with set screw. b. Install J34291-23 (gauging plunger) into gauging cylinder. SAT980A SAT981A SAT982AA AT-348 ASSEMBLY Adjustment (Cont’d) c. Install original thrust washer on oil pump. Place shim setting gauge legs onto machined surface of oil pump assembly. Allow gauging plunger to rest on thrust washer. Lock plunger in place with set screw. GI MA EM LC SAT983A d. 쐌 Use feeler gauge to measure gap between gauging plunger and gauging cylinder. This measurement should give you exact reverse clutch drum end 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-361. EC FE CL MT SAT984A Assembly (2) 1. a. 쐌 NAAT0157 Install brake band and band strut. Install band strut on brake band. Apply petroleum jelly to band strut. TF PD AX SU SAT985A b. Place brake band on periphery of reverse clutch drum, and insert band strut into end of band servo piston stem. BR ST RS BT SAT986A c. Install anchor end bolt on transmission case. Then, tighten anchor end bolt just enough so that reverse clutch drum (clutch pack) will not tilt forward. HA SC EL IDX SAT987A AT-349 ASSEMBLY Assembly (2) (Cont’d) 2. 쐌 3. Install input shaft on transmission case. Pay attention to its direction — O-ring groove side is front. Install gasket on transmission case. 4. a. 쐌 b. 쐌 Install oil pump assembly. Install needle bearing on oil pump assembly. Apply petroleum jelly to the needle bearing. Install selected thrust washer on oil pump assembly. Apply petroleum jelly to thrust washer. c. Carefully install seal rings into grooves and press them into the petroleum jelly so that they are a tight fit. d. 쐌 Install O-ring on oil pump assembly. Apply petroleum jelly to O-ring. e. Apply petroleum jelly to mating surface of transmission case and oil pump assembly. SAT988A SAT989A SAT990A SAT991A SAT992A AT-350 ASSEMBLY Assembly (2) (Cont’d) f. 쐌 Install oil pump assembly. Install two converter housing securing bolts in bolt holes in oil pump assembly as guides. GI MA EM LC SAT993A 쐌 Insert oil pump assembly to the specified position in transmission, as shown at left. EC FE CL MT SAT994A 5. 쐌 Install O-ring on input shaft. Apply ATF to O-rings. TF PD AX SU SAT114B 6. a. 쐌 Install converter housing. Apply recommended sealant (Genuine Anaerobic Liquid Gasket or equivalent. Refer to GI section.) to outer periphery of bolt holes in converter housing. Do not apply too much sealant. BR ST RS BT SAT397C b. c. Apply recommended sealant (Genuine Anaerobic Liquid Gasket or equivalent. Refer to GI section.) to seating surfaces of bolts that secure front of converter housing. Install converter housing on transmission case. HA SC EL IDX SAT158G AT-351 ASSEMBLY Assembly (2) (Cont’d) 7. 8. a. b. Install turbine revolution sensor. Adjust brake band. Tighten anchor end bolt to specified torque. Anchor end bolt: : 4 - 6 N·m (0.4 - 0.6 kg-m, 35 - 52 in-lb) Back off anchor end bolt two and a half turns. SAT001B c. While holding anchor end bolt, tighten lock nut. Ancher end bolt nut: : 41 - 50 N·m (4.1 - 5.2 kg-m, 30 - 37 ft-lb) 9. a. 쐌 b. Install terminal cord assembly. Install O-ring on terminal cord assembly. Apply petroleum jelly to O-ring. Compress terminal cord assembly stopper and install terminal cord assembly on transmission case. SAT002B SAT115B 10. Install control valve assembly. a. Install accumulator piston return springs B, C and D. Free length of return springs: Refer to SDS, AT-357. SAT004BA b. 쐌 Install manual valve on control valve. Apply ATF to manual valve. SAT005B AT-352 ASSEMBLY Assembly (2) (Cont’d) c. d. Place control valve assembly on transmission case. Connect solenoid connector for upper body. Install connector clip. GI MA EM LC SAT006B e. f. 쐌 Install control valve assembly on transmission case. Install connector tube brackets and tighten bolts A and B. Check that terminal assembly does not catch. Bolt symbol EC FE  mm (in) A 33 (1.30) B 45 (1.77) CL MT TF PD AX SU SAT353B g. 쐌 h. Install O-ring on oil strainer. Apply petroleum jelly to O-ring. Install oil strainer on control valve. BR ST RS BT SAT221B i. Securely fasten terminal harness with clips. HA SC EL IDX SAT009B AT-353 ASSEMBLY Assembly (2) (Cont’d) j. Install torque converter clutch solenoid valve and A/T fluid temperature sensor connectors. SAT010B 11. Install oil pan. a. Attach a magnet to oil pan. SAT011B b. c. 쐌 쐌 d. Install new oil pan gasket on transmission case. Install oil pan and bracket on transmission case. Always replace oil pan bolts as they are self-sealing bolts. 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 dislocation of gasket. Tighten drain plug. 12. a. b. c. Install PNP switch. Check that manual shaft is in “1” position. Temporarily install PNP switch on manual shaft. Move manual shaft to “N”. d. Tighten bolts while inserting 4.0 mm (0.157 in) dia. pin vertically into locating holes in PNP switch and manual shaft. 쐌 SAT365I SAT299I SAT014B AT-354 ASSEMBLY Assembly (2) (Cont’d) 13. Install torque converter. a. Pour ATF into torque converter. 쐌 Approximately 2 liters (2-1/8 US qt, 1-3/4 Imp qt) of fluid are required for a new torque converter. 쐌 When reusing old torque converter, add the same amount of fluid as was drained. GI MA EM LC SAT428DA b. Install torque converter while aligning notches and oil pump. EC FE CL MT SAT016B c. Measure distance A to check that torque converter is in proper position. Distance “A”: 25.0 mm (0.984 in) or more TF PD AX SU SAT017B BR ST RS BT HA SC EL IDX AT-355 SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications General Specifications NAAT0160 VQ35DE engine Applied model 2WD 4WD Automatic transmission model RE4R01A Transmission model code number 4EX74 4EX75, 4EX76 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 Nissan Automatic Transmission Fluid (Canada)*1 Recommended fluid Fluid capacity 8.5 (9 US qt, 7-1/2 Imp qt) *1: Refer to MA-12, “Fluids and Lubricants”. Shift Schedule NAAT0178 VEHICLE SPEED WHEN SHIFTING GEARS THROTTLE POSITION NAAT0178S01 Vehicle speed km/h (MPH) Throttle position D 1 , D2 D2 , D 3 D3 , D 4 D4 , D 3 D3 , D 2 D2 , D 1 12 , 1 1 Full throttle 55 - 59 (34 - 37) 105 - 113 (65 - 70) 174 - 184 (108 - 114) 170 - 180 (106 - 112) 102 - 110 (63 - 68) 43 - 47 (27 - 29) 43 - 47 (27 - 29) Half throttle 37 - 41 (23 - 25) 71 - 79 (44 - 49) 129 - 139 (80 - 86) 81 - 91 (50 - 57) 33 - 41 (21 - 25) 12 - 16 (7 - 10) 43 - 47 (27 - 29) VEHICLE SPEED WHEN PERFORMING AND RELEASING LOCK-UP Throttle position NAAT0178S02 Vehicle speed km/h (MPH) Overdrive control switch [Shift position] Lock-up “ON” Lock-up “OFF” ON [D4] 174 - 184 (108 - 114) 170 - 180 (106 - 112) OFF [D3] 104 - 114 (65 - 71) 101 - 111 (63 - 69) ON [D4] 151 - 161 (94 - 100) 106 - 116 (66 - 72) OFF [D3] 85 - 95 (53 - 59) 82 - 92 (51 - 57) Full throttle Half throttle Stall Revolution Stall revolution NAAT0163 rpm 2,440 - 2,640 Line Pressure NAAT0164 2 Line pressure kPa (kg/cm , psi) Engine speed rpm D, 2 and 1 positions R position Idle 422 - 461 (4.3 - 4.7, 61 - 67) 667 - 706 (6.8 - 7.2, 97 - 102) Stall 1,020 - 1,098 (10.4 - 11.2, 148 - 159) 1,422 - 1,500 (14.5 - 15.3, 206 - 218) AT-356 SERVICE DATA AND SPECIFICATIONS (SDS) Return Springs Return Springs NAAT0165 GI Unit: mm (in) Item MA Parts Part No.* Free length Outer diameter 1 Torque converter relief valve spring 31742-41X23 38.0 (1.496) 9.0 (0.354) 2 Pressure regulator valve spring 31742-41X24 44.02 (1.7331) 14.0 (0.551) 3 Pressure modifier valve spring 31742-41X19 31.95 (1.2579) 6.8 (0.268) — Accumulator control valve spring — — — 4 Shuttle shift valve D spring 31762-41X01 25.0 (0.984) 7.0 (0.276) 5 4-2 sequence valve spring 31756-41X00 29.1 (1.146) 6.95 (0.2736) 6 Shift valve B spring 31762-41X01 25.0 (0.984) 7.0 (0.276) 7 4-2 relay valve spring 31756-41X00 29.1 (1.146) 6.95 (0.2736) 8 Shift valve A spring 31762-41X01 25.0 (0.984) 7.0 (0.276) 9 Overrun clutch control valve spring 31762-41X03 23.6 (0.929) 7.0 (0.276) 10 Overrun clutch reducing valve spring 31742-41X14 38.9 (1.531) 7.0 (0.276) 11 Shuttle shift valve S spring 31762-41X04 51.0 (2.008) 5.65 (0.2224) 12 Pilot valve spring 31742-41X13 25.7 (1.012) 9.0 (0.354) 13 Torque converter clutch control valve spring 31742-41X22 18.5 (0.728) 13.0 (0.512) 1 Modifier accumulator piston spring 31742-27X70 31.4 (1.236) 9.8 (0.386) 2 1st reducing valve spring 31756-60X00 29.5 (1.161) 7.0 (0.276) 3 3-2 timing valve spring 31742-41X06 23.0 (0.906) 6.7 (0.264) 4 Servo charger valve spring 31742-41X06 23.0 (0.906) 6.7 (0.264) 31505-41X07 — — Upper body Control valve EM LC EC FE CL MT TF Lower body Reverse clutch — High clutch 10 pcs 31521-41X03 (Assembly) 24.2 (0.9528) 11.6 (0.457) Forward clutch (Overrun clutch) 20 pcs 31521-41X04 (Assembly) 35.77 (1.4083) 9.7 (0.382) Low & reverse brake 18 pcs 31655-41X00 (Assembly) 22.3 (0.878) 11.2 (0.441) Spring A 31605-4AX03 45.6 (1.795) 34.3 (1.350) Spring B 31605-41X01 29.7 (1.169) 27.6 (1.087) Accumulator A 31605-41X02 43.0 (1.693) 18.0 (0.709) Accumulator B 31605-41X14 47.6 (1.874) 26.5 (1.043) Accumulator C 31605-41X09 45.0 (1.772) 29.3 (1.154) Accumulator D 31605-41X06 58.4 (2.299) 17.3 (0.681) PD AX SU Band servo BR ST RS Accumulator *: Always check with the Parts Department for the latest parts information. BT HA SC EL IDX AT-357 SERVICE DATA AND SPECIFICATIONS (SDS) Accumulator O-ring Accumulator O-ring NAAT0166 Diameter mm (in) Accumulator A B C D Small diameter end 29 (1.14) 32 (1.26) 45 (1.77) 29 (1.14) Large diameter end 45 (1.77) 50 (1.97) 50 (1.97) 45 (1.77) Clutches and Brakes NAAT0167 REVERSE CLUTCH Code number NAAT0167S01 4EX74 4EX75, 4EX76 Number of drive plates 3 Number of driven plates 3 Thickness of drive plate mm (in) Standard 1.90 - 2.05 (0.0748 - 0.0807) Wear limit 1.80 (0.0709) Standard 0.5 - 0.8 (0.020 - 0.031) Clearance mm (in) Allowable limit 1.2 (0.047) Thickness mm (in) Thickness of retaining plate 4.6 4.8 5.0 5.2 5.4 Part number* (0.181) (0.189) (0.197) (0.205) (0.213) 31537-42X20 31537-42X21 31537-42X22 31537-42X23 31537-42X24 *: Always check with the Parts Department for the latest parts information. HIGH CLUTCH NAAT0167S02 Code number 4EX74 4EX75, 4EX76 Number of drive plates 5 Number of driven plates 6 Thickness of drive plate mm (in) Standard 1.52 - 1.67 (0.0598 - 0.0657) Wear limit 1.40 (0.0551) Standard 1.8 - 2.2 (0.071 - 0.087) Clearance mm (in) Allowable limit 3.2 (0.126) Thickness mm (in) Thickness of retaining plate 4.0 4.2 4.4 4.6 4.8 5.0 (0.157) (0.165) (0.173) (0.181) (0.189) (0.197) *: Always check with the Parts Department for the latest parts information. AT-358 Part number* 31537-41X63 31537-41X64 31537-41X65 31537-41X66 31537-41X67 31537-41X68 SERVICE DATA AND SPECIFICATIONS (SDS) Clutches and Brakes (Cont’d) FORWARD CLUTCH NAAT0167S03 Code number 4EX74 4EX75, 4EX76 Number of drive plates 7 8 Number of driven plates 7 8 Thickness of drive plate mm (in) Standard 1.52 - 1.67 (0.0598 - 0.0657) Wear limit 1.40 (0.0551) Standard 0.35 - 0.75 (0.0138 - 0.0295) GI MA EM LC Clearance mm (in) Allowable limit 2.15 (0.0846) Thickness mm (in) Thickness of retaining plate 4.6 4.8 5.0 5.2 5.4 5.6 2.35 (0.0925) Part number* (0.181) (0.189) (0.197) (0.205) (0.213) (0.220) Thickness mm (in) 31537-42X13 31537-42X14 31537-42X15 31537-4AX00 31537-4AX01 31537-4AX02 4.2 4.4 4.6 4.8 5.0 5.2 5.4 (0.165) (0.173) (0.181) (0.189) (0.197) (0.205) (0.213) Part number* 31537-42X11 31537-42X12 31537-42X13 31537-42X14 31537-42X15 31537-4AX00 31537-4AX01 *: Always check with the Parts Department for the latest parts information. CL NAAT0167S04 4EX74 4EX75, 4EX76 Number of drive plates 3 Number of driven plates 5 Thickness of drive plate mm (in) FE MT OVERRUN CLUTCH Code number EC Standard 1.90 - 2.05 (0.0748 - 0.0807) Wear limit 1.80 (0.0709) Standard 1.0 - 1.4 (0.039 - 0.055) TF PD Clearance mm (in) Allowable limit Thickness mm (in) Thickness of retaining plate AX 2.0 (0.079) 4.2 4.4 4.6 4.8 5.0 (0.165) (0.173) (0.181) (0.189) (0.197) Part number* 31537-41X80 31537-41X81 31537-41X82 31537-41X83 31537-41X84 SU BR *: Always check with the Parts Department for the latest parts information. ST RS BT HA SC EL IDX AT-359 SERVICE DATA AND SPECIFICATIONS (SDS) Clutches and Brakes (Cont’d) LOW & REVERSE BRAKE NAAT0167S05 Code number 4EX74 4EX75, 4EX76 Number of drive plates 8 Number of driven plates 8 Thickness of drive plate mm (in) Standard 1.90 - 2.05 (0.0748 - 0.0807) 1.52 - 1.67 (0.0598 - 0.0657) Wear limit 1.40 (0.0551) Standard 0.8 - 1.1 (0.031 - 0.043) Clearance mm (in) Allowable limit 2.7 (0.106) Thickness mm (in) 7.6 7.8 8.0 8.2 8.4 8.6 8.8 9.0 9.2 9.4 9.6 Thickness of retaining plate Part number* (0.299) (0.307) (0.315) (0.323) (0.331) (0.339) (0.346) (0.354) (0.362) (0.370) (0.378) 31667-41X07 31667-41X08 31667-41X00 31667-41X01 31667-41X02 31667-41X03 31667-41X04 31667-41X05 31667-41X06 31667-41X09 31667-41X10 *: Always check with the Parts Department for the latest parts information. BRAKE BAND NAAT0167S06 Anchor end bolt nut tightening torque 40 - 51 N·m (4.1 - 5.2 kg-m, 30 - 38 ft-lb) Anchor end bolt tightening torque 4 - 6 N·m (0.4 - 0.6 kg-m, 35 - 52 in-lb) Number of returning revolution for anchor end bolt 2.5 Oil Pump and Low One-way Clutch NAAT0168 Unit: mm (in) Oil pump clearance Cam ring — oil pump housing Standard 0.01 - 0.024 (0.0004 - 0.0009) Rotor, vanes and control piston — oil pump housing Standard 0.03 - 0.044 (0.0012 - 0.0017) Standard 0.10 - 0.25 (0.0039 - 0.0098) Seal ring clearance Allowable limit 0.25 (0.0098) Total End Play Total end play “T1” NAAT0169 0.25 - 0.55 mm (0.0098 - 0.0217 in) Thickness mm (in) Thickness of oil pump cover bearing race 0.8 1.0 1.2 1.4 1.6 1.8 2.0 (0.031) (0.039) (0.047) (0.055) (0.063) (0.071) (0.079) *: Always check with the Parts Department for the latest parts information. AT-360 Part number* 31435-41X01 31435-41X02 31435-41X03 31435-41X04 31435-41X05 31435-41X06 31435-41X07 SERVICE DATA AND SPECIFICATIONS (SDS) Reverse Clutch Drum End Play Reverse Clutch Drum End Play Reverse clutch drum end play “T2” NAAT0170 GI 0.55 - 0.90 mm (0.0217 - 0.0354 in) Thickness mm (in) 0.9 1.1 1.3 1.5 1.7 1.9 Thickness of oil pump thrust washer MA Part number* (0.035) (0.043) (0.051) (0.059) (0.067) (0.075) 31528-21X01 31528-21X02 31528-21X03 31528-21X04 31528-21X05 31528-21X06 EM LC *: Always check with the Parts Department for the latest parts information. EC Removal and Installation NAAT0171 Number of returning revolutions for lock nut 2 Manual control linkage Distance between end of converter housing and torque converter CL 25.0 mm (0.984 in) or more Shift Solenoid Valves NAAT0217 Gear position 1 2 3 4 Shift solenoid valve A ON (Closed) OFF (Open) OFF (Open) ON (Closed) Shift solenoid valve B ON (Closed) ON (Closed) OFF (Open) OFF (Open) Resistance (Approx.) MT TF Solenoid Valves Solenoid valves FE 4.4 - 5.9 N·m (0.45 - 0.60 kg-m, 39.1 - 52.1 in-lb) Lock nut tightening torque NAAT0218 Ω Terminal No. Shift solenoid valve A 20 - 40 3 Shift solenoid valve B 20 - 40 2 Overrun clutch solenoid valve 20 - 40 4 Line pressure solenoid valve 2.5 - 5 6 Torque converter clutch solenoid valve 10 - 20 7 PD AX SU BR A/T Fluid Temperature Sensor NAAT0219 Remarks: Specification data are reference values. Monitor item Condition A/T fluid temperature sensor Cold [20°C (68°F)] " Hot [80°C (176°F)] ST Specification Approximately 1.5V " Approximately 0.5V Approximately 2.5 kΩ " Approximately 0.3 kΩ Turbine Revolution Sensor Terminal No. RS NAAT0232 BT Resistance 1 2 2.4 - 2.8 kΩ 2 3 No continuity 1 3 No continuity HA SC EL IDX AT-361 SERVICE DATA AND SPECIFICATIONS (SDS) Revolution Sensor Revolution Sensor NAAT0220 Terminal No. Resistance 1 2 500 - 650Ω 2 3 No continuity 1 3 No continuity Dropping Resistor Resistance NAAT0221 11.2 - 12.8Ω AT-362